Domino s Pizza GT Side Loader Tech Manual

6/5/2013 JDR/RLL

Domino’s Pizza

GT Side Loader Tech Manual

Waltco Lift Corp. Waltco Lift Corp. Waltco Lift Inc. Corporate Office United States United States Canada 285 Northeast Ave. 620 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

www.waltco.com [email protected]

Tech Support 330.633.9191

Waltco Parts Dept. 800.411.5685

http://www.waltco.com/

mailto:[email protected]

Table of Contents

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

LIFTGATE TERMINOLOGY...................................................................................................... 4-5

KEY COMPONENTS ................................................................................................................ 6-8

SIDE LOADER GRAVITY DOWN SINGLE PUMP ................................................................... 9

SIDE LOADER HYDRAULIC SCHEMATIC ............................................................................. 10

SIDE LOADER ELECTRICAL SCHEMATIC ............................................................................ 11

TROUBLESHOOTING GUIDE ................................................................................................. 12-16

ONE PIECE GALVANIZED PLATFORM PM ............................................................................ 17

MOUNT FRAME PM ................................................................................................................. 18

TRACK FRAME PM .................................................................................................................. 19

HYDRAULIC LAYOUT PM ....................................................................................................... 20

HYDRAULIC AND ELECTRICAL COMPONENTS ................................................................... 21

ELECTRICAL COMPONENTS ................................................................................................. 22

HOW TO ORDER PARTS ......................................................................................................... 23

Improper operation and maintenance of this liftgate could result in severe personal injury or death.

Read and understand the contents of the owner’s manual and all warning and operation decals before operating and/or performing maintenance on this liftgate.

Introduction

Each Waltco liftgate is manufactured to stringent quality standards for years of reliable service. To ensure maximum performance of your Waltco liftgate, always specify and use “OEM Parts” from Waltco. Service and repair should only be performed by an authorized Waltco distributor. For information on the nearest authorized Waltco distributor contact: Waltco Lift Corp. 285 Northeast Avenue Tallmadge, OH 44278 Phone: 800.411.5685 Fax: 800.411.5684 E-mail: [email protected]

The use 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 posted on the vehicle and an OWNER’S MANUAL in the vehicle at all times as a guide for proper operation and maintenance.

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 symbol

to avoid personal injury or death.

mailto:[email protected]

Liftgate Terminology

1. Deck 2. Mount Tube 3. Lift Cylinder 4. Lift Arm 5. Parallel Arm 6. Pump Box 7. In/Out, Raise/Lower Switches 8. Slide Tube 9. Mount Angles 10. Up Stops 11. Transit Latch Bail 12. Platform Light

84

Liftgate Terminology

EXPLANATION OF SPECIFICATION TAG MODEL NO. DESCRIPTION CAPACITY

GT33 GT-33 SLIDER LIFTGATE 3300 LBS. GT44 GT-44 SLIDER LIFTGATE 4400 LBS.

MODEL NUMBER RATED CAPACITY

Based on an evenlydistributed load on theplatform flat surface

SERIAL NUMBERof Liftgate. To be usedwhen ordering parts orwhen contacting Waltcofor service or warranty.

DATE OFMANUFACTUREMONTH/YEAR

GR02685

Rear Gate Side Gate

Key Components

Drive Motor

Cylinder Lock Valve & Coil Assembly

Rail Cap

Chain Bracket Bar (stop)

Chain Adjuster Bolt

Chain Adjuster Bolt

Track Stop

Drive Chain

Front view of Liftgate

Rear view of Liftgate

Platform Work Light

Flasher Lights

Key Components

Phillips Permalogic Charging System-Nose Box

Dual Pole Socket

Platform Indicator lights

Red light- Platform is not stored

Green light- Platform is stored

Lower set of lights represent the Side Gate

Upper set of lights represent the Rear Gate

Contact Phillips Industries direct for troubleshooting the Permalogic System. 800.423.4512 or www.phillpsind.com

Key Components

Proximity Switch

Platform Door Light Green light indicates platform is at floor level

Side Loader Gravity Down Single Pump

“D” Out

“C” Out

Pressure Compensating Flow Control Valve

Back side of Valve Body

Ground

“B” Lower

Brake

“C” (IN) & “D” (Out) Valve & Coils

“A” Raise & “BB” Lower Valve & Coils

Top View of Valve Body

Lock Valve and Coil

Ground

Front View of Valve Body

Thermal switch wires

Motor Solenoid

“A” Port Driver Side/Curb Side Raise/Lower

Reservoir Return Ports

Side Loader Hydraulic Schematic

To Motor To Lifts Cylinders

“C” Port In

“D” Port Out

“A” Ports

Lock Valve

Side Loader Electrical Schematic

Domino’s GT Side Loader

Trouble Shooting Guide

CHECKING THE OIL LEVEL IN THE RESERVOIR

The liftgate is shipped with Shell Tellus 15. Check the owner’s manual for additional recommended oils.

