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Installation

www.zepro.com

7.15

Purging the cylinders

Purge the lift cylinders by lowering the

platform fully to the ground a couple of

times. You may have to lift the vehicle

in order to lower the platform fully.

For the tilt cylinder model

Purge the tilt cylinders by raising the

platform fully against the vehicle body

and then tilting it all the way down.

Oil may need to be filled during aera

tion of cylinders.

NOTE.

7.16

Transport lock

Electric hose rupture valves serve as

locks for the loading platform. The lock

opens automatically if the down function

is actuated from the control device. The

valves are actually non-return valves

that let fluid into the cylinders, but not

out until they are actuated by the flow

from the lowering valve. The platform

is thereby hydraulically locked during

transport.

Содержание ZHZ 500-850

Страница 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 73161TL 2020 06 02 Installation Instruction Tail Lift ZHZ 500 600 850...

Страница 2: ......

Страница 3: ...ers 11 4 5 Attaching decals 11 5 Calculating the installed dimensions 12 5 1 C dimension 12 5 2 D dimension 12 5 3 H dimension 12 6 Installation kits 13 7 Installation 15 7 1 Installation of installat...

Страница 4: ...rea 70 9 7 Warning tape 70 9 8 Warning flags 71 9 9 CE marking 71 10 Lubrication and fluid level check 72 10 1 Lubrication 72 10 2 Fluid level check 72 11 Testing and verification 73 11 1 Static test...

Страница 5: ...tion instructions and are intended to draw your attention to circumstances potentially causing unwanted situations near misses personal injury or damage to the product etc Take care Risk of damage to...

Страница 6: ...n using the control device and its functions 1 3 Hydraulic fluid Our tail lift must work just as well in tropical heat as in the Arctic cold The heat is no problem for the fluid The cold on the other...

Страница 7: ...www zepro com 1 4 Identification Max lifting capacity x 1 kg Max lifting height 850 850 mm Cylinder model MA Double acting adjustable tilt Single acting lift Identification list E g 600 850 MA _ _ _ _...

Страница 8: ...age the cylinder seals Boots hydraulic hoses and cables must not be painted coated as the solvent in the paint could damage the hoses cables and significantly impair their durability NOTE Fig 1 Piston...

Страница 9: ...k chassis member for rear lights number plate and the lift s chassis bracket with short overhangs Final inspection must be performed with the platform by the vehicle floor and tilted down 10 The clear...

Страница 10: ...5 Installation The lift s platform must not be installed so that it cannot reach ground level Zepro s tail lifts are only approved for installation with Zepro s installation kits The lift s capacity m...

Страница 11: ...tall the hydraulic hoses Add hydraulic oil in the hydraulic oil tank 4 2 Electrical connection Install the control devices Install the control devices cables Install the main power cable 4 3 Installin...

Страница 12: ...eeds to be installed under the vehicle body D dimension and the space between the lift arms in the upper position and the vehicle floor level A dimension 5 2 D dimension The D dimension is the space t...

Страница 13: ...5 Mercedes Sprinter 2018 3 5t RWD L 3665 24 9 kg 73167TL 7 1 6 Mercedes Sprinter 2018 5t RWD L 4325 Vehicle lenght 6967 17 6 kg 76796TL 7 1 7 Mercedes Sprinter 2006 2016 5t RWD L 4325 Vehicle lenght...

Страница 14: ...D 15 5 Kg 78012TL 7 1 18 Mercedes Sprinter 2018 5t RWD L 4325 15 2 Kg 78128TL 7 1 19 Mercedes Sprinter 2018 3 5t RWD L 3665 26 8 kg 78130TL 7 1 20 Mercedes Sprinter 2018 3 5t RWD L 4325 15 2 Kg 78160T...

Страница 15: ...ut tightening Installation play between chassis bracket and the lift s dimen sions 997 mm may not exceed 2 mm 4 When installing a folding platform slide the chassis bracket 20 mm to the left to avoid...

Страница 16: ...height difference between the lift arm and the floor of the body to ap prox 25 mm Then adjust the lift so it is as close to the rear doors as possible Fig 12 Adjust the lift so it is as close to the...

Страница 17: ...r 1 x M10 nyloc nut 1 x Spacer 20 mm Tightening torque 50 Nm 1 x M14x1 5 screw L 30 1 x Square washer Tightening torque 120 Nm 2 x M10x85 screws 1 x Washer 1 x M10 nyloc nut Tightening torque 50 Nm 2...

