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WALTCO ZS MK2, Owner'S Manual

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WALTCO ZS MK2 Owner'S Manual Download Page 47

47

5 

Service and maintenance

Regular service and maintenance are essential for keeping maintenance costs low, sa-

fety high and product life long. Daily and weekly maintenance and regular lubrication as 

described in this owner's manual must be carried out for the best results. Once a year, the 

Liftgate must also be handed to an authorised provider for service.
This manual includes WALTCO’s recommendations for checks, lubrication and service.
5.3 Daily checks
5.4 Weekly checks
5.5 Lubrication
5.6 Service

5.1 

Hydraulic oil

If the hydraulic oil needs to be replenished, only the oil recommended by WALTCO is permit-

ted to be used.  WALTCO ships and recommends all liftgates use Shell Tellus 15 or equiva-

lent.  Recommended all year round.

Hydraulic systems with hydraulic oil tanks marked with a specification for the hydraulic oil 

May only be filled with the oil specified on the label.

Service and maintenance

Summary of Contents for ZS MK2

Page 1: ...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...

Page 2: ......

Page 3: ...ral 12 2 2 Damage and malfunctions 12 2 3 Max permissible load 13 2 4 Maintenance repairs and service 14 2 5 Modifications 14 2 6 Operation 15 2 7 Intended use 17 2 8 Danger area 17 2 9 Work area 18 2...

Page 4: ...ntrol 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 lo...

Page 5: ...nded 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...

Page 6: ...ut 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...

Page 7: ...n 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 av...

Page 8: ...d maintenance character Replacing fuses adjusting hydraulic pressure adjusting tilt cylinders adjusting torque Hydraulic components con taminated by dirty hydraulic oil Dissonance caused by neglected...

Page 9: ...e 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...

Page 10: ...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...

Page 11: ...ct etc m WARNING WARNING indicates a potential hazard which if ignored may lead to serious life threatening injury m CAUTION CAUTION indicates a potential hazard which if ignored may lead to minor inj...

Page 12: ...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...

Page 13: ...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 floor If the load s centre of gravity is placed 60 inches from the edge of the v...

Page 14: ...mended 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 Modifications Modifications not described or approve...

Page 15: ...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 dam...

Page 16: ...g injury m CAUTION 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 tra...

Page 17: ...e 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...

Page 18: ...s 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 ha...

Page 19: ...anger from passing traffic Also make sure the work area is clear m WARNING The vehicle must be positioned to allow liftgate operation without danger from passing traffic Risk of material damage and li...

Page 20: ...lly 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 b...

Page 21: ...iven hydraulic pump supplies oil to the product s hydraulic cylin ders via hoses and valves and to power the hydraulic functions Great importance has been given to safety A bypass valve protects again...

Page 22: ...witch The Liftgate can be fitted with a cab switch to switch control power On Off When the con trol circuit is switched off the lift is locked The cab switch should always be in the OFF position durin...

Page 23: ...the Liftgate simultaneously from different control devices The active control device temporarily disconnects other control devices while it is in use 3 8 2 Warning flags In order to draw attention to...

Page 24: ...is the primary control device which means it includes all pos sible functions for the liftgate concerned The remaining control devices are secondary which may mean the number of functions is limited...

Page 25: ...rol devices are installed on the vehicle superstructure or on brackets below the superstructure The control devices must be positioned according to app licable regulations with a certain distance from...

Page 26: ...tform down towards the ground In autotilt down the tilt function is driven solely by gravity For fastest operation the plat form should first be tilted manually to the horizontal position before enabl...

Page 27: ...during e g conti nuous intensive use The amount of continuous work the liftgate is able to perform is influenced by ambient temperature and the load the liftgate is exposed to Generally speaking it t...

Page 28: ...person to comply with the recommendations warnings and instructions set forth in this owner s manual NB In the event of damage or accident Immediately report such to the person responsible for action...

Page 29: ...cle floor If the load s centre of gravity is placed 60 inches from the edge of the vehicle floor max permissible weight decreases to 2200 lbs Sticker max permissible load 4400 lbs Load centre distance...

Page 30: ...ger from passing traffic Also make sure the work area is clear m WARNING The vehicle must be positioned to allow liftgate operation without danger from passing traffic Risk of material damage and life...

Page 31: ...edges to avoid stepping off by mistake Also be aware of the risk of tripping especially if the platform is fitted with warning lights or wheel stops Risk of injury m CAUTION The greatest risk for cut...

Page 32: ...form increases the risk of tripping and falling over the edge Risk of injury and material damage Operation m CAUTION Make sure the load is placed securely on the platform when the liftgate is operated...

Page 33: ...an additional weight equivalent to the speci fied maximum load The weight of the load may not exceed the maximum capacity of the liftgate Platform load Forklift Load on truck Liftgate load Total load...

Page 34: ...le It can happen that the platform rises so far that it must be tilted down to the dock before unloading can continue especially when unloading heavy goods The transfer load may not exceed half the lo...

Page 35: ...t form down at regular intervals Check that the platform has sufficient overlap min 6 and that it rests safely and stably on the dock Platform length L Hmax 47 8 59 10 67 11 6 79 13 7 98 17 4 6 2 Maxi...

Page 36: ...h the load will be transferred as the transfer ramp The transfer load may not exceed half the load capacity of the lift Example Liftgate with lifting capacity 4400 lbs maximum permissible overrunning...

Page 37: ...relevant control device section for detailed information Lock the liftgate On liftgates with cab switches switch off control power by setting the cab switch to Off On liftgates with cab switches switc...

