/wdlxt_series_om by William Kean

WDL XT Generation III Visit us at www.waltco.com

Owner’s Manual 3500 – 6600 lb. Capacity Rail Lift

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 See page 1-3 for Warranty Information See chapter 4 for Preventive Maintenance See Chapter 6 for Lubrication Instructions

1-09 GR02413

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

1395 N. Cobb Parkway Marietta, GA 30062 (770) 425-0922 FAX – (770) 425-5886

EO 5885GG Rev.05 Effective from 1/09

80131902

Table of Contents Chapter

INTRODUCTION SAFETY INFORMATION ........................................................................................... 1-1 WARRANTY INFORMATION ..................................................................................... 1-3 LIFTGATE TERMINOLOGY .......................................................................................... 2 OPERATION ................................................................................................................. 3 PREVENTIVE MAINTENANCE ..................................................................................... 4 PLACEMENT OF DECALS ........................................................................................... 5 LUBRICATION INSTRUCTIONS .................................................................................. 6 SCHEMATICS AND PARTS MANUALS ...................................................................... 7 HOW TO ORDER PARTS ............................................................................................. 8

EO 5885GG Rev.05 Effective from 1/09

80131902

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. REPLACEMENT 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 EO 5422

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 EO 5422

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 EO 5422

WALTCO Warranty Policy WALTCO warrants its products free of defects in materials and workmanship. WALTCO will replace components found defective during the warranty period. Labor will be reimbursed according to our flat rate labor schedule at the prevailing shop rate. Contact our Sales or Warranty departments for the warranty period of your model or for information regarding our flat rate labor schedule.

WALTCO Warranty Claim Procedure For consideration, all claims must be received within 30 days of repair and include the following information: • Liftgate Serial Number • Description of problem and corrective actions • Itemization of the labor charge to include the number of hours and labor rate Replacement warranty parts can be obtained by contacting Waltco’s Parts Department. Parts must be returned for inspection when requested. Exclusions: Waltco’s warranty does not include reimbursement for service calls, vehicle rental, towing, travel time, fabrication of parts available from WALTCO, damage from misuse or abuse, negligence, accidents, alteration, loss of income or overtime expense, oil, or normal wear. Diagnosis and troubleshooting time are included in the flat rate labor times. Warranty and technical information is available from WALTCO’s toll free customer service lines from 8:00 a.m. to 5:00 p.m. EST.

Waltco Truck Equipment Co. 285 Northeast Ave, Box 354, Tallmadge, OH 44278 1-800-211-3074, 330-633-9191 Please visit our websites: http://www.waltco.com or http://www.hiab.com

We're behind you all the way!

Page 1-3

Chapter 2 Liftgate Terminology 1. Street Side Upright 2. Curb Side Upright 3. Lights 4. Upright Covers 5. Sill Extension 6. Toe Guard Plate 7. Support Chain 8. Chain Linkage Bar 9. Lock Valve Override Slide Bar 10. Bottom Stop Pin 11. Linkage Anchor

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Pivot Tube Main Deck Deck Extension Folding Ramp Street Side Runner Curb Side Runner Platform Fold Stop Block Platform Fold Stop Roller Cartridge Pins Control Switches

22. 23. 24. 25. 26. 27. 28. 29. 30.

Closing Cylinder Closing Cylinder Air Assist Valve Bottom Stop Catch Ramp retention Cable Pin OK to Fold/Unfold Indicators Street Side Lift Cylinder Curb Side Lift Cylinder

GR02507

Page 2-1

Chapter 2 Liftgate Terminology 31. 32. 33. 34. 35.

Adjustable Roller Cartridge Assy Fixed Roller Cartridge Assy Inside Column Control Switches Specification Tag Adjustment Bolt and Locknut for Adjustable Roller Cartridge 36. Upper Line Clamp

37. 38. 39. 40. 41. 42.

Switch Wiring Harness Fixed Roller Cartridge Handle Magnetic Filter Lights Curb Side Upright

GR02508

Page 2-2

Chapter 2 Liftgate Terminology 43. 44. 45. 46. 47. 48. 49. 50. 51. 52.

Hydraulic Enclosure Battery Box (Optional) 150 Amp Circuit Breaker Return Line Hydraulic Reservoir Filler / Breather Cap Liftgate W iring Harness Motor Wiring Harness Pump or Hydraulic Unit Pump Starter Solenoid

53. 54. 55. 56. 57. 58. 59.

10 Amp Fuse Relays Liftgate Shut-off / Selector Switch Control Solenoid Valves Pump Motor Platform Open / Close Speed Control Orifices Auxiliary Control Switch for Dual Motor Pumps (Optional) 60. Batteries

GR02509

Page 2-3

Chapter 2 Liftgate Terminology EXPLANATION OF SPECIFICATION TAG MODEL NO.

MODEL NAME

DESCRIPTION

CAPACITY

319-1

WDL-35 XT

WDL-35 XT Series (96” Wide)

3500 lb.

319-1

WDL-45 XT

WDL-45 XT Series (96” Wide)

4500 lb.

319-1

WDL-55 XT

WDL-55 XT Series (96” Wide)

5500 lb.

319-1

WDL-66 XT

WDL-66 XT Series (96” Wide)

6600 lb.

319-2

WDL-35 XT

WDL-35 XT Series (102” Wide)

3500 lb.

319-2

WDL-45 XT

WDL-45 XT Series (102” Wide)

4500 lb.

319-2

WDL-55 XT

WDL-55 XT Series (102” Wide)

5500 lb.

319-2

WDL-66 XT

WDL-66 XT Series (102” Wide)

6600 lb.

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

Page 2-4

Chapter 3 Operation Instructions OPENING PLATFORM FOR LOADING Assure toggle switch located in Hydraulic Enclosure is in the “ON” position.

RAISE OPEN/CLOSE

Raise the platform until travel stops.

LOWER

Lower platform until arrow on runner is below arrow on upright, (or approximately 18”). Push and hold open/close button (center button). Press lower button simultaneously to open platform.

GR02035

RAISING AND LOWERING PLATFORM Press lower button to lower platform.

RAISE OPEN/CLOSE

Press raise button to raise platform.

LOWER

GR02036

CLOSING PLATFORM FOR TRANSIT

Assure platform is at least 18” below bed level. Push and hold open/close button (center button). Press raise button simultaneously to close platform.

RAISE OPEN/CLOSE

Raise folded platform up travel stops. Assure link arms are behind pins on upright.

LOWER

IMPORTANT: Always raise platform into the transit position before moving vehicle. GR02037

LOWERING PLATFORM FOR DOCK LOADING Raise platform until travel stops. Lower platform until bottom stop pins on platform engage with hooks on the insides of the uprights.

RAISE OPEN/CLOSE LOWER

GR02038

Page 3-1

Chapter 3 Operation Instructions Stop Bar

CART STOP OPTION OPERATION INSTRUCTIONS Push lever away from platform to release stop bar. Rotate stop bar to lock in vertical position. Lever Lock

Rotate brace to engage stop bar.

Lever

Stop Bar

Brace

GR01552

FOLDING RAMP OPTION OPERATION INSTRUCTIONS

Ramp Latch

Unlatch ramp and unfold to loading position. Use cables for cart stop application. Assure ramp is latched when in transit position.

GR01553

Page 3-2

Chapter 3 Operation Instructions DUAL PUMP OPERATION INSTRUCTIONS The liftgate may be equipped with an optional Dual Pump Unit. The purpose of the Auxiliary Pump unit is to provide a backup in the event of a malfunction of the Primary Pump or the switches on the column of the liftgate.

Toggle Switch

The Auxiliary Pump is NOT INTENDED FOR NORMAL OPERATION of the liftgate. Liftgate must be repaired as soon as possible after a malfunction of the Primary Pump unit occurs. The Auxiliary Pump unit is operated with the Hand Held Remote Control located in the Hydraulic Enclosure. TO OPERATE THE PRIMARY PUMP: Move toggle switch on the pump to the “Primary Position”. Operate liftgate with controls on columns as usual. TO OPERATE THE AUXILIARY PUMP: Move toggle switch on the pump to the “Auxiliary Position”. Operate liftgate with Hand Held Remote Control. GR02135

AUXILIARY HAND HELD REMOTE CONTROL: If Equipped with a Dual Pump option, the Auxiliary Pump Hand held remote operates in the same manner as the outside Main Control Switches.

Raise Button

Open / Close Button

Lower Button

GR02043

Page 3-3

Chapter 3 Operation Instructions HAND PUMP OPERATION INSTRUCTIONS: The liftgate may be equipped with an optional Hand Pump. The purpose of the Hand Pump unit is to provide a backup in the event of a malfunction of the batteries, pump unit or controls. The Hand Pump is NOT INTENDED FOR NORMAL OPERATION of the liftgate. Liftgate must be repaired as soon as possible after a malfunction occurs.

OPERATION OF HAND PUMP ON GRAVITY DOWN PUMPS Raise platform to within approximately 18” of bed level with Hand Pump. C

Make certain platform surface is clear of all objects. Close manual valve (C), by turning clockwise, then use Hand Pump to close platform all the way. Open manual valve (C), by turning counter-clockwise. Continue to operate Hand Pump until platform is in fully raised position.

GR01986

OPERATION OF MANUAL OVERRIDE VALVES TO LOWER AND UNFOLD PLATFORM Make certain that the area around the platform is clear before and during operation of liftgate. Use valve (B) to manually open lowering valve then locate Lock Valve Slide Bar and lower platform down to approximately 18” from stored position by operating Lock Valve Slide Bar per Manual Lowering Decal.

Use valve (A) to open platform. Then valve (B) again to lower platform to ground. Make certain Manual Override Valves (A & B) are closed, and Valve (C) is open when finished using Hand Pump.

GR01987

Page 3-4

Chapter 3 Operation Instructions OPERATION OF HAND PUMP ON POWER DOWN PUMPS The Hand Pump is NOT INTENDED FOR NORMAL OPERATION of the liftgate. Liftgate must be repaired as soon as possible after a malfunction occurs. Raise platform, using Hand Pump, to approximately 18” below bed level.

