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Zepro ZS 150-135, Installation Instruction

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Zepro ZS 150-135 Installation Instruction Download Page 38

Ctrl 4

Spiral

Ctrl 3

Radio

Ctrl 2

Ctrl 1

Control Power

Sensor Power

Ground

IN OUT

Ai 1

Ai 2

Di 1

Di 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

Ou

t

In GN

D

LLE

D

Ctrl 5

Indication

Se appendix in

installation manual

Outputs

Sensor

s

Not in use

4

10

4

10

P

Pump unit

Tiltcylinder

NC 60bar

8A

12-24v

CS

8A

Max. 12W

38

6. Electric and hydraulic diagram

Cabin switch, Alarm for open platform

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

Liftcylinder

Pumpunit

Summary of Contents for ZS 150-135

Page 1: ...PRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 54273TL 2019 11 12 Installation Instruction Tail Lift ZS ZSS 150 200 135 155 175 ZD 150 200 155 175 ZT ZTS 150 200 250 140 ZS ZSS 250 135 155 ...

Page 2: ......

Page 3: ... 20 5 Electrical installation 32 6 Electric and hydraulic diagram 35 7 Functional schematic drawing 42 8 Connection unit 46 9 Accessories 52 10 Important information 54 11 Markings positioning of decals on lift 55 12 Post installation maintenance 57 13 Testing the lift 58 14 Dismantling 60 ...

Page 4: ...to certify conformity to the Machi nery Directive if the product is subsequently changed without his knowledge or approval In order for the product s CE marking to remain applicable the forms supplied by ZEPRO must be completed in case of modification Welding is not necessary unless specifically recom mended by the manufacturer In order to increase security additional decals which are diagrammatic...

Page 5: ... current should be swit ched off when the lift is not used The lift can also be operated from other optional units To ensure safe operation even with very long control cables the hydraulic unit is equipped with relays The relays situated in the electrical connection box placed in the support frame steer current directly from the main cable to the valves and the main switch for the motor The electr...

Page 6: ...ame ZT ZTS 150 200 250 76 kg Lift arm ZS ZSS ZD 150 200 135 46 kg Lift arm ZS ZSS ZD 250 135 50 kg Lift arm ZS ZSS ZD 150 200 155 50 kg Lift arm ZS ZSS ZD 250 155 54 kg Lift arm ZS ZSS ZD 150 200 175 54 kg Lift arm ZT ZTS 150 200 250 140 51 kg Lift cylinder ZT ZTS 150 140 13 1 kg pce Lift cylinder ZT ZTS 200 250 140 14 3 kg pce Lift cylinder ZS ZSS ZD 150 200 135 8 5 kg pce Lift cylinder ZS ZSS ZD...

Page 7: ... A 2 1 A 0 75 A 0 85 A 1 5 mm2 35 mm2 35 mm2 50 mm2 180 Ah 18 Volt 7000 2 General Max Power Consumption Pump Motor Unit Magnet hydraulic unit Magnet electric safety valve Solenoid Cable area Control cable Main cable 8 m Main cable 8 15 m Main cable 15 m Power source Min capacity Min voltage Pump Motor Unit Magnet hydraulic unit Magnet electric safety valve Solenoid Cable area Control cable Main ca...

Page 8: ...8 ZT ZTS 150 200 250 ZS ZSS ZD 150 200 250 Loading Diagram 2 General ...

Page 9: ...hicle body so that the platform can be folded out Ensure that the installation position is such that the lift when folded meets the legal dimensions for underrun protection See illustration below Distance between the beam and the ground when the vehicle is unloaded Max 550 mm Horizontal distance from the outermost part of the platform to the underrun protection Max 375 mm Max 550 mm Max 375 mm ...

Page 10: ... Total Overhang O 600 1370 1590 1700 600 800 800 P1 mm Slide profile length mm NOTE If the cables are a limiting factor be careful to check the overhang at max frame width 1040 C 525 500 450 400 350 300 235 A 198 183 169 158 145 130 100 P1 545 675 750 P2 1005 960 910 O 1605 1735 1810 1500 2000 kg C 630 600 550 450 450 400 350 A 200 187 172 161 153 134 114 P1 545 675 750 P2 1005 960 910 O 1667 1797...

Page 11: ... Overhang O 700 1590 1700 700 P1 mm Sliderprofile length mm NOTE If the cables are a limiting factor be careful to check the overhang at max frame width 1040 C 635 600 550 500 450 400 350 A 210 191 177 167 158 147 134 P1 545 675 750 P2 1005 960 910 O 1725 1855 1930 1500 2000 kg C 740 700 650 600 550 500 450 A 209 201 179 168 160 148 136 262 118 400 121 370 106 P1 545 675 750 P2 1005 960 910 O 1787...

