WALTCO ZS MK2 User manual

79256TL - Owner's Manual, English translation
2022-06-30
Must be kept in the vehicle on which the liftgate is installed
OWNER'S MANUAL
INFORMATION FOR OWNERS AND USERS
ZS MK2 Liftgate
SLIDER LIFT

3
Table of contents
1 Important information ..........................................................................5
1.1 Technical support ...................................................................................... 5
1.2 Spare parts & accessories......................................................................... 6
1.3 Service ........................................................................................................ 6
1.4 Product discontinuation ............................................................................ 6
1.5 Warranty...................................................................................................... 6
1.6 Information concerning the clause on remote diagnostics ..................10
1.7 Privacy ......................................................................................................10
1.8 Attention! ..................................................................................................11
2 Safety rules ........................................................................................12
2.1 General...................................................................................................... 12
2.2 Damage and malfunctions ......................................................................12
2.3 Max permissible load...............................................................................13
2.4 Maintenance, repairs and service ...........................................................14
2.5 Modications............................................................................................14
2.6 Operation ..................................................................................................15
2.7 Intended use
17
2.8 Danger area .............................................................................................. 17
2.9 Work area .................................................................................................18
2.10 Operator working position ....................................................................... 19
3 Design and Function ...........................................................................20
3.1 General...................................................................................................... 20
3.2 Frame .......................................................................................................20
3.3 Lift arm ...................................................................................................21
3.4 Platform....................................................................................................21
3.5 Sliderproles...........................................................................................21
3.6 Hydraulic system......................................................................................21
3.7 Cab switch................................................................................................22
3.8 Safety devices ..........................................................................................23
3.9 Controllers ................................................................................................24
3.10 Electric autotilt ......................................................................................... 26
3.11 Overheating protection ............................................................................27

4
4 Operation............................................................................................28
4.1 General...................................................................................................... 28
4.2 Max load ...................................................................................................29
4.3 Operator working position ....................................................................... 30
4.4 Working on the platform..........................................................................31
4.5 Loading and unloading with the platform on ground ............................33
4.6 Loading and unloading with the platform on a loading dock .....................34
4.7 Moving load from one vehicle to another...............................................36
4.8 After use ...................................................................................................37
4.9 Operatingwiththexedcontroldevice(CD19) .....................................38
4.10 Operatingwiththecoiledcablecontroldevice(CD9) ...........................42
4.11 Operatingwiththecoiledcablecontroldevice(CD10) .........................45
5 Service and maintenance....................................................................47
5.1 Hydraulic oil..............................................................................................47
5.2 Before starting work ................................................................................48
5.3 Daily checks .............................................................................................49
5.4 Weekly check............................................................................................ 50
5.5 Lubrication................................................................................................51
5.6 Service ......................................................................................................52
6 Marking..............................................................................................53
6.1 Maximum load rating...............................................................................54
6.2 Identicationplate ..................................................................................55
6.3 Work area .................................................................................................55
6.4 Warning tape ...........................................................................................55
6.5 Control device sticker .............................................................................56
6.6 Danger area .............................................................................................58
6.7 Warningags........................................................................................... 58
7 Troubleshooting .................................................................................59
8 Technical specifications .....................................................................60
8.1 Noise declaration ....................................................................................60
9 Product discontinuation......................................................................61
8.2 General...................................................................................................... 61
8.3 Applicable regulations and legislation....................................................61
10 Service record ....................................................................................63
11 Own remarks ......................................................................................65
12 Declaration of conformity during assembly.........................................67
13 Certificate of registration, delivery card..............................................67

5
1 Important information
Before using the WALTCO Liftgate, you must read and understand the contents of this
manual and especially the sections describing safety.
The owner’s manual is primarily intended to inform you about the Liftgate’s functions and
characteristics and how to use it in the best way. It also contains important safety and
maintenance information and describes any problems that might occur during operation.
Always keep the owner's manual in the vehicle, as the need for important information
regarding operation, safety and maintenance may be necessary.
Informationaboutourproductsisalsoavailableonourwebsite.Youcanndusatwww.
waltco.com.
Allinformation,images,illustrationsandspecicationsarebasedontheproductinformation
available when this manual was printed. Images and illustrations contained in the Instructions
for use are generic and not intended to be exact depictions of various parts of the product.
We reserve the right to make changes to the product without prior notice.
1.1 Technical support
If technical support is required, contact your nearest service provider.
Always quote the Liftgate’s serial number to make sure you receive the correct information.
The serial number is found on the rating plate located on the Liftgate frame.
Identication plate




