WALTCO GT-33 Installation Manual Download

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80127801

Installation Manual

GT-33, 44, 55

3300, 4400, 5500 lb. Capacity Flipaway Liftgates

Last Change:

Date

Pages

Description

01-2022

ALL

Updated mounting requirements and line drawings

Waltco Lift Corp.
Corporate Office United States

1777 Miller Pkwy
Streetsboro, OH 44241
P: 330.633.9191
F: 330.633.1418

EO:10

848

Rev 03

01-2022

www.waltco.com

Phone:

800.411.5685

[email protected]

Fax:

800.411.5684

Summary of Contents for GT-33

Page 1: ...ange Date Pages Description 01 2022 ALL Updated mounting requirements and line drawings Waltco Lift Corp Corporate Office United States 1777 Miller Pkwy Streetsboro OH 44241 P 330 633 9191 F 330 633 1418 EO 10848 Rev 03 01 2022 www waltco com Phone 800 411 5685 parts waltco com Fax 800 411 5684 ...

Page 2: ...al Kit Instructions Hand Held Remote Kit 35 Kit 80001433 Aux Battery Kits Trailer 36 Improper installation of this liftgate could result in severe personal injury or death Read and understand the contents of these instructions before proceeding When installed this liftgate must not alter or prevent vehicle compliance to any existing state or federal standards Each chassis manufacturer s recommenda...

Page 3: ...te 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 encourage usage or repair of the liftgate by those who are not qualified to do so The contents of the owner s manual include but are not limited to general operation instructions routine lubrication parts lists an...

Page 4: ...otor Vehicle Safety 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 harmful materials All protective covers guards and safety devices must be in place and access doors closed before operating liftgate Do not allow anyone to stand in or near area i...

Page 5: ...pect 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 This is the safety alert symbol This manual uses this symbol to alert you to potential personal injury hazards Obey all safety messages that follow this ...

Page 6: ...extension 11 Spec tag Includes serial number 3 Retention ramp 12 Switches 4 Platform Handle 13 Mount Frame 5 Mount tube 14 Mount angles 6 Lift cylinder 15 Platform Pin Torsion springs hidden behind guards 7 Lift arm 8 Parallel arm 9 Pump Battery box GR10134 6 ...

Page 7: ... Liftgate Terminology EXPLANATION OF SPECIFICATION TAG MODEL NO DESCRIPTION CAPACITY GT33 GT 33 SLIDER LIFTGATE 3300 LBS GT44 GT 44 SLIDER LIFTGATE 4400 LBS GT55 GT 55 SLIDER LIFTGATE 5500 LBS GR00241 SPEC TAG 7 ...

Page 8: ...ces GR10129 GR10130 DETERMINE MOUNTING DIMENSIONS NOTE Measure all dimensions when trailer is unloaded and on a flat horizontal surface 1 Determine the Bed Height Measure from top of trailer floor down to ground level 2 Determine A dimension Bed Thickness Measure from top of trailer floor to bottom of the trailer s cross members 3 Determine Sill depth GR10131 TOP VIEW OF TRAILER 8 ...

Page 9: ...Chapter 3 Basic Mounting Requirements GR10132 9 ...

Page 10: ... of supporting liftgate forces when liftgate is in stored position and when liftgate is loaded to full capacity Note that forces shown here are in pounds and are distributed over two liftgate rails GT 33 GT 44 GATE STORED GATE DEPLOYED GT 55 1 000 800 10 500 6 000 13 000 7 500 16 000 9 000 10 ...

Page 11: ... or Under Ride Guard License Plate Mud Flaps Other projections Move Slide Axles forward if necessary to attain required liftgate Mount Frame Clearance This dimension is found in Installation Dimensions Determine where new full length mud flap provided will attach Should be as close to wheels as possible Do not mount at this time Req d Liftgate Mount Frame Clearance GR01256 Mud Flaps Ground Cable P...

Page 12: ...ht GR02617 LIFTING THE GATE Always lift gate up from shown position under 4 channels NOTE Set forks to widest width possible to avoid bowing of 4 channels Use fork extensions if needed NOTE Failure to lift gate up according to instructions can damage the gate Lift up from here 4 Channel During the final positioning adjustments Hole Column Number may change depending on Rear Sill configuration Neve...

Page 13: ... Rear Sill do not include misc hardware such as Eyebrows or Door Locks in measurement Checking 6 dimension in 2 places will assist in getting Liftgate square with the Rear Sill Note Usually Liftgate can be aligned only to a certain degree with a forklift truck After that final adjustments usually require such tools as a crowbar and rubber mallet Note Verify Liftgate is square and properly aligned ...