LOCK

Using Hand Pump, close/fold platform. To close platform: •

Push down on manual override valve and rotate clockwise to lock in over ride position.

•

Use hand pump to fully close platform.

MANUAL OVERRIDE VALVE

Using Hand Pump, raise closed platform to transit position. To again raise platform: •

Push down on manual override valve and rotate counter-clockwise to unlock valve.

•

Use hand pump to fully raise platform.

Make sure the Manual Override Valve is in the unlocked position when finished using hand pump. 80101475 DRWG

Page 3-5

Chapter 4 Preventive Maintenance Waltco recommends that the WDL XT liftgate be inspected at 6 month or 3000 cycle intervals to help assure proper function and operation of the liftgate. Note: Photocopy the following PM Checklist to help keep track of periodic maintenance on the liftgate. Keep completed form with maintenance records. For more detailed instructions on the following checklist items, refer to the appropriate sections in this Owner’s Manual.

WALTCO WDL XT LIFTGATE PREVENTIVE MAINTENANCE CHECKLIST PM Interval: 6 Months or 3000 Cycles

Date: ______________

Vehicle No.__________

Mechanic:_________________

Liftgate S/N:____________

Model:______________

Check appropriate box below for each step: 6 Month Liftgate PM Procedures 1

Repair Required

Corrected

Check that all controls operate properly. For Dual Pumps check the Auxiliary pump and controls.

Repair Required

Corrected

Check that the Positive Transit Mechanism (PTM) is properly functioning.

Repair Required

Corrected

Check that all decals are in place and legible.

Repair Required

Corrected

Check for oil leaks at cylinders, fittings, valves, steel lines and hoses.

Repair Required

Corrected

Check for apparent damage to the lifting structure, such as bent or distorted members or cracked welds, which may have resulted from overloading or abuse.

Repair Required

Corrected

Check that all pins, bolts and fasteners are tight and secure.

Repair Required

Corrected

Check that all rollers are turning when platform is raised & lowered and adjustable roller cartridge is properly adjusted.

Repair Required

Corrected

Inspect all bushings and bearings for wear and/or damage.

Repair Required

Corrected

Check all stop pads and blocks for wear and/or damage.

Repair Required

Corrected

Check that all protective covers are intact and secured.

Repair Required

Corrected

Check the batteries.

Repair Required

Corrected

Check all battery cables and connections (both positive and ground cables) to be sure they are tight and free of corrosion.

Repair Required

Corrected

Check the oil level in the reservoir.

Repair Required

Corrected

Lubricate the liftgate per the “Lubrication Instructions”.

12 Month Liftgate PM Procedures (Includes steps 1-14 above) 15

Repair Required

Corrected

Inspect Pump Motor for wear or damage.

Repair Required

Corrected

Replace Hydraulic Fluid.

Page 4-1

Chapter 4 Preventive Maintenance OPENING THE COLUMN ACCESS COVERS In order to provide for easy access for service and inspection, the columns are equipped with hinged, removable access covers. To open the access covers, remove the Hex Head Bolts in the lower portion of the covers.

Column Access Cover

The covers can now be opened. If required the covers can be removed by lifting them up to disengage the hinges.

Cover is held in place with five (5) bolts

GR02047

Page 4-2

Chapter 4 Preventive Maintenance Check that all bolts, fasteners and pins are tight and secure: 1. All Cylinder Pin bolts. 2. Platform Pivot Pin Retention bolts (see below). 3. Lower Closer Cylinder Clevis bolt. 4. Pivot tube and linkage anchor bolts on platform and support chains.

GR02417

Check the Platform Pivot Pin Retention Bolts are in place and are secured with two screws as shown.

Two screws must be in place to keep Bolt from loosening Platform Pivot Pin Retention Bolt must be in place

Page 4-3

GR02048

Chapter 4 Preventive Maintenance CHECK BATTERIES Check electrolyte level of batteries. Check that all wiring and battery cable connections are tight and free of corrosion.

GR01471B

CHECK OIL LEVEL Filler Plug Lower platform to ground in open position. Fill hydraulic reservoir to within ½” of top of reservoir.

GR02135

Recommended Fluids Temperature Range Acceptable Fluids Exxon Univis J-26 32 to 150° F

-10 to 110° F

-40 to 120° F

Mobil DTE 13 Chevron AW 32 Shell Tellus 23 Exxon Univis J-13 Shell Tellus 15

Fill reservoir • Fill with recommended fluid or equivalent. • With the platform on the ground, 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)

Mobil DTE 11

A good quality SAE 10W motor oil may also be used if the recommended fluids are unavailable

Page 4-4

Chapter 4 Preventive Maintenance LUBRICATION INSTRUCTIONS Grease Fittings

This liftgate is equipped with Teflon bearings on most major pivot points and does not require any regular lubrication, except as outlined below. â&#x20AC;˘

The Roller Cartridges in the uprights are equipped with sealed tapered roller bearings and should only require lubrication once every three to six (6) months as outlined in the lubrication schedule below. They should be lubricated with a good quality chassis grease at the six (6) grease fittings in each upright as shown.

NOTE: The Upright Covers will have to be opened to gain access to the outer three (3) grease fittings on each upright. Suggested lubrication schedule Cycles per year

Frequency of Roller Bearing lubrication

Less than 6000

6 months

More than 6000

3 months Grease Fittings GR02052

The only other points on the liftgate that require any lubrication are the points indicated below. These should be lubricated approximately once every three (3) months. â&#x20AC;˘

Use a light weight machine oil to lubricate chain connecting link areas and (if equipped) the folding ramp hinges.

Linkage Anchors

Ramp Hinges GR02418

Page 4-5

Chapter 4 Preventive Maintenance SIGNS THAT CARTRIDGES NEED ADJUSTED

Under certain loading applications this liftgate can experience a break in period, during which the rolling surfaces of the Runners will wear in, conforming to the shape of the roller.

Runner Toe In

Excessive wear on the rolling surfaces of the Runners may cause the Runners to become loose, requiring the Adjustable Cartridges to be tightened.

If any of the following are observed, the Adjustable Cartridge may need tightened. •

With the Platform at Bed Height: o Contact between Runner and Column. o Significant toe in of the Runners, especially with a load on the platform.

Runner/Column Contact

GR02138

•

Contact between Runner and PTM Valve.

•

With the Platform in the closed position and the Open/Close position indicator arrows aligned, a loose Driver’s Side Runner. This can be observed by shaking Closed Platform.

If any of the above occurs, see the next section for Cartridge Adjustment.

Runner/PTM Valve Contact Align Open/Close Arrows Loose Driver’s Side Runner Closed Platform

GR02139

Page 4-6

Chapter 4 Preventive Maintenance Cartridge Adjustment

Jam Nut

The Adjustable Roller Cartridges must be adjusted as follows: •

Open platform and raise to bed height.

•

Open Column Access Covers to access Adjustment Bolt.

•

Loosen or remove Jam Nut.

•

Tighten Adjusting Bolts until Runners are parallel and square to the Uprights.

Runner must be parallel and square to Upright

GR02064

•

Lower platform until the Open/Close position indicator arrows are aligned and close the platform.

•

Check if Driver’s Side Runner is loose by shaking Closed Platform. If movement is observed at the top of the Runner, tighten the Adjustment Bolt.

Align Open/Close Arrows

•

Open the platform and completely cycle the liftgate to check that all contact issues have been resolved.

Column Access Cover

•

Apply non permanent thread locking compound to the threads of the Adjusting Bolts.

•

Re-install jam nuts on Adjusting Bolts to secure them in place.

Driver’s Side Runner

Adjustment Bolt Closed Platform

GR02140

Page 4-7

Chapter 4 Preventive Maintenance ANNUAL INSPECTION

Reservoir

Perform procedures outlined in semi-annual inspection. Inspect pump motor: •

Disconnect battery cables.

•

Remove motor end cover.

•

Examine armature brushes for wear. Brushes should be replaced if they are less than 1/8" long.

•

Clean residue from inside motor housing.

•

Apply several drops of light weight machine oil to armature shaft bearing in motor end cover and reassemble motor end cover.

To replace Hydraulic Fluid: •

Open platform and lower to ground.

•

Drain oil from hydraulic system using drain port located on bottom of reservoir and flush entire system.

•

Fill reservoir to within ½” of top of reservoir.

Motor

GR02135

Recommended Fluids Temperature Range Acceptable Fluids Exxon Univis J-26 32 to 150° F

-10 to 110° F

-40 to 120° F

Mobil DTE 13 Chevron AW 32 Shell Tellus 23 Exxon Univis J-13 Shell Tellus 15

Fill reservoir • Fill with recommended fluid or equivalent. • With the platform on the ground, 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)

Mobil DTE 11

A good quality SAE 10W motor oil may also be used if the recommended fluids are unavailable

Page 4-8

Chapter 4 Preventive Maintenance PURGING THE LIFT CIRCUIT WDL-XT Liftgates are equipped with two lift cylinders that operate in series (commonly referred to as a Master Slave Hydraulic Circuit). If for any reason there is a loss of hydraulic fluid between the curb side and street side cylinders, the following purging procedure must be followed. Failure to do so can damage structural components of the liftgate. 1. Hold the Raise Switch until the Curb Side Runner begins to move. Let go of Raise Switch immediately once movement is seen.

PUMP

STREET SIDE (SLAVE) CYLINDER

GR02125

CURB SIDE (MASTER) CYLINDER

Direction of Fluid Flow when Raising

2. With a hoist or a forklift, mechanically raise the Street Side Runner while at the same time raising the Curb Side Runner by holding the Raise Button. Do not allow the platform to get more than 2â&#x20AC;? out of level. 3. Once the platform is raised to bed level, continue to hold the Raise Switch for 60-90 seconds. NOTE: Before, during and after the purging procedure, be certain there is sufficient oil in pump reservoir.

Raise Street Side Runner with Hoist or Forklift

Raise Curb Side Runner with Pump and Controls

GR02098

Page 4-9

Chapter 5 Placement of Decals Most decals are pre-installed by Waltco. Check that all are in place and install any that are supplied loose with the liftgate as shown below.

All decals must be in place and legible or all warranties are void. ITEM

DECAL

QTY PART NO.

