EO:7006A Rev 01

12-2012 80117202

Owner’s Manual

BZ-33, BZ-44 Gen 5 3300 lb. & 4400 lb. Capacity Cantilever Liftgates

GR02912

Waltco Lift Corp. Waltco Lift Corp. Waltco Lift Inc. Corporate Office United State 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 Phone: 800.211.3074 sales@waltco.com Fax: 800.211.3075

Page 1

Table of Contents

Introduction ................................

Safety Information ................................

Warranty ................................

Liftgate Model Information ................................

Placement of Decals ................................

Lubrication ................................

General Information ................................

Additional Safety Information

Technical Description ................................

Operating BZ Liftgate ................................

Loading Limits ................................

Advice and Warnings ................................

How to Order Parts ................................

Improper operation and maintenance of this liftgate could result 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.

Table of Contents

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Safety Information ..........................................................................................

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

Read and understand the contents of this manual and all warning and operation operating and/or performing maintenance on this liftgate.

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mproper operation and maintenance of this liftgate could result in severe

Read and understand the contents of this manual and all warning and operation operating and/or performing maintenance on this liftgate.

Page 2

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 Owner’s 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.

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, 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, loose fasteners, 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 LIFT CORP.

Page 3

Chapter 1 Safety Information

WARNING

Read, understand, and follow all of the warning listed below.

Failure to follow these warning could result in severe personal injury or death.

• Read and understand the Owner’s Manual, all decals and warning 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.

• Wheeled loads must be properly retained from rolling.

• Tall, high center of gravity loads must be retained from falling over.

• Never overload liftgate:

Load platform as close to the vehicle, and towards the middle of the platform as possible. Refer to owner’s manual and capacity decal of liftgate for maximum load and load placement.

• Keep hands and feet clear of all potential pinch points.

• 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.

• 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.

• 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, in which Platform will open and close before opening or closing Platform.

• Do not allow anyone to stand near the Platform where a falling load could land on them.

• Platform is always to be properly stored and secured for transit. See the Owner’s Manual for details.

• 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.

• A Lock-Out device or Shut-Off Switch should always be used to prevent unauthorized use of liftgate.

• For liftgates with Runners, never use liftgate if Runners do not travel freely and smoothly.

• 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.

• 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.

• 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.

• Vehicle must comply with all state and federal standards.

• Follow the “Maintenance Guide” chapter in the Owner’s Manual.

Page 4

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-Series Liftgates

• Make certain Platform Brake mechanisms are operating properly.

• The Runners are always to remain powered up against the Up-stops 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.

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.

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. NOTICE Indicates a potentially hazardous situation, which if not avoided, may result in property damage.

WARNING

CAUTION

NOTICE

Page 5

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 Lift Corp 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 6

Model Information

EXPLANATION OF SPECIFICATION TAG MODEL NAME DESCRIPTION CAPACITY

BZ33 G5 LEVEL LIFT 3300 LBS. BZ44 G5 LEVEL LIFT 4400 LBS.

MODEL NAME RATED CAPACITY

Based on an evenly distributed load on the platform flat surface

SERIAL NUMBER

of Liftgate. To be used when ordering parts or when contacting Waltco for service or warranty.

DATE OF MANUFACTURE

MONTH/YEAR

GR00053

LOCATION OF SPECIFICATION TAG Can be found on driver’s side, end of mount tube.

GR02226

Usually found on this end

On some older liftgates may be located here

Mount Tube

Page 7

Chapter 5 Placement of Decals INSTALLATION OF CONTROL DECALS

Install all decals listed below. Be certain they are installed in the proper location and are legible.

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

Each of the following four (4) decals are to be 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 three (2) decals is to be positioned in a conspicuous place near the control switches as shown.

80101415 – BZ-33 Capacity Decal

80101416 – BZ-44 Capacity Decal

If your liftgate is equipped with dual

controls, an additional Safety Instruction

decal (80100850) is to be placed in a

conspicuous place near the second set of

controls.

GR02913 INSTALLATION OF DRIVE-OVER WARNING DECAL

The following decal is to be positioned in a conspicuous place near the control switches as shown.

80100592 – Drive Over Decal

If unit is equipped with drive over kit decal

80101330 must be used in place of decal

80100592.

