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Zepro Z 1500-135, Installation Instructions Manual

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Zepro Z 1500-135 Installation Instructions Manual Download Page 1

ZEPRO
Tel.: +46 (0)10-459 05 00

Email: [email protected]   

|

   zepro.com

75976TL

Installation instructions

 

Tail Lift

Z 1500/2000-135/155/175

ZL 1500/2000-135/155/175

2021-12-08

Summary of Contents for Z 1500-135

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 Email zeprotech hiab com zepro com 75976TL Installation instructions Tail Lift Z 1500 2000 135 155 175 ZL 1500 2000 135 155 175 2021 12 08...

Page 2: ......

Page 3: ...n 16 3 7 Connecting the control device to the ZePRO1 control card 17 3 8 Connecting the control device to the TLC B1 relay card 18 4 Installation 19 4 1 Frame 19 4 2 Platform 22 4 3 Purging the cylind...

Page 4: ...49 7 9 Cab switch and open platform alarm ZePRO1 50 7 10 Cab switch and open platform alarm TLC B1 51 8 Powering up the tail lift 52 9 Lubrication and oil level check 53 9 1 Lubrication 53 9 2 Oil le...

Page 5: ...tening injury m CAUTION CAUTION indicates a potential hazard which if ignored may lead to minor injuries IMPORTANT IMPORTANT indicates a risk of equipment damage NOTE NOTE refers to additional informa...

Page 6: ...llation instructions carefully Modifications not approved in writing by the manufacturer are not permitted Welding is not permitted 1 5 Product approval Properly assembled this product meets relevant...

Page 7: ...the main switch or by releasing the lift s main fuse in order to reduce the risk of the battery discharging The length of time the vehicle can be stored without the battery charge level becoming too...

Page 8: ...e to the closest part of the cylinder must be at least 40 mm Figure 6 The platform may not be tilted down more than 10 from the horizontal 2 2 Connection of third party equipment is forbidden m WARNIN...

Page 9: ...t of inertia of 937cm4 around the x axis See Figure 7 If in doubt contact ZEPRO for support 3 2 Statutory dimensions Distance between the beam and the ground when the vehicle is unloaded Max 450 mm fo...

Page 10: ...e lift arms in their upper position to vehicle floor level dimension A 3 3 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 su...

Page 11: ...764 144 420 800 126 360 835 104 815 max 1530 220 C A 40 D C D A 715 680 229 680 725 212 630 781 194 580 828 179 530 869 164 480 904 145 430 934 129 910 max 1710 220 C A 40 D Figure 11 Z 1500 2000 175...

Page 12: ...175 12 Safety rules www zepro com Figure 12 Z 1500 2000 Figure 13 ZL 1500 2000 1014 min 750 max 930 1435 2424 1515 1870 1246 min 982 max 1162 1669 2481 1749 2102 D 28 336 35 62 305 133 301 617 817 Fi...

Page 13: ...on Cut out size is determined by the calculated integration dimension A see figure below 1 Measure and mark the location and depth of the cut outs on the rear beam Centre the two rear beam cut outs i...

Page 14: ...unscrewing the wing nut and corresponding screw C see Figure 20 and pull out the hydraulic unit until the tank cap is accessible see Figure 22 m CAUTION Make sure no cables are pinched or in any othe...

Page 15: ...cessary replace the transport plug with a regular tank cap Figure 22 Hydraulic unit and relay card RELAY CARD TANK CAP MOTOR OIL TANK SOLENOID VALVE HOUSING 5 Check whether the hydraulic tank is fitte...

Page 16: ...relay card to simulate switch CS being on Remove the cable immediately after completed operation m WARNING Take great care while running the lift functions and make sure nothing gets pinched risk of p...

Page 17: ...2 Di 3 Di 4 Di 5 Di 6 PA PA CSPWR CS B E C 2H1 B E C 2H2 B E C Lock B E C Lock U7 U6 U5 U4 U3 U5 U4 U2 U1 U0 Ctrl 6 Out In GND LLED Ctrl 5 Outputs Sensors o Brun B Gul E Bl C Bl 2H CD1 CD2 B C 2H1 E C...