LOCATION

Safety Instructions

80100850

Operation

80101471

Switch Operation

80101470

3500 # Capacity Decal

80100586

4500 # Capacity Decal

80100261

5500 # Capacity Decal

80101308

6600 # Capacity Decal

80101309

Important Decal

80100828

Thermalpak Decal

80101156

Hazard Decal

80101370

Caution Decal

75089296

Locate one in a conspicuous place near controls. Locate one in a conspicuous place on driver side upright.

Folding Ramp Decal

80100482

Locate on side of ramp latch

Warning Decal

80100829

Locate next to each circuit breaker. In applications where multiple circuit breakers are used, place in all locations.

Dual Pump Decal

80101021

Hand Pump Decal

80101456

Hand Pump Decal

80101475

Locate decal inside hydraulic enclosure cover for all dual pumps. Locate decal inside hydraulic enclosure cover for Gravity Down hand pumps Only (Single and Dual). Locate decal inside hydraulic enclosure cover for Power Down hand pumps Only.

Single Pump Gravity Down Valve Block Decal

80101477

Single Pump Power Down Valve Block Decal

80101476

Dual Pump Gravity Down Valve Block Decal

80101478

Dual Pump Power Down Valve Block Decal

80101484

Manual Lowering Decal

80101514

Current Switch Decal, Single Pump Only Selector Switch Decal, Dual Pump Only

80101371

80101380

Locate in a conspicuous place near controls.

Locate appropriate decal inside hydraulic enclosure cover.

Locate appropriate decal on pump unit

Reflective switch decal

80101455

Placed on face of switches

Closer Cylinder decal

80101466

Placed on barrel of Closer Cylinder near Air Valve

Page 5-1

Chapter 5 Placement of Decals

GR02419

Page 5-2

Chapter 6 Lubrication LUBRICATION INSTRUCTIONS

Grease Fittings

This liftgate is equipped with Teflon bearings on most major pivot points and does not require any regular lubrication, except as outlined below. â&#x20AC;˘

NOTE: The Upright Covers will have to be opened to gain access to the outer three (3) grease fittings on each upright. Suggested lubrication schedule Cycles per year

Frequency of Roller Bearing lubrication

Less than 6000

6 months

More than 6000

3 months Grease Fittings GR02052

The only other points on the liftgate that require any lubrication are the points indicated below. These should be lubricated approximately once every three (3) months. â&#x20AC;˘

Use a light weight machine oil to lubricate chain connecting link areas and (if equipped) the folding ramp hinges.

Linkage Anchors

Ramp Hinges GR02053

Page 6-1

Chapter 7 PMs & Schematics Table of Contents Single Pump and Single Pump with Hand Pump Gravity Down Electrical Schematic ............ 7-2 Single Pump and Single Pump with Hand Pump Gravity Down Hydraulic Schematic ............ 7-3 Single Pump and Single Pump with Hand Pump Power Down Electrical Schematic ............. 7-4 Single Pump and Single Pump with Hand Pump Power Down Hydraulic Schematic ............. 7-5 Dual Pump and Dual Pump with Hand Pump Gravity Down Electrical Schematic ................. 7-6 Dual Pump Gravity Down Hydraulic Schematic ...................................................................... 7-7 Dual Pump with Hand Pump Gravity Down Hydraulic Schematic........................................... 7-8 Dual Pump Power Down Electrical Schematic ....................................................................... 7-9 Dual Pump Power Down Hydraulic Schematic ..................................................................... 7-10 Light Schematics .................................................................................................................. 7-11 WDL-XT Platform & Linkage – Steel .............................................................................. PM-716 WDL-XT Platform & Linkage – Steel w/Folding Ramp .................................................... PM-717 WDL-XT Platform & Linkage – Aluminum ....................................................................... PM-718 WDL-XT Platform & Linkage – Aluminum w/Folding Ramp ............................................ PM-719 WDL-XT Runners & Pivot Tube ...................................................................................... PM-722 WDL-XT “H” Frame ....................................................................................................... PM-724B WDL-XT Liftgate Hydraulic & Electrical Layout, Gravity Down ..................................... PM-725B WDL-XT Liftgate Hydraulic & Electrical Layout, Power Down ...................................... PM-741B WDL-XT Single Pump & Single Pump w/Hand Pump – Gravity Down Hydraulic & Electrical Layout ........................................................................................................... PM-726A WDL-XT Single Pump & Single Pump w/Hand Pump – Power Down Hydraulic & Electrical Layout ........................................................................................................... PM-727A WDL-XT Dual Pump – Gravity Down Hydraulic & Electrical Layout ............................. PM-728B WDL-XT Dual Pump – Power Down Hydraulic & Electrical Layout ..............................PM-730C WDL-XT Battery Enclosure – All Pumps ......................................................................... PM-742

Page 7-1

Chapter 7 PMs & Schematics SINGLE PUMP AND SINGLE PUMP WITH HAND PUMP GRAVITY DOWN ELECTRICAL SCHEMATIC

GR02425

Page 7-2

Chapter 7 PMs & Schematics SINGLE PUMP AND SINGLE PUMP WITH HAND PUMP GRAVITY DOWN HYDRAULIC SCHEMATIC

GR02426

Page 7-3

Chapter 7 PMs & Schematics SINGLE PUMP AND SINGLE PUMP WITH HAND PUMP POWER DOWN ELECTRICAL SCHEMATIC

GR02427

Page 7-4

Chapter 7 PMs & Schematics SINGLE PUMP AND SINGLE PUMP WITH HAND PUMP POWER DOWN HYDRAULIC SCHEMATIC

GR02428

Page 7-5

Chapter 7 PMs & Schematics DUAL PUMP AND DUAL PUMP WITH HAND PUMP GRAVITY DOWN ELECTRICAL SCHEMATIC

GR02429

Page 7-6

Chapter 7 PMs & Schematics DUAL PUMP GRAVITY DOWN HYDRAULIC SCHEMATIC

GR02430

Page 7-7

Chapter 7 PMs & Schematics DUAL PUMP WITH HAND PUMP GRAVITY DOWN HYDRAULIC SCHEMATIC

GR02431

Page 7-8

Chapter 7 PMs & Schematics DUAL PUMP POWER DOWN ELECTRICAL SCHEMATIC

GR02432

Page 7-9

Chapter 7 PMs & Schematics DUAL PUMP POWER DOWN HYDRAULIC SCHEMATIC

GR02424

Page 7-10

Chapter 7 PMs & Schematics TRUCK AND TRAILER LIGHT SCHEMATICS

GR01666

Page 7-11

ITEM 1

4 5 6 7 8 9

QTY 1

8 8 2

DESCRIPTION Pivot Tube, 96 OAW Pivot Tube, 102 OAW Deck, 96 OAW, 72+15, 86 BE Deck, 96 OAW, 60+15, 72 BE Deck, 96 OAW, 60 BE Deck, 102 OAW, 72+15, 86 BE Deck, 102 OAW, 60+15, 72 BE Deck, 102 OAW, 60 BE Extension, 96 OAW, 72x80+15 Cart Stop Extension, 96 OAW, 60x80+15, Cart Stop Extension 102 OAW 72x86+15, Cart Stop Extension 102 OAW 60x86+15, Cart Stop Extension, 96 OAW, 72x80+15 Extension, 96 OAW, 60x80+15 Extension, 102 OAW, 72x86+15 Extension, 102 OAW, 60x86+15 1/2”-20 x 1-1/2” Long Flanged Bolt 1/2”-20 Flanged Hex Nut Downstop Pin Weldment

7500007-3 3190166-1 3190166-3 3190166-5 3190166-2 3190166-4 3190166-6 3190046

7500005-1

3/8”-16 x 3/4” Long Hex Socket Cap Screw Low Head

10010180

1-1/4” ID x 1-1/2” OD x 1/2” Long Polygon Bearing

1 2

WALTCO TRUCK EQUIPMENT CO. WDL XT

1/4”-20 x 3/4” Long Flathead Screw Curb Side Linkage Bar, (60+15 & 72 BE) Curb Side Linkage Bar, (72+15 & 86 BE) Curb Side Linkage Bar, (60 BE) Driver Side Linkage Bar, (60+15 &72 BE) Driver Side Linkage Bar, (72+15 &86 BE) Driver Side Linkage Bar, (60 BE) Linkage Bar Retaining Washer

ITEM 15

PART NUMBER 3190165-4 3190165-6

QTY 2

16 17 18 19 20 21

3190125-1 23370800 75088081 75086055 85803456 75088057

2 2 2 2 2 1

75089547

75084052

24 25

75088067 35440502

1 1

35442002

75089752 85803192 85803419

35442501

30 31 32 33

85803391 85803550-1 75085161 75086215

2 2 2 2

DESCRIPTION Chain Linkage Assembly (60 BE) Chain Linkage Assembly (60+15, 72+15, 72BE, 86 BE) Inner Chain Anchor Extension Hinge Pin 3/8” Lock Washer 3/8”-16 x 3/4” Long Hex Bolt Double Clevis Link Assembly 5/8” Washer (Cart Stop Platforms Only) 3/16” x 1” Coiled Pin (Cart Stop Platforms Only) 5/32” x 1” Cotter Pin (Cart Stop Platforms Only) 1/2” Washer (Cart Stop Platforms Only) Pin Assembly (Cart Stop Platforms Only) Lever Assembly (Cart Stop Platforms Only) Spring (Cart Stop Platforms Only) 80” Cart Stop (Cart Stop Platforms Only) 86” Cart Stop (Cart Stop Platforms Only) Cart Stop Brace Assembly (Cart Stop Platforms Only) 1-1/4” O.D. X 1” I.D. X 1” Long Bearing Linkage Retainer Collar 1/4”-20 Lock Nut 1/4”-20 x 2-1/2” Hex Bolt

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

PART NUMBER 3190085-1 3190085-2 3190031-1 3190031-2 3190031-3 3190031-4 3190031-5 3190031-6 3190037-7 3190037-8 3190037-9 3190037-10 3190037-11 3190037-12 3190037-13 3190037-14 7500002-3 7500001-2 3190102

REVISED: E.O. REV.

