WALTCO WDV Tech Manual Download

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Table of Contents

INTRODUCTION .......................................................................................................................................... 3

LIFTGATE TERMINOLOGY ........................................................................................................................ 4-7

HYDRAULIC CIRCUIT DIAGRAM .............................................................................................................. 8

POWER UNIT KEY COMPONENTS ........................................................................................................... 9-14

ELECTRICAL & HYDRAULIC FLOW SCHEMATICS ................................................................................ 15-18

HYDRAULIC & ELECTRICAL SCHEMATICS BUILT FROM 4/09 THRU 10/11 ....................................... 19-20

HYDRAULIC & ELECTRICAL SCHEMATICS BUILT FROM 10/11 .......................................................... 21-22

HYDRAULIC & ELECTRICAL SCHEMATIC - WORK LIGHT .................................................................... 23

HYDRAULIC & ELECTRICAL SCHEMATICS – CYCLE COUNTER ......................................................... 24-25

HYDRAULIC & ELECTRICAL SCHEMATIC- GRAVITY DOWN ON DEMAND ........................................ 26-27

HYDRAULIC & ELECTRICAL SCHEMATIC .............................................................................................. 28-31

TROUBLESHOOTING GUIDE .................................................................................................................... 32-36

LIFT CYLINDER REPLACEMENT INSTRUCTION .................................................................................... 37-38

CLOSING CYLINDER BLEEDING PROCEDURE ...................................................................................... 39

HYDRAULIC OIL CHANGING PROCEDURE ............................................................................................ 40

HIGH PITCH NOISE REPAIR ...................................................................................................................... 41

REPLACING SWITCH AND POWER CLOSE HOSES .............................................................................. 42-43

TRAVEL LATCH ENGAGMENT ................................................................................................................. 44

PREVENTIVE MAINTENANCE ................................................................................................................... 45-46

HOW TO ORDER PARTS............................................................................................................................ 47

Summary of Contents for WDV

Page 1: ...0 S Hambledon Ave 90 North Queen St Tallmadge OH 44278 City of Industry CA 91744 Etobicoke ON M8Z 2C5 P 330 633 9191 P 626 964 0990 P 888 343 4550 F 330 633 1418 F 626 964 0149 Waltco Tech Support Pho...

Page 2: ...LIC ELECTRICAL SCHEMATIC WORK LIGHT 23 HYDRAULIC ELECTRICAL SCHEMATICS CYCLE COUNTER 24 25 HYDRAULIC ELECTRICAL SCHEMATIC GRAVITY DOWN ON DEMAND 26 27 HYDRAULIC ELECTRICAL SCHEMATIC 28 31 TROUBLESHOOT...

Page 3: ...se of non standard or makeshift parts can be extremely hazardous and result in serious injury or death Every vehicle that has a WALTCO Liftgate must have legible WARNING AND OPERATION DECALS clearly p...

Page 4: ...Chain 7 Chain Linkage Bar 8 Bottom Stop Catch 9 Main Deck 10 Deck Extension 11 Folding Ramp 12 Street Side Runner 13 Curb Side Runner 14 Control Switches 15 Closing Cylinder 16 Street Side Lift Cylin...

Page 5: ...tension Wires Optional 25 Extension Hoses Optional 26 Circuit Breaker 15A Control Switches 27 Power Unit Motor 28 Charging Battery Cable 29 Grounding Battery Cable 30 Power Unit Battery Box 31 Box Cov...

Page 6: ...ate Terminology 35 Side Rail Assembly 36 Outer Guard Rail Assembly 37 Guard Rail Latch Assembly 38 Inner Guard Rail Assembly 39 Ramp Assembly 40 Gas Bottle Retention Chain WDVBG GR02366 35 36 37 39 38...

Page 7: ...s 3500 lb WDV45 WDV 45 Series 4500 lb WDV55 WDV 55 Series 5500 lb WDV66 WDV 66 Series 6600 lb MODEL NUMBER RATED CAPACITY Based on an evenly distributed load on the platform flat surface SERIAL NUMBER...

Page 8: ...ies hydraulic circuit diagrams Oil is pumped into one cylinder and the oil displaced from the other end feeds the second cylinder When platform is at floor level the oil bypasses to the tank and the p...

Page 9: ...ackup Switch Primary Power Unit Call out of MTE Main Auxiliary Power Unit Motor Solenoid Motor selector switch Backup Power Unit Motor Solenoid RV4 Down 500 psi RV3 Open 1500 psi RV2 Up Close 2800 psi...

Page 10: ...p Platform Lower Down Hydraulic Connection Connect to top port on Driver Side Cylinder and C Port marked on the pump Hydraulic Power Open Hydraulic Connection Connect to top port on Power Close Cylind...

Page 11: ...nt Main Auxiliary Power Unit Motor Solenoid Motor selector switch Backup Power Unit Motor Solenoid RV4 Down 500 psi RV3 Open 1500 psi RV2 Up Close 2800 psi Tank Tank Ground Ground 150 amp Circuit Brea...

Page 12: ...ydraulic Connection Connect to top port on Driver Side Cylinder and C Port marked on the pump Hydraulic Power Close Hydraulic Connection Connect to top port on Power Close Cylinder and A Port marked o...

Page 13: ...Manifold Auxiliary Motor Solenoid Motor selector switch Auxiliary Power Unit RV4 Down 500 psi RV3 Open 1500 psi backside of manifold RV2 Up Close 2900 psi underside of manifold Auxiliary back up Alarm...