GR02914

PLACE DECALS IN THIS AREA

To maximize decal adhesion to surfaces: Surface must be dry and clean Firm pressure must be applied to decal Minimum surface temperature 65º

Heat gun may be used to heat surface

Page 8

Chapter 5 Placement of Decals INSTALLATION OF PLATFORM DECALS

The following decals are to be placed on the underside of the platform and both sides of vehicle as shown.

75089296 – Stand Clear Decal (4)

One (1) of the following three (2) decals is to be positioned in a conspicuous place on the bottom of the platform as shown

80101415 – BZ-33 Capacity Decal

80101416 – BZ-44 Capacity Decal

GR00511 INSTALLATION OF SAFETY TAPE

Tape (Z20290) is to be placed on the sides of platform so it is visible from the side and back of vehicle as shown.

IMPORTANT! Safety tape must wrap around side of platform as shown.

GR00511

STAND CLEAR DECALS HERE

IMPORTANT! Safety tape must wrap around side of

platform as shown.

CAPACITY DECAL HERE

Page 9

Chapter 5 Placement of Decals SAFETY TAPE AND FLAGS

Tape (Z20290) is to be placed on the sides of platform so it is visible from the side.

Locate 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), install flag mount brackets as shown.

Slide flags (75089905) into mount brackets and crimp ends of each bracket to prevent flags from sliding out.

GR00043 & GR01761

SHUT-OFF DECAL

The following decal is to be placed next to the liftgate shut-off switch as shown.

75089267 – Liftgate Shut-Off Decal PLACEDECAL ASSHOWN

GR00121 CIRCUIT BREAKER DECAL

The following decal is to be placed next to the liftgate circuit breaker as shown.

80100829 – Circuit Breaker Decal

PLACE DECALIN THIS AREA

GR00122

9” 9” 9” Tape

Flag mount bracket

Flag

Page 10

Lubrication

LUBRICATION INSTRUCTIONS

12 grease fittings should be lubricated with a grease gun per the lubrication schedule below.

Note: All fittings should be greased with the platform in the stored position. Note: If unsure of duty or cycles always lubricate more frequently.

1. Tilt cylinder, lower pin 2. Lift cylinder, lower pin 3. Lift arm, lower pin 4. Tilt cylinder, upper pin 5. Lift cylinder, upper pin 6. Lift arm, upper pin

GR00508

4 6

5 3

2 1

SUGGESTED MINIMUM LUBRICATION SCHEDULE (IN DAYS)

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 Contact Factory for Instructions

Page 11

This manual contains useful information about your Z-tail lift: Technical description of equipment and function of these, technical safeguard, safety instructions for op-erators, everything according to: En 1756-1: English standard: Vehicles - Safety requirements for tail lifts for mounting on wheeled vehicles.

The manual must be kept in the vehicle on which the tail lift is placed and be used as a guide for safety and maneuvering. For safety of the operator and third party must the tail lift only be used by educated persons who can and understand the content of this manual.

Operators which hasn’t the above knowledge constitute a big risk for them selves, assistant at loading and unloading, and third party.

A tail lift is used to lift or lower heavy load, this may cause injuries if the safety in-struction in this manual isn’t followed.

Note!It is the employers responsibility to ensure that the operator is conversant with the tail lift and its uses. The operators attention should be drawn to the risks and to the permitted loads allowed.

ImportantBefore allowing the operator to use the lift he should be thoroughly conversant with the lift’s functions and usage according to the following: 1. During any phase of operation the lift must never, either whilst stationary or during up or down movements, be loaded with more than the given maximum for that particular lift. See loading diagram.2. The centre of gravity of the maximum load should not be placed further back than the loading diagram for the specific lift admits.3. Nobody but the operator must operate the lift.4. The lowering and lifting speed must not exceed 0.15 m per second = 1.5m per 10 seconds. The tilt down speed may not exceed 10°/second from transport position to work position.5. Beware of the risk of trapping parts of the body between lift and truck body when lifting and closing. Keep feet clear from the front edge of the platform.6. Carry out a daily control and always check the lift’s parts and correct function after accidents.

Don’t use a damaged lift. Contact authorized workshop immediately.

General information

4Page 12

SafetyGenral safety

Only use the tail lift if the vehicle is parked and the handbrake is tightened so you are certain that the vehicle doesn’t move during the use. When its necessary use stop blocks.

