C-15RM, C-20RM

Transcription

C-15RM, C-20RM

BZ- 33/44/55 SERIES
Visit us at www.waltco.com
Owners Manual
3300, 4400, & 5500 lb. Capacity
IMPORTANT
KEEP IN VEHICLE
ATTENTION
THE SUCCESS OR FAILURE
OF THIS EQUIPMENT COULD
VERY WELL DEPEND ON
THOROUGH AND PROPER
OPERATION AND
MAINTENANCE OF THIS
EQUIPMENT.
READ AND UNDERSTAND
THE CONTENTS OF THIS
MANUAL BEFORE
OPERATING THIS
EQUIPMENT
10-08
GR00511
OHIO
CALIFORNIA
GEORGIA
285 Northeast Avenue
Tallmadge, OH 44278
(330) 633-9191
FAX – (330) 633-1418
227 E. Compton Blvd
Gardena, CA 90248
(310) 243-6800
FAX – (310) 538-1136
8960 Highway #5
Building A
Douglasville, GA 30134
(770) 949-5342
FAX – (770) 949-5344
E.O. 6133 Rev. 08
80116602
Table of Contents
Chapter
ATTENTION
SAFETY INFORMATION ----------------------------
---------------
1
LIFTGATE TERMINOLOGY ------------------------
---------------
2
OPERATION --------------------------------------------
---------------
3
INSPECTION -------------------------------------------
---------------
4
PLACEMENT OF DECALS -------------------------
---------------
5
LUBRICATION INSTRUCTIONS -----------------
---------------
6
PMs & SCHEMATICS---------------------------------
---------------
7
HOW TO ORDER PARTS --------------------------
----------------
8
SERVICE BULLETINS & TROUBLESHOOTING
E.O. 6133 Rev. 08
80116602
INTRODUCTION
If anyone observes improper installation, improper operation, or damage, they should immediately
contact a qualified person for assistance and correction. We strongly urge anyone that has any
questions or doubts as to the installation, condition, use, operation, maintenance or repair of the liftgate
to contact us at Waltco where we have qualified personnel that will be happy to assist you. Telephone
numbers and addresses of these locations are listed in the Owners Manual and Installation Instructions.
INSTALLATION
Waltco liftgates should only be installed by those with sufficient basic skills to understand the
installation and operation of the liftgate, along with the equipment on which the liftgate is being
installed. Waltco’s installation instructions are not intended to give rationale for all the instructions that
are given; however, it is the intent of these instructions to give the installer both the operations and
what we believe to be the most desirable sequence of implementing these operations. These
instructions can in no way expand into an area where they will replace a qualified person, or clear
thinking and a basic knowledge that must be possessed by the installer.
It has been our experience that a knowledgeable journeyman following these instructions and
observing the operation of the liftgate will have a sufficient comprehension of the liftgate to enable this
person to troubleshoot and correct all normal problems that may be encountered.
Failure to follow the installation instructions, adjustments and mounting dimensions may result in
improper and unsafe operation of the liftgate. Unauthorized alterations of the liftgate can cause an
undesirable and dangerous condition.
OWNERS MANUAL
The Waltco Owners Manual is intended to act as a guide for operation and routine maintenance but
is no way intended to encourage usage or repair of the liftgate by those who are not qualified to do so.
The contents of the owners manual include, but are not limited to general operation instructions,
routine lubrication, parts lists, and an outline of things that should be checked but may not be obvious
to those not technically qualified. This manual assumes the liftgate is properly installed, undamaged
and operates correctly. Improper installation, improper operation, or damage should be immediately
corrected by a qualified person.
INSPECTION
As part of the regular inspection of a liftgate and after damage or suspicion of an overload, inspect
for wear or structural damage and make necessary repairs or replacements. Check all structural
components and their attachment to the liftgate for cracked welds, wear and part deformation. Check
cylinder and hose for leaks. Inspections and repairs should be made by a qualified mechanic.
REPLACEMANT PARTS
Use only Waltco original equipment replacement parts. Components of other liftgate manufacturers
may outwardly appear to be the same but are not interchangeable with Waltco products. Waltco
components are specifically designed for safety requirements, reliability and compatibility with our
products. Refer to your Waltco parts manual when ordering parts. NOTE: When ordering, give model
and serial number of liftgate.
DECALS
It is important that every vehicle that has a WALTCO Liftgate have legible DECALS clearly posted on
the vehicle and an OWNER’S MANUAL in the vehicle at all times as a guide for proper operation and
maintenance.
Additional DECALS and OWNER’S MANUALS can be obtained from WALTCO TRUCK
EQUIPMENT COMPANY.
80101388 Rev 01
Chapter 1
Safety Information
The following safety information must be read before operating Waltco liftgates.
Read and understand the Owner’s Manual and all decals on liftgate before operating
liftgate.
Do not operate liftgate without a thorough knowledge and understanding of the operation of
the liftgate.
Liftgate hazards can result in crushing or falling
This liftgate is designed for loading and unloading of cargo. If personnel are required to ride
liftgate, observe and familiarize yourself with the liftgate operation, decals and manuals.
Ensure stable footing at all times
Do not ride liftgate with unstable loads.
Keep hands and feet clear of all potential pinch points.
Do not attempt any repairs unless you are qualified to do so. Care should be taken when
work is performed on a disabled liftgate located near moving traffic. When possible the
vehicle should be moved away from traffic areas for repair. Precautionary measures should
be taken to ensure personal safety including those recommended in Federal Motor Vehicle
Safety Standards 571.125.
NEVER OVERLOAD LIFTGATE
Refer to the Explanation of Specification Tag in the Liftgate Terminology chapter for liftgate
capacity rating.
Never use liftgate if it makes any unusual noise, has unusual vibration, raises or lowers
unevenly, or fails to operate smoothly.
Never use liftgate if it shows any signs of structural damage such as cracked welds, bent or
distorted members.
For liftgates with Runners, never use liftgate if Runners do not travel freely and smoothly.
All protective covers, guards, and safety devices must be in place and access doors closed
before operating liftgate.
Make certain the Platform area, including the area in which loads may fall, is clear before
and at all times during the operation of the liftgate.
