Zepro Z 45-90 Installation Instructions Manual Download

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

Email: [email protected]

zepro.com

54990TL

2022-07-04

Installation instructions

Tail Lift

Z/ZU 45/75-90/110

ZL/ZLU 45/75-90/110

ZN/ZNU 45/75-90/110

Summary of Contents for Z 45-90

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 Email zeprotech hiab com zepro com 54990TL 2022 07 04 Installation instructions Tail Lift Z ZU 45 75 90 110 ZL ZLU 45 75 90 110 ZN ZNU 45 75 90 110...

Page 2: ......

Page 3: ...Temporary connection 18 3 6 Connecting the control device to the ZePRO1 control card 19 3 7 Connecting the control device to the TLC B1 relay card 20 4 Installation 21 4 1 Hydraulic unit 21 4 2 Suppo...

Page 4: ...LC B1 50 6 9 Cabin switch and open platform alarm ZePRO 51 7 Electrical and hydraulic diagrams 52 7 1 Z 45 75 TLC B1 52 7 2 Z 45 75 ZePRO1 53 7 3 Z 45 75 with electric Autotilt TLC B1 54 7 4 Z 45 75 w...

Page 5: ...njury 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 information tha...

Page 6: ...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 specification for the hydraulic oil are...

Page 7: ...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 low depen...

Page 8: ...he closest part of the cylinder must be at least 40 mm Image 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 Conne...

Page 9: ...of personal injury and material damage If necessary to install other equipment check the vehicle manufacturer s body instructions and use the attachment options on the vehicle 2 5 Installation m WARN...

Page 10: ...t of inertia of 306 cm4 around the x axis See Image 7 If in doubt contact ZEPRO for support Image 7 Cross section of vehi cle chassis frame beam X 140 70 3 x2 Y m WARNING The dimensions above are the...

Page 11: ...the room required by the lift 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 o...

Page 12: ...height 900 1100 mm Lifting height 900 mm C A D 450 170 384 400 154 444 350 143 490 300 134 526 250 127 554 Lifting height 1100 mm C A D 550 186 432 500 168 498 450 155 549 400 145 590 350 137 624 310...

Page 13: ...0 170 384 Approved 400 154 444 350 143 490 310 134 526 250 127 554 Approved Approved when installing longer underrun brackets available as option Lifting height 1100 mm C A D R58 3 550 186 432 Approve...

Page 14: ...110 250 183 72 122 1410 min 550 max 1110 1410 2100 1900 min 700 500 min 550 max 1110 459 1171 500 318 418 524 250 183 72 122 ZU 45 90 ZU 75 90 250 183 72 122 424 524 Longer underrun brackets that give...

Page 15: ...75 90 ZLU 45 110 ZLU 75 110 250 183 72 122 1720 min 750 max 1410 1720 2100 1900 min 1000 350 min 750 max 1410 758 1474 350 318 418 250 183 72 122 424 524 524 250 183 72 122 Longer underrun brackets th...

Page 16: ...90 ZNU 45 110 ZNU 75 110 1280 1960 1700 min 350 575 min 660 max 1020 446 446 575 318 418 250 183 72 122 424 524 524 250 183 72 122 250 183 72 122 1280 min 660 max 1020 Longer underrun brackets that g...

Page 17: ...the location and depth of the cut outs on the rear beam Centre the two rear beam cut outs i e the cut outs must be equidistant from the centre point of the beam 2 Cut out along the markings 3 Remove a...

Page 18: ...and CS on the 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 pi...

Page 19: ...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 CD...

Page 20: ...necting 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 Dow...

Page 21: ...o Operator s manual before installation m WARNING Zepro tail lifts are only approved for installation with Zepro assembly kits 4 1 Hydraulic unit Image 15 Overview hydraulic unit Motor Solenoid s Oil...

Page 22: ...rap is not to be used for fastening the plastic hood 2 Install the hydraulic unit on the lifting frame see Image 17 Image 16 Remove the tension ing strap before installation Image 17 Assembly of hydra...

Page 23: ...frame to the ideal height under the chassis A workshop jack 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...