2/7/09 5885GG 03

PM-716

PLATFORM & LINKAGE â&#x20AC;&#x201C; STEEL with FIXED RAMP

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

Assembly Notes: 1. Use Non-Permanent Thread Locking Compound on Threads. 2. Install Linkage Bar on the following Chain Link from the Platform end of the Chain: Platform Size Chain Link 60+15 21 72+15 27

See Note 2

See Note 1

See Note 2

See Note 1

WALTCO TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O. REV.

2/7/09 5885GG 03

PM-716

ITEM 1

5 6 7 8 9 10

7500007-3

QTY

DESCRIPTION

8 8 2

Pivot Tube, 96 OAW Pivot Tube, 102 OAW Deck, 96 OAW, 72+15, 86 BE Deck, 96 OAW, 60+15, 72 BE Deck, 96 OAW, 60 BE Deck, 102 OAW, 72+15, 86 BE Deck, 102 OAW, 60+15, 72 BE Deck, 102 OAW, 60 BE Extension 96 OAW, 86 BE Extension 96 OAW, 72 BE Extension 96 OAW, 60 BE Extension 102 OAW, 86 BE Extension 102 OAW, 72 BE Extension 102 OAW, 60 BE Extension 96 OAW, 86x80+12 Steel Ramp Extension 96 OAW, 72x80+12 Steel Ramp Extension 96 OAW, 60x80+12 Steel Ramp Extension 102 OAW, 86x86+12 Steel Ramp Extension 102 OAW, 72x86+12 Steel Ramp Extension 102 OAW, 60x86+12 Steel Ramp Extension 96 OAW, 86x80+16 Alum. Ramp Extension 96 OAW, 72x80+16 Alum. Ramp Extension 96 OAW, 60x80+16 Alum. Ramp Extension 102 OAW, 86x86+16 Alum. Ramp Extension 102 OAW, 72x86+16 Alum. Ramp Extension 102 OAW, 60x86+16 Alum. Ramp 16” Aluminum Ramp (96” OAW) 16” Aluminum Ramp (102” OAW) 12” Steel Ramp (96” OAW) 12” Steel Ramp (102” OAW) 1/2”-20 x 1-1/2” Long Flanged Bolt 1/2”-20 Flanged Hex Nut Downstop Pin Weldment

1/4”-20 x 3/4” Long Hex Socket Screw

WALTCO TRUCK EQUIPMENT CO. WDL XT

ITEM

PART NUMBER

QTY

3190166-1 3190166-3 3190166-5 3190166-2 3190166-4 3190166-6 3190046

7500005-1

10010180

1 2

3190165-4 16

3190165-6

17 18 19 20 21 22 23

3190125-1 23370800 75088081 75086055 85803456 37419502 37414801

2 2 2 2 2 2 2

37415551

25 26

37415401 75085193

2 10

75086057

37415501

29 30 31 32 33 34 35

27310303 75084053 85803391 85803550-1 75085161 75086215 37414501

2 2 2 2 2 2 1

DESCRIPTION Curb Side Linkage Bar, (60+15 & 72 BE) Curb Side Linkage Bar, (72+15 & 86 BE) Curb Side Linkage Bar, (60 BE) Driver Side Linkage Bar, (60+15 &72 BE) Driver Side Linkage Bar, (72+15 &86 BE) Driver Side Linkage Bar, (60 BE) Linkage Bar Retaining Washer 3/8”-16 x 3/4” Long Hex Socket Cap Screw Low Head 1-1/4” ID x 1-1/2” OD x 1/2” Long Polygon Bearing Chain Linkage Assembly (60 BE) Chain Linkage Assembly (60+15, 72+15, 72BE, 86 BE) Inner Chain Anchor Extension Hinge Pin 3/8” Lock Washer 3/8”-16 x 3/4” Long Hex Bolt Double Clevis Link Assembly Retention Cable Assembly Ramp Hinge Clevis Hinge Plate, Driver Side (Aluminum Ramp Only) Ramp Brace Bar 3/8”-16 Hex Lock Nut (Aluminum Ramp Only) 3/8”-16 x 1-1/4” Long Bolt (Aluminum Ramp Only) Curb Side Hinge Plate (Aluminum Ramp Only) 1/2” Dia. Clevis Pin 3/32” x 1” Long Cotter Pin 1-1/4” O.D. X 1” I.D. X 1” Long Bearing Linkage Retainer Collar 1/4”-20 Lock Nut 1/4”-20 x 2-1/2” Hex Bolt Ramp Latch Assembly

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

PART NUMBER 3190085-1 3190085-2 3190031-1 3190031-2 3190031-3 3190031-4 3190031-5 3190031-6 3190037-1 3190037-2 3190037-3 3190037-4 3190037-5 3190037-6 3190037-15 3190037-16 3190037-17 3190037-18 3190037-19 3190037-20 3190037-21 3190037-22 3190037-23 3190037-24 3190037-25 3190037-26 85803187 85803151 3190173-1 3190173-2 7500002-3 7500001-2 3190102

REVISED: E.O. REV.

2/7/09 5885GG 03

PM-717

PLATFORM & LINKAGE â&#x20AC;&#x201C; STEEL with FOLDING RAMP

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

See Note 2

See Note 1

See Note 2

See Note 1

WALTCO TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O. REV.

2/7/09 5885GG 03

PM-717

ITEM 1

3 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18

3190041-1 3190041-3 3190041-6 3190041-8 3190166-1 3190166-3 3190166-5 3190166-2 3190166-4 3190166-6 3190125-1

QTY 1

2 8 8 2 16 12 12 9 6 3 18 1 1 1 1 1 2

WALTCO TRUCK EQUIPMENT CO. WDL XT

DESCRIPTION Pivot Tube, 96 OAW Pivot Tube, 102 OAW Platform, 60X77-1/2+15 Platform, 72X77-1/2+15 Platform, 60X83-1/2+15 Platform, 72X83-1/2+15 Platform, 60X77-1/2+15, Cart Stop Platform, 72X77-1/2+15, Cart Stop Platform, 60X83-1/2+15, Cart Stop Platform, 72X83-1/2+15, Cart Stop Chain Linkage Assembly, 60 BE Chain Linkage Assembly, 60+15 & 72 BE Chain Linkage Assembly, 72+15 & 86 BE 1/2-20 x 2” Long Flanged Bolt 1/2-20 Flanged Hex Nut Down Stop Pin 1/2” Washer 1/2” Lock Washer 1/2-20 x 1-3/4” Long Hex Bolt 1-3/16 O.D. x 5/8” I.D. Washer Cotter Pin Deck Hinge Pin 9/16” ID x 3/4” OD x 2” Long Polygon Bearing Link Anchor, Curb Side, 72+15 Link Anchor, Curb Side, 60+15 Link Anchor, Driver Side, 72+15 Link Anchor, Driver Side, 60+15 Link Bar, Curb Side, 60+15 & 72 BE Link Bar, Curb Side, 72+15 & 86 BE Link Bar, Curb Side, 60 BE Link Bar, Driver Side,60+15 & 72 BE Link Bar, Driver Side,72+15 & 86 BE Link Bar, Driver Side, 60 BE Inner Chain Anchor

ITEM 19 20 21 22

PART NUMBER 7500007-3 3190286-1 3190286-2 10010180

QTY 4 1 1 2

23 24 25 26 27 28 29 30

3190046 7500005-1 31719600 85803464 75086222 75088255 75085005 22515100 22515403 32518500 22515453 32518550 22513803 32518700 75088131 22515200 22515300 22515500 75086924 85803550-1 75085161 75086215

2 2 2 8 4 8 4 2

31 32 33 34 35 36 37 38 39 40 41

1 1 1 3 1 1 2 4 2 2 2

DESCRIPTION 1/4-20 x 1-1/4” Long Flathead Screw Chain Bracket, Curb side Chain Bracket, Driver side 1-1/4” ID x 1-1/2” OD x 1/2” Long Polygon Bearing Linkage Bar Retaining Washer 3/8-16 x 3/4” Long Screw 7/16”-20 U-Bolt 7/16-20 Nut 3/8-16 x 1-3/4” Long Hex Bolt 3/8” Washer 3/8-16 Hex Nut Spring Bar Curb Side Cart Stop, 96 OAW Curb Side Cart Stop, 102 OAW Driver Side Cart Stop, 96 OAW Driver Side Cart Stop, 102 OAW Rod, Cart Stop Hinge, 96 OAW Rod, Cart Stop Hinge, 102 OAW .875 O.D. Washer Torsion Spring, Driver Side Torsion Spring, Curb Side Cart Stop Retainer 1/4-20 X 1 Hex Bolt Linkage Retainer Collar 1/4-20 Nylon Lock Nut 1/4-20 X 2-1/2 Hex Bolt

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

PART NUMBER 3190085-1 3190085-2 3190040-7 3190040-9 3190040-17 3190040-19 3190040-8 3190040-10 3190040-18 3190040-20 3190165-1 3190165-2 3190165-3 7500002-2 7500001-2 3190231 75088256 75088083 75086237 75088262 75084052 31517500 10010174

REVISED: E.O. REV.

2/7/09 5885GG 04

PM-718

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

PLATFORM AND LINKAGE â&#x20AC;&#x201C; ALUMINUM with FIXED RAMP

See Note 2 See Note 1

See Note 2

See Note 1

WALTCO TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O. REV.

