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Zepro Z 10, Installation Instructions Manual, Page: 10 / 57

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Zepro Z 10 Installation Instructions Manual Download Page 10

Z 10/15/20

10

Safety rules

www.zepro.com

1.1 

Third-party equipment must not be attached

You must not attach equipment (electric or hydraulic) to Zepro tail lifts that has not been approved. 

Attaching unapproved equipment may interfere with the lift system and its safety functions. Risk of 

injury and damage. If it is necessary to install other equipment, check the vehicle manufacturer’s body 

instructions and use the attachment features on the vehicle.

 

WARNING!

 

2.4 

Installation

 

The platform must not be installed so it cannot reach ground level.

 

WARNING!

 

Zepro tail lifts are only approved for installation with Zepro assembly kits.

 

WARNING!

 

All specified torque values apply for use with a screw or impact wrench with torque control. Torque distribu

-

tion max ± 5%.

NOTE!

 

Summary of Contents for Z 10

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 55757TL 2021 03 26 Installation Instructions Tail Lift Z 10 15 20 ...

Page 2: ......

Page 3: ...lling the platform 11 3 4 Installing the cylinders 11 3 5 Attaching stickers 11 4 Calculating the installed dimensions 12 4 1 C dimension 12 4 2 D dimension 12 4 3 A dimension 12 4 4 H dimension 12 5 Rear member cut outs 15 6 Installation 16 6 1 Support frame 16 6 2 Control power cable 19 6 3 Controllers 20 6 4 Warning lighting foot controls 21 6 5 Main power cable 23 6 6 Installation of main fuse...

Page 4: ...on plate 43 9 3 Work area 43 9 4 Warning tape 43 9 5 Controller sticker 44 9 6 Danger area 45 9 7 Warning flags 45 10 Lubrication and fluid level check 46 10 1 Lubrication 46 10 2 Oil level check 46 11 Testing and verification 47 11 1 Static load test 47 11 2 Dynamic load test 49 11 3 Test of safety functions 50 12 Disassembly 51 13 Specifications 52 13 1 Weights 52 13 2 Maximum power consumption ...

Page 5: ...stallation instructions and are intended to draw your atten tion to circumstances potentially causing unwanted situations near misses personal injury or damage to the product etc Take care Risk of damage to the product NOTE Take extra care Risk of personal injury or damage to the product and the surroundings WARNING ...

Page 6: ...meets relevant requirements according to EN 1756 1 2001 A1 2008 1 4 Hydraulic oil If the hydraulic oil needs to be replenished only the oil recommended by ZEPRO is permitted to be used Hydraulic systems with hydraulic oil tanks without labelling are only permitted to be filled with highly refined mineral oil art no 21963 1 litre Hydraulic systems with hydraulic oil tanks marked with a specificatio...

Page 7: ...dentification E g Z 15 130 S _ _ _ _ _ _ _ _ _ _ _ Z Standard model ZL Wide frame wide 1st boom Max lifting capacity x 1 kg Max lifting height 130 1300 mm 150 1500 mm Cylinder model S Single acting Single speed Tilt Single acting Single speed Lift ...

Page 8: ...ng could damage the cylinder gaskets Boots hydraulic hoses and cables must not be painted as the solvent in the paint could damage hoses cables and significantly impair durability NOTE Image 1 Piston rods cylinder covers and boots must not be painted Image 2 Hydraulic hoses must not be painted Image 3 Cables must not be painted ...

Page 9: ...s subframe truck chassis beam for rear light number plate and the chassis bracket of the lift with a short overhang The final inspection must be carried out with the platform at the vehicle floor and tilted down 10 The clearance from the closest part of the cylinder must be at least 40 mm WARNING The platform must not be tilted down more than max 10 from horizontal when people are on the platform ...

Page 10: ... Risk of injury and damage If it is necessary to install other equipment check the vehicle manufacturer s body instructions and use the attachment features on the vehicle WARNING 2 4 Installation The platform must not be installed so it cannot reach ground level WARNING Zepro tail lifts are only approved for installation with Zepro assembly kits WARNING All specified torque values apply for use wi...