Page 18: ...onnecting more than one controller to each connection is not permitted Risk of material damage WL1 U7 U6 U5 U5 U4 U4 U3 U2 U1 U0 U0 U1 U2 U3 WL2 PA S5 S1 S4 S3 S2 S1 S5 S4 S3 S2 PA CS CS Down 2H Out D...

Page 19: ...ack is helpful The frame must be positioned 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 th...

Page 20: ...all the associated washer and nut on the inside of the vehicle frame Install the bolts but do not tighten 11 Check and fine trim the lift s position Then tighten the bolts with a torque wrench Tighten...

Page 21: ...chment bolts in each of the brackets two upper round holes Use suitable bolts strength M14 10 9 or higher and install the associated washer and nut on the inside of the vehicle frame See Figure 30 Tig...

Page 22: ...tform grease all bearings including the two regular grease nipples see section 9 Lubrication and oil level check on page 53 3 Install the platform on the arms using the shafts and bolts supplied Tight...

Page 23: ...hree locking screws on the cylinder mounted on the platform Figure 36 Figure 34 Check the position in rela tion to the rear beam of the vehicle Vehicle floor level A Max 40 mm Min 38 mm Figure 35 The...

Page 24: ...he tilt cylinder aligns with the platform attachment point See Figure 38 IMPORTANT The max length of both cylinders must be adjusted equally to avoid unwanted bending forces 8 Install the other tilt c...

Page 25: ...he tilt angle Figure 41 Installing boots 12 Fit the tilt cylinder boots Figure 41 Lift model A 1500 2000 135 180 5 1500 2000 155 300 5 1500 2000 175 420 5 IMPORTANT After finishing the adjustment make...

Page 26: ...the platform reaches the vehicle floor 3 6 2 Loosen the lock screw of the end stop 2 Screw the stop all the way back toward the platform 3 Figure 29 3 Tilt the platform down to max 10 degrees below th...

Page 27: ...he tilt cylinders by tilting the platform all the way up to the vehicle body and then all the way down 4 4 Open platform alarm When installing tail lifts on the trailer it is recommended a main power...

Page 28: ...and attach the cable using cable time see Figure 45 2 Connection is described later in section 6 Figure 45 Installing the angle sensor x4 x4 4 5 2 Tail lift with inclinometer for autotilt 1 Install th...

Page 29: ...t 1 Install the angle sensor on the platform using the nuts bolts and washers supplied and attach the cable using cable time see Figure 47 2 Route the cables and secure with cable ties Connection is d...

Page 30: ...grommet Connection is dealt with later in section 6 Figure 48 Installing controllers m WARNING The primary controller must always be fitted on the side that is facing away from moving traffic Fitting...

Page 31: ...tor unit 245 A 145 A Minimum recommended conductor cross sectional area copper cables plus and minus cables Control power cable 1 5 mm2 1 5 mm2 Main power cable L 8m 35 mm2 35 mm2 Main power cable L 8...

Page 32: ...the vehicle s normal electrical system The cable must be protected by rubber grommets when it passes through beams or walls Cables must be installed sufficiently far from or be protected against shar...

Page 33: ...se to the battery as possible 2 Run the main power cable from the battery to the fuse box Prepare the cable with cable terminals with out connecting 3 Run the main power cable from the fuse box to the...

Page 34: ...e 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 wir ing diagram 7 8 7 9 5 4 1 Installing on...

Page 35: ...oom is in motion Measure the distance A from the centre of the lift arm shaft to the centre of the underrun protection see Figure 56 3 Measure the same distance A on the lift arm see Figure 56 4 Then...

Page 36: ...Z ZL 1500 2000 135 155 175 36 Cable routing www zepro com Figure 54 Installing cabling Figure 55 Installing cabling A A 100 mm 200 mm Figure 56 Quick connector location...

Page 37: ...ee Figure 59 Cables can now be installed removed ad justed in the grommet When installing the cable it should be done together with existing cabling using cable ties Make sure the cable is long enough...

Page 38: ...re no cables are pinched or in any other way damaged when the control card relay card is folded out in Figure 60 Installing cabling with cable ties 6 2 1 After connection 1 When all cables are suitabl...