For liftgates with Roller Lifting Chain, the Chain should be replaced every (5) five years or
15,000 cycles, whichever comes first. Replace only with Waltco approved Roller Chain.
A Lock-Out device or Shut-Off Switch should always be used to prevent unauthorized use
of liftgate.
Never transfer loads which exceed lifting capacity on or over any part of the Platform
unless the liftgate is equipped with a special reinforced Platform and Platform Support Bars
for use when the Platform is used as loading ramp (dock board). Refer to the “Using
Platform as a loading ramp” Chapter in the Operation Instructions of the BZ/RZ series
Owner’s Manual.
Platform is always to be properly stored and secured for transit. See the Owner’s Manual
for details.
For liftgates equipped with Trailer Hitches, never exceed the rated capacity of the hitch. Do
not exceed the vehicle’s weight rating. Refer to the vehicle’s Owner’s Manual.
Page 1 - 1
80101253 Rev 02
Chapter 1
Safety Information
Take care to retain cargo during transit for liftgate Platforms which function as the tailgate
or door of the cargo area. Small objects can fall through the space between the vehicle and
the folded Platform.
Vehicle must comply with all state and federal standards.
Follow the “Maintenance Guide” chapter in the Owner’s Manual.
Liftgates with Tilt Function
Proper use of the Control Switches is of extreme importance.
Improper use of Tilt Switch could cause load to fall from the Platform or damage the liftgate.
Platform should be in a generally horizontal position when raising or lowering with a load.
In any tilt position, the Platform may vary from level while raising or lowering the Platform.
Liftgates equipped with spring operated Cam Closer
Replace Cam Release Spring every five (5) years or 15,000 cycles, whichever comes first.
RGL
Make certain Platform Brake mechanisms are operating properly.
The Runners are always to remain powered up against the Upstops Pins when in transit.
Inspect Cables every three (3) months or 750 cycles, whichever comes first. Cables must
be replaced if they show signs of wear, distortion, kinking or if any broken wires are visible
Replace cables every five (5) years or 10,000 cycles, whichever comes first.
SIGNAL WORDS
WARNING
Indicates a potentially hazardous situation, which if
not avoided, could result in death or serious injury.
Black letters on an orange background
CAUTION
Indicates a potentially hazardous situation, which if
not avoided, may result in minor or moderate
injury. May also be used to alert against unsafe
practices.
Black letters on a yellow background.
WARNING
CAUTION
Page 1 - 2
80101253 Rev 02
Chapter 2 Liftgate Terminology
1. Platform
2. Mount Tube
16
3. Pump and Motor Tray
15
4. Lift Arm
5. Bumper
6. Lift Cylinder
1
7. Tilt Cylinder
8. Upper Lift Arm Pin
14
9. Lower Lift Arm Pin
10. Upper Lift Cylinder Pin
17
11. Lower Lift Cylinder Pin
17
12. Upper Tilt Cylinder Pin
14
13. Lower Tilt Cylinder Pin
14. Marker Lights
15. Sill Extension
16. Mount Plates
17. Cart stop (optional)
GR00828
14
12
7
14
4
8
5
5
3
10
7
6
5
13
11
2
6
9
GR00829
Page 2-1
Chapter 2 Liftgate Terminology
EXPLANATION OF SPECIFICATION TAG
MODEL NO.
MODEL NAME
DESCRIPTION
CAPACITY
166
BZ-33
LEVEL LIFT
3300 LBS.
167
BZ-44
LEVEL LIFT
4400 LBS.
168
BZ-55
LEVEL LIFT
5500 LBS.
MODEL NUMBER
RATED CAPACITY
Based on an evenly
distributed load on the
platform flat surface
SERIAL NUMBER
DATE OF
MANUFACTURE
of Liftgate. To be used
when ordering parts or
when contacting Waltco
for service or warranty.
MONTH/YEAR
GR00053
LOCATION OF SPECIFICATION TAG
On some older liftgates
may be located here
Can be found on driver’s side, end of mount tube.
Usually found
on this end
Mount Tube
GR02226
Page 2-2
Chapter 3 Operations Instructions
IMPORTANT
Understand these instructions before operating liftgate
When in transit, platform is to be closed
When not in use, electrical shut off switch is to be off.
In any tilt position, the attitude of the platform may vary from level while raising or lowering the platform.
Make certain area in which platform will open and close is clear before opening or closing, and at all times
during operation.
Make certain platform area, including the area in which loads may fall from platform, is clear before and at all
times during operation of liftgate.
Never close liftgate with any objects on platform.
OPENING PLATFORM
Turn shut-off switch on.
KEY SHUTOFF SWITCH
Typically on trucks a toggle switch is located in cab.
Typically on trailers, a key switch is located near
liftgate control switches.
CAB SHUT-OFF
SWITCH
GR00697
Page 3-1
SWITCH FUNCTIONS / FIXED CONTROLS
RAISE
Raise switch
TILT
Raises platform.
Used with tilt switch to tilt platform up.
Tilt switch
Used with raise and lower switches to tilt platform.
TILT
RAISE / SLIDE OUT
Lower switch
Lowers platform.
LOWER / SLIDE IN
+
!
-
TILT
Used with tilt switch to tilt platform down.
LOWER
TILT
GR01759
SWITCH FUNCTIONS / HAND HELD CONTROLS
TILT
PRESS IN TO
ACTIVATE
Raise switch
Raises platform.
Used with tilt switch to tilt platform up.
Tilt switch (press in to activate)
RAISE
Lower switch
Lowers platform.
Used with tilt switch to tilt platform down.
RAISE
LOWER
Used with raise and lower switches to tilt platform.
LOWER
GR01611
Page 3-2
TO OPEN PLATFORM
Turn shut-off switch on (located in cab or near
controls).
Always make certain area in which platform will
open is clear.
Turn and hold tilt switch then turn lower switch to
unfold platform.
NOTE! Tilt switch can be activated by rotating up or
down.
GR00480
TO RAISE AND LOWER PLATFORM IN LOADING
POSITION
Turn raise switch to raise platform.
Or
Turn lower switch to lower platform.