Page 11: ...gning the support frame Mounting chassis brackets Detaching the mounting jig 3 2 Electrical connections Installing the controller Installing the controller cables Installing the main power cable 3 3 Installing the platform Installing the platform Installing seals and end stops Installing the armstops 3 4 Installing the cylinders Adjusting the tilting cylinder Testing 3 5 Attaching stickers ...

Page 12: ...ace there will be between the 1st booms in the upper position and the vehicle floor level A dimension 4 2 D dimension The D dimension is the space the lift needs measured from the rear edge of the body to the front edge of the support frame in the direction of the vehicle Once the C dimension is determined the D dimension can be obtained from the table 4 3 A dimension The A dimension is the space ...

Page 13: ...Z 10 15 20 150 194 C 40 D 1300 max min 685 max A C A D 615 188 608 550 158 689 500 142 738 450 130 779 400 120 814 350 111 843 300 103 867 285 101 873 194 C 40 D 1500 max min 785 max A C A D 715 192 674 650 163 757 600 150 809 550 138 853 500 128 891 450 119 924 400 112 952 350 105 976 325 102 987 ...

Page 14: ...Z 10 15 20 14 Calculating the installed dimensions www zepro com Image 9 Z 10 15 20 Image 10 Z 10 15 20 1836 min 740 max 930 2425 958 336 340 617 817 133 301 ...

Page 15: ... position The size of the cut outs depends on the calculated installed dimension A see illustration below 1 Measure and mark the location and depth of the cut outs on the rear beam The two cut outs must be centred on the rear beam i e both cut outs must be an equal distance from the mid point of the beam 2 Cut along the markings 3 Grind away any burrs or sharp edges Image 11 Z 10 15 20 1030 240 A ...

Page 16: ... parallel with the floor of the vehicle body and must not be in contact with the vehicle frame there must be a few millimetres of play If necessary adjust the angle of the arms by carefully operating the lift 7 Install the brackets on the support frame so that its opening is facing towards the front of the vehicle and adjust the position of the frame so they are in contact with the vehicle frame 8...

Page 17: ...120 Nm 13 Using a torque wrench tighten the bolts holding the U profiles Tightening torque 280 Nm 14 Drill holes in the vehicle chassis for mounting bolts Ø14 mm Drill in the outer holes of each bracket Use M14x45 bolts and install the associated washer and nut on the inside of the vehicle chas sis Installation must be performed with at least 6 bolts in the outer holes The bolt that was installed ...

Page 18: ...ehicle chassis for mounting bolts in each bracket s two upper round holes Use suitable bolts durability equivalent to M14 10 9 or higher and install the associated washer and nut on the inside of the vehicle chassis See Image 18 Tighten the bolts with a torque wrench Tightening torque Standard for se lected screw 20 Remove the mounting jig Welding is not permitted on the chassis brackets Do not mo...

Page 19: ... must be protected with rubber grom mets when it passes through beams or walls Position any quick connectors so they are well protected from moisture and dirt NOTE 2 Connect the control power cable to the cab switch CS on the vehicle instrument panel Connect to the on board electrical system via a 10 A 24 V 15 A 12 V fuse according the customer s wishes See the connection diagram 8 6 Connecting co...

Page 20: ...d surrounding area 2 The distance between the rear edge of the vehicle and the centre of the controllers must be betwen 300 600 mm See Image 20 All cable inlets must be pointing downwards NOTE 3 The controller cable connects to the control card See section 8 6 Connecting controllers on page 40 Image 20 Installing controllers A controller must always be fitted on the side that is facing away from t...

Page 21: ...nly foot controls see Image 23 On platforms with warning lighting alternatively warning lighting foot controls see Image 24 2 Attach the cable with the cable clips to the platform On platforms with warning lighting also attach the angle sensor s cabling with the same cable clips see Image 24 Image 22 Warning lighting and foot controls Image 23 Connection of cabling on platform with only foot contr...

Page 22: ...ith the existing cabling with cable ties Route the cable between the platform and the lift arm s pipe so that it is well protected when the platform hits the ground Leave enough slack to the first cable tie so that the cable is not at risk of being damaged when the lift is operated NOTE 4 Connect the cables to the control card see wir ing diagram in section 8 4 Connecting Open Platform Alarm on pa...

