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WALTCO HDC-33 Installation Manual Download Page 48

 

________________________________________________________________________________ 

FULL-DOOR SEAL KIT INSTALLATION 

1.

Rubber Air Foil

75089937 

2.

Double Rail

75089936 

3.

Rubber Seal

75089960 

4.

Rail

75089911 

5.

Rubber Sill

75089912 

Note:   Rubber Seals & Air Foils are 

cut back in details for clarity 

 80101285 

80101285 
EO4662 
Rev 02 
1-2002

4

8

Summary of Contents for HDC-33

Page 1: ...GR02912 Date Pages Description 01 2022 All New HDC Liftgate released January 2022 Waltco Lift Corp Corporate Office United States 1777 Miller Parkway Streetsboro OH 44241 P 330 633 9191 F 330 633 141...

Page 2: ...Decals 48 Lubrication Instructions 51 Final Inspection 52 Optional Kit Instructions Aux Battery Kit Truck 53 Kit 80001066 Aux Battery Kit Trailer Kit 80001069 Full Door Seal Kit 58 Kit 80000573 Cycle...

Page 3: ...f the liftgate can cause an undesirable and dangerous condition OWNER S MANUAL The Waltco Owner s Manual is intended to act as a guide for operation and routine maintenance but is no way intended to e...

Page 4: ...Standards 571 125 When welding to liftgate or liftgate components take all necessary safety precautions including using respiratory protection and other pertinent personal protective gear when welding...

Page 5: ...es this symbol to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid personal injury or death SIGNAL WORDS 12 2021 WARNING Indicates a potentially...

Page 6: ...6 Lift Cylinder 1 7 Tilt Cylinder 8 Upper Lift Arm Pin 9 Lower Lift Arm Pin 14 10 Upper Lift Cylinder Pin 17 11 Lower Lift Cylinder Pin 17 12 Upper Tilt Cylinder Pin 14 13 Lower Tilt Cylinder Pin 14...

Page 7: ...UMBER of liftgate To be used when ordering parts or when contacting Waltco for service or warranty questions DATE OF MANUFACTURE Month Year GR00241 HDC33 Level Lift 3300 lbs HDC 44 Level Lift 4400 lbs...

Page 8: ...lable for use IMPORTANT Do not modify mounting bracket bolts nuts or mounting surfaces that are in contact with mount tube 3 1 4 GR02987 GR00494 MOUNTING DIMENSIONS Determine bed height Measure from t...

Page 9: ...ce Ground Clearance Bed Height A Dim 10 25 NOTE Minimum allowable bed height is dependent solely on the required ground clearance Additional mounting configurations and dimensions may be available by...

Page 10: ...bumpers Trailer hitches GR00497 If rear sill is deeper than the Max Sill Depth as indicated in the Mounting Requirements notch as shown Mark a witness line at center of rear sill This line will be use...

Page 11: ...gle to cap off frame and tie it in with rear sill Add a tie strap on the side of the chassis frame to tie it together with the body long member REINFORCE REAR SILL AREA GR00498A Make two 2 plates with...

Page 12: ...he centerline marks of the jig with mark on sill Verify the 1 3 8 and 3 1 8 dimensions GR00060 Note The outer two cylinders are the tilt cylinders Do not remove any pins from mount frame Remove the te...

Page 13: ...Temporarily secure lift arms to mounting jig with long bolts and nuts supplied with liftgate or platform Other means may be used to support Mount Frame in position ALWAYS verify the safety of your sup...

Page 14: ...cle chassis frame Position mount plates over mount tube and up against vehicle chassis frame Open end of mount plates must face front of vehicle TRIM MOUNT PLATE Rotate liftgate and mount plate so pla...

Page 15: ...mount plates to vehicle chassis frame Install endplates as shown with provided nuts and washers and torque to 85 ft lbs Note Do not install any more bolts or weld mount plates to chassis frame at thi...

Page 16: ...formed in reverse order 1 Remove the protective cap which is secured with two quick release locks 2 Move the release latch A to the left and then fold out the control card B see Image Reinstall in rev...