2/7/09 5885GG 04

PM-718

ITEM 1

3 4 5 6 7 8 9 10 11 12 13 14

15 16

10010174 3190041-2 3190041-4 3190041-5 3190041-7 3190041-9 3190041-10 3190166-1 3190166-3

QTY 1

1 8 8 2 14 12 10 9 6 3 18 1

1 1

WALTCO TRUCK EQUIPMENT CO. WDL XT

DESCRIPTION Pivot Tube, 96 OAW Pivot Tube, 102 OAW Platform, 60X77-1/2 BE Platform, 72X77-1/2 BE Platform, 86X77-1/2 BE Platform, 60X83-1/2 BE Platform, 72X83-1/2 BE Platform, 86X83-1/2 BE Platform, 60X77-1/2+16, Retention Ramp Platform, 72X77-1/2+16, Retention Ramp Platform, 86X77-1/2+16, Retention Ramp Platform, 60X83-1/2+16, Retention Ramp Platform, 72X83-1/2+16, Retention Ramp Platform, 86X83-1/2+16, Retention Ramp Ramp Plate, 96 OAW Ramp Plate, 102 OAW 1/2-20 x 2” Long Flanged Bolt 1/2-20 Flanged Hex Nut Down Stop Pin 1/2” Washer 1/2” Lock Washer 1/2-20 x 1-3/4” Long Hex Bolt 1-3/16 O.D. x 5/8” I.D. Washer Cotter Pin Deck Hinge Pin 9/16” ID x 3/4” OD x 2” Long Polygon Bearing Link Anchor, Curb Side, 86 BE Link Anchor, Curb Side, 60 BE Link Anchor, Curb Side, 72 BE Link Anchor, Driver Side, 86 BE Link Anchor, Driver Side, 60 BE Link Anchor, Driver Side, 72 BE Link Bar, Curb Side, 60+15 & 72 BE Link Bar, Curb Side, 72+15 & 86 BE

ITEM

17 18 19 20 21

PART NUMBER 3190166-5 3190166-2 3190166-4 3190166-6 3190125-1 7500007-3 3190286-1 3190286-2

QTY

1 2 4 1 1

10010180

23 24 25 26 27 28 29

3190046 7500005-1 31719600 85803464 31714500 37419502 75085279 75086110 75086295 3170001-1 3170001-2 75086057 75085193 31715400 3190165-1 3190165-2 3190165-3 85803550-1 75085161 75086215 7500007-5 75086237 75085181 75088256

2 2 2 8 1 2 2

30 31 32 33 34 35 36 37 38 39 40 41

2 1 1 12 12 2 2 2 2 2 2 2

DESCRIPTION Link Bar, Curb Side, 60 BE Link Bar, Driver Side,60+15 & 72 BE Link Bar, Driver Side,72+15 & 86 BE Link Bar, Driver Side, 60 BE Inner Chain Anchor 1/4-20 x 1-1/4” Long Flathead Screw Chain Bracket, Curb side Chain Bracket, Driver side 1-1/4” ID x 1-1/2” OD x 1/2” Long Polygon Bearing Linkage Bar Retaining Washer 3/8-16 x 3/4” Long Screw 7/16”-20 U-Bolt 7/16-20 Nut Ramp Latch Assembly Cable Assembly 1/2-13 Lock Nut 1/2-13 X 2-1/2 Hex Bolt 1/2-13 X 3-1/2 Hex Bolt Curb Side Ramp Hinge Assembly Driver Side Ramp Hinge Assembly 3/8-16 x 1-1/4” Long Hex Screw 3/8-16 Hex Lock Nut ½” X 2” X 4” Bar Chain Linkage Assembly, 60 BE Chain Linkage Assembly, 60+15 & 72 BE Chain Linkage Assembly, 72+15 & 86 BE Linkage Retainer Collar 1/4-20 Nylon Lock Nut 1/4-20 X 2-1/2 Hex Bolt 1/2-20 X 2 Flathead Screw (60BE Only) 1/2-20 x 1-3/4” Long Hex Bolt 1/2-20 Lock Nut (60BE Only) 1/2” Washer

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

PART NUMBER 3190085-1 3190085-2 3190040-1 3190040-3 3190040-5 3190040-11 3190040-13 3190040-15 3190040-2 3190040-4 3190040-6 3190040-12 3190040-14 3190040-16 31714150 31714100 7500002-2 7500001-2 3190231 75088256 75088083 75086237 75088262 75084052 31517500

REVISED: E.O. REV.

2/7/09 5885GG 04

PM-719

Assembly Notes: 1. Use Non-Permanent Thread Locking Compound on Threads. 2. Install Linkage Bar on the following Chain Link from the Platform end of the Chain:: Platform Size Chain Link 60BE 22 72BE 32 86BE 32

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

PLATFORM & LINKAGE â&#x20AC;&#x201C; ALUMINUM with FOLDING RAMP

See Note 2

See Note 1

See Note 2 See Note 1

WALTCO TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O. REV.

2/7/09 5885GG 04

PM-719

ITEM 1

QTY 1 1 1 2 2 2 3 7 2 1 1 1 1 1

10010180

16 17 18 19 20

3190075 7500001-1 7500019-1 7500010-2 7500043-3

1 1 1 2 4

10010164

WALTCO TRUCK EQUIPMENT CO. WDL XT

DESCRIPTION Pivot Tube, 96 OAW Pivot Tube, 102 OAW Curb Side Runner Driver Side Runner Linkage Retainer Collar 1/4”-20 Lock Nut 1/4”-20 x 2-1/2” Long Hex Bolt Lower Cylinder Pin 3/8”-16 x 1” Long Hex Screw Backstop Block Curb Side Interface Bearing Driver Side Interface Bearing Curb Side Platform Pin Driver Side Platform Pin 1-1/2 ID x 1-3/4 OD x 1” Lg Polygon Bearing 1-1/2 ID x 1-3/4 OD x .5” Lg Polygon Bearing Closure Hub Flanged Hex Nut, 1/2-13 Socket Head Shoulder Screw Hex Bolt, 1/2-20 X 1 #8-32 x 1/2” Long Hex Socket Button Cap Screw 1-1/4 ID x 1-1/2 OD x 1” Lg Polygon Bearing

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

2 3 4 5 6 7 8 9 10 11 12 13 14

PART NUMBER 3190085-1 3190085-2 3190066-1 3190022-1 85803550-1 75085161 75086215 1000101-2 7500017-3 3190187 3190119-1 3190119-2 3190215 3190235 10010178

REVISED: E.O. REV.

5/27/08 5885Z 02

PM-722

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

RUNNERS & PIVOT TUBE

See Notes 1 & 3

See Notes 1 & 2

See Note 1

Assembly Notes: 1. Use anti-seize lubricant on Teeth/Thread. 2. Tighten Curb Side Bolt with Platform in the Open Position. 3. Tighten Driverâ&#x20AC;&#x2122;s Side Bolt with Platform in the Closed Position.

WALTCO TRUCK EQUIPMENT CO. WDL XT

See Note 1 REVISED: E.O. REV.

5/27/08 5885Z 02

PM-722

ITEM 1

3 4

3190069-9 3190154-1 3190154-2 3190186-1

QTY 1 1 1 1

3190186-2 5

3190186-3

3190186-4 3190176-1 3190176-2 7

3190176-3

3190176-4 8 9 10 11 12 13 14 15 16 17 18 19 20 21 24 26 28

3190155-2 3190155-1 7500064-1 3190067-1 75085161 1000101-1 7500017-4 75089569 7500010-11 3190238 1000101-3 7500016-2 75088067 3190296 7500007-4 7500004-2 75085198

2 2 2 2 4 2 8 2 10 3 6 2 2 2 4 4 1

WALTCO TRUCK EQUIPMENT CO. WDL XT

DESCRIPTION Curb Side Column Weldment Driver Side Column Weldment Driver Side Column Weldment with Controls Curb Side Upright Cover Driver Side Upright Cover Sill Extension, 96 OAW Sill Extension, 96 OAW, 23” Walkramp Hook Spacing Sill Extension, 102 OAW Sill Extension, 102 OAW, 23” Walkramp Hook Spacing Toe Guard, 96 OAW Toe Guard, 102 OAW Toe Guard, 96 OAW, 23” Walkramp Hook Spacing Toe Guard, 102 OAW, 23” Walkramp Hook Spacing Roller Cartridge Assembly, Adjustable Roller Cartridge Assembly, Fixed 1/2”-13 Hex Jam Nut Line Clamp 1/4”-20 Nylon Lock Nut Upper Lift Cylinder Pin 3/8-16 X 5/8 Hex Screw Plug, Plastic, 7/8” Hole 3/8-16 x 5/8 Long, S.S. Hex Bolt Switch Cover Cartridge Pins 1/2-13 x 2-1/2 Long Hex Bolt 1/2” X 1-1/16 X .095” Thick Washer Interface Plate, Sill Mounting 3/8-16 x 7/8 Hex Socket Screw, Flat Head Rivet, 1/4" x 3/4" Ramco nut, 3/4-16, grade 5, plated

ITEM 29 30 31

PART NUMBER 75086193 3190294 75088255

QTY 1 1 10

DESCRIPTION Hex bolt, 3/4-16x2, gr 5, plated Weldment, slide bar base plate 3/8” X 13/16” X .065” Thick Washer

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

PART NUMBER 3190069-1 3190069-5

REVISED: E.O.(dev) REV.

2/25/09 5885GG 01

PM-724B

H-FRAME

See Note 2 See Note 1 See Note 1

See Note 1 See Note 2 See Note 3

See Note 3 See Note 2

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

See Note 1

See Note 4

Assembly Notes: 1. Install with Rollers facing center of Column 2. Use Non-Permanent Thread Locking Compound on threads. 3. See page 4-7 of Ownerâ&#x20AC;&#x2122;s Manual for proper installation. 4. Must order 4 of Item 26 with Item 7.

WALTCO TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O.(dev) REV.

