MAY 14, 2024

Liftgates Weatherproofing Solutions: Ensuring Liftgate Parts Durability

When it comes to equipping your vehicles with liftgates, durability and reliability are paramount.

Whether you're navigating through rain-soaked streets, snow-covered highways, or dusty construction sites, your liftgate must withstand the elements to maintain optimal performance.

Moreover, you may operate within an industry that may expose your liftgate to corrosive and abrasive products, like the chemical industry, for example.

That's why the top liftgate manufacturers such as Maxon, Waltco, and Palfinger offer advanced weatherproofing solutions to safeguard your liftgate parts and accessories in any environment.

Let’s dive into the details of how and why these weatherproofing solutions are essential for your liftgate parts.

Understanding the Importance of Weatherproofing

Weatherproofing isn't just about keeping your cargo dry during a rainstorm—it's also about protecting your liftgate from the relentless attacks of nature.

Exposure to moisture, dirt, and other environmental factors can lead to rust, corrosion, and electrical malfunctions, compromising the functionality and safety of your liftgate over time.

As a result, you will experience diminished performance, increased maintenance costs, and potential safety hazards from different liftgate parts.

Here's how different liftgate parts can be adversely affected:

• Hydraulic System
  
  Moisture infiltration into the hydraulic system can lead to corrosion of hydraulic cylinders, valves, and seals. Rust and corrosion compromise the integrity of these components, causing leaks, reduced lifting capacity, and ultimately, hydraulic system failure.
  
  
  
• Structural Components
  
  Dirt and debris accumulation on structural components such as the liftgate platform, arms, and frame can accelerate wear and tear. Abrasive particles can scratch and erode paint and protective coatings, exposing metal surfaces to moisture and corrosion.
  
  
  
• Electrical Components
  
  Exposure to moisture and dirt can cause electrical components like wiring harnesses, connectors, and switches to short-circuit or malfunction. Corrosion of electrical contacts and terminals can disrupt signal transmission, leading to erratic operation or complete failure of liftgate controls.
  
  
  
• Seals and Gaskets
  
  Seals and gaskets play a crucial role in preventing water and debris from infiltrating sensitive components. Over time, exposure to moisture, dirt, and UV radiation can degrade rubber seals and gaskets, causing them to lose their elasticity and sealing properties. This compromises the liftgate's ability to maintain a watertight and dustproof seal, leading to increased risk of component damage and failure.
  
  
  
• Paint and Finish
  
  The paint and finish of your liftgate serves not only aesthetic purposes but also provides crucial protection against corrosion and environmental damage. Exposure to moisture, UV radiation, road salts, and abrasive materials can cause paint fading, chipping, and peeling, exposing underlying metal surfaces to rust and corrosion.
  
  
  
• Moving Parts and Bearings
  
  Moisture and dirt that get into moving parts such as hinges, bearings, and rollers can accelerate wear and cause premature failure. Contaminants can interfere with smooth operation, leading to increased friction, noise, and reduced efficiency of the liftgate mechanism.
  

In summary, exposure to moisture, dirt, and other environmental factors poses significant risks to the performance and longevity of various liftgate parts. Regular inspection, cleaning, and proactive maintenance are essential to mitigate these risks and ensure the reliable operation of your liftgate in diverse operating conditions.

Liftgates Weatherproofing Features

Liftgate manufacturers understand the challenges that operators face in various conditions. That's why their products are engineered with robust weatherproofing features designed to withstand the toughest environments.

From heavy-duty seals to corrosion-resistant coatings, liftgate manufacturers employ state-of-the-art materials and design elements to enhance durability and resilience against weather conditions.

Sealing Mechanisms

One of the cornerstones of weatherproofing strategies applied by liftgate manufacturers is advanced sealing mechanisms.

These mechanisms are meticulously designed to prevent water and debris from infiltrating critical components, ensuring reliable performance even in the harshest conditions.