Fill as required with the specified fluid in the owner’s manual. Do not overfill the reservoir. Domino’s

spec power unit 90908954: Lower the platform to the ground. Oil should be within ½ to the fill line

(over or above) marked on the side of the oil tank. Fill as required with the specified fluid in the owner’s

manual.

RECOMMENDED LIFTGATE BATTERY(S)

Domino’s preferred liftgate battery(s) as supplied at during the installation are AGM batteries. The battery specification is Group 31, 650-750 cold cranking amps and at least 180 minutes of reserve capacity. Batteries should be load tested before being replaced. When replacing the liftgate battery(s) inspect the cables and wires for corrosion. If the batteries are in need of replacement the charging system should be tested before releasing the trailer.

MOTOR DOES NOT RUN

The pump motor has built in thermal protection. The thermal switch will shut the motor down if the unit exceeds 240 degrees. Once the motor cools down the switch will reset automatically.

o Check the cab shut off switch confirm that the switch is “ON” and functional. Check for voltage on

both terminals of the cab switch. This voltage should be the same as the battery voltage. If you do not find battery voltage check all of the cables and wires for damage and poor connections. Clean any dirty connections and tighten any loose connections.

o Check the Circuit breaker; this is located directly on the liftgate battery(s). Check for voltage on both sides of the circuit breaker. This should also reflect battery voltage.

o Inspect the 15 amp switch fuse located in the switch wiring harness. o Check the battery(s) for a full state of charge. Load test the lift gate battery(s). Replace any

batteries that cannot be fully charged. o Check all cables and wires for shorts and poor connections; this includes grounds and the gauge

of the wire for ground. Check the cables for damages clean any dirty connections and tighten any loose connections.

o Check for voltage at the motor solenoid. Listen for a clicking noise at the motor solenoid when the raise switch is activated. If you have at least 10.5 volts at the solenoid when the raise switch is activated and you have no voltage to the motor, and then replace the motor solenoid. If the motor does not run after confirming battery voltage at the terminal on the motor, replace the defective motor.

o If you have no power to the motor solenoid with the switch activated you could have a problem with the relays. A relay is used for each function “UP”, “IN” and “OUT” to power the motor solenoid. The switch is not directly wired to the motor solenoid. Post 87 on each relay provides power to motor solenoid. When control switch is pressed for “UP”, “IN” or “OUT”, you should get voltage at the motor solenoid. If you are not getting voltage, then you should check the relays and wiring back to the switch that powers the relays.



PLATFORM DOES NOT RAISE OR RAISES SLOW- MOTOR RUNS

If the motor is not running see the section titled “MOTOR DOES NOT RUN” before proceeding.

o Check for any mechanical obstructions or any mechanical damage. Look for any broken, bent or worn parts that could interfere with normal operation.

o Check and inspect the oil level in the reservoir. Inspect for any contamination or water in fluid. Check the fluid viscosity. See Checking the oil level in the reservoir

o Check the Coil Valve (A). Check and confirm voltage to coil when the “Raise” switch is activated. Check for 10.5 volts at the coil. Test the coil for resistance (4.5ohms). Confirm that the valve is magnetizing. If the coil is working the valve may need to be replaced. If the valve is not getting voltage, check all cables and wires for shorts and poor connections. Check and test the control switch.

o If your voltage is under 10.5 volts with the “Raise” switch activated, check the battery(s) for a full state of charge. Load test the lift gate battery(s). Replace any batteries that cannot be fully charged.

o Check pumps pressure from the lift port (A).It should be 2900 psi.

