Waltco Lift BZ-33, Installation Manual

Page 1: ...ED SCHEMATICS 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 In...

Page 2: ...ls 47 Lubrication Instructions 50 Final Inspection 51 Optional Kit Instructions Aux Battery Kit Truck 52 Kit 80001066 Aux Battery Kit Trailer Kit 80001069 Full Door Seal Kit 57 Kit 80000573 Cycle Coun...

Page 3: ...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...

Page 4: ...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 g...

Page 5: ...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 ye...

Page 6: ...t Cylinder 8 Upper Lift Arm Pin 9 Lower Lift Arm Pin 10 Upper Lift Cylinder Pin 11 Lower Lift Cylinder Pin 12 Upper Tilt Cylinder Pin 13 Lower Tilt Cylinder Pin 14 Marker Lights 15 Sill Extension 16 M...

Page 7: ...on driver s side end of mount tube GR02226 Usually found on this end On some older liftgates may be located here Mount Tube MODEL NUMBER RATED CAPACITY Based on an evenly distributed load on the platf...

Page 8: ...Liftgates can be mounted to trucks and trailers with max frame width 45 1 2 Additional mounting configurations and dimensions may be available by contacting the Waltco Engineering Department GR00655 M...

Page 9: ...onal A Dimension Bed Height Maximum sill depth Mount tube clearance 15 5 43 4 33 00 18 45 5 31 5 20 47 5 5 30 21 75 49 6 5 28 5 23 75 51 7 26 25 25 5 52 5 7 75 24 5 BZ 33 44 Long arm 34 1 4 Standard A...

Page 10: ...Other projections GR00511 NOTCH REAR SILL Mark a witness line at center of rear sill This line will be used for centering the liftgate later If rear sill is deeper than the Max Sill Depth as indicate...

Page 11: ...dd bar or angle 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 GR00057 CONSTRUCT MOUNTING JIG Cut a length...

Page 12: ...g doors refer to section in back of manual For Vehicles with Swing Doors GR00499 MOUNT LIFTGATE TO MOUNTING JIG Disconnect all four 4 cylinders from the lift arms Remove the temporary shipping pins fr...

Page 13: ...cure 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 supporting method...

Page 14: ...lates over mount tube and up against vehicle chassis frame Open end of mount plates must face front of vehicle Rotate liftgate and mount plate so plate is 90 degrees to chassis frame Drill holes cente...

Page 15: ...ts and washers and torque to 85 ft lbs Note Do not install any more bolts or weld mount plates to chassis frame at this time GR00065 Re attach lift cylinders to lift arms Unbolt lift arms from mountin...

Page 16: ...gate Installation A 150 amp circuit breaker is to be installed on the main power cable running from the battery compartment This acts to protect the electrical systems from overloading and the risk of...

Page 17: ...Chapter 4 Liftgate Installation Electric and Hydraulic Diagram G page 17...

Page 18: ...Chapter 4 Liftgate Installation Electric and Hydraulic Diagram with Auto tilt G page 18...

Page 19: ...4 3 Button Control Unit Permanent Note The permanent switch control box comes with a resistor heater wire It is recommended that this wire be removed and not used Install the main gate control in con...

Page 20: ...cable must be installed together with existing cabling with cable ties Ensure the length of the cable is sufficient for moving the control card The outer sheathing on cable connected to the control c...

Page 21: ...rformed in reverse order To access the hydraulic unit and oil tank follow steps 1 to 6 refitting is performed in reverse order 1 Remove the protective cap which is secured with two quick release locks...

Page 22: ...ey Grau 10 Orange Orange Orange Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Control Power Sensor Power Ground IN OUT Ai 1 Ai 2 Di 1 Di 2 Di 3 Di 4 Di 5 Di 6 PA PA CSPWR CS B E C 2H1 B E C 2H2 B E C Lock...

Page 23: ...g is activated Ctrl 1 Ctrl 2 89 15 45 0 10 3 C E Di3 U0 U1 U3 U5 Opens the body from inside Ctrl 4 89 15 45 0 10 Lower 1 E Di5 Di6 U1 U2 U4 Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 Ctrl 6 2 Di1 Di3 Di5 Di6 U1 U2 U...

Page 24: ...1 Ctrl 2 Ctrl 3 Ctrl 4 Ctrl 6 3 B Di6 U0 U2 Manual up re places raise 1 and 2 at jumpered Di6 Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 Ctrl 6 Tilt up B C Di3 U0 U3 Tilting up to ap proximately 45 Ctrl 1 Ctrl 2 Ctr...

Page 25: ...tilt up function Di4 Tilt cylinder Open platform alarm Pressure sensor for falling pressure connected to side of tilt cylinder In the actuated state returns the connection signal to Di4 and results in...