Page 12: ...0 1590 1700 700 P1 mm Sliderprofile length mm NOTE If the cables are a limiting factor be careful to check the overhang at max frame width 1040 C 715 700 650 600 550 500 450 A 205 195 182 172 164 157 145 P1 545 675 750 P2 1005 960 910 O 1845 1975 2050 1500 2000 kg C 740 700 650 600 550 500 450 A 209 201 179 168 160 148 136 400 135 400 121 370 106 P1 545 675 750 P2 1005 960 910 O 1787 1917 1992 250...

Page 13: ...222 150 222 277 280 ZSS 150 200 250 135 100 P1 545 675 750 P2 1005 960 910 O 1667 1797 1872 550 1370 1590 1700 550 700 700 P1 mm 130 160 max 840 max 565 980 3 Dimensions for installation Sliderprofile length Total Overhang O Slide profile length mm 2500 kg P1 in Steel NOTE If the cables or valve system are a limiting factor be careful to check the overhang at max frame width1040 ...

Page 14: ...0 155 600 1590 1700 1820 600 800 800 P1 mm P1 545 675 750 P2 1005 960 910 O 1787 1917 1992 106 700 A 370 500 150 222 150 222 277 280 100 130 160 max 840 max 565 980 3 Dimensions for installation Sliderprofile length Total Overhang O Slide profile length mm 2500 kg P1 in Steel NOTE If the cables or valve system are a limiting factor be careful to check the overhang at max frame width1040 ...

Page 15: ...005 960 910 O 1907 2037 2112 550 1590 1700 1820 550 700 700 P1 mm 1500 2000 kg 125 450 150 222 277 280 100 130 160 222 150 max 840 max 565 980 3 Dimensions for installation Slide profile length Total Overhang O Sliderprofile length mm NOTE If the cables are a limiting factor be careful to check the overhang at max frame width1040 NOTE If the cables or valve system are a limiting factor be careful ...

Page 16: ...2 max 520 180 130 max 905 C max 635 C 635 600 550 500 A 210 191 177 167 450 158 400 147 350 134 285 118 P1 754 P2 639 O 1250 1500 2000 kg 80 max 630 980 3 Dimensions for installation Slide profile length 1095 Total overhang O NOTE If the cables are a limiting factor be careful to check the overhang at max frame width 1040 ...

Page 17: ... C 715 700 650 600 550 500 A 205 195 182 172 164 157 450 145 400 135 350 121 305 110 C max 715 P1 879 P2 764 O 1350 1500 2000 kg 150 222 277 380 80 max 630 980 3 Dimensions for installation Slide profile length 1215 Total overhang O NOTE If the cables are a limiting factor be careful to check the overhang at max frame width 1040 ...

Page 18: ...ensions for installation NOTE If the cables are a limiting factor be careful to check the overhang at max frame width 1300 1740 min 1200 max 1300 159 728 166 1740 min 1200 max 1300 159 728 166 210 max 1470 240 P2 P1 62 180 Cmax 450 max 480 A max 1020 537 271 110 431 210 2500 kg P1 in Steel P1 P0 945 2044 875 1974 750 1849 675 1774 O 1060 1005 960 910 880 ...

Page 19: ...nstallation Slide profile length 1590 Total Overhang O at max frame width 1300 NOTE If the cables or valve system are a limiting factor be careful to check the overhang 1740 min 1200 max 1300 159 728 166 P1 786 786 715 P2 960 910 910 O 1916 1916 1845 2500 kg P1 in Steel 210 max 1450 238 P2 P1 130 180 Cmax 540 max 472 A max 915 443 185 110 431 210 1096 ...

Page 20: ...me or tow hook device so that the platform can fold out If the slide frame is placed further forward there is a risk particularly for low ground clearance that the platform will not be able to fold out There are only two solutions Either to move the slide frame to the position that we recommend or choose a different platform combination but the new platform would have shorter first and second fold...

Page 21: ...orm 5 Liftarm platform over lap 4 Distance forward of the beam 62 mm ZS ZT 100 mm ZSS ZTS Beam 250 mm Lift arm 750 mm 135 815 mm 140 870 mm 155 990 mm 175 Fixed part of platform depends on the platform ordered Liftarm platform overlap 33mm AVI 35mm PML e g 1 Minimum overhang necessary for the installation of a ZS 200 155 with an AVI 500 mm 860 mm platform 62 250 870 500 33 1649 mm e g 2 Minimum ov...

