Zepro Z 15 User Manual Download Page 7

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Product approval

Declaration of conformity, installation

Installers stamp

The installer certifies that:

- installation has been carried out according to Zepros instructions.

- post installation check has been performed.

...........................................

...............................................................

Date of installation

Installers signature

The installer certifies at own responsibility that the tail lift as identifies at page 6 in this

manual has been installed according to instructions from Zepro and that post installation

check has been performed. In addition all vehicle manufacturer guidelines for auxiliary

equipment have been adhered to.

When Zepros installation instructions has been followed and possible modifications is

approved by Zepro, this document is a confirmation that both the tail lift and installation

confirms to the following directive.

Machinery Directive 2006 / 42 / EC

Summary of Contents for Z 15

Page 1: ...03 www zepro com USER MANUAL Operator safety instructions Inspection maintenance instructions USER MANUAL IN ORIGINAL This manual must be kept in the glove compartment in the truck at which the tail l...

Page 2: ......

Page 3: ...missions 22 Remote Diagnostics System 22 Function operation 23 Description function 23 Overview components 24 Operating standard lift 25 Operating standard lift 3 buttons turn switch 26 Operating slid...

Page 4: ...46 Once a week control of wear parts 46 Lubrication 47 Hydraulic oil Hydraulic cleanliness 49 Service protocol L Service Year 1 50 Service protocol L Service Year 2 52 Service protocol XL Service Year...

Page 5: ...sed written permission from the manufacturer If this is not followed the CE marking ceases to be valid and hence the responsibility for the safety level of the product is transferred to those who have...

Page 6: ...06 42 EC Annex 2A We also complies with all applicable provisions of EMC Directive 2004 108 EC Design and manufacture Standard EN 1756 1 Technical file in accordance with Directive 2006 42 EC Annex VI...

Page 7: ...that the tail lift as identifies at page 6 in this manual has been installed according to instructions from Zepro and that post installation check has been performed In addition all vehicle manufactur...

Page 8: ...8...

Page 9: ...tail lift and vehicle have been prepared by him for regular operation Checks 2 3 4 5 9 11 och 15 if available 1 Lift tilt and lowering with fixed control unit 2 Lift tilt and lowering with other cont...

Page 10: ...level see instructions at hydraulic unit 8 Ground connection between tail lift and vehicle frame See also manufacturers electric instructions 9 Function of control unit heating ele ment Option 10 Fun...

Page 11: ...t the tail lift 13 Greasing see page 46 14 Load testing the tail lift see instruction in installation instruction 15 Test of safety functions and possible accessory see instruction in installation ins...

Page 12: ...12 Possible notes and action taken Post installation check Pos Action taken Product approval...

Page 13: ...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 di...

Page 14: ...e handbrake is tightened so you are certain that the vehicle doesn t move during the use WARNING Don t let heavy loads fall down at the platform WARNING Before the platform lowers or lifts you must co...

Page 15: ...isfactory If there is any doubt concerning the tail lifts functionality call for or visit an authorized workshop When the tail lift is in use the operator must be aware of that all in nearby risks inj...

Page 16: ...s 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 th...

Page 17: ...Warning and information signs 1 Warning flag 2 Working area 3 Loading diagram 4 Warning tape 5 Operating instruction 6 Danger of crushing 7 Optional Function 3 button sprial cable with deactivation b...

Page 18: ...PRO tail lift is equipped with safety devices to prevent accidents Electric safety Electric safety valves are one way valves which allow oil to flow into the cylinders but not out from them provided t...

Page 19: ...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...

Page 20: ...at least 300 mm from the floor edge to prevent risk of foot injury Always use fixed control units at opening and closing of the tail lift In order to avoid crush damages at operators this person must...

Page 21: ...the centre of gravity is placed 1875 mm from the edge of the body floor decreases the max load to 1000 kg Example on how the load weight changes when the distance to the body floors edge increases Lo...

Page 22: ...at all times have the right to install maintain and dismantle automated remote diagnostics system or similar sensor based system the System in and from the Equipment access send receive collect store...

Page 23: ...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 buil...

Page 24: ...24 PLATFORM MOUNTING BRACKET SUPPORT FRAME TILT CYLINDER LIFT CYLINDER BUMPER BAR LIFT ARM 3 PART BUMPER BAR Function operation Overview components...

Page 25: ...25 Function operation Operating standard lift WARNING The vehicle should be positioned so that operation of the tailgate lift can take place without danger from moving traffic...

Page 26: ...ition use turn switch 4 tilt button 2 and down button 3 in mentioned order The constant flow valve gives the same speed independent of the load Lower Activate the turn switch 4 and down 3 button in me...

Page 27: ...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 platform at tilt up the overflow valve opens Lift Activate the turn...

Page 28: ...IDER OUT 4 SLIDER IN 2 5 Lower Push down button 3 The platform lowers with the same speed The constant flow valve gives the same speed independent of the load LOWER 3 Working position Push button 5 ar...

Page 29: ...hen the tail lift is locked for unauthorized people If the 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...

Page 30: ...nsport position use button 2 and button 3 The constant flow valve gives the same speed independent of the load Lower Use button 3 and button 4 The constant flow valve gives the same speed independent...

Page 31: ...tons 1 and button 2 The platform tilts up to horizontal level then it turns into normal lift function If the load is to heavy or placed to far back on the platform at tilt up the overflow valve opens...

Page 32: ...same speed independent of the load LOWER 3 AUTO TILT UP 1 3 6 Tilt down Push button 2 and button 3 Also here gives the constant flow valve the same speed independent of the load TILT DOWN 2 3 Automat...