GR00482
TO MANUALLY TILT PLATFORM UP AND DOWN
First turn and hold tilt switch, then simultaneously
turn raise switch to tilt platform up.
Or
First turn and hold tilt switch, then simultaneously
turn lower switch to tilt platform down.
GR00483
TO FOLD PLATFORM TO CLOSED POSITION
Make certain platform surface is clear of all objects.
Raise platform to bed level with raise switch.
Turn and hold tilt switch then simultaneously turn
raise switch to close platform.
Turn shut-off switch off.
When in transit, platform must be closed vertically, and
shut-off switch is to be turned “off.”
GR00485
Page 3-3
IMPORTANT!
To avoid vehicle or liftgate damage, never attempt to
close platform until platform is first at bed level.
GR00705
SECURE PLATFORM FOR TRANSIT
Close platform.
Turn shut-off switch off.
KEY SHUTOFF SWITCH
CAUTION!
Keep hands away from pinch points.
IMPORTANT!
Electrical shut-off switch is a safety device and must be
working properly at all times.
CAB SHUT-OFF
SWITCH
GR00697
PROPER OPERATION OF TILT
Platform should always be in a generally level
position.
Load is to be stabilized to prevent rolling or falling off
platform.
CAUTION! Improper use of tilt controls could cause load
to fall from platform.
In any tilt position, the attitude of the platform may vary
from level while raising or lowering the platform.
GR00702
Page 3-4
Never tilt platform with a load except when loading
and unloading cargo at ground, or to stabilize load.
GR00703
Tilting platform may cause an unstable load to roll
off if unattended.
GR00704
BZ-33 Only
3300 lbs.
2300 lbs.
If the load is centered no farther than 30” out from the
vehicle rear sill, the maximum capacity is 3300 lbs.
As the load is centered farther out on the platform, the
maximum capacity is reduced, as shown.
1800 lbs.
1450 lbs.
1250 lbs.
78"
IMPORTANT! Never over load platform.
66"
54"
42"
30"
CENTER OF GRAVITY
GR00490
BZ-44 Only
4400 lbs.
3100 lbs.
2400 lbs.
1950 lbs.
1650 lbs.
78"
66"
54"
42"
30"
CENTER OF GRAVITY
GR00491
Page 3-5
BZ-55 Only
5500 lbs.
3850 lbs.
3000 lbs.
2450 lbs.
2050 lbs.
78"
66"
54"
42"
30"
CENTER OF GRAVITY
GR00492
LOADING OF PLATFORM
Before loading, tilt platform slightly upwards to
compensate for load.
Always load as close to the center of the platform and as
close to the vehicle as possible.
CARGO
POSIOTIONED TOO
CLOSE TO REAR
SILL
AS PLATFORM IS
LOWERED CARGO
HITS REAR SILL
This liftgate is intended for loading and unloading of
cargo only, do not use it for anything but it’s intended
use.
Never transfer loads which exceed rated capacity on or
over platform unless liftgate is equipped with reinforced
platform and platform support bars.
IMPORTANT! When platform is tilted up to compensate
for an incline, make certain cargo does not contact rear
sill of vehicle as liftgate is lowered.
HILL
HILL
PLATFORM TILTED
UP FOR INCLINE
GR00709
WARNING LIGHTS
Warning lights will automatically activate when platform
is tilted down for five (5) seconds and automatically shut
down when platform is tilted up five (5) seconds.
Warning lights will automatically shut down after 20
minutes after activation.
If re-activation of warning lights is needed, tilt the
platform up for five (5) seconds and then tilt down back
to working position.
GR00879
Page 3-6
DRIVE OVER OPTION
If properly equipped, platform may be used as a loading
ramp.
IMPORTANT!
Maximum capacity as a loading ramp includes combined
weight of cargo and cargo carrier.
GR00700
Only use platform as a loading ramp if liftgate is properly
equipped with these support bars and used as directed
on Drive Over Operation Decal.
IMPORTANT! Maximum capacity:
5,500 lbs. for aluminum and non-reinforced steel
platforms.
Support Bars fully
extended
10,000 lbs. for reinforced steel platforms.
GR00493
Locate Drive Over Operation Decal attached to vehicle
for information on maximum drive over capacity.
Decal 80101499 will show max. capacity of 5,500 lbs.
Decal 80101330 will show max. capacity of 10,000 lbs.
Drive Over Operation
Decal 80101499 or
80101330 would be
attached in this area.
GR02227
Page 3-7
Make certain vehicle is properly and securely braked.
Before opening platform, pull both support bars fully out
(4-1/2”).
Tilt platform down to loading dock.
Loading dock must always support end of platform.
Platform must overlap loading dock at least 24”.
Always use the center portion of the platform.
Cargo is to be positioned on cargo carrier so as to be
stable when rolling over inclined platform.
GR00698
Never roll a load onto the platform if:
The loading dock does not support the platform.
Both support bars are not pulled out.
IMPORTANT! It may be necessary to readjust tilt of
platform as vehicle is unloaded. The vehicle suspension
may cause the floor level to raise as load is removed.
GR00699
Page 3-8
Chapter 4 Inspection
The following inspection and maintenance operations should be performed monthly, or at anytime the unit shows
signs of abuse, and/or improper or abnormal operation. Adherence to this guide will help insure the maximum in
operator safety and satisfaction with your Waltco liftgate through preventive maintenance.
CAUTION: Never get under the platform or in the area in which the platform will open, unless the platform is first
secured.
Operate the liftgate throughout it’s entire operational
cycles and check for the following:
Apparent damage to the lifting structure, such as
bent or distorted members.
Cracked welds, which may have resulted from
overloading or abuse.
Check that the liftgate operates freely and smoothly,
and that there are no unusual noises or vibrations.
GR00407
Inspect for oil leaks in:
Hydraulic cylinders
Hydraulic hoses. Replace hoses if they show signs
of excessive abrasion.
Inspect all hydraulic components
Hydraulic fittings and valves.
Tighten or replace all hydraulic components as may be
required to stop oil leakage.
CHECK OIL LEVEL
Lower platform to the ground and tilt down to the
ground.
BREATHER PLUG
Open breather plug.
Oil should be ½” from top of reservoir.
Fill as may be required.