Whether it's a tight-fitting seal around the liftgate edges or specialized gaskets at key points of entry, most liftgate manufacturers leave no room for compromise when it comes to keeping the elements at bay.

Here's a short list of some of the seals used in liftgates:

• Cylinder Seals
  
  These seals prevent hydraulic fluid leaks and protect cylinders from moisture and contamination.
  
  Good examples can be found in Palfinger ILK cylinders and ILD cylinders.
  
  
  
• Control Box Seals
  
  Seals around the control box components, such as switches and wiring, help prevent water ingress and safeguard electrical connections from corrosion.
  
  
  
• Wiring Harness Seals
  
  Seals around wiring harness connectors and entry points protect electrical connections from moisture and corrosion, ensuring reliable operation of the liftgate's electrical systems.
  
  
  
• Hydraulic Pump Seals
  
  Seals around the hydraulic pump and motor assembly prevent hydraulic fluid leaks and protect the internal components from environmental damage.
  
  
  
• Rubber Bumpers
  
  While not traditional seals, rubber bumpers are often used on liftgate components to provide cushioning and protection against impacts, reducing the risk of damage from external forces.
  

Corrosion Resistance Technologies

Corrosion is the arch-nemesis of any liftgate, eating away at metal components and compromising structural integrity. Top manufacturers tackle this challenge head-on with innovative corrosion resistance technologies.

Most liftgate parts are built to withstand the rigors of daily operation without succumbing to rust and decay thanks to the application of either e-coat or galvanized steel protection.

Let’s see each of these solutions in more detail.

E-coat protection

Electro-coating, commonly known as e-coating or electro-deposition coating, is a highly efficient and environmentally friendly method used to provide corrosion protection to various metal surfaces, including liftgate parts. The process involves the following steps:

• Preparation of the Substrate
  
  Before the electro-coating process begins, the metal surfaces of the liftgate and liftgate parts undergo thorough cleaning to remove any dirt, oil, grease, or other contaminants. This cleaning process ensures that the e-coat adheres properly to the surface and provides effective protection against corrosion.
  
  
  
• Pretreatment
  
  After cleaning, the metal surfaces are usually treated with a series of chemical solutions to prepare them for the e-coating process. These pretreatment steps typically include degreasing, rinsing, etching, and applying a conversion coating. The conversion coating helps improve the adhesion of the e-coat to the metal surface and enhances corrosion resistance.
  
  
  
• E-Coating Bath
  
  The liftgate and liftgate parts to be treated are then immersed in a specially formulated paint bath containing the e-coat material. This bath consists of a water-based solution containing pigments, resins, and other additives. The liftgate acts as the cathode (negative electrode) while an anode (positive electrode) is also present in the bath.
  
  
  
• Electro-Deposition
  
  When an electric current is applied to the e-coating bath, the e-coat material is deposited onto the surface of the liftgate through an electrochemical process. The positively charged e-coat particles in the bath are attracted to the negatively charged metal surface of the liftgate, forming a uniform and tightly adherent coating.
  
  
  
• Post-Treatment
  
  After the electro-deposition process, the coated liftgate parts are typically rinsed to remove any excess e-coat material and then cured in an oven at high temperatures. Curing helps cross-link the resin molecules in the e-coat, forming a durable and protective coating layer.
  
  
  
• Quality Control
  
  Throughout the electro-coating process, quality control measures are implemented to ensure that the coating thickness, adhesion, and overall quality meet the desired specifications. Various testing methods, such as salt spray testing and adhesion testing, may be performed to assess the performance of the e-coat coating.
  
  
  
• Final Finishing
  
  Once the electro-coating process is complete and the liftgate has passed quality control inspections, it may undergo additional finishing processes, such as painting or powder coating, to further enhance its appearance and durability.
  

Overall, electro-coating is a highly effective and widely used method for protecting liftgates, liftgate parts and other metal components from corrosion, providing long-lasting durability and resistance to harsh environmental conditions.