2/25/09 5885GG 01

PM-724B

ITEM

QTY

DESCRIPTION

1 2 3 4 5 6

1000801-14 1000801-17 1000800-2 1000101-1 7500017-4 1000101-2

1 1 1 2 2 3

7500059-1

7010001-4

7500037-1

3190291

3190024

3190067-1

80001140

80001144

15 16 17 18

10099360 3190104 3190111 75085997

2 1 1 4

7500086-1

75082869

7500027-1

75083334

7500038-2

Driver Side Lift Cylinder Curb Side Lift Cylinder Closure Cylinder Upper Lift Cylinder Pin 3/8”-16 X 5/8” Long Hex Screw Lower Cylinder Pin 90 Degree Elbow, 9/16”-18 SAE-ORB Female X 9/16”-18 SAE-ORB Male In Line Pressure Compensating Flow Valve, 9/16”-18 SAE-ORB Female X 9/16”-18 SAE-ORB Male 90 Degree Straight Thread Elbow, 13/16”-16 ORFS Male X 9/16”-18 SAE-ORB Male Tube Assembly, ¾-16 JICF X ¾-16 JICF Hardline & Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female Line Clamp Closure Hardline & Hose Assembly, 9/16”-18 ORFS Male X 11/16”-16 ORFS Male Hardline Assembly, 11/16”-16 ORFS Female X 11/16”-16 ORFS Female Inside Switch Switch Wiring Harness 3 Button Switch Assembly 10-24 x 5/8” Flat Head Screw 90 Degree Elbow, 9/16-18 ORB male X 9/16-18 JIC female SWVL 90 Degree Elbow, 9/16-18 ORBM X 9/16-18 JICM 90 Degree Swivel Elbow, 13/16”-16 ORFS Female X 13/16”-16 ORFS Male 90 Degree Elbow, 11/16”-16 ORFS Female X 11/16”16 ORFS Male Straight Thread Swivel Connecter, 9/16”-18 ORFS Female X 7/16”-20 SAE-ORB Male

7010001-5

7500021-7 26

7500021-8

7500021-9 27

7500029-5

WALTCO TRUCK EQUIPMENT CO. WDL XT

In Line Pressure Compensating Flow Valve, 7/16”-20 SAE-ORB Female X 9/16”-18 SAE-ORB Male 76” Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female (Truck) 216” Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female (Short Trailer) 372” Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female (Long Trailer) 76” Hose Assembly, 9/16”-18 ORFS Female X 11/16”-16 ORFS Male (Truck)

ITEM

PART NUMBER

QTY

7500029-6 7500029-7 28

7500029-4

7500021-10

75083333

7500074-1

7500074-2

7500074-3

32 32 33 34

7500091-1 7500091-1 90802975 7500017-3

1 1 1 3

3190144

7500033-1

7500068-1

75082045

3190028

40 41 42

3190103 75089428 75089376 75089374 75089428 75082031 3190292 7500079-3 70110100

2 2 4

43 44 45 46 47 48 49 50 51

2 2 1 1 1

7500040-6

7500083-1 3190293 3190294

1 1 1

DESCRIPTION 216” Hose Assembly, 9/16”-18 ORFS Female X 11/16”-16 ORFS Male (Short Trailer) 372” Hose Assembly, 9/16”-18 ORFS Female X 11/16”-16 ORFS Male (Long Trailer) Hose Assembly, 13/16”-16 ORFS Male X 13/16”-16 ORFS Female Hose Assembly, 11/16”-16 ORFS Female X 9/16”-18 ORFS Female Straight Bulkhead, 11/16”-16 ORFS Male X 11/16”-16 ORFS Male 76” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Truck) 216” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Short Trailer) 372” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Long Trailer) 90 Degree Elbow, 9/16-18 SAEM X 9/16-18 JICM 90 Degree Elbow, 9/16-18 SAEM X 9/16-18 JICM Blocking Valve, 9/16-18 SAEF X 9/16-18 SAEF 3/8”-16 X 1” Long Hex Screw Hardline & Hose Assembly, 11/16”-16 ORFS Female X 11/16”-16 ORFS Female Straight Bulkhead, 13/16”-16 ORFS Male X 13/16”-16 ORFS Male 90 Degree Straight Thread Elbow, 11/16”-16 ORFS Male X 9/16”-18 SAE-ORB Male Clevis Rod End Assembly, Nylon, #10-32 Hardline & Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female Light Wiring Harness (Red) Led Taillight Light Grommet (White) Oval Backup Light (Red) Led Taillight Cable Clamp, 1/8” ID Cable, 1/16 Dia. Coated Nipple, 7/8-14 SAE male X ¾-16 JIC male Filter, Inline Magnetic Straight Thread Connector, 9/16-18 ORFS male X 7/8-14 ORB male 90 Degree Elbow, 7/16-20 ORFS Bar, Lock Valve Slide Weldment, Lock Valve Slide

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

PART NUMBER

REVISED: E.O.(dev) REV.

2/25/09 5885GG 01

PM-725B

LIFTGATE HYDRAULIC & ELECTRIC – GRAVITY DOWN

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers. 2/25/09 5885GG 01

PM-725B

TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O.(dev) REV.

WALTCO

ITEM

PART NUMBER

DESCRIPTION

1000801-14 1000801-17 1000800-2 1000101-1 7500017-4 1000101-2

1 1 1 2 2 3

7500059-1

7010001-4

7500037-1

Driver Side Lift Cylinder Curb Side Lift Cylinder Closer Cylinder Upper Lift Cylinder Pin 3/8”-16 X 5/8” Long Hex Screw Lower Cylinder Pin 90 Degree Elbow, 9/16”-18 SAE-ORB Female X 9/16”-18 SAE-ORB Male In Line Pressure Compensating Flow Valve, 9/16”18 SAE-ORB Female X 9/16”-18 SAE-ORB Male 90 Degree Straight Thread Elbow, 13/16”-16 ORFS Male X 9/16”-18 SAE-ORB Male

3190291

3190024

3190067-1

80001140

80001144

15 16 17 18

10099360 3190104 3190111 75085997

2 1 1 4

7500086-1

75082869

Tube Assembly, ¾-16 JICF X ¾-16 JICF

Hardline & Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female Line Clamp Closure Hardline & Hose Assembly, 11/16”-16 ORFS Male X 9/16”-18 ORFS Male Hardline Assembly, 11/16”-16 ORFS Female X 11/16”-16 ORFS Female Inside Switch Switch Wiring Harness 3 Button Switch Assembly 10-24 x 5/8” Flat Head Screw 90 Degree Elbow, 9/16-18 ORB male X 9/16-18 JIC female SWVL 90 Degree Elbow, 9/16-18 ORBM X 9/16-18 JICM

90 Degree Swivel Elbow, 13/16”-16 ORFS Female X 13/16”-16 ORFS Male 90 Degree Elbow, 11/16”-16 ORFS Female X 11/16”-16 ORFS Male Straight Thread Swivel Connecter, 9/16”-18 ORFS Female X 7/16”-20 SAE-ORB Male

7500027-1

75083334

7500038-2

7010001-5

In Line Pressure Compensating Flow Valve, 7/1620 SAE-ORB Female X 9/16”-18 SAE-ORB Male

76” Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female (Truck) 216” Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female (Short Trailer) 372” Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female (Long Trailer)

7500021-7 26

7500021-8 7500021-9

WALTCO TRUCK EQUIPMENT CO. WDL XT

ITEM

PART NUMBER

QTY

7500029-5 27

7500029-6

7500029-7 28

7500029-4

DESCRIPTION 76” Hose Assembly, 9/16”-18 ORFS Female X 11/16”-16 ORFS Male (Truck) 216” Hose Assembly, 9/16”-18 ORFS Female X 11/16”-16 ORFS Male (Short Trailer) 372” Hose Assembly, 9/16”-18 ORFS Female X 11/16”-16 ORFS Male (Long Trailer) Hose Assembly, 13/16”-16 ORFS Male X 13/16”16 ORFS Female

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

QTY

1 2 3 4 5 6

7500091-1

90 Degree Elbow, 9/16-18 SAEM X 9/16-18 JICM

7500017-3

3190028

3/8”-16 X 1” Long Hex Screw Hardline & Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female

90802975

75083603 33

75083607

75083600 34

7500068-1

75083333

7500033-1

3190144

3190103 75089374 75089428 75089428 75089376

75082045 75082031

1 2

3190292 7500079-3 70110100

1 1 1

7500040-6

48 49

3190293 3190294

1 1

39 40 41 42 43 44 45 46

2 2 4

Blocking Valve, 9/16-18 SAEF X 9/16-18 SAEF

153” Long Hose Assembly, 11/16”-16 ORFS Female X 11/16”-16 ORFS Female (Truck) 293” Long Hose Assembly, 11/16”-16 ORFS Female X 11/16”-16 ORFS Female (Short Trailer) 372” Long Hose Assembly, 11/16”-16 ORFS Female X 11/16”-16 ORFS Female (Long Trailer) 90 Degree Straight Thread Elbow, 11/16”-16 ORFS Male X 9/16”-18 SAE-ORB Male Bulkhead, 11/16”-16 ORFS Male X 11/16”-16 ORFS Male Straight Bulkhead, 13/16”-16 ORFS Male X 13/16”-16 ORFS Male Hardline & Hose Assembly, 11/16”-16 ORFS Female X 11/16”-16 ORFS Female Light Wiring Harness (White) Oval Backup Light (Red) Led Taillight (Red) Led Taillight Light Grommet Clevis Rod End Assembly, Nylon, #10-32 Cable Clamp, 1/8” ID Cable, 1/16 Dia. Coated Nipple, 7/8-14 SAE male X ¾-16 JIC male Filter, Inline Magnetic Straight Thread Connector, 9/16-18 ORFS male X 7/8-14 ORB male Bar, Lock Valve Slide Weldment, Lock Valve Slide

REVISED: E.O.(dev) REV.

2/25/09 5885GG 01

PM-741B

LIFTGATE HYDRAULIC & ELECTRIC – POWER DOWN

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers. 2/25/09 5885GG 01

PM-741B

TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O.(dev) REV.