Страница 18: ...M10 x 55 x 1 25 22765TL Sexkantskruv fing ngad Hexagon head screw 4 12 Z50404 72794TL Distans 20 mm Distance 20 mm 6 11 1 DIN 125 A 13 20181TL Bricka Plain washer 4 10 1 DIN 985 M10 20170TL Sexkantsm...

Страница 19: ...Sexkantskruv Hexagon head screw 2 14 5 ISO 7089 10 140 HV 20184TL Bricka Plain washer 8 13 8 DIN 960 M10 x 55 x 1 25 22765TL Sexkantskruv fing ngad Hexagon head screw 4 12 Z50404 72794TL Distans 20 mm...

Страница 20: ...with rustproof ing agent 3 Check that the supplied spacer tubes fit in the frame If necessary drill the holes to 20 5 so that the spacers can be installed Apply rustproofing agent See Fig 15 4 Install...

Страница 21: ...HZ 600 Ford Transit V3 5 This drawing is property of Z Lyften Produktion AB and is loaned subject to return upon demand It is not to be reproduced or used directly or indirectly in any way detrimental...

Страница 22: ...lose to the exhaust mounting as possible See Fig 16 4 Cut the towing eyelet as close to the mount as possible See Fig 17 5 Cut the left mounting bracket for the bumper by approx 200 mm See Fig 18 6 Ch...

Страница 23: ...sis brack ets and bumper brackets 7 Install the chassis brackets and the bumper brackets with the supplied 5 x M12x110 screws M12 nyloc nuts and washers Tighten with the aid of a torque wrench See Fig...

Страница 24: ...rance Surface finish Welding Mont sats ZHZ 600 Ford tran 2014 2014 06 24 TC 1 3 MJ TC 10 2 Z52993 74914TL A3 1 1 EN ISO 13920 A Z Lyften Produktion AB Drawn TC A CARGOTEC BRAND Used on Mounting kit ZH...

Страница 25: ...3 If needed cut the exhaust pipe to avoid interference with the lift chassis 4 Cut the towing eyelet as close to the mount as possible see Fig 20 5 Install the chassis brackets and the bumper bracket...

Страница 26: ...c king Hex Nut 18 3 Z53064 2 75017TL Ram f ste ZHZ 600 V Frame bracket ZHZ 600 L 1 2 Z53064 1 75016TL Ram f ste ZHZ 600 H Frame bracket ZHZ 600 R 1 1 Rev Drawing nr Stock nr Title Description Qty Item...

Страница 27: ...illed hole See Fig 22 3 Install the chassis bracket on the outside and the base plate on the inside of the vehicle s frame Use 1 x M10x90 screw M10 nyloc nut washer and spacer Tighten with the aid of...

Страница 28: ...m Satsen passar f ljande modeller Generation 906 2006 VW Crafter MB Sprinter Vans 3 5 t med hjulbas 4325 verh ng 1615 2015 Kit fits the following models Generation 906 2006 VW Crafter MB Sprinter Vans...

Страница 29: ...rews Fig 26 Install outer and inner chassis brackets in the vehicle chassis Use four M12x100 screws Fig 25 Install the spacer tubes 4 Drill a 12 5 hole in the frame from the outside and inside using t...

Страница 30: ...agningsmoment f r skruv och mutter Tightening torque for screws and nuts M12 80Nm Satsen passar f ljande modeller Generation 906 2006 VW Crafter MB Sprinter Vans 3 5 t med hjulbas 3665 verh ng 1240 Ki...

Страница 31: ...x 90 22305TL Sexkantskruv M10 Screw M10 2 5 Z41759 01 63242TL Distansr r Spacer 2 4 ISO 7089 10 140 HV 20184TL Bricka Plain washer 2 3 Z54326 2 76795TL Ramf ste V Mounting bracket L 1 2 Z54326 1 7679...

Страница 32: ...M12 21980TL Mutter M6MF M12 Loc king Nut M12 8 4 ISO 4014 M12 x 110 22304TL Sexkantsskruv Hexagon head screw 8 3 Z54329 1 76799TL Ramf ste H Bracket R 1 2 Z54329 2 76800TL Ramf ste V Bracket L 1 1 Dr...

Страница 33: ...and one reinforcement plate see Fig 28 Tightening torque 80 Nm It may be necessary to create a cut out in the bumper NOTE 3 Drill up the holes on the vehicle chassis inside to 15 mm so that the spacer...