Page 24: ...120 Nm 14 Tighten the bolts that hold the chassis bracket to the support frame Tightening torque 120 Nm NOTE Welding is not permitted on the chassis brackets Do not run the lift all the way to the arm...

Page 25: ...m Use the supplied shafts and locking nuts Tightening torque 25 Nm NOTE The tilt cylinders should be adjusted before fixing to the platform 4 Test the lift by carefully raising it to the vehicle floor...

Page 26: ...otilt option Applies only to ZePRO1 with hydraulic autotilt When installing autotilt mount the angle sensor onto the lift arm see Image 28 NOTE When installing on the left arm the sensor s cable input...

Page 27: ...the sensor is mounted in such a way that its cable connection is facing down see Image 29 4 7 Angle sensor IFM for autotilt TLC B1 option only 1 Measure out and place the sensor bracket as shown below...

Page 28: ...he beam to the outside of the wheel Max 100 mm See Image 31 The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm See Image 32 Each of the in...

Page 29: ...utwards Remove the frame end plugs so as to reach the fastening points for the outer brackets Tightening torque 90 Nm 4 Fasten the inner brackets with two M12x30 8 8 bolts each The bolts are inserted...

Page 30: ...es 5 Fasten the aluminium profiles with two M8x20 8 8 bolts each The head of the bolt is threaded in the aluminium rail and the rail is then posi tioned and screwed into the bracket Tightening torque...

Page 31: ...surface for the arm stop 2 Adjust with the adjustment screws so that both arm stops make contact with the rear member stop at the same time NOTE When installing arm stops use Loctite 243 or equiva le...

Page 32: ...eel or aluminium 5 Fit the rubber strip in the track 4 11 Sealing strip vertical 1 Check that the distance between the vehicle floor and the platform is 38 40 mm 2 Attach the tracks with countersunk s...

Page 33: ...d mount them on the stop profile seeImage 42 and Image 43 6 Place the arm stop according to the position of the lift arms and fix by tightening its screws see Image 47 7 Screw the stop profile into th...

Page 34: ...nts with full hydraulic pressure in the tilt cylinders 3 Undo the locking nut 4 Turn the pushrod so that the platform comes into the desired position On vehicle bodies without rear doors the platform...

Page 35: ...justing collar and the end of the thread is no more than 30 mm Lift model A 45 75 90 73 5 45 75 110 156 5 4 14 Transport lock For all CE marked lifts with 1000 kg lifting capacity or more platforms ar...

Page 36: ...g cables to get longer life for the cables and to reduce the risk of unnecessary downtime The cable must not be fastened to brake lines or the vehicle s normal electrical system The cable must be prot...

Page 37: ...and their working area 2 The distance between the vehicle s rear edge and the centre of the controllers must be 300 600 mm The distance between the controllers must be at least 260 mm See Image 54 3...

Page 38: ...onnection 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 mus...

Page 39: ...th and main power cables L L Umin Imin Imin Umin 5 2 Sizing electrical systems Ensure that the battery and charger capacity is sufficient for the product in question and that cable with suf ficient cr...

Page 40: ...cables Control cable 1 5 mm2 1 5 mm2 Supply cable L 8 m 25 mm2 25 mm2 Supply cable L 8 15 m 35 mm2 35 mm2 Supply cable L 15 m 35 mm2 Battery Min capacity Imin 140 Ah 110 Ah Min voltage during operati...

Page 41: ...he 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 earth ing point When installing without main switch 5 On...

Page 42: ...nd controller cables on the underside of the arm and fasten with cable ties 5 Pull the main power cable from the main switch to the fuse box battery plus pole Prepare the cable with a cable terminal a...

Page 43: ...of an alarm for open platform This can be in the form of warning light in the cab or when mounted on a trailer a lamp mounted on the outside of the body visible in the rear view mirror from the drive...

Page 44: ...tem via a 10 A 24 V 15 A 12 V fuse according the customer s wishes See wiring diagram in Sections 6 8 and 6 9 5 6 Warning lighting foot controller If the tail lift is equipped with warning lights and...