Ensure that the area under and around the tail lift is empty and stays empty as long as the tail lift is in use.

Only one person is allowed to operate the tail lift at time.

Only educated personnel is allowed to use the lift.

In order to operate the tail lift, only use control units that’s approved by Zepro.

Before the platform lowers or lifts you must control and secure the load. Al to minimize the risk of falling load.

Do not drive the vehicle if the platform is loaded or open.

Don’t let heavy loads fall down at plat-forms.

Always have full overseen of the work-ing area when the lift is in use.

If there is any doubt about the function-ality of the tail lift, contact authorized workshop.

Despite the tail lift is equipped with a non-slip surface must precaution to be taken at locomotion.

Only use spare parts that’s approved by Zepro.

5Page 13

Restricted area of use

Safety

A tail lift is only meant to be used when the function is satisfactory. If there is any doubt concerning the tail lifts func-tionality call for or visit an authorized workshop.

A tail lift has the sole purpose of aiding the loading and unloading of vehicles, thus, preventing the operator from making unnecessary physical efforts.

Under no circumstances must a tail lift be used to scoop objects or material up from the ground or drive objects in the ground using the platform or other parts of the tail lift as driving tools.

I.E. the platform or other parts of the lift are´t allowed to use as working tool for other than intended use.

6Page 14

When the tail lift is in use the operator must be aware of that all in nearby risks injuries.

The tail lift is delivered with a working area decal as clearly show at which dis-tance other vehicles is allowed to park.

Ensure that other vehicles doesn’t park closer than 5 m from the edge of the body.

Pay special attention to that no kids or animals set foot on working area when the tail lift is in use.Instability in heavy loads can give inju-ries at people.

SafetySafety for third party

The working area must always be free from persons and things. Al to avoid damages if loads should fall of.

Uneducated personnel can never be allowed to operate the tail lift.

7Page 15

SafetyWorking area

The control units are located in such a way, so they will give: * A good oversee over the working area and the surroundings.* A safe position in proportion to passing traffic.

NB!Dangerzone: The area in which the platform is moving. This area may under no circumstances set foot on when the tail lift is in use.Working area: The area outside the platform where the operator may stand when the lift is in use. If anyone else than the operator set foot on this area when the tail lift is in use must all up or down movement cease immediately.Area outside working area: The operator must be observant at the surroundings in order to detect potential danger.

Danger zone

Working area

8Page 16

The biggest risk for snips and catch in-juries is in the danger zone between the platform and body floor when the plat-form rises to body floor level and when the platform closes against the body. A person who rides with the goods at the platform must keep back feet and other parts of the body from this danger zone.

SafetyTechnical safety

Your ZEPRO tail lift is equipped with safety devices to prevent accidents.

Electric safetyElectric safety valves are one-way valves which allow oil to flow into the cylinders but not out from them unlesscurrent has been supplied to them via the lowering valves. In the event of a leakage, the platform is supported by the oil which is trapped securely in the cylinder by the safety valve.ZEPRO supplies one such valve on the tilt cylinder circuit and one on lift cylinder circuit so that both circuits are protected.

Mechanical safety valvesUnlike electrical safety valves as pro-tect at leakage, these protect the tail lift against plummeting at hose breakage.

Control unit3-button control + turn switch is used at all opening/down tilting/lowering and closing/up tilting/lifting movements to avoid catch injuries. This means that the turn switch must be activated together with normal buttons in order to the above movement is to be carried out.

Warning flags & warning lightTo mark ”platform out” there is warn-ing flags and warning lights at platforms, mounted as alerts the surroundings during the tail lifts movement. The flags have reflectors to enable good visibility at all times, thus ensuring safe work in the evenings and nights.

Main fuseIn order to prevent electrical overload of circuits and the consequent risk of fire a 160A (24V) or 250A (12V) has been integrated into the electrical circuit.

9Page 17

Safety

The hydraulic system at Zepro tail lifts works under high pressure (up to 200 bar) and shall be maintained continuously in order to function at a reliable and safe way. All hydraulic units are equipped with an overflow valve as prevents that the tail lift can be raised or tilted with an overload.

The operator isn’t allowed to make any changes or adjustments of parts belonging to the hydraulic system. If anything of the above has to be done, this must be car-ried out by an authorized workshop.

