Waltco Lift BZ-33 User manual

EO:10338 Rev 02
03/2018 80117222
Owner’s Manual
BZ-33, BZ-44 Gen 7
3300 lb. & 4400 lb. Capacity Cantilever Liftgates
GR02912
Last Change
Date Pages Description
03/20/2018 23-25 REVISED ELECTRICAL 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 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: [phone]
[e-mail] Fax: [phone]

Table of Contents
Introduction ........................................................................................................................3
Safety Information..............................................................................................................4
Warranty ............................................................................................................................6
Liftgate Terminology ..........................................................................................................7
Operation Instructions........................................................................................................9
Preventive Maintenance .................................................................................................15
Placement of Decals.......................................................................................................19
Lubrication ......................................................................................................................22
Schematics .....................................................................................................................23
Electrical Trouble Shooting .............................................................................................29
How to Order Parts .........................................................................................................38
I
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
decals before 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.
80101388 Rev 03 EO 7820
page 3

Chapter 1 Safety Information
80101253 Rev 04 EO 6309JJ
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

Chapter 1 Safety Information
80101253 Rev 04 EO 6309JJ
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 Upstops 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.
NOTICE
WARNING
CAUTION
page 5

EO:7714 Rev 01
5-2015 80101667
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

Chapter 2 Liftgate Terminology
1. Platform
2. Mount Tube
3. Pump and Motor Tray
4. Lift Arm
5. Bumper
6. Lift Cylinder
7. Tilt 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. Mount Plates
17. Cart stop (optional)
14
14
17
17
15
16
1
GR00828
12
75
3
13
11
6
2
9
6
5
5
7
8
4
10
14
14
GR00829
page 7

Chapter 2 Liftgate Terminology
Explanation of Specification Tag
BZ33 G7 Level Lift 3300 lbs.
BZ44 G7 Level Lift 4400 lbs.
GR00241
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
MODEL NUMBER
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
questions
DATE OF
MANUFACTURE
Month / Year
page 8

Chapter 3 Operations Instructions
IMPORTANT
Understand these instructions before operating liftgate
When in transit, platform is to be closed
When not in use, electrical shut off switch is to be off.
In any tilt position, the attitude of the platform may vary from level while raising or lowering the platform.
Make certain area in 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 before and at all
times during operation of liftgate.
Never close liftgate with any objects on platform.
OPENING PLATFORM
Turn shut-off switch on.
Typically on trucks a toggle switch is located in cab.
Typically on trailers, a key switch is located near
liftgate control switches.
GR00697
CAB SHUT-OFF
SWITCH
KEY SHUT-
OFF SWITCH
page 9

Chapter 3 Operations Instructions
TO OPEN PLATFORM
Turn shut-off switch on (located in cab or near
controls).
Always make certain area in which platform will
open is clear.
Push and hold tilt switch then lower switch to unfold
platform.
GR00106
TO RAISE AND LOWER PLATFORM IN LOADING
POSITION
Push raise switch to raise platform
Or
Push lower switch to lower platform
GR00107
TO TILT PLATFORM 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 down.
GR00108
TO FOLD PLATFORM TO CLOSED POSITION
Make certain platform surface is clear of all objects.
Raise platform to bed level with raise switch.
Push and hold tilt switch then simultaneously push
raise switch to close platform.
Turn shut-off switch off.
When in transit, platform must be closed vertically, and
shut-off switch is to be turned “off.”
GR00110
LOWER
TILT
RAISE
page 10

Chapter 3 Operations Instructions
IMPORTANT!
To avoid vehicle or liftgate damage, never attempt to
close platform until platform is first at bed level.
GR00705
SECURE PLATFORM FOR TRANSIT
Close platform.
Turn shut-off switch off.
CAUTION!
Keep hands away from pinch points.
IMPORTANT!
Electrical 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 prevent rolling or falling
off platform.
CAUTION! Improper use of tilt controls could cause load
to fall from platform.
In any tilt position, the attitude of the platform may vary
from level while raising or lowering the platform.
GR00702
KEY SHUT-
OFF SWITCH
CAB SHUT-OFF
SWITCH
page 11

Chapter 3 Operations Instructions
Never tilt platform with a load except when loading
and unloading cargo at ground, or to stabilize load.
GR00703
Tilting platform may cause an unstable load to roll
off if unattended.
GR00704
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
page 12

Chapter 3 Operations Instructions
LOADING OF PLATFORM
Before loading, tilt platform slightly upwards to
compensate for load.
Always load as close to the center of the platform and
as close to the vehicle as possible.
This liftgate is intended for loading and unloading of
cargo only, do not use it for anything but it’s intended
use.
Never transfer loads which exceed rated capacity on or
over platform unless liftgate is equipped with reinforced
platform and platform support bars.
IMPORTANT!When platform is tilted up to compensate
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 capacity as a loading ramp includes
combined weight of cargo and cargo carrier.
GR00700
Only use platform as a loading ramp if liftgate is properly
equipped with these support bars and used as directed
on Drive Over Operation Decal.
IMPORTANT!Maximum capacity:
5,500 lbs. for aluminum and non-reinforced steel
platforms.
10,000 lbs. for reinforced steel platforms.
GR00493
HILL HILL
AS PLATFORM IS
LOWERED CARGO
HITS REAR SILL
CARGO
POSIOTIONED TOO
CLOSE TO REAR
SILL
PLATFORM TILTED
UP FOR INCLINE
Support Bars fully
extended
page 13

