Waltco Lift BZ-33, Owner'S Manual

Page 1: ...TRICAL 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 o...

Page 2: ...f Decals 19 Lubrication 22 Schematics 23 Electrical Trouble Shooting 29 How to Order Parts 38 Improper operation and maintenance of this liftgate could result in severe personal injury or death Read a...

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: ...rge 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 Wal...

Page 7: ...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 8: ...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 9: ...which platform will open and close is clear before opening or closing and at all times during operation Make certain platform area including the area in which loads may fall from platform is clear bef...

Page 10: ...LATFORM UP AND DOWN First push and hold tilt switch then simultaneously push raise switch to tilt platform up Or First push and hold tilt switch then simultaneously push lower switch to tilt platform...

Page 11: ...rical shut off switch is a safety device and must be working properly at all times GR00697 PROPER OPERATION OF TILT Platform should always be in a generally level position Load is to be stabilized to...

Page 12: ...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...

Page 13: ...for an incline make certain cargo does not contact rear sill of vehicle as liftgate is lowered GR00709 DRIVE OVER OPTION If properly equipped platform may be used as a loading ramp IMPORTANT Maximum...

Page 14: ...ust always support end of platform Platform must overlap loading dock at least 24 Always use the center portion of the platform Cargo is to be positioned on cargo carrier so as to be stable when rolli...

Page 15: ...OK Repair Required Corrected Check for apparent damage to the lifting structure such as bent or distorted members or cracked welds which may have resulted from overloading or abuse 2 OK Repair Requir...

Page 16: ...ate if any points of inspection listed at left or below may cause you to think the liftgate is unsafe Repair immediately If liftgate is found to be in need of repair or adjustment not covered in this...

Page 17: ...luids Fill reservoir Temperature Range Acceptable Fluids Fill with recommended fluid or equivalent 0 to 120 F Waltco Biodegradable Liftlube TM part 85803860 Fill the reservoir to within 1 2 from the t...

Page 18: ...r Examine armature brushes for wear motor should be replaced if brushes are less than 1 8 long Clean out all residue inside of motor housing Apply several drops of light weight machine oil to armature...

Page 19: ...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 20: ...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 21: ...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 22: ...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 23: ...Electrical Information Electric and Hydraulic Diagram G page 23...

Page 24: ...Electrical Information Electric and Hydraulic Diagram with Auto tilt G page 24...

Page 25: ...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 control...

Page 26: ...le 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 card...

Page 27: ...med 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 2 D...

Page 28: ...Gr Grey 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...

Page 29: ...pening 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...

Page 30: ...trl 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...

Page 31: ...the 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 resul...

Page 32: ...re displayed to facilitate troubleshooting The display indicates Active control device Fault display Program configuration Sensors current status The flashing light indicates Supply voltage Off No sup...

Page 33: ...ile 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...

Page 34: ...a short 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 volt...

Page 35: ...will 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 f...

Page 36: ...the 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 d...

Page 37: ...ended 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...

Page 38: ...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 39: ...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 40: ...ftgate 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 liftg...