The safety of the hydraulic system

The tail lift is equipped with a control unit.The control units must be approved by Zepro and must be mounted at the same time as the tail lift is mounted at the truck.

Control units can also be mounted at fixed brackets below the body.

User safety

10Page 18

SafetyUser safety

The spiral cable control unit (remote) can be used from inside the vehicle stand-ing at least 300 mm from the floor-edge to prevent risk of foot injury.

Always use fixed control units at opening and closing of the tail lift. In order to avoid crush damages at operators, this person must always pay attention to the positioning of the feet in order to avoid the danger zone between body and the platform.

11Page 19

Technical descriptionThe ZEPRO-lift is electro hydraulically driven. An electric motor which gets its power from the truck’s ordinary battery drives a hydraulic pump which supplies oil to the working hydraulic cylinders.The system is steered by electrical valves. The hydraulic unit with all details is either built into the lifts support frame or contained in a separate box. Both systems are easy to reach for service and maintenance. The ”power pack” is easy to replace.

The platform is supported by the lift arm which is very strong and rigid. The under run bar is bolted to the lift arms or is di-rectly attached to the support frame. The platform has a nonslip surface.

The lift arm lifting work is done by lift cylinders which have built in safety valves for protection against hose breakage. The cylinders are equipped with electric safety valves, which are leak proof. These safety valves also act as a transport lock for the platform.

The platform’s tilt function is also pro-vided by cylinders with the same con-struction as the lift cylinders. Lifting and tilting up speed are fixed by the pump capacity, and it’s naturally conformed to statutory velocity.

Lowering and tilting speeds can be ad-justed with special constant flow valves that are accessible to service person-nel. These valves give the same speed independent of the load.

The cylinder piston rods are treated with methods which gives them very long life.

The hydraulic system is protected with a pressure regulator when lifting or tilt-ing up. Note! This regulator does not prevent overload at rest position or lowering.

The electric power is taken from the trucks ordinary battery. Current to the tail lifts electrical motor is lead by a fuse which also has a function as main switch to the tail lift. The fuse is located in a plastic box near the trucks battery.

Control current is taken from the dash board. When the control currents isolator switch is switched off, the lift is ”locked”. At all transport situations must the control current be broken.To save current the control ought to be switched off when the lift not is in use.

The lift can be operated from optional units connected in parallel. It can also be operated by remote control.

12Page 20

Technical description

The electric motor is equipped with a so-called ”thermo guard”, a thermostat-ic steered switch as break the solenoids manoeuvre circuit if the motor is over-heated. When the motor has to cool down the solenoid will work again.

13Page 21

Technical description

Platform

Mounting bracket

Support frame

Tiltcylinder

Liftcylinder

Bumper bar

Lift arm

3-parts bumper bar

14Page 22

Operating, standardlift CENB!Ensure that the tail lifts working area and periphery are clear.

OPEN/TILT DOWN 4+2+3

LOWER4+3

Function, fixed control unit

3-button control unit + turn switch 3 button + turn switch is used to all operating of the tail lift in order to avoid crushing.

Open/tilt downAt opening from transport position: use turn switch (4) tilt button (2) and down button (3) in mentioned order. The con-stant flow valve gives the same speed independent of the load.

LowerActivate the turn switch (4) and down (3) button in mentioned order. The con-stant flow valve gives the same speed independent of the load.

Tilt downActivate the turn switch (4) and push tilt (2) and down button (3) in mentio-ned order. The platform tilts down with the same speed. Also here gives the constant flow valve the same speed independent of the load.

TILT DOWN 4+2+3

123

UP

TILT

DOWNFIXED

CONTROL UNIT 4 TURN SWITCH

15Page 23

TILTING UP4+2+1

Operating, standardlift CE

LIFT4+1

NB! Always lift up the platform against body floor before tilt up/closing to transport position. NB!The platforms movement can stop at anytime (if the push buttons are released) and in al positions be-cause the push buttons break the current to respective function.

NB!The hydraulic system is protected against overload at lift and tilt up of a built in overflow valve. Notice that this valve doesn’t protect at resting or low-ering. This may under no circumstances be used for overloading at lowering.

OPERATING INSTRUCTION

The tail lift can only be used by autho-rized personnel.

DO NOT OVERLOAD THE TAIL LIFT!