Page 17: ...5803866 Waltco All Season Hyd Oil Part 85803867 Shell Tellus S2 V 15 Mobil DTE 10 Excell 15 Chevron Rando HDZ 15 OPERATING GATE WITHOUT BATTERIES If the liftgate needs to be operated before the batter...

Page 18: ...alled removed adjusted in the grommet On installation the cable must be installed together with existing cabling with cable ties Ensure the length of the cable is sufficient for moving the control car...

Page 19: ...tance from the risk zone between the platform and the body All control units should be connected to the correct terminals on the control card Avoid running two control units in parallel to each other...

Page 20: ...he dash The black wire runs to the center post of the switch Run a ground from the Bronze post of the switch to any ground point near the dash Connect a wire to the silver post and connect other end t...

Page 21: ...o give good protection against any objects coming into contact with circuit breaker terminals and causing a short Position must also be readily accessible to reset breaker NOTE Circuit Breaker is to r...

Page 22: ...tubing onto cable Insert bare wire into compression nut until it seats Note Copper wire should be flush with or slightly past the nut Grip nut with wrench and turn terminal until nut seats GR00301 Hea...

Page 23: ...TO BATTERY Connect the end of the Positive battery cable from the liftgate to the circuit breaker as shown Connect the end of the negative battery cable from the liftgate to the negative post of the b...

Page 24: ...or application Note If the full door seal kit or flip up door option are to be used they will use a different type of sill extension INSTALL REAR SILL EXTENSION Cut extension so it will extend to with...

Page 25: ...ot holes in Platform Hinges by using the Raise and Tilt or Lower and Tilt switches Install Tilt Cylinder Pins washers support wheel and lock nuts as shown GR00837 ADJUSTMENT OF PLATFORM GAP Bring plat...

Page 26: ...rm use the rivets supplied 2 Secure the sensor cable with cable ties IMPORTANT Route the cable between the platform and the lift arm tube such that it is well protected when the plat form touches the...

Page 27: ...can melt cables or burst hoses causing personal injury DO NOT GROUND WELDING MACHINE TO CYLINDERS GR00508 PAINTING IMPORTANT Do not paint the cylinder piston rods Any paint applied to piston rods wil...

Page 28: ...up stops on top of lift arms and against vehicle chassis frame Tack weld up stops to chassis frame and lower platform to the ground Verify that hydraulic hoses or wires will not get crushed between l...

Page 29: ...e collar 3 Washer 4 Lock screw x3 5 Ring 6 Ring s Lock Screw GR02813 Note Make sure the grease zerk Is facing upwards Note Do not adjust the tilt cylinders before they are installed onto the platform...

Page 30: ...g over 90 The tilt cylinders should be fully extended If platform will tilt over 90 tilt cylinders must be adjusted in order to prevent damage of over tilting GR02815 Only for trucks with ceiling and...

Page 31: ...m a maximum of 10 below the horizontal as shown in Fig GR02829 1 2 GR02816 Tighten the ring to the top of the cylinder 3 and then tighten the lock screw into the ring 4 after tilt down angle is establ...

Page 32: ...s so that the platform firmly contacts the stops when fully closed Space rubber stops out from corner post as may be required Spacers not provided GR01606 RUBBER STOP OR PIECE OF SEALING FLAT BED APPL...

Page 33: ...nuts supplied Install 3 piece bumper as shown NOTE All 3 pieces need to be installed INSTALLATION OF 3 PIECE BUMPER GR00111 SWING DOOR APPLICATION Platform must be spaced away from the vehicle such t...

Page 34: ...Electrical and hydraulic diagrams 34 SCHEMATIC...

Page 35: ...nstructed such that its strength is not compromised by the notching Note Widening bridge further spaces platform away from vehicle GR00112 INSTALLING BRIDGE There must approximately 5 8 gap between pl...

Page 36: ...115 Bridge will pivot over back of platform when lowered Mark back of platform as a no loading area as necessary LOADING AREA GR00106 OPERATION CHECK Turn shut off switch on located in cab Always make...

