Zepro Z 1500 Installation Instructions Manual Download

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

Email: [email protected]

zepro.com

75976TL

Installation instructions

Tail Lift

Z 1500/2000-135/155/175

2023-06-09

Summary of Contents for Z 1500

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 2023 06 09...

Page 2: ......

Page 3: ...ed dimensions 11 3 4 Rear beam cut outs 14 3 5 Prepare the tail lift 15 3 6 Temporary connection 17 4 Installation 20 4 1 Frame 20 4 2 Platform 23 4 3 Armstops 28 4 4 Sealing strip horizontal 28 4 5 S...

Page 4: ...autotilt Angle sensor IFM ZePRO1 56 8 6 Z 1500 2000 DA ZePRO1 57 9 Lubrication and oil level check 58 9 1 Lubrication 58 9 2 Oil level check 58 10 Marking 59 10 1 Loading diagram 60 10 2 Identificatio...

Page 5: ...ening 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 informat...

Page 6: ...er are not permitted Welding is not permitted 1 5 Product approval Properly assembled this product meets relevant requirements according to EN 1756 1 2001 A1 2008 1 6 Hydraulic oil If the hydraulic oi...

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 l...

Page 8: ...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 WARNING...

Page 9: ...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 for...

Page 10: ...See Figure 9 The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm See Figure 10 Each of the individual parts of the underrun protec tion mu...

Page 11: ...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 supp...

Page 12: ...64 144 420 800 126 360 835 104 815 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 13 Z 1500 2000 175 C...

Page 13: ...Z 1500 2000 135 155 175 Safety rules 13 www zepro com Figure 14 Z 1500 2000 135 Figure 15 Z 1500 2000 155 550 550 650 650 Figure 16 Z 1500 2000 175 775 775...

Page 14: ...is in the top position 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 r...

Page 15: ...ewing the wing nut and corresponding screw C see Figure 21 and pull out the hydraulic unit until the tank cap is accessible see Figure 23 m CAUTION Make sure no cables are pinched or in any other way...

Page 16: ...ssary replace the transport plug with a regular tank cap Figure 23 Hydraulic unit and relay card RELAY CARD TANK CAP MOTOR OIL TANK SOLENOID VALVE HOUSING 5 Check whether the hydraulic tank is fitted...

Page 17: ...control card to simulate that the CS switch is turned on Remove the jumper immediately after complet ed operation m WARNING Take great care while running the lift functions and make sure nothing gets...

Page 18: ...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 o Brun B Gul E Bl C...

Page 19: ...trol relay is disconnected from power before connecting Connecting 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 WL...

Page 20: ...ed par allel 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 operat...

Page 21: ...on the exterior of the vehicle frame Use M14x45 bolts and install 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...

Page 22: ...s Tightening torque 280 Nm 18 Drill holes in the vehicle frame for attachment bolts in each of the brackets two upper round holes Use suitable bolts strength M14 10 9 or higher and install the associa...

Page 23: ...he two regular grease nipples see section 9 Lubrication and oil level check on page 58 3 Install the platform on the arms using the shafts and bolts supplied Tighten the bolts using a torque wrench Ti...

Page 24: ...on the cylinder mounted on the platform Figure 37 Figure 35 Check the position in rela tion to the rear beam of the vehicle Vehicle floor level A 38 mm 40 mm Figure 36 The platform underhang A varies...

Page 25: ...ax length of both cylinders must be adjusted equally to avoid unwanted bending forces 7 Install the other tilt cylinder on the platform at tachment point Use the shaft and support wheel supplied 8 Tig...

Page 26: ...e tilt angle Figure 42 Installing boots 11 Fit the tilt cylinder boots Figure 42 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 27: ...e 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 44 3 Tilt the platform down to max 10 degrees below the...

Page 28: ...t arm Installation must take place against the vehicle body 4 4 Sealing strip horizontal The track is fitted using the self tapping screws provided 1 Mark where to drill holes for the self tapping scr...

Page 29: ...s on page 9 Use the associated bolts M12x80 Assemble without tightening the bolts See Figure 50 3 Check that the installation meets the statutory re quirements see section 3 2 Statutory dimensions on...

Page 30: ...l profile using 4 x M12x110 bolts on the brackets See Figure 52 Tightening torque 55 Nm 3 Tighten the bolts used to install the inner brack ets in step 1 Tightening torque 55 Nm 4 Install the outer sh...

Page 31: ...be greater than 4 second 4 If necessary adjust the tilt speed using the knob on the hydraulic unit The knob is fastened with a check nut Then repeat steps 1 4 until the desired tilt speed is attained...

Page 32: ...nd attach the cable using cable ties see Figure 55 2 Connection is described later in section 6 Figure 55 Installing the angle sensor x4 x4 4 9 2 Tail lift with inclinometer for autotilt 1 Install the...

Page 33: ...th cable ties Connection is described later in section 6 Figure 57 Installing an angle sensor for auto tilt Bracket on the platform Autotilt angle setting By default the autotilt angle is set to 0 If...