Страница 34: ...Nut M12 18 4 Z54199 76594TL F rst rkning insida Crafter 2017 Reinforcement pl Crafter 2017 2 3 Z54282 2 76743TL Ramf ste ZHZ 600 Crafter 2017 V Mount br ZHZ600 Crafter 2017 L 1 2 Z54282 1 76742TL Ramf...

Страница 35: ...acket in the ve hicle chassis use excisting holes Use four M12x110 screws and one reinforcement plate see Fig 30 Tightening torque 80 Nm It may be necessary to create a cut out in the bumper NOTE 3 Dr...

Страница 36: ...Z54199 76594TL F rst rkning insida Crafter 2017 Reinforcement pl Crafter 2017 2 4 Z54473 77090TL Distans bricka Spacer 2 3 Z54476 2 77130TL Ramf ste ZHZ 600 V nster Mount br ZHZ 600 Left 1 2 Z54476 1...

Страница 37: ...5 5 ISO 7089 12 140HV 20181 Bricka Plain washer 26 4 5 ISO 7089 10 140 HV 20184 Bricka Plain washer 4 3 A Z52558 2 74481TL Ramf ste v nster Mounting bracket left 1 2 A Z52558 1 74480TL Ramf ste Renau...

Страница 38: ...2 140HV 20181 Bricka Plain washer 26 4 1 ISO 4017 M12 x 45 22213 Sexkantskruv Six head screw 16 3 Z52562 1 74485TL Ramf ste h ger Mount bracket right 1 2 Z52562 2 74486TL Ramf ste v nster Mount bracke...

Страница 39: ...28 4 Z52563 74483TL Distans pl t Spacer plate 2 3 A Z53235 1 75234TL Ramf ste ZHZ H Mounting bracket ZHZ R 1 2 A Z53235 2 75235TL Ramf ste ZHZ V Mounting bracket ZHZ L 1 1 Rev Drawing nr Stock nr Titl...

Страница 40: ...22304TL Sexkantsskruv Hexagon head screw 8 6 ISO 4014 M10 x 100 21190TL Sexkantskruv Hexagon head screw 2 5 Z41759 01 63242TL Distansr r Spacer 2 4 ISO 7089 10 140 HV 20184TL Bricka Plain washer 2 3...

Страница 41: ...TL Mutter M6MF M12 Loc king Nut M12 8 4 ISO 4014 M12 x 110 22304TL Sexkantsskruv Hexagon head screw 8 3 Z54329 1 76799TL Ramf ste H Bracket R 1 2 Z54329 2 76800TL Ramf ste V Bracket L 1 1 Drawing nr S...

Страница 42: ...agon head screw 10 5 Z54199 76594TL F rst rkning insida Crafter 2017 Reinforcement pl Crafter 2017 2 4 Z54473 77090TL Distans bricka Spacer 2 3 Z54476 2 77130TL Ramf ste ZHZ 600 V nster Mount br ZHZ 6...

Страница 43: ...Reinforcement plate 2 4 1 ISO 4014 M12 x 100 21597TL Sexkantskruv Hexagon head screw 8 3 ISO 7043 M12 21980TL Mutter M6MF M12 Loc king Nut M12 8 2 Z54910 77832TL Ramf ste pl t Mounting bracket 2 1 Rev...

Страница 44: ...tsmutter M12 Loc king Hex Nut 4 3 5 ISO 4017 M12 x 35 21311TL Sexkantskruv Hexagon head screw 4 2 ISO 7043 M12 21980TL Mutter M6MF M12 Loc king Nut M12 8 1 Rev Drawing nr Stock nr Title Description Qt...

Страница 45: ...1759 01 63242TL Distansr r Spacer 2 6 ISO 7043 M12 21980TL Mutter M6MF M12 Loc king Nut M12 8 5 8 ISO 4014 M12 x 110 22304TL Sexkantsskruv Hexagon head screw 8 4 Z47217 53925TL F rst rkning insida Rei...

Страница 46: ...nr Title Description Qty Item All defined tightening torques applies when use of torque wrench or nut runners with torque control torque spread max 5 Tightening torque requirements M12 80 Nm Passar S...

Страница 47: ...king Hex Nut 10 8 1 DIN 125 A 13 20181TL Bricka Plain washer 10 7 5 ISO 7089 10 140 HV 20184TL Bricka Plain washer 2 6 1 DIN 985 M10 20170TL Sexkantsmutter Hex Nut 2 5 8 ISO 4014 M10 x 100 21190TL Se...