WALTCO

ITEM

DESCRIPTION

3190180-1

See PM 742 31590902 70430160 70400858 75089833 70092519 70092521 70092520 3190268 70091734 80001124

1 1 1 1 1 1 2 2 1 1 1

7500025-2

7500025-1

7500021-3

7500021-1

10 11

85803482 70401651

2 1 1

75086707

75085000

75089571

1 3 2

7500023-2

7500023-1

3190104 3190107

7500074-1

7500074-2

Pump Box Base Assembly (Direct Power) Pump & Battery Box Assembly (Auxiliary Battery) Battery Box Assembly Enclosure Cover Hydraulic Pump Unit, Single Pump Motor Start Solenoid Cartridge Valve, 3 Way, 2 Position Solenoid, 12V DC, 16W Cartridge Valve, 2 Way, 2 Position Delay Solenoid, 12V DC, 16W Breather Hand Pump Kit 45 Degree Straight Thread Elbow, 9/16”-18 ORFS Male X 9/16”-18 SAE-ORB Male 45 Degree Straight Thread Elbow, 13/16”-16 ORFS Male X 3/4”-16 SAE-ORB Male 18-1/2” Long Hose Assembly, 9/16”-18 ORFS Female X 9/16”-18 ORFS Female 18-1/2” Long Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female Spring Clip Holder Hand Pump Handle #10-32 x 5/8” Long Round Head Screw #10-32 x 5/8” Long Round Head Screw (With Hand Pump) #10-32 Serrated Hex Nut #10-32 Serrated Hex Nut (With Hand Pump) 3/4” Hole Plug 45 Degree Bulkhead Elbow, 9/16”-18 ORFS Male X 9/16”-18 ORFS Male 45 Degree Bulkhead Elbow, 13/16”-16 ORFS Male X 13/16”-16 ORFS Male Switch Wire Harness (Truck) Harness Extension (Trailer) 76” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Truck) 216” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Short Trailer)

2 3 4 4A 4B 4C 4D 4E 4F 4G 5

WALTCO TRUCK EQUIPMENT CO. WDL XT

ITEM

PART NUMBER

QTY

7500074-3

19 20 21 22

70401310 75089309 75089313 75089807

6 1 3 1

75083031

24 25 26 27 28 29 30 31 32 33 34 35

75086055 7500024-1 75088081 75089851 31491501 85803921 3190105 10099500 75086217 75085003 7500024-2 10195536

4 1 4 1 1 1 1 1 1 2 1 1

10195836

75089744

75089436

39 40

75085020 75086036

2 4 4 8 1 1

DESCRIPTION 372” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Long Trailer) O-Ring Split Grommet Split Grommet, 1/2” ID Toggle Switch 90 Degree Elbow, 1/4” NPSM Female X 1/4” NPT Male 3/8”-16 x 3/4” Long Hex Screw 13/16”-16 Bulkhead Locknut 3/8” Lock Washer Fuse, 10 Amp Wire with Fuse Holder Relay, 12V, 30 Amp Motor Wiring Harness Terminal Link 5/16”-18 x 1-1/4” Long Hex Bolt 5/16”-18 Serrated Hex Nut 9/16”-18 Bulkhead Locknut 36” Battery Cable Assembly (Auxiliary Battery) 36” Positive Battery Cable Assembly (Auxiliary Battery) Rubber Draw Latch (Direct Power) Rubber Draw Latch (Auxiliary Battery) 5/32” Aluminum Rivet (Direct Power) 5/32” Aluminum Rivet (Auxiliary Battery) 5/16”-24 Jam Nut 5/16-18 X 1 Long Hex Screw

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

QTY

3190021-2 1

PART NUMBER

REVISED: E.O. REV.

2/7/09 5885GG 02

PM-726A

SINGLE PUMP & SINGLE PUMP w/ HAND PUMP GRAVITY DOWN HYDRAULIC & ELECTRICAL LAYOUT

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

WALTCO TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O. REV.

2/7/09 5885GG 02

PM-726A

ITEM

PART NUMBER

QTY 1

3190180-1

See PM 742 31590902 70430180

1 1 1

70430200

4A 4B

70400858 75089833

1 1

70092522

4D 4E 4F 4G 4H 4J 5

70092521 70092523 70092520 70092525 70092526 70091734 70092527

3 1 1 1 1 1 1

7500037-3

7500037-1

7500025-2

7500037-4

10 11

85803482 70401651

2 1 2

75086707

2 3 4

75085000

75089571

2 4 1

75083333

7500036-1

17 18

7500024-2 7500024-3

1 1

WALTCO TRUCK EQUIPMENT CO. WDL XT

ITEM

QTY

DESCRIPTION

7500024-1

7500023-2

21 22 23 24 25 26 27 28 29 30 31 32 33

70401310 75089309 75089313 75085005 75086217 10099500 75085020 85803921 31491501 75089851 75086055 75088081 75085003

2 1 3 3 1 1 1 2 1 1 5 5 2

75083031

35 36

75089807 10195536

1 1

10195836

75089744

75089436

7500021-1

3190108

7500021-3

75083604

7500074-1

7500074-2

7500074-3

3190104 3190107 75086036

1 1 1

13/16”-16 Bulkhead Locknut 45 Degree Bulkhead Elbow, 9/16”-18 ORFS Male X 9/16”-18 ORFS Male O-Ring Split Grommet Split Grommet, 1/2” ID 3/8-16 Serrated Hex Nut 5/16”-18 x 1-1/4” Long Hex Bolt Terminal Link 5/16”-24 Jam Nut Relay, 12V, 30 Amp Wire with Fuse Holder Fuse, 10 Amp 3/8”-16 x 3/4” Long Hex Screw 3/8” Lock Washer 5/16”-18 Serrated Hex Nut 90 Degree Elbow, 1/4” NPSM Female X 1/4” NPT Male Toggle Switch 36” Battery Cable Assembly (Auxiliary Battery) 36” Positive Battery Cable Assembly (Auxiliary Battery) Rubber Draw Latch (Direct Power) Rubber Draw Latch (Auxiliary Battery) 5/32” Aluminum Rivet (Direct Power) 5/32” Aluminum Rivet (Auxiliary Battery) 18-1/2” Long Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female Motor Wiring Harness 18-1/2” Long Hose Assembly, 9/16”-18 ORFS Female X 9/16”-18 ORFS Female 11/16-16 ORFS Female x 11/16-16 ORFS Female 3/8” Hose Assembly 76” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Truck) 216” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Short Trailer) 372” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Long Trailer) Switch Wire Harness (Truck) Harness Extension (Trailer) 5/16-18 X 1 Long Hex Screw

45 46

PART NUMBER

2 4 4 8

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

3190021-2 1

DESCRIPTION Hydraulic Enclosure Base Assembly (Direct Power) Pump and Battery Box Assembly (Auxiliary Power) Battery Box Assembly Enclosure Cover Hydraulic Pump Unit, Single Pump Hydraulic Pump Unit, Single Pump with Hand Pump Motor Start Solenoid Cartridge Valve, 3 Way, 2 Position, Manual Override Solenoid, 12V DC, 16W Cartridge Valve, 4 Way, 2 Position Cartridge Valve, 2 Way, 2 Position #10 Cartridge Valve, 2 Way, 2 Position #10 Solenoid, 12V DC, 16W Breather Hand Pump Kit, Power Down 90 Degree Elbow, 11-16 ORFS Male x 9/16-18 SAE ORB Male 90 Degree Elbow, 13/16-16 ORFS Male x 9/1618 SAE ORB Male 45 Degree Elbow, 9/16-18 ORFS Male x 9/16-18 SAE ORB Male 90 Degree Elbow, 13/16-16 ORFS Male x 3/4-16 SAE ORB Male Spring Clip Holder Hand Pump Handle #10-32 x 5/8” Long Round Head Screw #10-32 x 5/8” Long Round Head Screw (With Hand Pump) #10-32 Serrated Hex Nut #10-32 Serrated Hex Nut (With Hand Pump) 3/4” Hole Plug Bulkhead, 11/16-16 ORFS Male x 11/16-16 ORFS Male Bulkhead Run Tee, 13/16-16 ORFS Male x 13/16-16 ORFS Male x 13/16-16 ORFS Male 9/16-18 Bulkhead Locknut 11/16-16 Bulkhead Locknut

REVISED: E.O. REV.

2/7/09 5885GG 02

PM-727A

SINGLE PUMP & SINGLE PUMP w/ HAND PUMP POWER DOWN HYDRAULIC & ELECTRICAL LAYOUT

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

WALTCO TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O. REV.

2/7/09 5885GG 02

PM-727A

ITEM 1

QTY

DESCRIPTION

3190021-2

3190180-1

See PM 742 31590902 70430170

1 1

Pump Box Base Assembly (Direct Power) Pump & Battery Box Assembly (Auxiliary Battery) Battery Box Assembly Enclosure Cover Hydraulic Pump Unit, Dual Pump Hydraulic Pump Unit, Dual Pump with Hand Pump Motor Start Solenoid Cartridge Valve, 3 Way, 2 Position Solenoid, 12V DC, 16W Cartridge Valve, 2 Way, 2 Position 2-Wire Solenoid, 12V DC, 16W Breather Cartridge Valve w/ Manual Release stem, 2 Way, 2 Position 18” Battery Cable Assembly 45 Degree Straight Thread Elbow, 9/16”-18 ORFS Male X 9/16”-18 SAE-ORB Male 45 Degree Straight Thread Elbow, 13/16”-16 ORFS Male X 3/4”-16 SAE-ORB Male 18-1/2” Long Hose Assembly, 9/16”-18 ORFS Female X 9/16”-18 ORFS Female 18-1/2” Long Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female Wire with Fuse Holder Fuse, 10 Amp 13/16”-16 Bulkhead Locknut Auxiliary Push Button Control 3/4” Hole Plug 90 Degree Elbow, 1/4” NPSM Female X 1/4” NPT Male 45 Degree Bulkhead Elbow, 13/16”-16 ORFS Male X 13/16”-16 ORFS Male 45 Degree Bulkhead Elbow, 9/16”-18 ORFS Male X 9/16”-18 ORFS Male 76” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Truck)

70430175

4A 4B 4C 4D 4E 4F 4G 4H

70400858 75089833 70092519 70092521 70092520 70092533 70091734 70092532

2 2 2 4 3 2 1 1

10195518

7500025-2

7500025-1

7500021-3

7500021-1

10 11 12 13 14

31491501 75089851 7500024-1 31499001 75089571

2 1 1 1 2

75083031

7500023-1

7500023-2

7500074-1

17 18

WALTCO TRUCK EQUIPMENT CO. WDL XT

ITEM

PART NUMBER

QTY

7500074-2

7500074-3

1 1

20 21 22 23 24

3190104 3190107 70401310 75089309 75089313 7500024-2 85803921

25 26

3190106 75085000

75086707

6 1 3 1 4 1 2 4 2 4

28 29 30 31 32 33

70401651 75089832 85803482 75086055 75088081 10195536

1 1 2 4 4 1

10195836

35 36 37 38 39 40

75086217 10099500 75085003 75085020 80001124 75089744

75089436

75086036

2 1 2 1 1 2 4 4 8 1

DESCRIPTION 216” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Short Trailer) 372” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Long Trailer) Switch Wire Harness (Truck) Harness Extension (Trailer) O-Ring Split Grommet Split Grommet, 1/2” ID 9/16”-18 Bulkhead Locknut Relay, 12V, 30 Amp Dual Pump Gravity Down Motor Wiring Harness #10-32 Serrated Hex Nut #10-32 Serrated Hex Nut (With Hand Pump) #10-32 x 5/8” Long Round Head Screw #10-32 x 5/8” Long Round Head Screw (With Hand Pump) Hand Pump Handle Selector Switch Spring Clip Holder 3/8”-16 x 3/4” Long Hex Screw 3/8” Lock Washer 36” Battery Cable Assembly (Auxiliary Battery) 36” Positive Battery Cable Assembly (Auxiliary Battery) 5/16”-18 x 1-1/4” Long Hex Bolt Terminal Link 5/16”-18 Serrated Hex Nut 5/16”-24 Jam Nut Hand Pump Kit Rubber Draw Latch (Direct Power) Rubber Draw Latch (Auxiliary Battery) 5/32” Aluminum Rivet (Direct Power) 5/32” Aluminum Rivet (Auxiliary Battery) 5/16-18 X 1 Long Hex Screw

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

2 3

PART NUMBER

REVISED: E.O. REV.