Page 34: ...ng away from moving traffic Fitting in any other way involves increased risk of injury Figure 59 Installing controllers IMPORTANT The controller s cable intake must always face downwards Pay attention...

Page 35: ...roller cabling to the tail lift cable grom met Connection is described later in section 6 Figure 60 Installing controller CD 1 with two handed grip Min 260 mm 300 600 mm 4 10 2 Controller UCU CD 19 In...

Page 36: ...pplied 4 10 3 Connector for a hand held controller Installing the controller bracket The connector is usually mounted on the bracket and connected to the lift Bolt the bracket in the con troller brack...

Page 37: ...tion must be made primarily to the negative terminal of the battery Alternatively another well protected earthing point which will not increase the voltage drop can be used The earthing point must be...

Page 38: ...a 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 15m 50 mm2 35 mm2 Main power cable L 15m 50 mm2 Battery Min capacity...

Page 39: ...ct the earth cable to the quick connector 4 Route connect the tail lift earth cable to the negative terminal of the battery or to a well protected earthing point When installing without main switch 5...

Page 40: ...t power supply cable 3 Connect the power supply cable to the other quick connector on the main power switch cabling 4 Run the power supply cable from the main power switch to the fuse box battery posi...

Page 41: ...er warning lighting cable 2 Route the cable and install with cable ties according to Figure 71 and Figure 72 The quick connector must be positioned in such a way that it does not conflict with the und...

Page 42: ...ing cabling using cable ties En sure the length of the cable is sufficient The outer casing should be stripped back 350 mm See Figure 76 6 1 2 After connection 1 Tighten the five screws once all cable...

Page 43: ...ection 6 2 3 6 2 4 5 Where appropriate plug in cab switch CS and open platform alarm See Section 6 2 5 6 2 7 6 Route the cabling on the reverse of the control board relay board and secure it with cabl...

Page 44: ...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 Down Down C1 C1 Up Tilt In C2 Up Tilt C3 Up Ctrl 3 Ctrl 2 Ctrl 1 CD9 Up Tilt Down CD10 Up Down CD14 Up S D...

Page 45: ...U4 U2 U1 U0 Ctrl 6 Out In GND LLED Ctrl 5 Outputs Sensors o CD11 CD1 CD2 B C 2H1 E CD15 Black 2H Black Black Black White White CD14 B S E CD12 Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Contr l Power S...

Page 46: ...esigner 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 Elschema Electric sche...

Page 47: ...ad 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 drawing is property of Z Lyften Produktion AB and is...

Page 48: ...E H Schematic Larm f r ppen brygga Detection open Platform Z55598 79037TL 2021 09 23 MB ME MB MK C A2 1 1 Z Lyften Produktion AB BK VT VT BK OG Connection for Truck Connection for Trailer Output fuse...

Page 49: ...rm f r ppen brygga Detection open Platform Z54870 77752TL 2018 11 21 MB OE MB MK B A2 1 1 Z Lyften Produktion AB Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Control Power Sensor Power Ground IN OUT Ai 1...

Page 50: ...Z 1500 2000 135 155 175 50 Connection www zepro com 6 2 7 Open platform alarm Applies when installing with main switch 4 11...

Page 51: ...r cable 3 to the fuse box positive terminal see Figure 78 Figure 79 6 Screw tight the cable connections and fuse with the knob 4 Install the cables at 90 or 180 from each other Install the fuse at rig...

Page 52: ...rawing 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 c000 Z1500 2000 c000...

Page 53: ...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 75864TL 2016 10 07 MB MB PS...

Page 54: ...erances 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 Z1500 2000 c000 E AT Z55482 78723TL 2021 01 11 M...

Page 55: ...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 EATilt g 3 C14 Z54746 77539TL...

Page 56: ...ision 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 C14 Z1500 2000 EATilt C14 Z55689 79201...

Page 57: ...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 D A2 1 1 Z Lyften Produktion AB t GND GND GND GND...

Page 58: ...ylinder 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 ri...

Page 59: ...re 84 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 for...

Page 60: ...suitable conspicuous place on the platform and in the vicinity of the primary con troller or in the designated location on the controller CD19 Figure 85 Load diagram for load capacity 1500 kg load cen...

Page 61: ...ift 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 electroma...

Page 62: ...L 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 opposite s...

Page 63: ...0 Grey PMS Cool Grey 4 C Yellow PMS 7405 C www hiab com 55053TL 2021 11 19 W x H 80 x 210 mm 25 x 210 mm Four stickers on the same back paper Print colours Black CMYK 0 0 0 100 Grey PMS Cool Grey 4 C...

Page 64: ...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 co...

Page 65: ...orm 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 ta...

Page 66: ...ested 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 canno...

Page 67: ...135 51 kg Z 2000 135 321 kg Lift arm Z 1500 2000 155 56 kg Z 2000 155 334 kg Lift arm Z 1500 2000 175 61 kg Z 2000 175 373 kg 3 part underrun protection complete adjustable 54 kg 3 part underrun prote...

Page 68: ...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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