Obey oil recommendations.
GR00830
Page 4-1
BLEEDING CYLINDERS
Lift cylinders:
Fully lower platform a few times. You may have to
jack up vehicle to fully extend lift cylinders.
Tilt cylinders:
Fully lower the platform a few times.
GR00407
Recommended Fluids
Temperature Range
Acceptable Fluids
Mobil DTE 13M
-10 to 195 F
Shell Tellus 32T
Mobil DTE 11M
-25 to 140 F
Shell Tellus 15T
Mobil Aero HFA
-40 to 145 F
Exxon Univis HVI 13
Exxon Univis HVI 26
-45 to 200 F
A good quality SAE 10W motor oil may also be used in
temperatures above 32 F.
Page 4-2
Fill reservoir
Fill with recommended fluid or equivalent.
Fill the reservoir to within 1/2” from the top.
IMPORTANT:
Do not use the following fluids:
Brake Fluid
Power steering fluid
Automatic Transmission Fluid (ATF)
S
LIFT UP
LOWER DOWN
TILT UP
TILT DOWN
V1
V2
X
X
X
X
X
X
V3
V4
V5
X
X
X
X
X
X
V3
V2
V4 & V5
V1
S
V4 LOCATED AT CURB
SIDE LIFT CYLINDER
V5 LOCATED AT DRIVER
SIDE TILT CYLINDER
GR00831 & GR00832
Page 4-3
TROUBLE SHOOTING THERMALPAK AND
VOLTAGE GUARD
OVERHEATING
RED
®
This liftgate is equipped with Waltco’s Thermalpak with
TM
Voltage Guard .
This feature protects the liftgate motor and solenoid from
damage due to overheating and low voltage.
TILT
RAISE / SLIDE OUT
Systems warning lights are located in controls.
Red light indicates overheating
Yellow light indicates low voltage
LOWER / SLIDE IN
+
!
-
TILT
LOW VOLTAGE
YELLOW
GR01759
OVERHEATING
®
When the Thermalpak with Voltage Guard
occurs:
TM
controller detects a liftgate motor overheating condition, the following
The red LED on the controller lights.
The liftgate motor is temporarily disabled.
An alarm will sound intermittently each time the Raise function of the liftgate is activated.
Solution:
Allow motor to cool until red LED on controller turns off and that the alarm no longer sounds when activating the
Raise function of the liftgate.
Hold Raise Switch for five (5) seconds to reset controller. Liftgate motor will then activate and normal operation
will be restored.
During the shut down period the liftgate may still be lowered.
Troubleshooting (Why did liftgate motor overheat?):
Some conditions that may have caused the motor to overheat are:
Overuse: Liftgate is being operated too many times within a short period of time.
Battery cables are not securely connected or cable ends are corroded.
Bad or insufficient ground.
Insufficiently charged or bad batteries.
Page 4-4
LOW VOLTAGE
®
TM
When the Thermalpak with Voltage Guard controller senses long term battery voltage falling to a level that would
prevent the vehicle from starting or when it senses a short term severe drop in voltage that would cause solenoid
“door belling” (rapid chattering of solenoid), the following occurs:
The yellow LED on the controller lights.
The liftgate motor is temporarily disabled.
A steady alarm will sound each time the Raise function of the liftgate is activated.
Solution:
Run vehicle motor to charge batteries.
®
TM
If the Thermalpak with Voltage Guard does not automatically reset, turn off the vehicle. Disconnect the (+)
positive battery cable from the battery(s) operating the lift gate for approx. (1) minute. Reconnect the battery
cable.
During the shut down period the liftgate may still be lowered.
Troubleshooting (Why did liftgate motor stop working?):
Some conditions that may have caused a low voltage condition are:
Overuse: Liftgate is being operated too many times with the vehicle engine not running.
Battery cables are not securely connected or cable ends are corroded.
Bad or insufficient ground.
Insufficiently charged or bad batteries.
If liftgate is mounted on a trailer, the tractor/trailer plug supplying charging power to the liftgate batteries is
unplugged.
Page 4-5
Chapter 5 Placement of Decals
INSTALLATION OF CONTROL DECALS
Install all decals listed below. Be certain they are
installed in the proper location and are legible.
NOTE! All decals must be in place and legible or all
warranties are void!
Each of the following four (4) decals are to be positioned
in a conspicuous place near the control switches as
shown.
80100850 – Safety Instruction Decal
80101436 – Operation Decal
80100828 – Important Decal
80101370 – Hazard decal
One (1) of the following three (3) decals is to be
positioned in a conspicuous place near the control
switches as shown.
PLACE DECALS IN THIS AREA
80101415 – BZ-33 Capacity Decal
Note: A second set of the previous five (5) decals must
be installed if unit is equipped with dual controls
GR00511 & GR01484
INSTALLATION OF DRIVE-OVER WARNING DECAL
The following decal is to be positioned in a conspicuous
place near the control switches as shown.
80100592 – Drive Over Decal
Note: If unit is equipped with drive over kit decal
80101330 should be used in place of decal 80100592.
GR00511
Page 5-1
INSTALLATION OF PLATFORM DECALS
The following decals are to be placed on the underside
of the platform as shown.
75089296 – Stand Clear Decal (2)
One (1) of the following three (3) decals is to be
positioned in a conspicuous place on the bottom of the
platform as shown
STAND CLEAR
DECALS HERE
CAPACITY DECAL HERE
GR00511
INSTALLATION OF SAFETY TAPE
IMPORTANT! Safety
tape must wrap
around side of
platform as shown.
Tape is to be placed on the sides of platform so it is
visible from the side and back of vehicle as shown.
IMPORTANT! Safety tape must wrap around side of
platform as shown.
GR00511
Page 5-2
SAFETY TAPE AND FLAGS
Tape is to be placed on the sides of platform so it is
visible from the side.
Tape
Locate corner flag mount brackets, one on each side of
platform and drill (3) holes per bracket into platform as
shown. Use bracket as a template.
9”
9”
9”
Flag
Using slotted head screws provided (three per bracket),
install flag mount brackets as shown.
Slide flags into mount brackets and crimp ends of each
bracket to prevent flags from sliding out.