Page 23: ...hat it cannot chafe or otherwise sustain damage that can lead to a short circuit and cable fires Do not bend the cable with too small a radius as this can cause damage to the cable In general care must be taken when routing all the cables in order to obtain a longer cable service life and to reduce the risk of unnecessary stoppages NOTE The fuse box must be located in a well protected position as ...

Page 24: ...0 2 3 Connect a cable from the battery s positive terminal see Image 20 3 4 Screw the cable connections and fuse into place with the knob Install the cables at 90 or 180 from each other Install the fuse at right angles to the cables see Image 20 The knob must lie against and centre the cable clip so that it does not come into contact with the bolt Incorrect installation can cause the fuse to malfu...

Page 25: ...ound the x axis See illustration If in doubt contact ZEPRO for support 6 7 2 Statutory dimensions for underrun protection Distance between the beam and the ground when the vehicle is unloaded Max 450 mm for vehicles with air suspension Max 500 mm for vehicles with conventional suspension If the exit angle with the above setting is less than 8º the distance between beam and ground in an unladen ve ...

Page 26: ...Image 34 The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm See Image 35 Each of the individual parts of the underrun protec tion must have a surface area of at least 350 cm2 See Image 35 Image 34 Statutory dimensions Image 35 Statutory dimensions Max 25 mm Max 25 mm Min Area 350 cm2 ...

Page 27: ...nsions for underrun protection on page 25 Check carefully that there is no risk of the outer part of each bracket colliding with any part of the cylinders when using the lift s functions In particu lar check in relation to the cylinders hose con nections especially when the outer parts of the brackets are installed a long way in WARNING Use the associated bolts M12x80 Assemble without tightening t...

Page 28: ... 1st booms and the rear beam of the vehicle floor 6 9 Sealing strip horizontal The track is fitted using the self tapping screws provided 1 Mark where to drill holes for the self tapping screw 2 Drill holes Ø 7 2 mm for the screws 3 Fit the horizontal stop strip steel or aluminium 4 Fit the rubber strip in the track 6 10 Sealing strip vertical 1 Fit the tracks with countersunk screws rivets or by ...

Page 29: ...d to 750 mm see 9 1 Loading diagram on page 42 NOTE 3 Fitting the platform to the arms Tighten the nuts using a torque wrench see Image 43 Tightening torque 280 Nm 4 Fit one of the tilting cylinders to the platform Use the provided shaft and support wheel see Image 43 Make sure the cylinders are installed with the grease nipples facing up NOTE Tighten the bolts using a torque wrench Tightening tor...

Page 30: ...y raising it to the vehicle floor level and tilting it to the vertical position Check the position in relation to the rear beam and side posts of the vehicle See Image 44 6 The platform underhang A see Image 45 var ies according to platform type and this should be taken into account when fitting the upper seal Max 40 mm Min 38 mm Image 44 Check the position in relation to the rear beam of the vehi...

Page 31: ... ZEPRO tool part no 59693 60 mm Always adjust both cylinders 4 Unscrew the lock screws pos 5 6 7 see Image 48 Zepro recommends securing the screws with Loctite 243 or equivalent Must always be adjusted with full hydraulic pres sure in the tilting cylinders NOTE Check the dimension see Maximum length must not exceed 33 mm see Image 49 The max length of both cylinders must be adjust ed equally to av...

Page 32: ... level and adjust to hori zontal position 2 Tilt down the platform and measure the angle pos 5 Image 51 Adjust to max 10º 3 Loosen the end stop lock screw 1 2 Screw the end stop all the way back towards the platform 3 Image 50 4 Tilt the platform down to max 10 degrees below the horizontal see Image 52 5 Tighten the lock screw in the end stop 5 See Image 51 Zepro recommends securing the screws wit...

Page 33: ...ing the platform fully against the vehicle body and then tilt ing all the way down 6 13 Transport lock Electric hose rupture valves serve as locks for the platform The lock opens automatically if the down function is actuated from the controller The valves are check valves that let fluid into the cylinders but not out before they are actuated by the flow from the lowering valve The platform is thu...