Page 45: ...le should be installed together with existing cabling using cable ties Image 66 The cable grommet s five screws Hydraulic unit 5915 6 2 Connection 1 Run the cabling through the grommet 2 Connect the r...

Page 46: ...U4 U2 U1 U0 Ctrl 6 Out In GND LLED Ctrl 5 Outputs Sensors o CD11 Brown B Yellow E Blue C Blue 2H CD1 CD2 B C 2H1 E CD15 B C 2H E Black Black 2H Black Black Black White White White CD14 B S E CD12 Ctr...

Page 47: ...2 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 CD14 Up...

Page 48: ...shed 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 Welding 1 1...

Page 49: ...yftens 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 drawing is property of Z Lyf...

Page 50: ...et 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 Detection open Platform...

Page 51: ...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 2018 11 21 MB OE...

Page 52: ...be reproduced or used directly or indirectly in any way detrimental to the interest of Z Lyften Produktion AB D r annat ej anges Drawing interpretation unless otherwise specified All measures intends...

Page 53: ...55 ME CL D r annat ej anges Drawing interpretation unless otherwise specified All measures intends finished product Alla m tt avser f rdig produkt Ben mning Title Material Dimension Datum Date Vikt We...

Page 54: ...he interest of Z Lyften Produktion AB D r annat ej anges Drawing interpretation unless otherwise specified All measures intends finished product Alla m tt avser f rdig produkt Ben mning Title Material...

Page 55: ...r Designer Kontr Checked by Godk Approved by Artikelnr Stock nr Ritningsnr Drawing nr Blad Sheet Format Size Revision F r denna ritning g ller IS0 toleranser SMS ritregler Toleranser Tolerance Ytj mnh...

Page 56: ...wer bearing 4 Left lift cylinder at lower bearing 5 Left tilt cylinder at lower bearing 6 Lift arm left side at lower bearing 7 Left tilt cylinder at upper bearing 8 Right tilt cylinder at upper beari...

Page 57: ...erspannung ACHTUNG Notsteuerung istnurmitder Hauptsteuerung m glich Fermeture d urgencelorsquelatensionest tropfaible NB Seulel unit decommande principalestfonctionnel Cierredeemergencia y www zepro c...

Page 58: ...ams for the appropriate lift model close to the primary controller and in a suitable clearly visible position on the vehicle body Image 69 Load diagram for load capacity 450 kg load centre distance 60...

Page 59: ...number Year of manufacture Address and tel no of manufacturer Country of manufacture Type number for approved underrun protection URPD Type number for electromagnetic compatibility EMC 9 3 Work area A...

Page 60: ...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 for affixing on the opposite sid...

Page 61: ...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...

Page 62: ...or its fixing 10 1 2 Drift Place a test load on the platform according to the table The tail lift must be at the same level and angle as the vehicle floor Leave the test load for 15 minutes Verify tha...

Page 63: ...r the respective tail lift model lifting capacity The test load should be 1 25 x the lift model s max load Verify that the tail lift cannot lift the load when the up function is switched on it may how...

Page 64: ...vated when the main switch fuse is removed That the overflow valve is activated when the lift is operated up to the vehicle floor level or end stops That the tail lift cannot be lowered or tilted down...

Page 65: ...the tail lift s guarantee to be valid the delivery card must be registered in C care www c office com The bodybuilder is responsible for registration in C care and must certify in the intended locatio...

Page 66: ...arm ZL ZLU 45 75 110 26 0 kg ZU 45 75 110 154 5 kg Lift arm ZN ZNU 45 75 90 17 0 kg ZLU 45 75 90 159 kg Lift arm ZN ZNU 45 75 110 19 0 kg ZLU 45 75 110 164 5 kg Complete frame bracket 4 2 kg ZNU 45 75...

Page 67: ...0 Specifications 67 www zepro com Image 82 Tightening torque 12 2 Tightening torque NOTE All specified tightening torques apply when using torque wrench or screw nut runner with torque control Torque...

Page 68: ...l 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 o...

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