Page 14: ...ection Connect to top port on Power Close Cylinder Column Switch Point Connection External Double Toggle Switch Point Connection Call Out of Generation 2 Main Auxiliary Power Unit Continued C Port Hyd...

Page 15: ...Electric Hydraulic Flow Schematics Power Up S4 Valve Coil activated for Up function 15...

Page 16: ...Electric Hydraulic Flow Schematics Power Down S3 S4 Valve Coil activated for the Down function 16...

Page 17: ...Electric Hydraulic Flow Schematics Power Close S1 Valve Coil activated for the Close function 17...

Page 18: ...Electric Hydraulic Flow Schematics Power Open S1 S2 Valve Coil activated for the Open function 18...

Page 19: ...Electric Hydraulic Schematics Built from 4 09 thru 10 11 Single pump Motor Single Relay 19...

Page 20: ...Electric Hydraulic Schematics Built from 4 09 thru 10 11 Dual Pump Motor with Back Up Auxiliary Single Relay 20...

Page 21: ...Electric Hydraulic Schematics Built from 10 11 Single Pump Motor Dual Relay 21...

Page 22: ...Electric Hydraulic Schematics Built from 10 11 Dual Pump Motor with Backup Auxiliary Dual Relay 22...

Page 23: ...Work Light Electrical Hydraulic Schematic 23...

Page 24: ...Cycle Counter Schematics POWER UNIT HYDRAULIC ELECTRICAL SCHEMATIC SINGLE POWER UNIT POWER DOWN REF 80101542 REV04 24...

Page 25: ...Cycle Counter Schematics POWER UNIT HYDRAULIC ELECTRICAL SCHEMATIC DUAL PUMP MOTOR WITH BACKUP AUXILLARY POWER DOWN REF 80101542 REV04 25...

Page 26: ...Gravity Down On Demand Schematics POWER UNIT HYDRAULIC ELECTRICAL SCHEMATIC SINGLE POWER UNIT GRAVITY DOWN ON DEMAND REF 80101585 REV04 26...

Page 27: ...Gravity Down On Demand Schematics POWER UNIT HYDRAULIC ELECTRICAL SCHEMATIC DUAL PUMP MOTOR WITH BACKUP AUXILLARY GRAVITY DOWN ON DEMAND REF 80101582 REV04 27...

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Page 32: ...and wires for corrosion LIFTGATE WILL NOT RAISE MOTOR DOES NOT RUN Check the cab shut off switch confirm that the switch is on and functional Check the master disconnect switch located on the pump bo...

Page 33: ...ge It should 600 1000psi to raise an empty platform PLATFORM GOES DOWN WHEN THE UP BUTTON IS PRESSED MOTOR RUNS Check and inspect the hose connections The hoses could potentially be reversed where the...

Page 34: ...the wiring for damages clean dirty connections and tighten any loose connections Check and inspect for a short in switch control wire Check for a defective switch Check for defective coils on valves...

Page 35: ...east 10 5 volts and magnetizing If both coils are magnetizing the valve maybe faulty If you are getting power to both coils and you have checked that the valve is working fine the orifice built into t...

Page 36: ...ondition may be normal if the liftgate motor experiences high cycles of operation in a short period of time without cooling The Thermal switch will reset after the motor cools down Check for low volta...

Page 37: ...der and attach the hose directly back to the adaptor on the cylinder On 5500 lb and 6600 lb models the flow control valve is not pre installed Please note that on these models we have provided fitting...

Page 38: ...ydraulic reservoir to from top 9 Activate the UP switch for 35 seconds Wait 5 minutes activate the UP switch for another 35 seconds 70 seconds total This will bleed the cylinders 10 Activate the DOWN...

Page 39: ...lly extend closing cylinder using switch Hold body of cylinder back while extending to clear Platform clevis 10 Remove hose from lower fitting of closing cylinder 11 Run fluid through hose by operatin...

Page 40: ...container for used oil 5 While keeping return line inside container press the up toggle switch to run liftgate until it fully raised Be sure to watch oil level while raising and add new oil if needed...

Page 41: ...ounces the noise does not stop or diminish contact factory 2 Defective Flow valve Noise would happen mostly in the lowering cycle See procedure for flow valve replacement 3 Hose guard and column swit...

Page 42: ...es that hold the switch wire in place 3 On the cover you also need to remove the bolt holding the bracket securing hose to the cover 4 With cover removed disconnect the hoses from the cylinder and dis...

Page 43: ...guard using the holes provided using wire ties 8 Secure the other end of the hose with shield to the inside guard using bolts and brackets removed in step 4 9 Install outside guard back in place usin...

Page 44: ...ALLING PLATFORM RETAINING RING a Retaining rings should be zip tied to one of the hydraulic hoses inside the pumpbox Two are included if necessary b Lower platform to 20 above ground c Push platform t...

Page 45: ...Liftgate platform OK Repair Needed Corrected 7 Inspect for loose nuts bolts and roll pins Main hinge pin bolt folding hinge bolt roll stop and flip ramp bolts OK Repair Needed Corrected 8 ALUMINUM PL...

Page 46: ...ctric coating OK Repair Needed Corrected 28 Inspect entire length of battery cable positive and ground and exposed switch wires for chaffing OK Repair Needed Corrected 29 Load test battery and perform...

Page 47: ...__________________________________________________________ THEN INCLUDE THE FOLLOWING INFORMATION 5 PART NUMBERS 6 DESCRIPTION 7 QUANTITY REQUIRED _____________________________________________________...

Page 48: ...Notes 48...

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