7
Explanation
of
Specification
Tag
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
GR00241
HDC33
Level
Lift
3300
lbs.
HDC
44
Level
Lift
4400
lbs.
GR02226
Mount
Tube
Usually
found
on this end
On
some
older
liftgates
may be located here
LOCATION OF SPECIFICATION TAG
Can be found on driver’s side, end of mount tube.
Model number
Date of manufacture
Month/year
Serial number
of liftgate. To be used
when ordering parts or
when contacting WALTCO
for service or warranty
questions
Rated capacity
Based on an evenly
distributed load on the
platform at surface.
Important information

6
1.2 Spare parts & accessories
If spare parts or accessories are required, contact your nearest service provider.
1.3 Service
If service is required, contact your nearest service provider.
1.4 Product discontinuation
For information on product discontinuation, see section ”9 Product discontinuation” on page 61.
1.5 Warranty
1.5.1 Warranty period
The Liftgate comes with a 24-month warranty valid from the ex-works delivery date.
If the Liftgate is stored before being put into service or delivered to the end customer, the
warranty period may be extended by a period corresponding to the storage period, but
not more than 6 months, i.e. the warranty is valid for a maximum of 30 months from the
factory delivery date.
Spare parts are supplied with a 12-month warranty from the ex works delivery date.
When storing spare parts before installation on the Liftgate, the warranty period may be
extended by a period corresponding to the storage period, but not more than 6 months, i.e.
the warranty is valid for a maximum of 30 months from the factory delivery date. The spare
parts warranty is subject to proof of purchase.
Important information

7
1.5.2 Warranty conditions
WALTCO warranty rights are only valid if the following conditions are met:
• Claims are made within 30 days of the repair.
• Installation was carried out in accordance with WALTCO installation instructions and
also by a WALTCO-approved superstructure builder.
• Delivery acceptance inspection was carried out in accordance with WALTCO’s instruc-
tionsandcertiedinthisowner'smanual.Seesection”12Declarationofconformity
during assembly” on page 67.
• The annual service was carried out according to WALTCO’s instructions and by a
WALTCO-approved service provider. Service must be noted in the service record. See
section ”10 Service record” on page 63.
• Warranty work may only be carried out by WALTCO-approved service provide.
There is information on our website about service providers and distributors. If no service
provider information is available, contact WALTCO
1.5.3 Warranty compensation:
Liftgate
Following an approved Liftgate claim during the ordinary warranty period, the warranty will
cover material and labour costs for the person performing the warranty work.
Spare Parts
Following an approved part claim within the ordinary warranty period, the warranty will cover
material costs for the person performing the warranty work. The warranty on parts does not
cover labour costs.
1.5.4 The warranty covers:
Factory and material defects on:
• WALTCO original parts found to be defective.
• WALTCO original spare parts found to be defective.
• WALTCO original accessories found to be missing.
Important information

8
1.5.5 The warranty does not apply in the case of:
• Damage caused by electrical overload:
Damagetoelectricalpartscausedbyinsucientbatterycapacity,e.g.insucient
installedbatterycapacityand/orinsucientbatterychargeinrelationtotheamount
of lift use.
• Damage caused by hydraulic overload:
Damage to lift parts caused by tampering with the hydraulic system
• Damage caused by mechanical overload:
Damage to lift parts caused by overloading or external force.
• Wear parts:
e.g.supportwheels,bearings,shafts,wornordamagedpaint,warningags,decals,
batteries, rubber bellows, seals between the Liftgate and vehicle.
• Service and maintenance related:
Measures of a purely service and maintenance character. Replacing fuses, adjusting
hydraulic pressure, adjusting tilt cylinders, adjusting torque. Hydraulic components con-
taminatedbydirtyhydraulicoil.Dissonancecausedbyneglectedmaintenance(lubrica-
tion).
• Incorrect installation:
Damage caused by incorrect installation. Claims for this type of damage must be
submitted to the Liftgate seller or installer, or to the service provider that installed the
spare part.
• External equipment:
Damage caused by external equipment or materials not approved by WALTCO. For
example, equipment connected to the Liftgate electrical system. Parts that have pre-
viously been repaired without WALTCO approval.
• Parts that have been disassembled:
For example, motors, cylinders, solenoids, pressure switches, valves and similar parts.
• Corrosion:
Surface corrosion on standard fasteners or on components with damaged surface treatment.
Important information