Flag mount
bracket
GR00043 & GR01761
SHUT-OFF DECAL
The following decal is to be placed next to the liftgate
shut-off switch as shown.
75089267 – Liftgate Shut-Off Decal
PLACE
DECAL AS
SHOWN
GR00121
CIRCUIT BREAKER DECAL
PLACE DECAL
IN THIS AREA
The following decal is to be placed next to the liftgate
circuit breaker as shown.
80100829 – Circuit Breaker Decal
GR00122
Page 5-3
Chapter 6 Lubrication
LUBRICATION INSTRUCTIONS
12 grease fittings should be lubricated with a grease gun per the lubrication schedule below.
Note: All fittings should be greased with the platform in the stored position.
SUGGESTED MINIMUM LUBRICATION SCHEDULE (IN DAYS)
Monthly Cycles
Light Duty
Med. Duty
Heavy Duty
250 Or Less
45
30
21
250-350
30
21
14
350-450
21
14
7
More Than 450
Contact Factory for Instructions
Note: If unsure of duty or cycles always lubricate more frequently.
1. Tilt cylinder, lower pin
2. Lift cylinder, lower pin
3. Lift arm, lower pin
4. Tilt cylinder, upper pin
5. Lift cylinder, upper pin
6. Lift arm, upper pin
4
6
3
5
1
2
GR00508
Page 6-1
Chapter 7 PMs & Schematics
Part Manual and Schematics Table of Contents
Wiring diagram ...................................................................................................................... 7-2 & 7-3
Wiring schematic ................................................................................................................... 7-4
Hydraulic schematic ............................................................................................................... 7-4
Warning lights wiring diagram................................................................................................ 7-5
Platform assembly ................................................................................................................. PM – 646A
Liftgate assembly ................................................................................................................... PM – 647A
Hose set ................................................................................................................................. PM – 648B
Electric Safety Lock Valves.................................................................................................... PM – 675
Hydraulic pump unit ............................................................................................................... PM – 649A
Control units ........................................................................................................................... PM – 650A
Tilt cylinder ............................................................................................................................. PM – 663
Lift cylinder ............................................................................................................................. PM – 664
Page 7-1
RED
RED
BLACK
MOTOR
BLACK
BLACK
PUMP UNIT
BROWN
RED 2GA BATTERY
CABLE
BLACK 2GA
BATTERY CABLE
V3
V2
V1
HEAT
SENSOR
BLACK
WHITE
BLACK 1
WHITE 1
BLACK 2
WHITE 2
BLACK
WHITE
BLUE
YELLOW
GREEN
BROWN
GREY
A
B
C
D
A
B
C
D
BLACK J
WHITE 1
BLACK K
WHITE 2
BLACK
WARNING LIGHTS
GREEN
YELLOW
BLUE
YELLOW
BLACK
BLACK
+
BLACK
-
10A FUSE
CAB
SHUT-OFF
SWITCH
WHITE
BLACK
WHITE
YELLOW
WHITE
V5
A
B
TILT
CYLINDER
LOCK
VALVE
BLACK
WHITE
LIFT
CYLINDER
LOCK
VALVE
WIRING DIAGRAM
BZ-33/44/55
07/06
BLUE
WHITE
A
B
V4
WHITE
A
B
BLACK
WHITE
WHITE
A
B
BLACK
SOLENOID
GND
BROWN
BLACK
BLACK
Page 7-2
BLACK
BLACK
HAND HELD REMOTE
(Raise/ Lower/ Tilt Functions)
A
B
A
B
BLACK
WHITE
CONTROLS
GR01760
GROUND POST
PUMP UNIT
CONTROLS
PRESSURE
SWITCH
Page 7-3
2- POLE CONNECTOR
CONTROLS
TILT CYLINDER
LOCK VALVE
CAB
SHUT-OFF
SWITCH
WARNING
LIGHTS
LIFT CYLINDER
LOCK
VALVE
B
A
WHITE
BLACK
PUMP UNIT
GREY WIRE
NOT USED
GROUND POST
E
B
WHITE
BLACK
F
WHITE
MAIN POWER CONNECTIONS
CAB
SHUT-OFF
SWITCH
BLACK
8- POLE CONNECTOR
GROUND POST
POWER MAIN
POWER CONNECTOR
PUMP
UNIT
WHITE
WHITE
WHITE
WHITE
WHITE
TO 8- POLE
CONNECTOR
-B-
B
A
F
GREEN
C
BROWN
BLUE
YELLOW
D
K
J
BLACK
BLACK
BLUE
E
YELLOW
10- POLE CONNECTOR
TILT CYLINDER
LOCK VALVE
LIFT CYLINDER
LOCK
VALVE
GROUND WIRE CONNECTIONS
TILT CYLINDER
LOCK VALVE
CAB
SHUT-OFF
SWITCH
WARNING
LIGHTS
GROUND POST
WARNING
LIGHTS
LIFT CYLINDER
LOCK
VALVE
GR01610
TILT CYLINDER LOCK
S5
BZ-33/44/55
WIRING SCHEMATIC
10 A
SOLENOID VALVE
V5
12 VDC
BATTERY
REVISED 12/05
FUSE
CAB SHUT-OFF
SWITCH
CONTROLS
STARTER
SOLENOID
GND
M
GND
CONTROL UNIT
S1
S2
S3
GND
HEAT
SENSOR
SHIFTING
SOLENOID VALVE
V1
LIFT CYLINDER
SOLENOID VALVE
V2
TILT CYLINDER
SOLENOID VALVE
V3
GND
WARNING LIGHTS
S4 LIFT CYLINDER LOCK
SOLENOID VALVE
V4
GND
GR01608
V4
V1
V2
V3
V5
GR01609
Page 7-4
GR01147
Page 7-5
ITEM
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
8
9
10
11
PART NUMBER
16610030
16610031
16610032
16610033
16610034
16610035
16610036
16610037
16610040
16610041
16610042
16610043
16610044
16610045
16610046
16610047
75086225
14612301
75085178
75086281
16612220
75089347
75083044
14612351
16612230
75089911
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
4
5
1
1
1
1
1
1
12
16650000
75089960
1
2
13
75089961
3
75090087
3
TRUCK EQUIPMENT CO.
