www.waltco.com Phone: 800.211.

3074
sales@waltco.com Fax: 800.211.3075

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

EO:7006A Rev 01
12-2012 80117202
Page 1
 Table of Contents
Improper
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.

Introduction ........................................................................................................................3
Safety Information ..............................................................................................................4
Warranty ............................................................................................................................6
Liftgate Model Information .................................................................................................7
Placement of Decals ..........................................................................................................8
Lubrication ...................................................................................................................... 11
General Information ........................................................................................................ 12
Additional Safety Information .......................................................................................... 13
Technical Description...................................................................................................... 20
Operating BZ Liftgate ...................................................................................................... 23
Loading Limits ................................................................................................................. 27
Advice and Warnings ...................................................................................................... 28
How to Order Parts ......................................................................................................... 42

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

of Liftgate. To be used MANUFACTURE
when ordering parts or MONTH/YEAR
when contacting Waltco
for service or warranty.
GR00053

LOCATION OF SPECIFICATION TAG On some older liftgates

may be located here
Can be found on driver’s side, end of mount tube.
Usually found
on this end

Mount Tube

GR02226

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. PLACE DECALS IN THIS AREA

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.

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

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

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.
STAND CLEAR
75089296 – Stand Clear Decal (4) DECALS HERE

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

CAPACITY DECAL HERE

GR00511

INSTALLATION OF SAFETY TAPE

IMPORTANT! Safety
tape must wrap
Tape (Z20290) is to be placed on the sides of platform around side of
so it is visible from the side and back of vehicle as platform as shown.
shown.

IMPORTANT! Safety tape must wrap around side of

platform as shown.

GR00511

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. Tape 9”
Locate corner flag mount brackets (Z20273), one on 9”
Flag
9”
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.

Flag mount
bracket

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

PLACE
DECAL AS
SHOWN

GR00121

CIRCUIT BREAKER DECAL

PLACE DECAL
IN THIS AREA
The following decal is to be placed next to the liftgate
circuit breaker as shown.

80100829 – Circuit Breaker Decal

GR00122

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.

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

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

4
6
3
5

1
2
GR00508

Page 11
 General information
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.

Important
Before 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.

Page
4 12
 Safety
Genral safety
Only use the tail lift if the vehicle is If there is any doubt about the function-
parked and the handbrake is tightened ality of the tail lift, contact authorized
so you are certain that the vehicle workshop.
doesn’t move during the use. When its
necessary use stop blocks. Despite the tail lift is equipped with a
non-slip surface must precaution to be
Ensure that the area under and around taken at locomotion.
the tail lift is empty and stays empty as
long as the tail lift is in use. Only use spare parts that’s approved by
Zepro.
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.

Page
5 13
 Safety
Restricted area of use
A tail lift has the sole purpose of aiding A tail lift is only meant to be used when
the loading and unloading of vehicles, the function is satisfactory. If there is
thus, preventing the operator from any doubt concerning the tail lifts func-
making unnecessary physical efforts. tionality call for or visit an authorized
workshop.
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.

Page
6 14
 Safety
Safety for third party
When the tail lift is in use the operator The working area must always be free
must be aware of that all in nearby risks from persons and things. Al to avoid
injuries. damages if loads should fall of.

The tail lift is delivered with a working Uneducated personnel can never be
area decal as clearly show at which dis- allowed to operate the tail lift.
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.

Page
7 15
 Safety
Working 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

Page
8 16
 Safety
Technical safety Mechanical safety valves
The biggest risk for snips and catch in- Unlike electrical safety valves as pro-
juries is in the danger zone between the tect at leakage, these protect the tail lift
platform and body floor when the plat- against plummeting at hose breakage.
form rises to body floor level and when
the platform closes against the body. A Control unit
person who rides with the goods at the 3-button control + turn switch is used
platform must keep back feet and other at all opening/down tilting/lowering and
parts of the body from this danger zone. 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 light

To 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.

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

Electric safety
Electric safety valves are one-way
valves which allow oil to flow into the
cylinders but not out from them unless
current 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.
Page
9 17
 Safety
The safety of the hydraulic system
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.

User safety
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.

Page
10 18
 Safety
User 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.
12"
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.

12" min

12" min

Page
11 19
 Technical description
The 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.
Page
12 20
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.
 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.

Page
13 21
 Technical description

Platform

Mounting bracket
Lift arm

Support frame
Tiltcylinder
Bumper bar
Liftcylinder

3-parts bumper bar

Page
14 22
 Operating, standardlift CE
NB!
Ensure that the tail lifts working area
and periphery are clear.

1 UP

2 TILT

3 DOWN
FIXED
CONTROL UNIT 4 TURN SWITCH

3-button control unit + turn switch Lower

3 button + turn switch is used to all Activate the turn switch (4) and down
operating of the tail lift in order to avoid (3) button in mentioned order. The con-
crushing. stant flow valve gives the same speed
independent of the load.
Function, fixed control unit
Open/tilt down LOWER
At opening from transport position: use 4+3
turn switch (4) tilt button (2) and down
button (3) in mentioned order. The con- Tilt down
stant flow valve gives the same speed Activate the turn switch (4) and push
independent of the load. tilt (2) and down button (3) in mentio-
ned order. The platform tilts down with
the same speed. Also here gives the
OPEN/ constant flow valve the same speed
TILT DOWN independent of the load.
4+2+3

TILT DOWN
4+2+3

Page
15 23
 Operating, standardlift CE
Tilt up
Activate 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.
TILTING UP
4+2+1
Lift
Activate the turn switch (4) and push
up button (1). If the load is to heavy the
over flow valve opens.
LIFT
4+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.
Close
DO NOT OVERLOAD THE TAIL LIFT!
Activate the turn switch (4) and push tilt
(2) and up (1). The platform tilts up and
After operating the tail lift
close against the body.
Lock the platform, turn of the maneu-
ver current in the cabin. Then the tail lift
CLOSE is locked for unauthorized people. If the
4+2+1 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.