9
• External costs:
Emergency actions, on-call, travel expenses, rental, lost income, damage to goods.
• Missing parts:
Ifmultiplepartsaresubmittedwithaclaimapplication,partsthathavenoidentied
defects covered by the warranty will not be replaced. Example: A valve is found to be
faulty and the valve and solenoid are both submitted; however, only the part that has a
defect covered by the warranty is replaced.
• Transportation costs:
Transportationcostsforreturnedgoods(claims).Theclaimantisliablefortransporta-
tioncostsforreturnedgoods(claims).
• Painted-over parts:
Hoses, piston rods, control devices, cables and similar. Parts where the ID plate has
beenpaintedover,makingidenticationimpossible.
Important information

10
1.6 Information concerning the clause on remote diagnostics
WALTCO,orathirdpartydesignatedbyWALTCO,shallatalltimeshavetherightto(i)
install, maintain and dismantle a remote diagnostics device in and from the products; and
(ii)access,send,receive,collect,store,copy,aggregate,combinewithotherinformation,
process, make available, further develop and use any and all information and data gathered
through the remote diagnostics device, including but not limited to, information concerning
equipmentidentity,eciency,availability,downtime,operation,operatingenvironment,mo-
vement,condition,logon,locationandsimilarinformationrelatingtotheproducts(the“In-
formation”).SuchInformationmaybeusedforproviding,delivering,optimizing,developing,
servicing and offering the products or any related equipment and services. The Information
may also be used for example for sales and marketing, WALTCO’s internal business and/
or operating purposes as well as for regulatory, warranty and contract compliance and for
proactive maintenance and diagnostics. The Information may be shared to WALTCO’s group
companies and to WALTCO’s and its group companies’ dealers, subcontractors, service
providers and other business partners for the above described purposes.
1.7 Privacy
Foradministrativepurposesrelatingtothewarrantyprogramandinordertofulltheobli-
gations under the contract and the law, and to manage the customer relationship, the seller
of the products, and WALTCO as the manufacturer of the products, is required to collect
and process information regarding the customer and owner of the product, which may in-
clude personal data of the contact persons and other possible representatives and employ-
ees of the customer and owner of the product. Information collected may also be used,
among other things, to satisfy requests made by the customer, to inform the customer
about new products and services, as well as for other promotional or marketing purposes.
The information may be shared within the WALTCO Group of companies and its associated
companies, and WALTCO’s authorised dealers, distributors and service workshops, and
othercompaniesprovidingservicesforthecustomer’sbenetfortheabovedescribedpur-
poses. WALTCO Group may also receive and use information provided to WALTCO Group
throughitsauthoriseddealerandservicenetwork(suchasfromtheauthorisedWALTCO
distributorordealerfromwhomthecustomerhaspurchasedtheproduct).
A more detailed description of how WALTCO processes personal data is available in its pri-
vacypolicy(https://hiab.com/en/privacy-policy).ThePrivacyPolicyappliestotheproces-
sing of personal data by WALTCO’s group of companies. Please note that in case you have
purchased the product from a WALTCO distributor or dealer, personal data may be further
processed by the seller of the product. In such case, please refer to the applicable policies
of the seller of the product.
Important information

11
1.8 Attention!
The Instructions for use contain the following warning signs. They are intended to alert you
to conditions that could cause problems, incidents, injury, and/or damage to the product, etc.
mWARNING!
WARNING indicatesapotentialhazard,whichifignoredmayleadtoserious,life-threateninginjury.
mCAUTION!
CAUTION indicatesapotentialhazard,whichifignored,mayleadtominorinjuries.
IMPORTANT!
IMPORTANT indicates a risk of equipment damage.
NOTE!
NOTE! refers to additional information that may help the reader understand, or perform, a given
operation.
Important information