BZ-33/44/55
DESCRIPTION
Platform, 48 x 94”, with lights
Platform, 48 x 94”, with lights and C/S
Hex bolt
Wear pad, driver side
Lock nut
Screw
Cover plate
Grommet
Hose clamp
Wear pad, curb side
Wiring harness to platform
Steel rail for rubber sill 75089912
(optional)
Sill extension, steel (7-angle)
Rubber seal strip (specify length)
(optional)
Steel rail for 75089960 (59” long)
(optional)
Steel rail for 75089960 (98” long)
(optional)
ITEM
14
15
16
17
19
19
20
21
22
23
24
25
25
26
27
28
29
30
31
32
A
PART NUMBER
75089936
10111700
10193000
Z20273
75089905
14641501
14641551
14241201
14241601
14641001
75086857
75085005
14640051
14640001
75086871
A
16612100
16612250
A
75086847
A
75089423
75089912
75089937
QTY
3
2
2
2
2
1
1
2
12
2
8
8
1
1
4
2
2
8
4
1
3
DESCRIPTION
Aluminum double rail for 75089960 and
75089937 (optional)
Chain clip (optional)
Latch chain (optional)
Corner flag mounting bracket
Corner flag
Stop assembly, curb side
Stop assembly, street side
Cart stop pivot pin (1 per cart stop)
Cart stop spring (6 per cart stop)
Cart stop base assy (1 per cart stop)
Button head socket
Hex nut
Cart stop, driver side
Cart stop, curb side
Screw
Warning light mount
Wiring harness to lights
Screw
Warning light, red
Rubber sill (optional)
Rubber air foil (specify length / optional)
Included in Warning light with mount 16591100
REVISED:
E.O.
REV.
5-9-06
5720A
01
PM-646A
PLATFORM
20
21 22
19
23
30
29
28
30
24
17 16
32
29
25
12
1
28
13
26
32
2
15
3
4
14
5
6
PLATFORM PART NUMBERS
SHOWN IN TABLE ABOVE,
USE THIS PIVOT PIN STYLE
13
7
12
GR01707
8
5
TRUCK EQUIPMENT CO.
BZ-33/44/55
27
9
11 31
10
REVISED:
E.O.
REV.
5-9-06
5720A
01
PM-646A
ITEM
1
2
2
2
2
3
3
3
3
4
4
4
4
11
12
13
14
15
PART NUMBER
Z53577
Z53629
Z53624
Z53621
Z53669
Z52031
Z51581
Z52032
Z51582
Z52023
Z52021
Z52024
Z52022
Z21597
Z21664
Z32673
Z51509
AB
Z32785
QTY
1
1
1
1
1
2
2
2
2
2
2
2
2
12
12
2
2
6
DESCRIPTION
Support frame
Lift arm, L=29-1/2”, BZ-33/44
Lift arm, L= 29-1/2”, BZ-55
Lift arm, L= 34-1/4”, BZ-33/44
Lift arm, L= 34-1/4”, BZ-55
Lift cylinder, for 29-1/2” lift arm, BZ-33/44
Lift cylinder, for 29-1/2” lift arm, BZ-55
Lift cylinder, for 34-1/4” lift arm, BZ-33/44
Lift cylinder, for 34-1/4” lift arm, BZ-55
Tilt cylinder, for 29-1/2” lift arm, BZ-33/44
Tilt cylinder, for 29-1/2” lift arm, BZ-55
Tilt cylinder, for 34-1/4” lift arm, BZ-33/44
Tilt cylinder, for 34-1/4” lift arm, BZ-55
Screw M12x100
Nut, M12
Mounting bracket
Bracket
Pivot bolt Ø1-3/16”, L=6-15/16”, BZ33/44/55
A
16
Z32782
2
Pivot bolt Ø1-3/16” / 1-3/8”, L=4-3/16”,
BZ-33/44/55
A
17
Z32783
2
Pivot bolt Ø1-3/16”, L=4-9/16”, BZ-33/44
A
17
Z32784
2
Pivot bolt Ø1-3/16”, L=4-3/4”, BZ-55
18
Z32037
1
Lock
19
Z32176
4
Bushing, complete
20
16661000
1
Bumper, middle
21
16662000
2
Bumper, side
22
Z21429
4
Washer
23
Z20171
4
Lock nut, M22
24
Z53696
2
Support wheel assembly complete
24.1
Z21674
4
Washer
24.2
Z50755
2
Support wheel
24.3
Z51564
2
Spacing sleeve
A
M24 Locknut included with pivot bolt.
B
Pivot bolt included in Support wheel assembly Z53696.
WALTCO
TRUCK EQUIPMENT CO.
BZ- 33/44/55
REVISED:
E.O.
REV.
6-4-08
6067
02
PM-647A
LIFTGATE ASSEMBLY
SUPPORT FRAME AND LIFT
ARM PART NUMBERS SHOWN
IN TABLE ABOVE, USE THIS
PIVOT PIN STYLE.
GRO1707
WALTCO
TRUCK EQUIPMENT CO.
BZ- 33/44/55
REVISED:
E.O.
REV.
6-4-08
6067
02
PM-647A
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
18
19
20
21
22
PART NUMBER
Z32563
Z52083
Z21025
Z20515
Z52012
Z31174
Z22158
Z52043
Z52040
Z20942
Z20356
Z21672
Z22179
Z22061
Z54128
Z22224
Z54129*
Z54127
Z54131*
Z20105
Z22322
QTY
1
2
2
4
1
9
2
1
1
4
3
3
2
4
1
2
1
1
1
1
1
DESCRIPTION
Aluminum Rail L= 65-3/8”
Clamp
Nut
Plug
Swivel joint
Swivel joint, complete
O-Ring
Sealing
Connection block
Washer
Adapter (for ¼” hyd. hose)
Hydraulic hose 1/4" L=42-1/8”
Valve housing, complete
EL. Safety Valve (Lift)
Valve housing, complete
EL. Safety Valve (Tilt)
Adapter (for 3/8” hyd. hose)
Hydraulic hose 3/8” L=42-1/8”
* See PM-675 for break-down of EL. Safety Valve
WALTCO
TRUCK EQUIPMENT CO.