Page 26: ...isplayed to facilitate troubleshooting The display indicates Active control device Fault display Program configuration Sensors current status The flashing light indicates Supply voltage Off No supply...

Page 27: ...to ensure that no other person operates the lift from another control device During the period the control system is locked for the current control device its number 1 7 will flash on the display This...

Page 28: ...ort locking period that there is no time to see the indication The number will stop flashing when one of the current control device s buttons are pressed If the control card has been without voltage a...

Page 29: ...be shown automatically The display is prioritised in the order in the table below L H E F and A When the CS is switched off the system will browse through a list containing the five most recent fault...

Page 30: ...list in section 11 2 2 Fault codes on page 8 Example Control device 2 is blocked the LED on the coil control device then flashes twice goes out for a moment flashes twice again etc Coil control device...

Page 31: ...d conductor cross sectional area on page 12 The lift is not working The lift is working but is issuing a warning This voltage range is only recommended for emergency operation The lift is working but...

Page 32: ...e Copper wire should be flush with or slightly past the nut Grip nut with wrench and turn terminal until nut seats GR00299 GR00300 Position heat shrinkable tubing over terminal and end of cable Shrink...

Page 33: ...if engine is not adequately grounded When there are two or more batteries in the installation all cables connecting the batteries together must be 2 Ga or heavier This includes all original equipment...

Page 34: ...Shell Tellus S2 V 32 Dept 1 800 411 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 O...

Page 35: ...POSITIONING OF PLATFORM Using the raise switch raise lift arms up off the ground as shown Lift Platform Using an Over Head Crane or Forklift as shown Other means may be used to support the platform i...

Page 36: ...ch direction the platform must be moved Lower the platform to the ground GR00837 Loosen mount bracket bolts Move mount frame as necessary Torque bolts to 85 ft lbs Raise Platform horizontal with bed o...

Page 37: ...welding point as possible Do not allow ground current go through pivot pins bearings cables or hydraulic hoses Welding current can melt cables or burst hoses causing personal injury GR00508 PAINTING...

Page 38: ...ops 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 lift ar...

Page 39: ...nstalling on the right arm the sensor s cable must be facing downward GR03023 CONSTRUCTION OF TILT CYLINDER 1 Screw 2 Adjustable collar 3 Washer 4 Lock screw x3 5 Ring 6 Ring s Lock Screw GR02803 ADJU...

Page 40: ...ock screws Turn adjustable case counter clockwise to decrease length of tilt cylinder or clockwise the increase length Adjust until the platform reaches top sill of truck GR02814 detail A Fine Adjust...

Page 41: ...he ring out in the direction of the platform 2 Tilt the platform a maximum of 10 below the horizontal as shown in Fig GR02829 GR02816 Tighten the ring to the top of the cylinder 3 and then tighten the...

Page 42: ...acts the stops when fully closed Space rubber stops out from corner post as may be required Spacers not provided GR01605 FLAT BED APPLICATIONS On flat bed applications vehicle must be equipped with co...

Page 43: ...same height position Every bumper bar must be secured with three bolts and lock nuts supplied GR02819 GR00507 SWING DOOR APPLICATION Platform must be spaced away from the vehicle such that when the l...

Page 44: ...ructed 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 platf...

Page 45: ...REA Bridge will pivot over back of platform when lowered Mark back of platform as a no loading area as necessary GR00115 OPERATION CHECK Turn shut off switch on located in cab Always make certain area...

Page 46: ...h 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 GR00108 TO FOLD PLATFORM TO CLOSED POSITION M...

Page 47: ...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...

Page 48: ...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 p...

Page 49: ...cket 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 i...

Page 50: ...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...

Page 51: ...perly H Vehicle meets all 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...

Page 52: ...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 Traile...

Page 53: ...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 r...

Page 54: ...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 c...

Page 55: ...rovided 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 a...

Page 56: ...ectric 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 on...

Page 57: ...____________ 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...

Page 58: ...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 fr...

Page 59: ...op 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 to...

Page 60: ...he 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 Do...

Page 61: ...Add silicone caulk to seal gaps between tracks and vehicle body page 61...

Page 62: ...d Locate and drill two mounting holes as shown if not already present Take necessary precautions to prevent metal shavings from contaminating the hydraulic system Mount cycle counter bracket using two...

Page 63: ...de or bottom of the platform 2 MODEL NUMBER Or capacity 3 PLATFORM SIZE ________________________________________________________________ THEN INCLUDE THE FOLLOWING INFORMATION 4 PART NUMBERS 5 DESCRIP...

Page 64: ...le 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 COR...

Page 65: ...This page left intentionally blank page 65...

Page 66: ...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 infor...