Page 22: ...on If you want to avoid that the following installation problem occurs ZS ZSS ZT ZTS models ZD models and would prefer the lift to be installed as in this diagram then take time to read these instructions carefully and follow them ZS ZSS ZT ZTS models ZD models ...

Page 23: ...ength fixed part of the platform the total lift length in the stowed position e The available overhang must be greater than the total lift length in the stowed position f Let s consider the case of the single folded plat forms In the stowed position the folding part of the platform cannot be longer than the space available above the fixed platform part and the lift arm up to the wheeled mounting b...

Page 24: ...tion The distance between the folding position and the working posi tion is shown here i When the lift has been slid completely out to the end of the slide profiles and the platform is folded out the position of the mounting brackets in the slide profiles is known as the folding position h On this page diagrams show sliding lifts in stalled with their slide profiles installed in the recom mended p...

Page 25: ... under run protection to be valid the slide profiles must be fastened in either of the fol lowing ways Eg 1 Weld a lock plated see diag Eg 2 Drill hole and screw in a locking nut bolt se diag Installation of slide profiles Position the lift under the trailer frame Bring the lift into position Adjust the slide profiles so it is in the centre of the trailer chassis Make sure there is no dirt between...

Page 26: ...locks are always mounted at equal distances from the end of each profile count links from the edge 1 Unscrew the nut that holds the respective working position lock 2 Move the working position lock to a position that provides the correct working position 3 Hook into position the lower part of the lock onto the chain 4 Fasten with a nut Torque setting 50 Nm 1 Unscrew and remove the protective end c...

Page 27: ...orm 3 connecting the lift battery cable cabin switch 4 installing the control units Installing the slider frame The installation is very simple if you follow the instructions for the positioning of the slider profiles in section 4 The slide profile mounting brackets are screwed into the outside of the truck chassis frame as on a standard lift installation see pict 2 The first bolt in each bracket ...

Page 28: ...be drilled after test running the lift Thus the slide can be adjusted if necessary by movement in the slot min 2 bolts min 4 bolts Holes 14 0mm Bolts M14 Hardness 10 9 Torque 95 Nm NB The mounting bracket fastening plate should be installed perpendicular to the support frame Any imprecision will result in an increased risk that the chain wheel does not run straight along the chain which will resul...

Page 29: ...eam Install them equal on both sides so they meet the liftarms at the same time The stops must reach as high up as possible on the liftarm Test run the lift carefully Fine adjust the position of the slide profiles forwards or backwards if necessary 4 Slider installation Hydraulic Automatic Tilt When hyd auto tilt is installed the angle sensor should be installed on the lift arm as in the diagram C...

Page 30: ... Screw the ring out in the direction of the platform 3 See pict 10 Tilt down the platform to maximum 10 degrees under horizontal or any other required tilt angle As per pict 9 Adjust the ring to the top of the cylinder 4 Tighten the lock screw in the ring 5 See pict 11 Test run all functions Adjustment of tilt down angle Pict 9 Pict 10 4 Slider installation ...

Page 31: ...platforms have an adjustable roll arm attached to the support frame to aid folding out of the platform This is installed at the factory but should be adjusted 410 660 mm after platform installation 4 Slider installation For ZD models ...

Page 32: ...ontrol device Control devices 1 Fit the control devices in the desired locations They must be positioned so that the operator is in the safest possible location and has a clear view of the load the tail lift and the surrounding area 2 The distance between the vehicle s rear edge and the centre of the controllers must be between 300 mm 600 mm See image All cable inlets must be pointing downwards NO...

Page 33: ...er cable running from the battery compartment This acts to protect the electrical systems from overloading and the risk of fire If you have a spiral cable unit its cable colours are different see electric diagram If you want an electrically heated spiral cable unit you can order a 5 part cable spare part no 21303 Note that the spiral cable unit must have its fastening plate for the wall spare part...

Page 34: ...ilar care to avoid damage from contact with edges of the frame and other parts of the vehicle This will increase the life of the cables and reduce the risk of unnecessary downtime Connection of non original components on zepro tail lifts It has always been forbidden to connect foreign equipment both electric and hydraulic on all Zepro tail lifts Using non original components can affect tail lift s...

Page 35: ...35 ZS ZD ZSS ZT ZTS 150 200 250 ML 6 Electric and hydraulic diagram ...