Of course, each manufacturer may have something unique to its e-coating process. For example, Palfinger claims their liftgates are finally cured at high temperature for only 1 hour.

Galvanized Steel Protection

Galvanization is a process used to protect steel surfaces from corrosion by applying a protective zinc coating. Here's how the galvanization process works for protecting liftgates:

• Surface Preparation
  
  Before galvanizing, the steel surface of the liftgate undergoes thorough cleaning to remove any dirt, oil, grease, or rust. This cleaning process ensures that the zinc coating adheres properly to the steel surface.
  
  
  
• Pickling
  
  After cleaning, the steel is usually pickled in a solution of acidic chemicals to remove any mill scale or oxide layers from the surface. Pickling creates a clean surface for the zinc coating to bond to and ensures maximum adhesion.
  
  
  
• Fluxing
  
  Once pickling is complete, the steel is immersed in a flux solution to prevent oxidation before it is galvanized. Fluxing also helps remove any remaining oxides and prepares the surface for the zinc coating.
  
  
  
• Galvanizing
  
  The prepared steel is then dipped into a bath of molten zinc at temperatures typically around 450°C (850°F). This immersion process allows the steel to be completely coated with a layer of zinc, which bonds metallurgically with the steel substrate.
  
  
  
• Withdrawal and Cooling
  
  After the steel has been fully immersed in the molten zinc for a specified period, it is withdrawn from the zinc bath and allowed to cool. As the steel cools, the zinc solidifies to form a protective coating over the surface.
  
  
  
• Inspection
  
  Once the galvanizing process is complete, the coated liftgate undergoes inspection to ensure that the zinc coating is uniform and free from defects. Visual inspection, as well as various thickness and adhesion tests, may be performed to verify the quality of the galvanized coating.
  
  
  
• Final Finishing (Optional)
  
  The result of galvanizing is usually an abrasion resistant coating with a greyish matte finish. So, depending on the desired appearance and additional protection requirements, the galvanized liftgate may undergo further finishing processes such as painting or powder coating.
  

Galvanized steel is highly resistant to corrosion, making it an excellent choice for protecting liftgates and other outdoor applications exposed to harsh environmental conditions. The zinc coating provides sacrificial protection, corroding preferentially to the steel substrate and extending the service life of the liftgate.

A good example of a galvanized finish is the galvanized option for Maxon ME2 pickup gates.

Electrical Protection

In addition to protecting against mechanical wear and tear, top liftgate manufacturers prioritize electrical protection to safeguard against moisture and environmental factors.

Sealed connectors, weatherproof wiring, and other electrical components are carefully integrated into the design, ensuring reliable operation even in the most demanding conditions.

For example, a new technology called solid state electronic controls with built in diagnostics have come to the premium Palfinger liftgate models. These controls have internal protection against electric shorts and built-in diagnostics to reduce the time to troubleshooting any possible electrical issues.

Maintenance Tips for Long-Term Weatherproofing

To maximize the lifespan of your liftgate's weatherproofing features, regular maintenance is essential.

Inspect seals and gaskets for signs of wear, clean debris from critical components, and follow recommended maintenance schedules to keep your liftgate operating at peak performance.

Additionally, consider investing in aftermarket weatherproofing products to provide an extra layer of protection against the elements.

By carefully considering these factors and consulting with industry experts, you can make informed decisions when selecting your next Maxon liftgate systems to meet your specific needs and requirements.

Conclusion

With advanced sealing mechanisms and corrosion resistance technologies, liftgates top manufacturers ensure that all their liftgate parts will perform reliably in any environment.

Unfortunately, even with these measures, liftgate parts suffer wear and tear and may eventually fail. Therefore, having a reliable liftgate parts supplier as your partner is vital.

Ready to weatherproof your liftgate for the long haul?

Contact us today to learn more about liftgates parts and services, and take the first step toward ensuring durability and reliability for your fleet.