2/7/09 5885GG 01

PM-728B

DUAL PUMP & DUAL PUMP WITH HAND PUMP GRAVITY DOWN HYDRAULIC & ELECTRICAL LAYOUT

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

WALTCO TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O. REV.

2/7/09 5885GG 01

PM-728B

ITEM

DESCRIPTION

3190180-1

2 3 4 4A 4B 4C 4D 4E 4F 4G 4H

See PM 742 31590902 70430197 70400858 75089833 70092520 70092521 70092523 70092519 70091734 70092533

1 1 1 2 2 2 4 1 2 1 2

70092528

70092536

70092534

4K 5

70092525 10195524

2 1

7500025-2

7500040-1

7500040-4

7500021-3

7500021-1

75083604

12 13 14

75085020 31499001 75089571

1 1 1

75083031

Pump Box Base Assembly (Direct Power) Pump & Battery Box Assembly (Auxiliary Battery) Battery Box Assembly Enclosure Cover Hydraulic Pump Unit, Dual Pump Power Down Motor Start Solenoid Cartridge Valve, 2 Way, 2 Position Solenoid, 12V DC, 16W Cartridge Valve, 4 Way, 2 Position Cartridge Valve, 3 Way, 2 Position Breather 2-Wire Solenoid, 12VDC, 16 Watt Cartridge Valve, 2 Way 2 Position, Normally Closed, Bi-Directional Cartridge Valve, w/Manual Release stem, 2 Way 2 Position, Bi-Directional Cartridge Valve, w/Manual Release stem, 4 Way 2 Position, Bi-Directional #10 Cartridge Valve, 2 Way, 2 Position 24” Battery Cable Assembly 45 Degree Elbow, 9/16-18 ORFS Male x 9/1618 SAE ORB Male Straight Thread Adapter, 13/16-16 ORFS Male x 3/4-16 SAE ORB Male Straight Thread Adapter, 11/16-16 ORFS Male x 9/16-18 SAE ORB Male 18-1/2” Long Hose Assembly, 9/16”-18 ORFS Female X 9/16”-18 ORFS Female 18-1/2” Long Hose Assembly, 13/16”-16 ORFS Female X 13/16”-16 ORFS Female 11/16-16 ORFS Female x 11/16-16 ORFS Female 3/8” Hose Assembly 5/16”-24 Jam Nut Auxiliary Push Button Control 3/4” Hole Plug 90 Degree Elbow, 1/4” NPSM Female X 1/4” NPT Male

WALTCO TRUCK EQUIPMENT CO. WDL XT

ITEM

PART NUMBER

QTY

75083333

7500023-2

7500023-1

7500024-2 7500024-3 7500024-1

1 1 1

7500074-1

7500074-2

7500074-3

24 25 26

3190104 3190107 75085003 75089309 75089313

75089744

75089436

29 30 31 32 33 34 35 36 37 38 39 40 41

75085000 75086707 3190287 85803921 31491501 75089851 75089832 75086055 75088081 10099500 75086217 75086036 10195536

1 1 2 1 3 2 4 4 8 2 2 1 6 2 2 1 4 4 1 1 1 1

10195836

20 21 22

DESCRIPTION Bulkhead, 11/16-16 ORFS Male x 11/16-16 ORFS Male 45 Degree Bulkhead Elbow, 9/16”-18 ORFS Male X 9/16”-18 ORFS Male 45 Degree Bulkhead Elbow, 13/16”-16 ORFS Male X 13/16”-16 ORFS Male 9/16”-18 Bulkhead Locknut 11/16”-16 Bulkhead Locknut 13/16”-16 Bulkhead Locknut 76” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Truck) 216” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Short Trailer) 372” Hose Assembly, ¼” NPT Male X 9/16”-18 ORFS Female (Long Trailer) Switch Wire Harness (Truck) Harness Extension (Trailer) 5/16”-18 Serrated Hex Nut Split Grommet Split Grommet, 1/2” ID Rubber Draw Latch (Direct Power) Rubber Draw Latch (Auxiliary Battery) 5/32” Aluminum Rivet (Direct Power) 5/32” Aluminum Rivet (Auxiliary Battery) #10-32 Serrated Hex Nut #10-32 x 5/8” Long Round Head Screw Motor Wiring Harness Relay, 12V, 30 Amp Wire with Fuse Holder Fuse, 10 Amp Selector Switch 3/8”-16 x 3/4” Long Hex Screw 3/8” Lock Washer Terminal Link 5/16”-18 x 1-1/4” Long Hex Bolt 5/16”-18 x 1” Long Hex Bolt 36” Battery Cable Assembly (Auxiliary Battery) 36” Positive Battery Cable Assembly (Auxiliary Battery)

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

QTY

3190021-2 1

PART NUMBER

REVISED: E.O. REV.

2/9/08 5885GG 01

PM-730C

DUAL PUMP POWER DOWN HYDRAULIC & ELECTRICAL LAYOUT

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers. 2/9/08 5885GG 01

PM-730C

TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O. REV.

WALTCO

PART NUMBER 3190180-1 10291503 75089321 10291403

QTY 1 1 3 2

75088052

6 7 8 9 10 11 12 13 14 15 16 17 18 19

75085177 10291804 75089744 75089243 10099500 75089436 75085003 75086217 10099501 10195836 10195536 See Table Below 10195508 See Table Below 75088036 75088038 75080041 75080042 75080040 75080006 75080005 75092001 75089328 75089031 75089033

4 2 4 1 1 8 2 1 1 1 1

20 21 22 23 24 25 26

2 N/A N/A N/A N/A N/A 1 1 1 N/A N/A N/A

WALTCO TRUCK EQUIPMENT CO. WDL XT

DESCRIPTION Pump & Battery Box Sub-Assembly Battery Cover 3/4” ID Grommet Battery Holder 5/16” x 7/8” OD x .083” Thick Steel Washer 5/16”-18 Lock Nut Threaded Battery Retainer Bar Rubber Draw Latch 150 Amp Circuit Breaker Terminal Link 5/32” Aluminum Rivet 5/16-18 Serrated Hex Nut 5/16-18 x 1-1/4” Long Hex Bolt 90 Degree Terminal Link 36” Long Positive Cable Assembly 36” Long Battery Cable Assembly Positive Battery Cable Assembly 8” Battery Cable Assembly Negative Battery Cable Assembly Black Heat Shrink Tube Red Heat Shrink Tube 2 GA Compression Type Nut 0 GA Compression Type Nut Compression Terminal w/ 3/8” Hole Plug (Single Pole) Socket (Single Pole) Socket (Dual Pole) Rubber Boot 0 GA Battery Cable 2 GA Battery Cable

AVAILABLE POSITIVE BATTERY CABLE ASSEMBLIES PART NUMBER DESCRIPTION 10195810 10195824 10195836 10195887

Positive (Red) Battery Cable Assy, 2 Ga. X 120” Lg Positive (Red) Battery Cable Assy, 2 Ga. X 24” Lg Positive (Red) Battery Cable Assy, 2 Ga. X 36” Lg w/ Boot Positive (Red) Battery Cable Assy, 2 Ga. X 87” Lg w/ Boot

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

ITEM 1 2 3 4

AVAILABLE NEGATIVE BATTERY CABLE ASSEMBLIES PART NUMBER DESCRIPTION 10195606 10195608 10195610 10195612 10195616 10195620 10195625 10195630 10195635 10195636 10195638

Negative (Black) Battery Cable Assy, 2 Ga. X 72” Lg w/ Boot Negative (Black) Battery Cable Assy, 2 Ga. X 96” Lg w/ Boot Negative (Black) Battery Cable Assy, 2 Ga. X 120” Lg w/ Boot Negative (Black) Battery Cable Assy, 2 Ga. X 144” Lg w/ Boot Negative (Black) Battery Cable Assy, 2 Ga. X 192” Lg w/ Boot Negative (Black) Battery Cable Assy, 2 Ga. X 240” Lg w/ Boot Negative (Black) Battery Cable Assy, 2 Ga. X 300” Lg w/ Boot Negative (Black) Battery Cable Assy, 2 Ga. X 360” Lg w/ Boot Negative (Black) Battery Cable Assy, 2 Ga. X 420” Lg w/ Boot Negative (Black) Battery Cable Assy, 2 Ga. X 432” Lg w/ Boot Negative (Black) Battery Cable Assy, 2 Ga. X 456” Lg w/ Boot

REVISED: E.O. REV.

2-27-08 6000 01

PM-742

AUXILIARY BATTERY ENCLOSURE COMPONENTS (OPTIONAL ON ALL PUMPS)

IMPORTANT: Parts shown may not match your liftgate. See PARTS NAVIGATOR or contact Waltco Parts to confirm correct part numbers.

WALTCO TRUCK EQUIPMENT CO. WDL XT

REVISED: E.O. REV.

2-27-08 6000 01

PM-742

Chapter 8 â&#x20AC;&#x201C; 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: parts@waltco.com 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 EO 5422