Page 36: ...y Artikelnr Stock nr Ritningsnr Drawing nr Blad Sheet Format Size Revision För denna ritning gäller IS0 toleranser SMS ritregler Toleranser Tolerance Ytjämnhet Surface finish Svets Welding 1 1 Ritad Drawn A HIAB brand part of Cargotec Corporation Samm Used on Rev Rev Tag Datum Date Ändring Rev number Införd av Revised by Kontrol Checked Godk Approved A 04 08 17 4789 JE MW CL B 06 02 06 5301 UB JE ...

Page 37: ...sion För denna ritning gäller IS0 toleranser SMS ritregler Toleranser Tolerance Ytjämnhet Surface finish Svets Welding 1 1 Ritad Drawn A HIAB brand part of Cargotec Corporation Samm Used on Rev Rev Tag Datum Date Ändring Rev number Införd av Revised by Kontrol Checked Godk Approved A 06 02 06 5301 UB JE MW CL B 2008 03 14 5819 MB MW CL C 2009 01 09 5983 MB MW CL D 2009 03 20 6054 MW MB CL E 2011 0...

Page 38: ...U4 U3 U5 U4 U2 U1 U0 Ctrl 6 Out In GND LLED Ctrl 5 Indication Se appendix in installation manual Outputs Sensors Not in use 4 10 4 10 P Pumpunit Tiltcylinder NC 60bar 8A 12 24v CS 8A Max 12W 38 6 Electric and hydraulic diagram Cabin switch Alarm for open platform 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 Liftcylinder Pumpunit ...

Page 39: ...llow 9 Grey 10 Orange 11 Purple 12 Pink Reconstruction for Alarm open bridge with main switch If the lift is fitted with a main switch reconnection must be effected as shown below in order for an Alarm open build to function with the main switch off 10 4 10 P NC 60bar 12 24v 2 3A Max 12W Lift cylinder Pump unit ...

Page 40: ...iltcylinder NC 60bar 40 6 Electric and hydraulic diagram ZEPRO recommends that a strobe lamp light placed on the trailer body exterior represents the alarm indica tion clearly visible so that the driver can see it in the rear mirror The light must be of amber color Connect the lamp indicator according to the electric diagram 3A fuse connected between the circuit card and the pressure switch Alarm ...

Page 41: ...U3 U5 U4 U2 U1 U0 Ctrl 6 Out In GND LLED Ctrl 5 Outputs Sensors Black Green White Grey Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Contr l Power Sensor Power Ground IN OUT Ai 2 Ai 1 Di 1 Di 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 CD13 1 2 3 4 8 7 6 5 Green In Grey Out CD11 1 3 Out 2 In 4...

Page 42: ... 2 Ctrl 3 Ctrl 4 Ctrl 6 45º 90º 0º 10º Raise B U0 U2 Autotilt up Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 Ctrl 6 10º 0º B U0 U2 Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 Ctrl 6 Tilt up 1 B C Di2 U0 U3 Tilting up to approximately 45º Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 Ctrl 6 45º 90º 0º 10º Only required at start of motion after change of sensor it is ignored until a re run takes place Restriction in use of control device All availa...

Page 43: ...ontinue to maintain the tilt up function Di3 Liftarm Angle sensor For Autotilt safety function Di4 Tiltcylinder Alarm for open platform Pressure sensor for falling pressure connected to side of lift cylinder In the actuated state returns the connection signal to Di4 and resulting in output signal at Pa Also phase signal out at Pa Di5 Not in use on this lift model and should not be connected Di6 No...

Page 44: ...Ctrl 2 Ctrl 3 Ctrl 4 Tilt down C E U0 U1 U3 U5 Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 45º 90º 0º 10º Raise B Di5 U0 U2 Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 Tilt up B C Di5 U0 U3 Tilting up to ap proximately 45º Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 45º 90º 0º 10º Only required at start of motion after change of sensor it is ignored until a re run takes place 7 Functional schematic drawing ...

Page 45: ... out Out U0 U1 U6 Ctrl 5 Ctrl 6 Platform is folded in manually Platform is folded in manually Slider in 1 In Di1 U0 U1 U7 Normal Ctrl 5 Ctrl 6 2 C In Di1 U0 U1 U7 Safe Ctrl 5 Ctrl 6 Endast krav vid start av rörelse efter omslag av sensor ignoreras den till dess att omtag sker 7 Functional schematic drawing ...

Page 46: ...e event of any operational disturbances fault codes are displayed to facilitate troubleshooting The display indicates Active control device Fault display Program configuration Sensors current status Flashing light indicates Supply voltage Off No supply voltage On Supply voltage available but CS cabin switch is not active Flashing CS cabin switch is active the system is awaiting input signal LED 1 ...