After operating the tail lift Lock the platform, turn of the maneu-ver current in the cabin. Then the tail lift is locked for unauthorized people. If the platforms lock handle (if available) goes heavily, the reason can be hose break at the lift or tilt system. Note! Certain models of control units are equipped with electric heating. The electric heating is connected to the control current. This will consume a little current from the battery if the control current is switched on.

Tilt upActivate the turn switch (4) tilt button (2) and up button (1) in mentioned order. The platform tilts up. If the load is to heavy or placed to far back on the plat-form at tilt up, the overflow valve opens.

LiftActivate the turn switch (4) and push up button (1). If the load is to heavy the over flow valve opens.

CloseActivate the turn switch (4) and push tilt (2) and up (1). The platform tilts up and close against the body.

CLOSE4+2+1

16Page 24

SPIRAL CABLECONTROL UNIT

RADIOCONTROL UNIT

Function, spiral cable and radio control unit.

LOWER3

TILT DOWN 2+3

LowerPush down button (3). The platform low-ers with the same speed. The constant flow valve gives the same speed inde-pendent of the load.

Tilt upPush tilt (2) and up (1) button in men-tioned order. The platform tilts up to horizontal position. If the load is to heavy or placed to far back on the plat-form at tilt up, the overflow valve opens.

TILT UP 2+1

LIFT1

NB!Opening and closing function is only allowed with fixed control units.

Operating with spiral cable/radio control unitTilt downPush tilt (2) and down button (3) in mentioned order. The platform tilts down against ground. Also here gives the constant flow valve the same speed independent of the load.

LiftPush up button (1) The platform lifts with the same speed. If the load is to heavy the over flow valve opens.

23

123

1 2 3UP

TILT

DOWN

Page 25

Function spiral cable control unit with deactivate button

Spiral cable control unit with deactivate button A lamp is light up when using spiral ca-ble control unit. The lamp indicates that the sprial cable control unit is active, and all other control units is locked. Press deactiavte button to turn off the lamp and unlock all other control units.

LampDeactivate button

24Page 26

Loading Limits

BZ-33 Only

If the load is centered no farther than 30” out from the vehicle rear sill, the maximum capacity is 3300 lbs.

As the load is centered farther out on the platform, the maximum capacity is reduced, as shown.

IMPORTANT! Never over load platform.

GR00490

BZ-44 Only

If the load is centered no farther than 30” out from the vehicle rear sill, the maximum capacity is 4400 lbs.

As the load is centered farther out on the platform, the maximum capacity is reduced, as shown.

IMPORTANT! Never over load platform.

GR00491

30"42"54"66"78"

CENTER OF GRAVITY

3300 lbs.2300 lbs.

1800 lbs.1450 lbs.

1250 lbs.

30"42"54"66"78"

CENTER OF GRAVITY

4400 lbs.3100 lbs.

2400 lbs.1950 lbs.

1650 lbs.

Page 27

A misunderstanding could be fatal. Never let an outsider get around to operate the tail lift.

Never let an ”outsider” operate the tail lift while you are handling the cargo.

Advice and warnings

Note!It is the employers responsibility to ensure that the operator is conversant with the tail lift and its uses. The operators attention should be drawn to the risks and to the permitted loads allowed.

IMPORTANT!Before the operator uses the lift he should be thoroughly familiar with its use and care.

28Page 28

lt’s too heavy and dangerous.

Not this way...

Cargo transfer - truck to truck / truck to trailerZeppo has to transfer a cargo of several tons from one truck to another. He has, however, forgotten that this can overload the platform.

29Page 29

..... this way.

Maximum transfer weight = Taillift loading capacity x 0,5

Use the platform of the truck to be loaded as a ramp. The platform can be raised or tilted up, but not lowered or tilted down without activating the control units.

Note !! Maximum transfer weight is taillft loading capacity x 0,5. For example, on a 2000kg taillift, allowed transfer weight is 1000kg.

Cargo transfer - truck to truck / truck to trailer

The tip of the platform should be kept clear in all loading situations

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Push tilt down.

Adjusting the platform to the dock

As the truck isunloaded, it rises relative to the dock.

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Before you unload each article onto the dock use the control unit to tilt down. Make sure that the platform overlaps sufficiently (min 150 mm) and have a secure and solid resting position. lt’s safer for the driver, the customer and his cargo.