Page
16 24
 Operating with spiral cable/radio control unit
NB! Tilt down
Opening and closing function Push tilt (2) and down button (3) in
mentioned order. The platform tilts
is only allowed with fixed down against ground. Also here gives
control units. the constant flow valve the same speed
independent of the load.

TILT DOWN
1 UP 123
2+3

2 TILT
3 DOWN
Tilt up
Push tilt (2) and up (1) button in men-
tioned order. The platform tilts up to
horizontal position. If the load is to
SPIRAL CABLE RADIO heavy or placed to far back on the plat-
CONTROL UNIT CONTROL UNIT form at tilt up, the overflow valve opens.

Function, spiral cable and

TILT UP
radio control unit.
2+1

Lower
Push down button (3). The platform low-
ers with the same speed. The constant
flow valve gives the same speed inde-
pendent of the load. Lift
Push up button (1) The platform lifts
LOWER with the same speed. If the load is to
3 heavy the over flow valve opens.

LIFT
1

Page
23 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.

Lamp
Deactivate button

Page
24 26
 Loading Limits
BZ-33 Only
3300 lbs.
2300 lbs.
1800 lbs.
If the load is centered no farther than 30” out from the 1450 lbs.
vehicle rear sill, the maximum capacity is 3300 lbs. 1250 lbs.

As the load is centered farther out on the platform, the

maximum capacity is reduced, as shown.
78" 66" 54" 42" 30"

IMPORTANT! Never over load platform.

CENTER OF GRAVITY
GR00490

BZ-44 Only
4400 lbs.
3100 lbs.
2400 lbs.
If the load is centered no farther than 30” out from the 1950 lbs.
vehicle rear sill, the maximum capacity is 4400 lbs. 1650 lbs.

As the load is centered farther out on the platform, the

maximum capacity is reduced, as shown.
78" 66" 54" 42" 30"

IMPORTANT! Never over load platform.

CENTER OF GRAVITY

GR00491

Page 27
 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.

Never let an ”outsider”

operate the tail lift
while you are handling
the cargo.

A misunderstanding could be fatal. Never let an outsider get

around to operate the tail lift.
Page
28 28
 Cargo transfer - truck to truck / truck to trailer
Zeppo has to transfer a cargo of several tons from one truck to another. He has,
however, forgotten that this can overload the platform.

Not this way...

lt’s too heavy and dangerous.

Page
29 29
Cargo transfer - truck to truck / truck to trailer
..... this way.

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

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.
Page
30 30
Adjusting the platform to the dock

Push tilt
down.

As the truck is
unloaded, it rises relative
to the dock.

Page
31 31
Adjusting the platform to the dock
Before you unload each article onto the dock use the
control unit to tilt down. Make sure that the platform
overlaps sufficiently (min
(6"150 mm) and have a secure and
min)
solid resting position. lt’s safer for the driver, the customer
and his cargo.

6" min
min 150 mm

Page
32 32
 Maximum tilt down angle

The driver must under no circumstances tilt down more

than 10º (check table below), and putting load on the plat-
form.

X max

Dock

Platform X max Before tilting down.

Length Check the table so that permitted tilt
down angle not is exceeded.
48" 1200 280 mm
11"
60" 1500 260 mm
10"
72" 1700 300 mm
12.5"
84" 2000 350 mm
14.5"
2500 435 mm

Page
33 33
Using the platform as a ramp for forklifts and
heavy pallet jacks

A platform is not capable of carrying the overload of

forklifts.

Page
35 34
 Using the platform as a ramp for forklifts and
heavy pallet jacks
Note! Forklift locks can only be used on taillifts with steel platforms and
loading capacity 1500
3300- -2500kg.
4400 lbs.

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.

Page
36 35
 Do not overload the tail lift
When 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 3300
The 1500 kg lb
lift lift takes
takes 15003300
kg 600lbs
mmatfrom
24"the
from
bedthe bed
edge, 750edge,
kg 12001650 lbsand
mm out at
only out
48" 450 kg
andat the
onlyback 990edge
lbson
atathe
2 metre
backplatform.
edge on a 72" deep platform.

See load diagram of the lift type.

Page
37 36
 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!

Page
38 37
 The CONCEALED overload
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.

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.

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),
(4400 lb)
the taillift will be loaded with 2000kg.
4400 lb
The platform is also loaded with the
weight from both forklift and load.

Check that there is enough room for

the platform below the dock
Page
39 38
 To unload from trailer when separated from truck
When 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!

Page
40 39
 If you have damaged your ZEPRO tail lift
If 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.

Page
41 40
 Think of the lift, too
The 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.

Page
42 41
 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.

Page 42
 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.
____________________

Page 43
 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

Page 44