Page 38: ...ops immediately The con trol device has a customised layout for mounting on the left and right sides of the vehicle FUNCTIONS 1 Up 2 Tilt down Slider out 3 Tilt up Slider in 4 Down 5 Two handed functi...

Page 39: ...release it from the transport locks IMPORTANT It is important to lower the platform to clear the transport stops before moving it outwards Failure to do so may result in damage Down 4 9 1 Switching fr...

Page 40: ...tion in the working position This procedure describes how to operate the liftgate in the working position The illustra tions show a control device installed on the right side of the vehicle Tilt down...

Page 41: ...to prepare the liftgate for transport after loading or unlo ading The illustrations show a control device installed on the right side of the vehicle First operate the liftgate up or down until the pl...

Page 42: ...The control device is used when the liftgate is in the working position and to control the Up Down and Tilt functions The control device is fitted with dead man s buttons when a but ton is released li...

Page 43: ...rm is then raised at an even pace Up Down Depress and hold down the Down button 2 The platform is lowered at an even pace Down 4 10 1 Operation in the working position This procedure describes how to...

Page 44: ...tform Risk of life threatening injury Operation Tilting up Depress and hold down the Tilt 2 and Up 1 buttons in that order The platform is then tilted up at an even pace Tilt up Tilting down Depress a...

Page 45: ...ce CD10 The control device is used when the liftgate is in the working position and to control the Up and Down functions The control device is fitted with dead man s buttons when a button is released...

Page 46: ...tform is raised at an even pace Up Down Depress and hold down the Down button 2 The platform is lowered at an even pace Down 4 11 1 Operation in the working position This procedure describes how to op...

Page 47: ...ervice This manual includes WALTCO s recommendations for checks lubrication and service 5 3 Daily checks 5 4 Weekly checks 5 5 Lubrication 5 6 Service 5 1 Hydraulic oil If the hydraulic oil needs to b...

Page 48: ...tenance Lower and tilt the platform down so that it rests on the ground to reduce pressure in the hydraulic system to a minimum Cut the power supply by disconnecting the cable at the main fuse or by s...

Page 49: ...e Liftgate to check for oil leaks Contact a qualified service engineer for troubleshooting or repair 4 Visually inspect all Liftgate components for cracks and deformations Contact a quali fied service...

Page 50: ...ch on page 22 Contact a qualified service engineer for trou bleshooting or repair 5 Check that visible cables cable glands and connectors are securely fastened and undamaged Contact a qualified servic...

Page 51: ...5 2 Interval At a minimum lubrication must be done every 3 months More frequent intervals may be necessary when driving in aggressive surroundings or the lift is washed often Contact WALTCO for advic...

Page 52: ...oved provider for the warranty to remain valid For information about the nearest provider visit the WALTCO website or contact your distributor The service record must be completed and signed following...

Page 53: ...g Below is an overview showing the location of the different markings Marking illustrations can be found under the relevant subheadings in the following pages www hiab com 55057TL 2020 03 04 6 1 6 3 6...

Page 54: ...marking on the platform or vehicle m WARNING Under no circumstances is it permitted to load the platform with loads greater than those spe cified on the marking Excessive load can cause structural dam...

Page 55: ...ith the edge marking and may in this case have expired ft 78995TL 16 Bild 1 Identification plate Explanation of Specification Tag MODEL NUMBER RATED CAPACITY Based on an evenly distributed load on the...

Page 56: ...5 x 210 mm Two stickers on the same back paper Print colours Black CMYK 0 0 0 100 Grey PMS Cool Grey 4 C Yellow PMS 7405 C Control device sticker for CD 9 www hiab com 78997TL 2021 09 07 W x H 80 x 90...

Page 57: ...th autotilt The stickers are available in standard versions and in reversed version Option for affixing on the opposite side of the vehicle Additional Auto tilt sticker for CD 9 W x H 80 x 90mm Print...

Page 58: ...the manual control device where fitted The sticker informs about the hazards area between the vehicle floor and platform where the risk of crush injuries is especially great when operating the liftgat...

Page 59: ...ernal conditions See section 3 11 Overheating protection on page 27 Blown fuse tripped circuit breaker Check fuses in cab and liftgate in the case of a blown fuse check that visible cables cable gland...

Page 60: ...cifications 8 1 Noise declaration Average emission sound pressure level does not exceed 70 dB Noise Directive 2000 14 EC Noise measurement according to EN ISO 11200 11204 Measurement was carried out i...

Page 61: ...recycling comply with local and national regulations and guidelines 9 2 1 Before disassembly Before disassembly drain the hydraulic oil tank hoses and cylinders The oil must be han ded in for destruct...

Page 62: ...en lifting heavy loads Make sure that heavy parts are completely resting on the ground or secured by a lifting device before removing shafts bolts or other fasteners Risk of injury 9 2 3 Recycling Met...

Page 63: ...tem s leakproofness Hydr connection unit tank cyl torques IE 0104 C 2 6 Pressure Relief Valve Valve should open when tilting against body check pressure if not opening IE 0108 C 2 7 Velocity lifting l...

Page 64: ...the service items indicate any action below Service check in the table below confirm actions have been carried out for each service item Service item Remark Action Checks and actions have been carrie...

Page 65: ...65 11 Own remarks Own remarks...

Page 66: ...66 Own remarks...

Page 67: ...taller hereby certifies that installation was carried out according to WALTCO s instructions installation delivery inspections have been performed Installer s signature Date Serial number manufacturin...

Page 68: ...ntelligent services and digital solutions for on road load handling As an industry pioneer our company commitment is to increase the efficiency of our customers operations and to shape the future of i...

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