Adjusting the platform to the dock

32

min 150 mm

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The driver must under no circumstances tilt down more than 10º (check table below), and putting load on the plat-form.

Maximum tilt down angle

X max

Platform Length

X max

1200 280 mm

1500 260 mm

1700 300 mm

2000 350 mm

2500 435 mm

Before tilting down.Check the table so that permitted tilt down angle not is exceeded.

Dock

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Using the platform as a ramp for forklifts and

heavy pallet jacks

A platform is not capable of carrying the overload offorklifts.

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Note! Forklift locks can only be used on taillifts with steel platforms and loading capacity 1500 - 2500kg.

If you install forklift locks, you can drive with a max 3,0 ton forklift including load over the platform.

Lock the platform at bed level using the forklift locks. Secure the rear wheels.

If you unload the vehicle, tilt the platform down to compensate for changes in the bed height, always make sure that the platform overlaps sufficiently (min 150 mm) and have a secure and solid resting position.

Using the platform as a ramp for forklifts andheavy pallet jacks

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Do not overload the tail liftWhen you are placing a load on the platform or are pulling a load out from the truck bed you must remember that the further out the load is positioned the lighter load should be.

The 1500 kg lift takes 1500 kg 600 mm from the bed edge, 750 kg 1200 mm out and only 450 kg at the back edge on a 2 metre platform.

See load diagram of the lift type.

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Overloading is very dangerous!Do not overload because of risk of damaging the lift and injuring people near the lift. As the operator you are responsible for the lift, even if someone else is loading it.

Locate the load correctly!See loading diagram.Never load more than the max. load!

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You can’t overload the ZEPRO-lift when lifting or tilting up. The pressure relief valve will prevent it. At lowering or at ”resting platform” is however the overload unlimited.

The CONCEALED overload

Check that there is enough room for the platform below the dock

Unloading from truck with a forklift on platform can also be dangerous.The forklift drives onto the platform which has been lowered to the ground. Be sure not to unload more than taillift maximum loading capacity. Example: When the forklift lifts the load (2000kg), the taillift will be loaded with 2000kg. The platform is also loaded with the weight from both forklift and load.

Unloading from dock with a fork-lift can be dangerous.When unloading from trucks to dock, without driving at a platform, lies the platform under the dock. The plat-form raises whereupon unloading take place. If the platform reaches permanent point under dock, the lift be loaded with all the load you have taken away from the trucks bed.

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To unload from trailer when separated from truckWhen the truck is driven away, the lift often has no source of power and can’t be operated. Think about that when loading and unloading, the platform will raise from the dock or from the ground.It is ABSOLUTELY FORBIDDEN to use a FORKLIFT for unloading or loading. This could have disastrous consequences for the lift and personnel.If you have that problem, contact your agent for a solution!

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If you have damaged your ZEPRO tail liftIf there has been an accident with the tail lift..Don’t hide or ”hush-up” any accident. It can be dangerous for you or somebody else.

Before you use the lift again:Make a test lift, preferably with max loads. Have a forklift in readiness under the platform or make the test lift near the ground. Replace damaged parts and check for cracks or damages on arms, platform and support frame.Contact your employer and tell what happened.Contact authorized workshop if you suspect damages at your tail lift.

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Think of the lift, tooThe ZEPRO-lift needs maintenance to give trouble-free service. Grease and control regularly. Also check that all details are not damaged: Hoses, cylinder covers etc.Follow the maintenance instructions and the inspection record.

When necessary...

Bleeding the cylinders

Lift cylinders:Lower the platform a few times. You may have to lift the truck to fully lower the platform.Tilt cylinders:Close the platform up against the vehicle body and then opening and tilting all the way down.

Greasing

At the vehicles greasing moments. At least 8 times a year. Grease the cylinders and piston rods bearing places and the lift arms upper and lower with lubricant for chassis.

Check the oil level in the tank. Oil quality: ZEPRO special oil is the very best for year round use. If not available check with agent.

Note! Change oil at least every autumn. Condensed water and dirt can prevent the lift from working perfectly.Please refer to your maintenance manual for more details.

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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: 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.

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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.

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. ____________________

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IMPORTANT KEEP THIS OWNER’S MANUAL IN THE VEHICLE

WARNING Improper operation and maintenance of this liftgate could result 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

80101519 EO6156

Rev 01

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