Page 34: ...be pulled a little way out of the frame V4 V5 V4 hose rupture valve lift cylinder V5 hose rupture valve tilting cylinder Function Input signal Output signal Comment Tilt down1 C E V1 V2 V4 V5 K1 K3 Tilt down2 E PS1 V1 V4 V5 K1 Hydraulic autotilt Lower E V1 V4 V5 K1 Raise B S K2 Tilt up B C S V2 K2 K3 VALVE BODY TANK CAP TANK SOLENOID S MOTOR K1 VALVE LOWERING V1 VALVE SHIFT V2 PRESSURE SWITCH PS1 ...

Page 35: ...Z 10 15 20 Electrical and hydraulic drawings 35 www zepro com 8 Electrical and hydraulic drawings 8 1 Z 10 15 20 ...

Page 36: ...Z 10 15 20 36 Electrical and hydraulic drawings www zepro com 8 2 Z 10 15 20 hydraulic autotilt ...

Page 37: ...l and hydraulic drawings 37 www zepro com 8 3 Connection to circuit board 4 button operation Pos Colour 1 Yellow Green 2 Blue 3 Brown 4 Black 5 Green 6 White 7 Red 8 Yellow 9 Grey 10 Orange 11 Purple 12 Pink Control Power ...

Page 38: ...ectrical and hydraulic drawings www zepro com 8 4 Connecting Open Platform Alarm 4 11 4 11 Vinklegivare Pos Colour 1 Yellow Green 2 Blue 3 Brown 4 Black 5 Green 6 White 7 Red 8 Yellow 9 Grey 10 Orange 11 Purple 12 Pink ...

Page 39: ...rawings 39 www zepro com 8 5 Connecting warning lighting and foot controls Pos Colour 1 Yellow Green 2 Blue 3 Brown 4 Black 5 Green 6 White 7 Red 8 Yellow 9 Grey 10 Orange 11 Purple 12 Pink S Signal U Up D Down S U D 6 4 3 8 6 4 3 8 3 2 4 ...

Page 40: ...s directly to the relay board see wiring diagram in 8 1 Z 10 15 20 on page 35 When installing a controller with locking function or when installing several controllers a connection card is used see wiring diagram in 8 3 Connection to circuit board 4 button operation on page 37 CD4 B C 2H E CD9 B C E CD10 B E CD14 A B S E CD14 B B S E B E C Black White if avail able Brown B Yellow E Blue C Brown B ...

Page 41: ...mage 53 Overview of labelling 9 Marking Below an overview of the location of the different markings is shown Image of marking and further informa tion can be found under the each subchapter for subsequent pages 9 1 9 5 9 3 9 4 9 5 9 6 9 7 ...

Page 42: ...rimary controller and in a suitable clearly visible position on the vehicle body Image 54 Load diagram for load capacity 1000 kg centre of gravity distance 750 mm Image 55 Load diagram for load capacity 1500 kg centre of gravity distance 750 mm Image 56 Load diagram for load capacity 2000 kg centre of gravity distance 600 mm ...

Page 43: ...on Type of lift Max permitted load in kg Production number Year of manufacture Address and tel no of manufacturer Country of manufacture Type number for approved underrun protection RUPD Type number for electromagnetic compatibility EMC 9 3 Work area Affix the sticker clearly visible on the rear of the vehicle Image 59 Warning tape 9 4 Warning tape Affixed along the platform edge strips to mark th...

Page 44: ... is discarded www hiab com 55053TL 2020 03 04 Image 61 Controller sticker for CD 10 www hiab com 77661TL 2020 03 04 9 5 Controller sticker Affix the controller sticker next to the relevant controller The stickers are available in standard versions and in reversed version Option for affixing on the opposite side of the vehicle Make sure the stickers are affixed so the image of the vehicle tail lift...

Page 45: ...de of the vehicle body next to the hand control unit 9 7 Warning flags Attach warning flags as close as possible to the top and edge of the platform where there is no risk of them coming loose when the platform is lowered to the ground Swage the tracks together to secure the warning flags www hiab com 65977TL 2020 05 14 min 300 mm min 300 mm ...

Page 46: ...nder at lower bearing 5 Left tilting cylinder at lower bearing 6 1st boom left side at lower bearing 7 Left tilting cylinder at upper bearing 8 Right tilting cylinder at upper bearing 9 1st boom right side at upper bearing 10 Right lift cylinder at upper bearing 11 Left lift cylinder at upper bearing 12 1st boom left side at upper bearing 10 2 Oil level check Check the fluid level in the tank duri...