Page 33: ...t is locked for unauthorized people If the 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 wit...

Page 34: ...down button 3 until the platform has reached sufficient level to slide out Function fixed control unit Slider out Push button 4 The platform slides out Lower Push down button 3 The platform lowers wi...

Page 35: ...son 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 li...

Page 36: ...the load Fold out the platform by means of manhandle The platform is double folded Lower Push down button 3 The platform lowers with the same speed The constant flow valve gives the same speed indepen...

Page 37: ...hen the tail lift is locked for unauthorized people If the 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...

Page 38: ...oad LIFT 3 1 Lift Push neutral 3 and up 1 button The platform lifts with the same speed If the load is to heavy the over flow valve opens LOWER 1 3 Lower Push neutral 1 and down 3 button The platform...

Page 39: ...xed control units TILT DOWN 2 3 Tilt up Push tilt 2 and up 1 button in mentioned order The platform tilts up to horizontal position If the load is to heavy or placed to far back on the platform at til...

Page 40: ...overload especially if the platforms are long 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...

Page 41: ...iver the customer and his cargo min 150 mm Adjusting the platform to the dock The driver must under no circumstances tilt down more than 10 check table below and putting load on the platform X max Bry...

Page 42: ...osition Using the platform as a ramp for forklifts and heavy pallet jacks The platform can not withstand truck driving without special locks Special handling If there has been an accident with the tai...

Page 43: ...r the platform below the dock 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 mo...

Page 44: ...able please contact us Change the oil once a year Water and dirt can prevent the lift from working properly See service instructions IE 0102 for oil change NOTE Lubrication Lubricate the lift accordin...

Page 45: ...ice check list 2 Once a week control of wear parts 3 Greasing 4 Service station maintenance The service should be carried out one time per year L service at Zepro approved service stations or Zepro ag...

Page 46: ...t who will arrange for rapid delivery of spare parts 5 6 if available Once a week control of wear parts 1 Lift tilt and lowering with all control units 2 Lowering and tilt down speeds 3 Function of lo...

Page 47: ...ons for details Generally More lubrication intervals may be required if you are running in a hostile environment or washing the lift often Contact Zepro for advice What should I consider Before lubric...

Page 48: ...48...

Page 49: ...must be used Alternative oils Arctic conditions ISO VG 22 or VG 32 ISO 11158 HV and DIN 51524 HVLP Castrol Hyspin AWV 32 BP Energol HFV LT Shell Tellus Arctic Texaco Rando Ashless 8401 Esso Univis HV...

Page 50: ...Hydr connection unit tank cyl torques IE 0104 C 2 5 Pressure Relief Valve Valve should open when tilting against body check pressure if not opening IE 0108 C 2 6 Velocity lifting lowering tilting Tha...

Page 51: ...med for each service point Signature Date Company stamp Service points Comments Actions Note If comment is marked for any of the service points complete the task below Inspection performed Actions per...

Page 52: ...Hydr connection unit tank cyl torques IE 0104 C 2 5 Pressure Relief Valve Valve should open when tilting against body check pressure if not opening IE 0108 C 2 6 Velocity lifting lowering tilting Tha...

Page 53: ...med for each service point Signature Date Company stamp Service points Comments Actions Note If comment is marked for any of the service points complete the task below Inspection performed Actions per...

Page 54: ...ge R 2 5 Filler cap Changes in connection with oil change C 2 6 The system s leakproofness Hydr connection unit tank cyl torques IE 0104 C 2 7 Pressure Relief Valve Valve should open when tilting agai...

Page 55: ...ed for each service point Signature Date Company stamp Service points Comments Actions it Note If comment is marked for any of the service points complete the task below Inspection performed Actions p...

Page 56: ...s IE 0104 C 2 5 Pressure Relief Valve Valve should open when tilting against body check pressure if not opening IE 0108 C 2 6 Velocity lifting lowering tilting That the lifts speed is within the corre...

Page 57: ...med for each service point Signature Date Company stamp Service points Comments Actions Note If comment is marked for any of the service points complete the task below Inspection performed Actions per...

Page 58: ...l change R 2 5 Filler cap Changes in connection with oil change C 2 6 The system s leakproofness Hydr connection unit tank cyl torques IE 0104 C 2 7 Pressure Relief Valve Valve should open when tiltin...

Page 59: ...ed for each service point Signature Date Company stamp Service points Comments Actions it Note If comment is marked for any of the service points complete the task below Inspection performed Actions p...

Page 60: ...ing at the same time Lower the platform to the ground fill up oil to max level Check fuses in truck cabin taillift and mainfuse between lift and battery Check wiring connections Wait for motor to cool...

Page 61: ...ndamaged Lubricate all bearings Check that no hoses is compressed Check wiring connections Check if oil is leaking Check wiring connections Tilting up Platform does not tilt up Motor starts Platform d...

Page 62: ...rical fault Oil is to thick The lifts bearings are rough ungreased or damaged Compressed hoses Electrical fault Leakage in hose or cylinder Electrical fault Check fuses in truck cabin taillift and mai...

Page 63: ...Notes...

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Page 66: ...es Importer KATRINEHOLM Mossv gen 8 0150 489550 0150 489551 Sales S 641 49 Katrineholm SWEDEN BISPG RDEN All v gen 4 0696 17200 0696 17244 Factory S 841 41 Bispg rden SWEDEN Address Telephone Fax Manu...

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