BZ-33/44/55
REVISED:
E.O.
REV.
6-4-08
6066
02
PM-648B
HOSES
L1
SJ1
P1
L3
P2
T3
T1
CURB
SIDE
DRIVER'S
SIDE
L2
T2
L4
SJ2
T4
3
(HOLE LOCATIONS ARE NOT MARKED ON ITEM #1,
THEY ARE ONLY TO ASSIST IN FINDING LOCATION)
1
SJ1
2
T3
P1 & P2
T4
L3
L4
5
4
10
SJ2
L1
21
L2
13
6
11
7
14
20
9
8
19
22
6
14
12
T2
17
T1
17
18
13
14
15
14
INCLUDED IN
ITEM 15
WALTCO
TRUCK EQUIPMENT CO.
BZ-33/44/55
REVISED:
E.O.
REV.
6-4-08
6066
02
PM-648B
ITEM
1
2
3
4
5
5.1
6
7
8
9
PART NUMBER
Z54129
Z54131
Z66652
Z31845
Z22199
Z31521
Z21663
Z31174
Z54114
Z66752
QTY
1
1
1
1
1
1
1
1
1
1
WALTCO
TRUCK EQUIPMENT CO.
DESCRIPTION
EL. SAFETY VALVE 12V (LIFT) COMP.
EL. SAFETY VALVE 12V (TILT) COMP.
CABLE SET L= 138” LG.
SWIVEL VALVE COMP.
VALVE EXCLUDING MAGNET
O-RING SET
MAGNET 12V
SWIVEL VALVE COMP.
VALVE HOUSING
VALVE HOUSING
REVISED:
E.O.
REV.
2-28-05
5515
01
PM-675
ELECTRIC SAFETY LOCK VALVES
LIFT CYLINDER
WALTCO
TRUCK EQUIPMENT CO.
TILT CYLINDER
REVISED:
E.O.
REV.
2-28-05
5515
01
PM-675
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
A
PART NUMBER
A
16628000
16621000
75086857
10195612
75086853
70093640
75085000
16621400
16626000
75086853
16690020
Z55220
Z55219
QTY
1
1
2
1
2
1
2
1
1
1
1
1
1
16625110
Z55178
Z55179
Z32626
Z32625
75080072
Z22360
Z21773
1
1
1
1
1
1
2
2
DESCRIPTION
Complete Pump Unit
Pump unit shelf
Button head socket
Battery cable
Screw
Solenoid, 4-Pole
Hex nut
Sealing
Temperature sensor
Hex bolt
Kit, Hydrualic Pump Unit
Main power cable, 2GA, red
Main power cable, 2GA, black, (with blue
connector)
Wiring cable (7-wire) for pump unit
Main power cable, 2GA, red
Main power cable, 2GA, blue
Connector complete, Red
Connector complete, Blue
Grommet Body and Lock Nut
Grommet Body
Lock Nut for Grommet Body
Includes items 1 through 10
WALTCO
TRUCK EQUIPMENT CO.
BZ- 33/44/55
REVISED:
E.O.
REV.
6-4-08
6067
02
PM-649A
HYDRAULIC PUMP UNIT
5
6
7
4
1
13
12
3
8
2
(BLACK CABLE WITH
BLUE CONNECTOR)
9
(BLUE)
18
15
(BLUE)
17
INCLUDED
WITH ITEM 15
14
10
(RED)
(RED)
16
INCLUDED
WITH ITEM 14
WALTCO
TRUCK EQUIPMENT CO.
BZ- 33/44/55
11
(RED)
19
(GROMMET BODY)
20
(LOCK NUT)
REVISED:
E.O.
REV.
6-4-08
6067
02
PM-649A
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
PART NUMBER
16692000
Z52104
Z52105
Z66652
Z66652
16612240
Z54126
16625220
15525220
16625210
15592402
16695250
C
16695215
75089807
80000582
A/B
16695401
A
15592401
B
16695140
A/B
75080063
A/B
75086601
A/B
75088050
A/B
75085160
A/B
75086703
A/B
75085001
16695500
C
16695560
C
75082881
C
75089313
C
75087550
C
75086854
16695300
16695310
15592900
Z21570
QTY
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
8
8
8
6
6
1
1
1
1
2
2
1
1
1
4
WALTCO
TRUCK EQUIPMENT CO.
BZ- 33/44/55
WZ-44/55Z
DESCRIPTION
Control unit
Control unit box
Control unit cover
Lock valve cable, sliders
Lock valve cable
Warning light cable
Cable, from control box to pump unit
Cabin switch cable (BZ = 29’-7” lg.)
Cabin switch cable (WZ = 37’-11” lg.)
Controls cable (BZ = 7’-1” lg.)
Controls cable (WZ = 17’-6” lg.)
Dual control cable, 120”
Hand held remote, Raise / Lower / Tilt
Toggle Switch
Key-Switch service kit
Control Box, Recessed
Sidewall Controls (WZ)
Sidewall Controls (BZ)
Strain Relief
Screw, #8-32x .75
3/16 Flat Washer
Nylon Lock Nut, #8-32
Screw, ¼-20 x .5
Hex Nut, Serrated, ¼-20
Mtg. Bracket for mounting Recessed
Control Box as Rub-Rail Outside Controls
Hanging Bracket for Hand Held Remote
Hose Clamp, Insulated
Rubber Grommet
Wood Screw, #10 x .75 Lg.
Screw, ¼-20 x .625 Lg. Self-tapping
Raise / Lower switch without connector
Tilt switch without connector (BZ)
Tilt / Slide switch without connector (WZ)
Screw
ITEM
31
32
A
B
C
PART NUMBER
Z53108
Z53107
QTY
2
2
DESCRIPTION
Plastic nut, L=3/4”
Plastic nut, L=1-3/16”
Included in Recessed Control Box “WZ” (complete) 15592400
Included in Recessed Control Box “BZ” (complete) 16695400
Included in Kit 80001098 (Hand Held Remote – raise / lower / tilt)
REVISED:
E.O.
REV.
6-4-08
6067
06
PM-650A
CONTROL UNITS
WALTCO
TRUCK EQUIPMENT CO.