PLATFORM DOES NOT SLIDE OUT


o Check for any mechanical obstructions or any mechanical damage. Look for any broken, bent or worn parts that could interfere with normal operation. Inspect the railing rollers and track system of the liftgate. Check for any obstructions in the path of travel. Lubricate all pins and bushings.

o Check the Coil Valve (D). Check and confirm voltage to coil when the “Out” switch is activated. Check for 10.5 volts at the coil. Test the coil for resistance (4.5ohms). Confirm that the valve is magnetizing. If the coil is working the valve may need to be replaced. If the valve is not getting voltage, check all cables and wires for shorts and poor connections.

o Check and inspect the hydraulic drive motor. Inspect the timing on the tracking system by taking the gate in and making sure that gate the touches the stops on both sides evenly. Check to see if the axle gears are engaging evenly on both sides of the chains. Inspect the drive motor for engagement. Then check the line out pressure (D) it should be about 1500 psi.

PLATFORM DOES NOT SLIDE IN - MOTOR RUNS


o Check for any mechanical obstructions or any mechanical damage. Look for any broken, bent or worn parts that could interfere with normal operation. Inspect the railing rollers and track system of the liftgate. Check for any obstructions in the path of travel. Lubricate all pins and bushings.

o Check the Coil Valve (C). Check for 10.5 volts at the coil when the “In” switch is activated. Test the coil for resistance (4.5ohms). Confirm that the valve is magnetizing. If the coil is working the valve may need to be replaced. If the valve is not getting voltage, check all cables and wires for shorts and poor connections.

o Check and inspect the hydraulic drive motor. Inspect the drive motor for engagement. Then check the line out pressure (C) it should be about 1500 psi.



PLATFORM WILL NOT LIFT TO FULL CAPACITY

o Check the serial tag on the liftgate and verify the load lifting capacity. Confirm that the platform is not over loaded. Confirm that the load is centered correctly on the platform.

o Check and inspect the oil level in the reservoir. Inspect for any contamination or water in fluid. Check the fluid viscosity. See checking the oil level in the reservoir.

o Check the battery(s) for a full state of charge. Load test the lift gate battery(s). Replace any batteries that cannot be fully charged


o Check for leaking hoses and lines. Replace any leaking lines or hoses. o Check for air in the hydraulic system; bleed any air from the lift gate at the cylinder. o Check the voltage at the pump motor with the “Raise” switch activated. The voltage should be

10.5 volts. o Check the pump pressure from the lift port. It should be 2900 psi.

PLATFORM DOES NOT LOWER OR LOWERS SLOW


o Check and inspect the oil level in the reservoir. Inspect for any contamination or water in fluid. Check the fluid viscosity. See Checking the oil level in the reservoir.

o Check voltage on the Lowering Valve (BB) while the “Lower” switch is being activated. The voltage should be at least 10.5 volts. Feel for a pulse on the valve. Test the coil (4.5ohms). Confirm that the valve is magnetizing. If the coil is good the valve may need to be replaced. If the coils are not getting power, check all cables and wires for shorts and poor connections.

o Check voltage on the Lock Valves while the “Lower” switch is being activated. The voltage should be at least 10.5 volts. Feel for a pulse on the valve. Test the coil (4.5ohms). Confirm that the valve is magnetizing. If the coil is good the valve may need to be replaced. If the coils are not getting voltage, check all cables and wires for shorts and poor connections.

THE CIRCUIT BREAKER TRIPS

o Check for a direct short in power cable. Inspect for damaged or cut cable. Also check for improperly size battery cable.

o A defective motor may draw to much current. Check amperage draw from lift gate motor. At 700 psi the motor should draw 80-100 amps.

o Defective circuit breaker. If the breaker is suspected it should be replaced.

CONTROL SWITCH FUSE BLOWN

o Check the wiring for damages, clean dirty connections and tighten any loose connections o Check and inspect for a short in switch control wire or switch contacts o .Check for defective coils on valves Test the coils (4.5ohms)



PLATFORM WILL ONLY LOWER ON ONE SIDE.

o Check for any mechanical obstructions or any mechanical damage. Look for any broken or bent parts that could interfere with normal operation.

o Test for voltage on lock valve. Check for 10.5 volts at the coil when the “lower” switch is pressed. Check for defective coils on valves. Test the coil for resistance (4.5ohms). Confirm that the valve is magnetizing. If the coil is working the valve may need to be replaced. If the valve is not getting voltage, check all cables and wires for shorts and poor connections

PUMP MOTOR IS GETTING HOT

o The Thermal sensor is set to activate at 240 F degrees .This condition 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.

o Check for low voltage. The voltage should be at least 10.5 volts at the motor. o Check batteries are fully charged, load test batteries. Check the cables for damages, clean dirty

connections and tighten any loose connections. o Check and confirm that the ground is adequate.