Page 14: ...ch to move Platform to working position Lower Platform to ground Open Platform Extension and Loading Ramps manually Note Use handle to open Platform Extension GR01233 HANDLE Trailer s cross members Weld parallel to Cross Members along the top of the Mounting Angles Never perpendicular to the Cross Members as structural damage to Trailer could result Do not go underneath of Liftgate or Platform bef...

Page 15: ...wn just over Rear Sill Radius allowing upstops to contact the Rear Sill If Platform is hitting Rear Sill too low Loosen Mounting Bolts from Mount Plates 12 plc s Pull liftgate out as much as needed Approximately 1 out will raise platform 1 Test that platform aligns properly Tighten all Mount Bolts 12 plc s to 80 ft lbs If Platform is hitting Rear Sill too high Loosen Mounting Bolts from Mount Plat...

Page 16: ...down to fit in between trailer I beams Shown to the right 2 of these reinforcements will be positioned closest to the rear of the trailer The other bar is located between trailer I beams at the rearmost part of the liftgate as shown Bar supports are positioned flush with the mount angles Weld fillet to each vertical web of each I beam For GT 33 44 Use remaining flat bar and cut 4 additional strips...

Page 17: ...ar supports are positioned flush with the mount angles Weld fillet to each vertical web of each I beam For GT 55 Use 8 provided angles and 2 remaining flatbars to connect the liftgate to reinforcement strips as shown in blue Weld bars and angles 10X total as shown to the right with fillet all around on each part 8 angle reinforcements at the front of the liftgate 2 at the rear of the liftgate SECU...

Page 18: ... smoothly and that there are no unusual noises or vibrations Run all movements several times to remove any air from hydraulic system GR01242 INSIDE SWITCH Drill hole 1 dia for cable in trailer floor Weld inside switch to corner post as shown Route cable to pump unit box and connect to pump units wiring harness by matching connectors and by grounding white wire Make sure that cable doesn t pinch wh...

Page 19: ...0 411 5685 www waltco com Chevron Rando HDZ 32 20 to 90 F Waltco Biodegradable LiftLube Arctic part 85803866 NOTE Do not use the following fluids Waltco All Season Hyd Oil Part 85803867 Shell Tellus S2 Vx 15 Mobil DTE 10 Excell 15 Brake Fluid Power steering fluid Automatic Transmission Fluid ATF Chevron Rando HDZ 15 Rev 06 FINISH WIRING For Direct Power kits run the charge line to the single or du...

Page 20: ...ftgate Installation ADD DIELECTRIC GREASE TO CONNECTORS All connectors must be covered with dielectric grease not supplied Note especially following locations Positive battery pole Control switch cables GR10133 20 ...

Page 21: ...Chapter 4 Liftgate Installation Hydraulic Schematic Single Pump Gravity Down 21 ...

Page 22: ...Chapter 4 Liftgate Installation Hydraulic Schematic Single Pump Power Down 22 ...

Page 23: ...Chapter 4 Liftgate Installation Hydraulic Schematic Dual Pump Gravity Down 23 ...

Page 24: ...Chapter 4 Liftgate Installation Hydraulic Schematic Dual Pump Power Down 24 ...

Page 25: ...Chapter 4 Liftgate Installation Electrical Schematic Single Pump Gravity Down Lights are Options 25 ...

Page 26: ...Chapter 4 Liftgate Installation Electrical Schematic Single Pump Power Down Lights are Options 26 ...

Page 27: ...Chapter 4 Liftgate Installation Electrical Schematic Dual Pump Gravity Down Lights are Options 27 ...

Page 28: ...Chapter 4 Liftgate Installation Electrical Schematic Dual Pump Power Down Lights are Options 28 ...

Page 29: ...Chapter 5 Placement of Decals To order complete set of GT Series liftgate decals order kits below GT 33 Kit part number 80002238 GT 44 Kit part number 80002239 GT 55 Kit part number 80002240 29 ...

Page 30: ...fer to the following diagram showing decal locations 4400 lb Capacity or 80100587 5500 lb Capacity 80101308 Operation Decal 1 80101445 Safety Decal 1 80100850 Stand Clear 1 75089296 Hazard 1 80101370 2 3300 lb Capacity or 2 80100585 Locate on parallel arms 4400 lb Capacity or 80100587 5500 lb Capacity 80101308 Stand Clear 2 75089296 3 Use Handle Decal 1 75089295 Locate next to handle on platform e...