Page 39: ...Lock U7 U6 U5 U4 U3 U5 U4 U2 U1 U0 Ctrl 6 Out In GND LLED Ctrl 5 Outputs Sensors o CD11 Brun B Gul E Bl C Bl 2H CD1 CD2 B C 2H1 E CD15 B C 2H E Black Black 2H Black Black Blue Black White White White...

Page 40: ...U4 U3 U2 U1 U0 U0 U1 U2 U3 WL2 PA S5 S1 S4 S3 S2 S1 S5 S4 S3 S2 PA CS CS Down 2H Out Down Down C1 C1 Up Tilt In C2 Up Tilt C3 Up Ctrl 3 Ctrl 2 Ctrl 1 CD4 Up Tilt 2H Down CD9 Up Tilt Down CD10 Up Down...

Page 41: ...S4 S3 S2 PA CS CS Down 2H Out Down Down C1 C1 Up Tilt In C2 Up Tilt C3 Up Ctrl 3 Ctrl 2 Ctrl 1 CD4 Up Tilt 2H Down CD9 Up Tilt Down Up Tilt Down 2H CD1 L4 L3 L2 L1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...

Page 42: ...B C D Denna ritning r Z Lyftens egendom och skyddad enligt internationellt g llande lag f r copyright och f r ej utan Z Lyftens skriftliga medgivande kopieras delges eller obeh rigen anv ndas This dra...

Page 43: ...ds finished product Title Material Dimension Date Weigh kg Scale Designer Checked by Approved by Stock nr Drawing nr Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Weldi...

Page 44: ...nr Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Z1500 2000 C14 Z1500 2000 C14 Z53807 75...

Page 45: ...gh kg Scale Designer Checked by Approved by Stock nr Drawing nr Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydrau...

Page 46: ...Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Z1500 2000 EATilt g 3 C14 Z1500 2000 EATil...

Page 47: ...Checked by Approved by Stock nr Drawing nr Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic...

Page 48: ...Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Z1500 2000 c000 E AT AD Z1500 2000 c000 E...

Page 49: ...ce Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Z1500 2000 Dvx4 C16 Z1500 2000 Dvx4 C16 Z53857 75938TL 2016 10 31 MB MB PS PS C A2 1 1 Z Lyften Produk...

Page 50: ...on IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Larm f r ppen brygga Detection open Platform Z54870 77752TL...

Page 51: ...nr Drawing nr Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Larm f r ppen brygga Detecti...

Page 52: ...e Figure 63 3 Connect the main power cable 3 to the connection point see Figure 63 4 Screw the cable connections and fuse into place using the knob 4 Install the cables at 90 or 180 from each other In...

Page 53: ...cylinder at lower bearing 5 Left tilting cylinder at lower bearing 6 Lift arm left side at lower bearing 7 Left tilting cylinder at upper bearing 8 Right tilting cylinder at upper bearing 9 Lift arm...

Page 54: ...gure 68 Overview of labelling 10 Marking Below an overview of the location of the different markings is shown Images of markings and additional information can be found under the relevant subchapter f...

Page 55: ...iagrams for the appropriate lift model close to the primary controller and in a suitable clearly visible position on the vehicle body Figure 69 Load diagram for load capacity 1500 kg load centre dista...

Page 56: ...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 electrom...

Page 57: ...77661TL 2020 03 04 10 5 Controller sticker Affix the controller sticker next to the relevant controller The stickers are available in standard versions and in reversed version for affixing on the oppo...

Page 58: ...e of the vehicle body next to the hand control unit 10 7 Warning flags Install warning flags as close to the top and as close to the edge of the platform as possible but without the risk of the flags...

Page 59: ...form Repeat the measurement of A B C D and verify that there has been no deformation of the lift or its at tachment point 11 1 2 Operation Place a test load on the platform as shown in the table The t...

Page 60: ...tested Check That the red lamp in the vehicle s driver s cab goes out when the platform is fully closed against the body and conversely that it comes on when the platform opens That the tail lift cann...

Page 61: ...0 2000 135 51 kg Z 2000 175 373 kg Lift arm ZL 1500 2000 135 53 kg ZL 1500 135 330 kg Lift arm Z 1500 2000 155 56 kg ZL 1500 155 343 kg Lift arm ZL 1500 2000 155 58 kg ZL 1500 175 359 kg Lift arm Z 15...

Page 62: ...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 c...

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