Page 47: ...l system for the current control device is locked for a while to ensure that no other person operates the lift from another control device During the period the control sys tem is locked for the current control device its number 1 7 will flash on the display This primarily applies to radio and coil control devices as other control devices have such a short locking period that there is hardly time ...

Page 48: ... control devices have such a short locking period that there is no time to see the indication The number will stop flashing when one of the current control device s buttons are pressed If the control card has been without voltage and receives the voltage again when the CS cabin switch is switched on 7 will flash on the display and the control card is locked until the Off On on the CS is operated 1...

Page 49: ...off after approx 5 minutes the control card then goes into power save mode Fault codes Identification Code 1 Code 2 Code 3 Information Other L Low battery voltage 07 35 Voltage measured H High battery voltage 07 35 Voltage measured E Control device locked 1 Fixed control device 1 incl two hand button 2h1 if they are monitored 2 Fixed control device 2 incl two hand button 2h2 if they are monitored ...

Page 50: ...n flashes the same number of times as the number on the control device in question see the list in page 47 Example Control device 2 is blocked the LED on the coil control device then flashes twice goes out for a moment flashes twice again etc Coil control device s LED Fixed light The coil control device is active Extinguished weak glim mer The coil control device is not active Flashing One of the ...

Page 51: ...LTANK TANKLOCK FILLER CAP TANKDECKEL VENTILHUS VALVE BODY VENTIL GEHAUSE MOTOR SOLENOID SWITCH MAGNETSCHELTER KRETSKORT CIRCUIT CARD GETRUCTE SCHALTUNG VENTIL SLÄDRÖRELSE VALVE SLIDE FUNCTIONS VENTIL SCHIEBEFUNKTION S KOPPLINGSENHET CONNECTION UNIT KOPPLUNGS EINHEIT ...

Page 52: ...hen the red diode lamp lights up The distance between the sensor and the stop plate in both cases eg 1 2 should be adjusted to between 5 10 mm 9 Accessories Working position indicator The working position sensor is already installed at the factory therefore only the stop plate needs to be installed see eg 1 2 Eg 1 Clamp Clamped to slide profile Eg 2 Screw drill a hole and screw in a bolt ...

Page 53: ...t to the floor height Run the lift into the body then the lift should stop at right working position if not adjust the stop plate When parking the lift into transport position drive the lift in with in button and middle button middle button disactivates working position indicator Working position indicator ...

Page 54: ...hen the final post installation testing is carried out it is important that there is sufficient clearance between the cylinders working envelopes and all fixed points During lift operation and cylinder mo vement there is a risk for conflict with the subframe truck frame number plate lamp holders and even the mounting brackets when the overhang is very limited due to lift arm angle Hence it is impo...

Page 55: ...dicates the nominal loading and the diagram shows the maximum permitted loading at different positions on the platform The name plate is installed on the support frame of the tail lift and contains the following information Lift type Maximum permitted load in kg Serial number Year of manufacture Address and tel no of the manufacturer Country of manufacture EU type no for bumper bar certificate The...

Page 56: ...56 11 Markings decals ...

Page 57: ...r bearing 6 Lift arm left side lower bearing 7 Lift tilt cylinder upper bearing 8 Right tiltcylinder upper bearing 9 Lift arm right side upper bearing 10 Right lift cylinder upper bearing 11 Left lift cylinder upper bearing 12 Lift arm left side upper bearing 13 Wheels in slider profile The hydraulic unit tank is filled with a mineral based hydraulic oil art no 21963 for 1 litre or a biodegra dabl...

Page 58: ...ackets Deflection Place a test load on the platform according to the table for the corresponding tail lift model and loading capacity The tail lift should be in the same level and angle as floor Leave the test load on the platform for 15 minutes Check that the platform s deflection is not more than 15mm vertically point A and D and that it is not more than 2º in angular deflection point b and C in...

Page 59: ...rflow valve is activated when the lift is run up to the floor level or armstops That the tail lift cannot be lowered or tilted down respectively if the electrical connector from the lift and tilt cylinders respectively electric safety valve is removed That the platforms max load marking has been included and is correctly positioned according to the loading diagram for the tail lift model concerned...

Page 60: ...e tilt cylinder s lower axle at the sup port frame Remove the cylinder and take away the hoses NB Oil can leak from the hoses and cylinder 6 Dismantle the side profiles from the platform Take away the grease nipples and the lock screws in the platform s axles Screw the special tool see diagram into the axle Using the sliding weight of the tool hammer the axle out of the profile Follow the sames pr...

Page 61: ......

Page 62: ...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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