Page 31: ...Chapter 5 Placement of Decals CONSPICUITY TAPE Conspicuity tape is attached to Main Deck Tube as shown 31 ...

Page 32: ...y or cycles always lubricate more frequently 1 Grease all grease fittings in liftarm and cylinders with grease gun 2 Lubricate ramp hinges deck extension hinges and springs with a light weight machine oil Monthly Cycles Light Duty Med Duty Heavy Duty 250 Or Less 45 30 21 250 350 30 21 14 350 450 21 14 7 More Than 450 Suggested Minimum Lubrication Schedule In Days Contact Factory for Instructions 1...

Page 33: ...ielectric grease I Are all parts properly lubricated according to the lubrication instructions J Is 150 amp circuit breaker installed at battery K Is license plate properly installed L Are all decals properly in place and legible according to the decal placement drawings M Is pump cover installed and securely latched N Has hydraulic system been properly bled of all air O Is pump reservoir full of ...

Page 34: ...____________________________________________________________ THEN INCLUDE THE FOLLOWING INFORMATION 5 PART NUMBERS 6 DESCRIPTION 7 QUANTITY REQUIRED ________________________________________________________________ MAIL E MAIL OR PHONE YOUR REQUEST TO Waltco Lift Corp 1777 Miller Pkwy Streetsboro OH 44241 1 800 411 5685 FAX 1 800 411 5684 E MAIL parts waltco com ALL PARTS ARE F O B FROM THE SHIPPIN...

Page 35: ...s shown Install wires according to colors W White Raise B or BK Black Lower G Green Power GR02240 CONNECT WIRES TO PUMP UNIT Route Control Cord to pump enclosure First connect Splitter cord assembly to Pump Box connector as shown Connect Control Cord connector and the standard auxiliary switch to Splitter as shown GR02934 1 1 4 DIA 7 32 DIA CONTROL CORD SPLITTER AUXILIARY SWITCH CORD 35 ...

Page 36: ...er the vehicle body Weld hanger channel to body crossmembers Install batteries into box GR02769 Install 1 ga power and ground cables to liftgate pump unit per liftgate instructions Route cables along chassis frame towards auxiliary battery box securing them every 24 with cable ties provided Do not connect any cables to batteries at this time Be certain cables are protected with grommets when passi...

Page 37: ...tact with other vehicle wiring fuel lines brake lines air hoses exhaust system etc Install cable lugs as shown below GR01961 INSTALLATION OF TERMINAL LUG Strip 7 8 to 1 of insulation from end of cable Slide heat shrinkable tubing onto cable Insert bare wire into compression nut until it seats IMPORTANT Be sure to use correct compression nut use 1 2 gauge nut for 1 gauge cable use 0 gauge nut for 0...

Page 38: ...e Red heat shrink is applied to power cable and black heat shrink to ground Shrink tubing using electric heat gun or torch Note To reduce chance of damaging tube and cable a heat gun is recommended Apply sufficient heat to produce thin bead of sealant all around tube edges Heat Shrinkable Tubing Beads of Sealant GR00301 38 ...

Page 39: ...tive Hot Battery terminals and Circuit Breaker terminals Install circuit breaker decal 80100829 near the circuit breaker For trucks use remaining length of cables supplied with liftgate and route from auxiliary batteries to vehicle batteries Install terminal lugs on cables as required per previous instructions Install circuit breaker and cables to vehicle batteries per previous instructions Protec...

Page 40: ...ous amount of Dielectric Grease over cable terminals IMPORTANT Be sure to orientate cables as shown power to the left ground to the right Power charge cable from tractor batteries to trailer must also be protected with a 150 amp circuit breaker at the tractor batteries GR02770 Note While these instructions can be used for single pole sockets Waltco recommends dual pole sockets be used for their su...

Page 41: ...it breaker at the tractor batteries GR02739 Ground trailer socket to main structure of trailer Use the 18 ground cable supplied and bolt it to the trailer socket and suitable structure on the nose of the trailer An angle has been provided it can be used by welding it to the crash plate or other suitable structure GR01414 For all trailer applications After single or dual pole socket is installed Co...

Page 42: ...This Page Left Intentionally Blank 42 ...

Page 43: ...hicle 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 CORP ____________________ NOTE When ordering give model and serial number of the liftgate ____________________ 43 ...

Page 44: ...lt 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 information on this liftgate see Chapter 1 of this manual 80101520 EO6156 Rev 01 44 ...

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