Chapter 3 Operations Instructions
Locate Drive Over Operation Decal attached to vehicle
for information on maximum drive over capacity.
Decal 80101499 will show max. capacity of 5,500 lbs.
Decal 80101330 will show max. capacity of 10,000 lbs.
GR02227
Make certain vehicle is properly and securely braked.
Before opening platform, pull both support bars fully out
(4-1/2”).
Tilt platform down to loading dock.
Loading dock must 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 rolling over inclined platform.
GR00698
Never roll a load onto the platform if:
The loading dock does not support the platform.
Both support bars are not pulled out.
IMPORTANT!It may be necessary to readjust tilt of
platform as vehicle is unloaded. The vehicle suspension
may cause the floor level to raise as load is removed.
GR00699
Drive Over Operation
Decal 80101499 or
80101330 would be
attached in this area.
page 14

Chapter 4 Preventive Maintenance
Waltco recommends that the BZ-Series liftgate be inspected at 6 month or 3000 cycle intervals to help assure
proper function and operation of the liftgate.
Note: Photocopy the following PM Checklist to help keep track of periodic maintenance on the liftgate. Keep
completed form with maintenance records.
For more detailed instructions on the following checklist items, refer to the appropriate sections in this Owner’s
Manual.
Do not continue to use liftgate 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 manual, contact
your nearest Waltco Distributor.
WALTCO BZ-SERIES LIFTGATE
PREVENTIVE MAINTENANCE CHECKLIST
PM Interval: 6 Months or 3000 Cycles Date: ______________ Vehicle No.__________
Mechanic:_________________ Liftgate S/N:____________ Model:______________
Check appropriate box below for each step:
6 Month Liftgate PM Procedures
1OK 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.
2OK Repair Required Corrected Check that all pins, bolts and fasteners are tight and secure.
3OK Repair Required Corrected Check for worn or damaged bearings.
4OK Repair Required Corrected Check that controls operate properly.
5OK Repair Required Corrected Check all battery cables and connections (both positive and ground
cables) to be sure they are tight and free of corrosion.
6OK Repair Required Corrected Check operation of lockout device.
7OK Repair Required Corrected Check for hydraulic leaks in hydraulic cylinder(s), hoses, fittings, and
valves.
8OK Repair Required Corrected Check oil level in reservoir.
9OK Repair Required Corrected Check lowering speed of platform.
10 OK Repair Required Corrected Check that all decals are in place and legible.
11 OK Repair Required Corrected Lubricate the liftgate per the “Lubrication Instructions”.
12 Month Liftgate PM Procedures (Includes steps 1-11 above)
13 OK Repair Required Corrected Inspect Pump Motor for wear or damage.
14 OK Repair Required Corrected Replace Hydraulic Fluid.
page 15

Chapter 4 Preventive Maintenance
MONTHLY INSPECTION
Operate the liftgate throughout its entire operational
cycle. Check for:
•
••
•Damage to lifting structure such as bent or
distorted members or cracked welds.
•
••
•Bent or distorted cylinder pins or damaged
cylinder.
•
••
•All pivot and cylinder pins are securely in place,
undamaged and retained by their proper
fasteners.
•
••
•Damaged or worn bearings that pivot and
cylinder pins rest in.
•Controls operate correctly (refer to chapter 3,
“Operations Instructions”)
•Check all power cables, ground cables, and
connections.
•Clean and tighten all loose connections.
Replace any damaged or corroded wires
or connectors.
Do not continue to use liftgate 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 manual,
contact your nearest Waltco Distributor.
Operate the liftgate throughout it’s entire operational
cycles and check for the following:
Apparent damage to the lifting structure, such as
bent or distorted members.
Cracked welds, which may have resulted from
overloading or abuse.
Check that the liftgate operates freely and smoothly,
and that there are no unusual noises or vibrations.
GR00407
Inspect for oil leaks in:
Hydraulic cylinders
Hydraulic hoses. Replace hoses if they show signs
of excessive abrasion.
Hydraulic fittings and valves.
Tighten or replace all hydraulic components as may be
required to stop oil leakage.
Inspect all hydraulic
components
page 16

Chapter 4 Preventive Maintenance
Check oil level
Lower platform to the ground and tilt down to the
ground.
Open breather plug.
Oil should be ½” from top of reservoir.
Fill as may be required.
Obey oil recommendations.
GR03015
BLEEDING CYLINDERS
Lift cylinders:
Fully lower platform a few times. You may have to jack
up vehicle to fully extend lift cylinders.
Tilt cylinders:
Fully lower the platform a few times.
GR00407
Recommended Fluids
Fill reservoir
Temperature Range Acceptable Fluids •Fill with recommended fluid or equivalent.
0°to 120°F Waltco Biodegradable
LiftlubeTM part #85803860
•Fill the reservoir to within 1/2” from the top.
•Fluids are available from the Waltco parts
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 Oil
Part 85803867
Shell Tellus S2 V 15
Mobil DTE 10 Excell 15
Chevron Rando HDZ 15
Brake Fluid
Power steering fluid
Automatic Transmission Fluid (ATF)
Rev 08
BREATHER PLUG
page 17

Chapter 4 Preventive Maintenance
SEMI ANNUAL INSPECTION
Inspect power motor:
•Disconnect battery cable.
•Remove end cover.
•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 shaft bearing in motor end cover.
•Reassemble motor.
GR0
3015
Remove cover to
check brushes and
clean out motor
page 18

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.
GR0
2913
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.
GR02913A
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 19

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 20