BZ- 33/44/55
WZ-44/55Z
REVISED:
E.O.
REV.
6-4-08
6067
06
PM-650A
ITEM
1
1
2
2
3
4
4
5
5
5
5
6
7
8
9
-
PART NUMBER
Z52023
Z52021
Z52024
Z52022
Z32580
Z32576
Z32591
Z32596
Z32598
Z32593
Z32597
Z32577
Z32578
Z32577
Z32578
Z32724
14281601
Z32595
Z32601
Z32623
Z32624
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
WALTCO
TRUCK EQUIPMENT CO.
BZ- 33/44/55
DESCRIPTION
Tilt cylinder, 29-1/2” lift arm, BZ-33/44
Tilt cylinder, 29-1/2” lift arm, BZ-55
Tilt cylinder, 34-1/4” lift arm, BZ-33/44
Tilt cylinder, 34-1/4” lift arm, BZ-55
Cylinder case for Z52023 and Z52024
Piston for Z52023 and Z52024
Piston rod
Ram nut for Z52023 and Z52024
Pressure rod for Z52023
Bearing kit
Bearing
Limit stop
Lock nut
Gasket set for Z52023 and Z52024
REVISED:
E.O.
REV.
6-5-08
6067
04
PM-663
TILT CYLINDER
WALTCO
TRUCK EQUIPMENT CO.
BZ- 33/44/55
REVISED:
E.O.
REV.
6-5-08
6067
04
PM-663
ITEM
1
1
2
2
3
3
4
4
5
5
5
5
6
-
PART NUMBER
Z52031
Z52032
Z51581
Z51582
Z32585
Z32572
Z32511
Z32590
Z32600
Z32594
Z32509
Z32592
Z32586
Z32587
Z32573
Z32574
Z32724
Z32493
Z32622
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
TRUCK EQUIPMENT CO.
BZ-33/44/55
DESCRIPTION
Lift cylinder, 29-1/2” lift arm, BZ-33/44
Lift cylinder, 34-1/4” lift arm, BZ-33/44
Lift cylinder, 29-1/2” lift arm, BZ-55
Lift cylinder, 34-1/4” lift arm, BZ-55
Piston rod for Z52031 and Z52032
Piston rod for Z51581 and Z51582
Bearing kit
REVISED:
E.O.
REV.
11-30-05
5656
02
PM-664
LIFT CYLINDER
TRUCK EQUIPMENT CO.
BZ-33/44/55
REVISED:
E.O.
REV.
11-30-05
5656
02
PM-664
Chapter 8 – How To Order Parts
Repairs should be made only by authorized mechanics using WALTCO
Replacement parts.
When ordering repair or replacement parts, please include all the
information asked for below. If this information is not available, a complete
written description or sketch of the required part will help WALTCO identify
and deliver the needed part to you.
________________________________________________________________
THE FOLLOWING INFORMATION MUST BE INCLUDED:
1. SERIAL NUMBER - [WALTCO liftgate serial numbers can be found on the
Specification Tag attached to the mount frame. (On older units the
Specification Tag is located on the side or bottom of the platform.)]
2. MODEL NUMBER - [Or capacity]
3. PLATFORM SIZE
________________________________________________________________
THEN INCLUDE THE FOLLOWING INFORMATION:
4. PART NUMBERS
5. DESCRIPTION
6. QUANTITY REQUIRED
________________________________________________________________
MAIL, E-MAIL OR PHONE YOUR REQUEST TO:
Waltco Truck Equipment Co.
285 Northeast Avenue
Tallmadge, OH 44278
1-800-411-5685
FAX: 1-800-411-5684
E-MAIL: [email protected]
ALL PARTS ARE F.O.B. FROM THE SHIPPING FACTORY
________________________________________________________________
PLEASE NOTE:
To assure you of continuing and effective quality control, our warranty
policy permits replacement of hydraulic cylinders, valves and motor pump
units when their factory seals are intact. Parts under warranty will be
exchanged promptly after careful inspection of the returned assemblies.
________________________________________________
80101389
Page 8-1
EO 5534A
Rev 02
IMPORTANT
TO BE KEPT IN VEHICLE
__________________________________________________________
CAUTION:
STAND CLEAR AND KEEP CLEAR OF PLATFORM
AREA WHILE OPERATING LIFTGATE.
__________________________________________________________
FOR OPERATION OF THIS UNIT, REFER TO THE “OPERATION INSTRUCTIONS” INSIDE THE
OWNER’S MANUAL AND THE OPERATION INSTRUCTIONS DECAL.
LUBRICATION INSTRUCTIONS
Refer to the lubrication chart in this manual.
DO’S AND DON’TS
DO:
DO:
DO:
DO:
DO:
DO:
DO:
DO:
DO:
DO:
DO:
DO:
DON’T:
DON’T:
DON’T:
DON’T:
DON’T:
Make certain area in which the platform will open and close is clear before opening or
closing platform.
Make certain platform is properly latched when in transit.
Make certain platform area, including the area in which loads may fall from platform, is
clear before and at all times during operation of the liftgate.
Operate the liftgate with the control switches only.
Check oil level monthly and change oil yearly.
Use hydraulic fluids listed on the HYDRAULIC FLUID CHART (found inside this manual)
or equivalent.
Lubricate as per the LUBRICATION INSTRUCTIONS AND LUBRICATION SCHEDULE
found in this book.
Read and follow WARNING DECALS, OPERATION DECALS and OWNER’S MANUAL.
Visually inspect the liftgate frequently and keep it in adjustment.
Be certain vehicle is properly and securely braked before using the liftgate.
Repair the liftgate when it is found to be faulty to prevent accidents.
Keep all decals in place and legible and retain the Owner’s Manual in the vehicle or ALL
WARRANTIES ARE VOID.
Allow the liftgate to be used by persons not familiar with its operation.
Use the liftgate if unit shows signs of abuse or fails to operate freely.
Permit the motor to run after the liftgate is raised to bed level.
Overload the liftgate (Refer to Manual for proper capacity of liftgate).
Use brake fluid.
80101390 Rev 01

C-15RM, C-20RM

Transcription

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