INDICATOR LIGHTS AT THE FRONT OF THE TRAILER ARE NOT WORKING.

o The liftgate has been equipped with two indicator lights that will allow the driver to see if the gate is stored or deployed. The “GREEN” indicator means that he gate is stored. The “RED” indicator means that the platform is deployed. In order for the indicators to illuminate, the 7 way connector will need to be plugged in.

o If the “GREEN” or ” RED” indicator lights are not getting voltage, check all cables and wires for shorts and poor connections. Check and test the “Signal Lights Relay” check for voltage on 87a for the “RED” indicator when the platform is deployed and 87 for the ”GREEN” when the platform is stored.

o Check and inspect the proximity switch, confirm that it is functional

o Check all of the cables and wires for damage and poor connections. Clean any dirty connections and tighten any loose connections.

PLATFORM WARNING LIGHTS ARE NOT WORKING

o Check lights test the lamps to confirm that the lamp does not have a broken filament. o Check the “Work Lights Relay” and confirm that the relay is operating properly. o Check and inspect the proximity switch, confirm that it is functional




AMBER WARNING SIGNAL LIGHTS ON PLATFORM ARE NOT WORKING

o Check lights test the lamps to confirm that the lamp does not have a broken filament. o Check the “Signal Lights Relay” and confirm that the relay is operating properly. o Check and inspect the proximity switch, confirm that it is functional


DOOR LIGHT INSIDE TRAILER TO INDICATE PLATFORM IS AT FLOOR LEVEL IS NOT WORKING.

o Check lights test the lamps to confirm that the lamp does not have a broken filament. o Check the” Door Lights Relay” and confirm that the relay is operating properly. o Check and inspect the proximity switch, confirm that it is functional


LIFT CORP.

DOMINO’S GTSL SERIES

REVISED: E.O. REV.

PM

ITEM PART NUMBER QTY DESCRIPTION

91265104 1 Platform Assembly Complete, 49x80+5.5 1pc stl galv, wrk lts, rogs, yellow ramp

(Includes all items listed below)

1 91265014 1 Finished Platform, 49-80+5.5 1pc, Galv 4 wear pads installed

2 23370800 2 Upper Pin Assy, 1.00x2.75 p

3 75088255

75088081

4

4

Washer 3/8 Stainless Steel

Lock Washer 3/8 Plated

4 75086055 4 Hex Bolt, 3/8-16x3/4 GR5

5 27371002 2 Lower Pin Assy, 1.00x7.0,p

6 91129785

91129786

2

2

Work Light,13-LED,2.5Dia, White

Grommet,Light,2.5Dia, Black

7 *34427307

*75086854

4

8

Bearing

1/4-20x5/8 Self Tapping Screw Type F Plated

* Item #7 Wear pads not shown on drawing below are installed on underside of platform one in each corner

LIFT CORP.

DOMINO’S GTSL SERIES

REVISED: E.O. REV.

PM

ONE PIECE GALVANIZED PLATFORM

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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.]

2. MODEL NUMBER 3. CAPACITY 4. PLATFORM SIZE ________________________________________________________________

THEN INCLUDE THE FOLLOWING INFORMATION:

5. PART NUMBERS 6. DESCRIPTION 7. QUANTITY REQUIRED ________________________________________________________________

MAIL, E-MAIL OR PHONE YOUR REQUEST TO:

Waltco Lift Corp 285 Northeast Avenue Tallmadge, OH 44278 1-800-411-5685 FAX: 1-800-411-5684 E-MAIL: [email protected]

ALL PARTS ARE F.O.B. FROM THE SHIPPING FACTORY ________________________________________________________________

PLEASE NOTE:

To assure you of continuing and effective quality control, our warranty policy permits replacement of hydraulic cylinders, valves and motor pump units when their factory seals are intact. Parts under warranty will be exchanged promptly after careful inspection of the returned assemblies. ________________________________________________

Domino s Pizza GT Side Loader Tech Manual

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Transcript of Domino s Pizza GT Side Loader Tech Manual