12
2 Safety rules
2.1 General
Because the Liftgate is used for handling heavy loads, extra care must be taken when using it.
It is important that you read and follow the instructions and safety regulations in these instruc-
tions for use before using the Liftgate. Improper use may result in injury, or damage to the
Liftgateandthevehicletowhichitistted.
NOTE!
WALTCO is not liable for any injury to persons or damage to property that may result from
failure of the operator or other person to comply with the recommendations, warnings and
instructions set forth in these instructions for use.
2.2 Damage and malfunctions
If in any situation you feel the Liftgate and its various functions are not behaving as expected,
or if you suspect something is wrong, discontinue use as soon as possible, switch off the main
power supply to the Liftgate and contact your authorised dealer for assistance without delay.
Safety rules

13
2.3 Max permissible load
Undernocircumstancesmaytheliftbeburdenedwithmoreweightthanthespecied
maximum load. Under no circumstances may the max load centre be placed further out on
theplatformthantheloadcentredistancespeciedfortheLiftgate.
Information about the max permissible platform load and the load centre distance for max
load is shown on decals a󰀩xed to the Liftgate or vehicle.
mWARNING!
Under no circumstances is it permitted to load the platform with loads greater than those
speciedonthedecals.Excessiveloadcancausestructuraldamage.Riskofmaterialdamage
and life-threatening injury.
Example: This Liftgate has a maximum load of 4400 lbs when the load’s centre of gravity is no more than
30 inches from the edge of the vehicle oor. If the load’s centre of gravity is placed 60 inches from the
edge of the vehicle oor, max permissible weight decreases to 2200 lbs.
Sticker, max permissible load 4400 lbs. Load centre distance 30’’.
Max. 4400 lbs
Max. 30 inches
Max. 40 inches
Max. 60 inches
4400 lbs
3300 lbs
2200 lbs
78969TL
30 40 6020 inches
Max. 4400 lbs
Max. 30 inches
Max. 40 inches
Max. 60 inches
4400 lbs
3300 lbs
2200 lbs
78969TL
30 40 6020 inches
Max. 4400 lbs
Max. 30 inches
Max. 40 inches
Max. 60 inches
4400 lbs
3300 lbs
2200 lbs
78969TL
30 40 6020 inches
Max. 4400 lbs
Max. 30 inches
Max. 40 inches
Max. 60 inches
4400 lbs
3300 lbs
2200 lbs
78969TL
30 40 6020 inches
Decal sheet with 4 decals.
Measurement:
LxH 90x65 mm.
Colors:
Background: PMS Cool Grey 4C
Graphics and text: PMS Black C
Dashed line shows border
between decals. (4 decals
on the same paper)
Safety rules

14
2.4 Maintenance, repairs and service
Onlyperformtheserviceandmaintenanceproceduresspeciedinthismanual.
Allotherservice,repairs,modicationsoractionsontheLiftgateandthevitalsystemsof
its accessories must be carried out by an authorised provider.
When working on the Liftgate, switch off the main power supply.
Use only spare parts and accessories approved or recommended by WALTCO. Any other
use may lead to changes that impair Liftgate function and safety. This may also render
your Liftgate warranty invalid.
2.5 Modications
ModicationsnotdescribedorapprovedbyWALTCOmaynotbemade.Suchmodications
may entail an increased risk of accidents, a negative impact on product life and render the
product warranty invalid.
mWARNING!
Modications to the Liftgate may affect safety. In the case of deviations from the docu-
mented CE-marked Liftgate, the CE-marking will cease to apply. Risk of material damage and
life-threatening injury.
Safety rules

15
2.6 Operation
2.6.1 General
Because the Liftgate is used for handling heavy loads, extra care must be taken when using
it. It is important that you read and follow the instructions and safety regulations in these
instructions for use before using the Liftgate. Improper use may result in injury or damage
totheLiftgateandthevehicletowhichitistted.
mWARNING!
Do not allow heavy loads to drop onto the platform. Risk of material damage and life-threatening injury.
mWARNING!
Exercise caution when present or working on or in the immediate vicinity of the platform or
Liftgate with respect to protruding parts and sharp edges. Never leave the Liftgate with the
platform raised and extended. Risk of material damage and life-threatening injury.
mCAUTION!
WALTCO is not liable for any injury to persons or damage to property that may result from
failure of the operator or other person to comply with the recommendations, warnings and
instructions set forth in these instructions for use.
2.6.2 Working in the dark
mCAUTION!
Make sure the necessary and appropriate lighting is available when working in the dark.
WALTCO recommendsttingtheLiftgatewithwarninglightsforworkinginpoorlylitareas.
Risk of injury.
Safety rules