Page 37: ...old tilt switch then simultaneously push raise switch to tilt platform up Or First push and hold tilt switch then simultaneously push lower switch to tilt platform down GR00110 TO FOLD PLATFORM TO CLO...

Page 38: ...positioned in a conspicuous place near the control switches as shown 80100850 Safety Instruction Decal 80101451 Operation Decal 80100828 Important Decal 80101370 Hazard decal One 1 of the following th...

Page 39: ...ecals is to be positioned in a conspicuous place on the bottom of the platform as shown 80101415 HDC 33 Capacity Decal 80101416 HDC 44 Capacity Decal CAPACITY DECAL HERE GR00511 GR00511 IMPORTANT Safe...

Page 40: ...te corner flag mount brackets Z20273 one on each side of platform and drill 3 holes per bracket into platform as shown Use bracket as a template Using slotted head screws provided three per bracket in...

Page 41: ...uty or cycles always lubricate more frequently Tilt cylinder lower pin Lift cylinder lower pin Lift arm lower pin Tilt cylinder upper pin Lift cylinder upper pin Lift arm upper pin SUGGESTED MINIMUM L...

Page 42: ...state and federal standards I Owner s Manual is in the vehicle J Pump reservoir is full of oil K All grease fittings are lubricated L All hydraulic connections are tight M Up stops Drive Over Bars Ru...

Page 43: ...e a cable supplied with the trailer kit Truck with auxiliary batteries Cable supplied with liftgate will be cut into two lengths to reach from pump to auxiliary batteries and to vehicle batteries Trai...

Page 44: ...ll battery cable supplied with liftgate to the pump starter solenoid For trucks Route cable to vehicle batteries cut to desired length Cut cable to reach auxiliary batteries and cut remaining piece to...

Page 45: ...0 gauge cable Note Copper wire should be flush with or slightly past nut GR00299 Grip nut with wrench and turn terminal until nut seats GR00300 Position heat shrinkable tubing over terminal and end of...

Page 46: ...provided Apply a generous amount of Dielectric Grease over cable terminal GR02739 Ground trailer socket to main structure of trailer Use the 18 ground cable supplied and bolt it to the trailer socket...

Page 47: ...ielectric Grease to all Positive Hot Battery terminals and Circuit Breaker terminals Secure all battery cables to chassis frame with cable ties provided NOTE Original equipment ground cable furnished...

Page 48: ..._______________ FULL DOOR SEAL KIT INSTALLATION 1 Rubber Air Foil 75089937 2 Double Rail 75089936 3 Rubber Seal 75089960 4 Rail 75089911 5 Rubber Sill 75089912 Note Rubber Seals Air Foils are cut back...

Page 49: ...s the Y Dimension Cut the Side Double Rails Side Rubber Seals and Side Air Foils to match the Y Dimension 2 Find the location of the Side Double Rails on the vehicle corner posts Measure the distance...

Page 50: ...e Pop Rivets or Counter Sunk Screws to attach the Double Rails to the vehicle corner post NOTE In some cases the width of the body requires that the Double Rails be notched Around the Locking Lugs due...

Page 51: ...o the Top Double Rail drill holes in the Top Double Rail and body header Angled cuts on Top Double Rail and Side Double Rails should make 90 corners as shown 7 Insert Rubber Seal and Air Foil into Top...

Page 52: ...Add silicone caulk to seal gaps between tracks and vehicle body 52...

Page 53: ...ag is located on the side or bottom of the platform 2 MODEL NUMBER Or capacity 3 PLATFORM SIZE ________________________________________________________________ THEN INCLUDE THE FOLLOWING INFORMATION 4...

Page 54: ...icle and an OWNER S MANUAL in the vehicle at all times as a guide for proper operation and maintenance Additional WARNING DECALS OPERATION DECALS and OWNER S MANUALS can be obtained from WALTCO LIFT C...

Page 55: ...t in severe personal injury or death Read and understand the contents of this manual and all warning and operation decals before operating and or performing maintenance on this liftgate For SAFETY inf...

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