Page 47: ...ns A B C D for comparison as illustrated in Image 68 Place a test load on the platform according to the table for the respective tail lift model lifting capacity Remove the test load from the platform Repeat the measurement of A B C D and verify that there has been no deformation of the lift or its fixing 11 1 2 Drift Place a test load on the platform according to the table The tail lift must be a...

Page 48: ...1000 mm Capacity Load 500 kg Load 1000 kg Distance on platform L 450 kg 450 kg 675 mm 500 kg 750 mm 700 kg 1050 mm 750 kg 1125 mm 1000 kg 1450 mm 750 mm 1500 kg 2250 mm 1125 mm 2000 kg 1550 mm 2500 kg 1875 mm 11 1 4 Static load Test load 1 25 x tail lift loading capacity For tail lifts with load centre of 750 mm Capacity Load 1000 kg Load 1500 kg Distance on platform L 1000 kg 940 mm 1500 kg 1410 ...

Page 49: ...e 1 25 x max load for each lift model Verify that the tail lift cannot lift the load when the up function is switched on it may however be possible to tilt up the load 11 2 3 Dynamic load Test load 1 0 x tail lift loading capacity For tail lifts with load centre of 600 mm Capacity Load 500 kg Load 1000 kg Distance on platform L 450 kg 600 mm 500 kg 600 mm 700 kg 800 mm 750 kg 900 mm 1000 kg 1200 m...

Page 50: ...oor level or end stops That the tail lift cannot be lowered or tilted down if the electrical connector from the electric hose rupture valves is disconnected from the lift and tilting cylinders respectively That there is a max load marking on the platform and it is correctly positioned according to the loading diagram for the tail lift model concerned That warning flags and reflectors are fitted an...

Page 51: ...um stroke limit to remove pressure from the circuit 4 Dismantle the side profiles from the platform Loosen the grease nipples and lock screws in the platform pivots Use the Zepro special tool for the platform pivots Hammer outside with the sliding weight 5 Follow the same procedures for the other side 6 Lift off the platform 7 Raise the 1st booms to their highest position 8 Disconnect 12 24 V from...

Page 52: ...kg Support frame Z 10 15 20 82 kg Z 10 150 328 kg Lift arm Z 10 15 20 130 45 kg Z 15 130 315 kg Lift arm Z 10 15 20 150 49 kg Z 15 150 328 kg 3 part underrun protection complete Z ZL 57 kg Z 20 130 317 kg Complete frame bracket Z 10 15 20 28 kg Z 20 150 330 kg Lift cylinder Z 10 15 130 11 4 kg each Lift cylinder Z 10 15 150 12 5 kg each Aluminium platforms Lift cylinder Z 20 130 12 5 kg each Plan ...

Page 53: ...work when the lift is operated repeat edly without the vehicle being started and used the battery charger must be used between operations to maintain the battery charge level The battery charger must not be connected when operating the lift Risk of material damage NOTE Ensure that the lift has access to the minimum recommended power capacity Imin Some vehicle models have restrictions regarding the...

Page 54: ...w zepro com Image 70 Loading diagram 13 4 Loading diagram 600 mm 750 mm Z 20 Max load NOTE The max load marking on alu minium platforms is located at 600 mm as standard On Z 10 and Z15 the marking can be moved to 750 mm Z 10 and Z 15 ...

Page 55: ... 465 TP1 mm C 615 236 191 123 TP2 mm 1500 kg 683 788 948 TP2 mm 2000 kg 596 701 861 C 325 C 515 TP1 mm C 715 280 233 144 TP2 mm 1500 kg 674 781 987 TP2 mm 2000 kg 590 697 903 TP2 TP1 40 C Z 15 20 130 steel platform 1700x2650 mm Z 15 20 150 steel platform 1700x2650 mm Max load ...

Page 56: ... www zepro com Image 71 Tightening torque 13 6 Tightening torque 280 Nm 280 Nm 80 Nm 115 Nm 280 Nm 280 Nm All specified torque values apply for use with a screw or impact wrench with torque control Torque distribu tion max 5 NOTE ...

Page 57: ...lifts Hiab is a world leading supplier of equipment intelligent 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 intelligent load handling ...

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