16
2.6.3 Working on the platform
mWARNING!
Thegreatestriskforcutandcrushinjuriesisinthehazardareabetweentheliftgateandthe
vehicleoorwhentheliftisraisedtovehicleoorheight.Anyonestandingontheliftgateorthe
vehicleoormustkeeptheirfeetandotherpartsofthebodyawayfromthishazardareawhen
the liftgate is in operation. Risk of life-threatening injury.
mCAUTION!
To reduce the risk of foot injuries, wear safety shoes with protective steel toe-caps when wor-
king on the platform. Even though the platform has a non-slip surface, take care when transfer-
ring goods. WALTCO recommends the use of anti-slip safety shoes with protective toecaps in
accordance with EN ISO 20345. Risk of injury.
mCAUTION!
Always be aware of the platform edges to avoid stepping off by mistake. Also be aware of the risk
oftripping,especiallyiftheplatformisttedwithwarninglightsorwheelstops.Riskofinjury.

min. 12 inches
min. 12 inches
Safety rules

17
Safety rules
2.7 Intended use
mWARNING!
The liftgate may only be used for its intended purpose, i.e. the loading and unloading of goods, and
then only in accordance with the regulations contained in this owner's manual. No other type of
use is permitted as this may damage the liftgate and give rise to dangerous situations. Risk of
material damage and life-threatening injury.
Use of the liftgate in a manner not described in this manual may also render the product war-
ranty invalid.
2.8 Danger area
mWARNING!
Thehazardareaistheareainwhichtheliftgatemovesduringoperation.Undernocircumstan-
ces may the operator or any other person enter this area when the liftgate is in operation. Risk
of material damage and life-threatening injury.
Danger area
Work area

18
Safety rules
2.9 Work area
The operator must make sure that the working area behind the liftgate is free from persons
and every kind of object when the liftgate is used. The operator must also pay attention
to the surroundings beyond the working area to have good forewarning of approaching
personsorobjectsthatmaycauseahazardoussituation.Negligentoperationofaliftgate
may entail a risk of injury and material damage.
mWARNING!
Make sure other vehicles are parked no closer than 5 m from the rear of the vehicle.
Make sure the work area is clear of persons and objects. Be especially aware of children and
animals.
Pay attention to the surroundings to have good forewarning of approaching persons or objects that
maycauseahazardoussituation.Stopworkimmediatelyifunsure.
During loading and unloading, handle cargo as described in this manual. In the event of instability,
loads may move uncontrollably. Risk of material damage and life-threatening injury.
When handling loads with wheels, the liftgate platform must be equipped with roll stops. Risk
of material damage and life-threatening injury.
Danger area
Work area

19
Safety rules
2.10 Operator working position
Alwayspositionthevehicletoallowliftgateoperationwithoutdangerfrompassingtrac.
Also make sure the work area is clear.
mWARNING!
Thevehiclemustbepositionedtoallowliftgateoperationwithoutdangerfrompassingtrac.
Risk of material damage and life-threatening injury.
mCAUTION!
Always make sure the work area is clear during platform operation. Risk of injury.

20
Design and Function
3 Design and Function
3.1 General
The WALTCO liftgate consists of a number of main components, namely the frame, lift
arms,platformandsliderproles.Theliftgateisoperatedelectro-hydraulically.Ahydrau-
lic pump powered by the vehicle's ordinary battery supplies hydraulic oil to the actuating
hydraulic cylinders. The hydraulic system is controlled by the control system, which is
operated by control devices.
3.2 Frame
The frame constitutes the liftgate’s chassis to which other components such as the slider
proles,liftarmsandhydraulicunitsaremounted.
Platform
Lift arm
Frame
Slider prole
Overview