Страница 48: ...ZHZ 600 Reinforcment plate ZHZ 600 2 3 Z54736 2 77520TL Ramf ste ZHZ 600 left Mounting Br ZHZ 600 left 1 2 Z54736 1 77521TL Ramf ste ZHZ 600 h ger Mounting Br ZHZ 600 right 1 1 Rev Drawing nr Stock n...

Страница 49: ...exkantskruv Hexagon head screw 12 1 Rev Drawing nr Stock nr Title Description Qty Item Tightening torque requirements M12 80 Nm All defined tightening torques applies when use of torque wrench or nut...

Страница 50: ...ires more space NOTE 4 Tighten the mounting screws using a torque wrench Tightening torque 80 Nm Fig 32 Mounting and adjustment of the lift Art no Hole pattern front Hole pattern rear 72807TL 2 screws...

Страница 51: ...haft inwards until its flush with the platforms suface on the opposite side see Fig 36 1 5 Fit in the screw attached see Fig 36 2 to lock the platform shaft 6 Refit the cover 7 Attach the cylinder to...

Страница 52: ...using the at tached screws see Fig 39 4 Mount the cable among existing cables using cable ties and connect to the 4 button operation circuit board See section 8 2 Connection to circuit board 4 button...

Страница 53: ...location for the hydraulic unit is on the wheel housing The unit is ideally secured with the supplied bracket The hydraulic unit can be installed hori zontally or vertically 7 5 1 Connection of hydra...

Страница 54: ...ator is in the safest possible working position and has a clear view of the load the tail lift and its working area 2 The distance between the vehicle s rear edge and the centre of the controllers mus...

Страница 55: ...location 2 When fitting the drainage tube must be facing downwards see Fig 44 3 Connect the controllers to the connection box and the connection box to the relay board see 8 1 ZHZ 600 850 MAConnectio...

Страница 56: ...ntrol power cable from the driver s cab to the lift When passing through a mem ber or wall the cable must be protected by rubber grommets If there are any quick release connectors make sure these are...

Страница 57: ...cannot chafe or otherwise sustain damage that can lead to a short circuit and cable fires Do not bend the cable with too small a radius as this can cause damage to the cable In general care must be ta...

Страница 58: ...ion point and connect the main power cable see Fig 47 The following image showing the connection point is an example and may vary from vehicle to vehicle 2 Secure the fuse and main power cable with th...

Страница 59: ...Fig 51 2 3 Connect a cable from the battery s positive terminal see Fig 51 3 4 Screw the cable connections and fuse into place with the knob Install the cables at 90 or 180 from each other Install the...

Страница 60: ...tion of license plate light Connect the license plate light to the vehicles ordinary lights cabeling Follow the manufacturer s recommendations Fig 55 Example of connecting the license plate light Vehi...

Страница 61: ...t with the adjustment screws so that both armstops contact the lift arms at the same time On some vehicle models the space can be so confined that the lift has to be lowered in order for the adjusting...

Страница 62: ...e to angle down the platform or anti clockwise to angle up the platform Lock the lug in place using a suitable tool Adjust the tilt cylinder in horizontal position The maximum permitted adjust ing dis...

Страница 63: ...st the vehicle body and then tilting it all the way down Oil may need to be filled during aera tion of cylinders NOTE 7 16 Transport lock Electric hose rupture valves serve as locks for the loading pl...

Страница 64: ...y detrimental to the 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 mn...

Страница 65: ...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 loaned subject to return upon demand I...

Страница 66: ...66 Electrical and hydraulic drawings www zepro com 8 3 Connection of cab switch and alarm for open platform 10 4 10 4...

Страница 67: ...elow Possible control device models vary depending on lift model configuration and relevant market Connect according to the table below and the electrical and hydraulic drawings see section 8 Electric...

Страница 68: ...68 Markings and decals www zepro com 9 Markings and decals 9 1 Overview The illustrations below show the positions of the various decals...

Страница 69: ...ers park ing behind the vehicle know that a 5 m clearance is required for the platform to open and that sufficient space should be left for loading and unloading 9 3 Identification plate The identific...

Страница 70: ...he vehicle The decal must be attached to the inside of the vehicle body close to where the manual control device is installed 9 7 Warning tape The warning tape is ideally attached along the platform s...

Страница 71: ...coming loose when the platform is lowered to the ground Swage the tracks together to secure the warning flags in place Fig 71 CE marking 9 9 CE marking The marking below represents the manufacturer s...

Страница 72: ...h slide bearings that must NOT be lubricated 10 2 Fluid level check Check the fluid level in the tank when performing servicing top up if necessary The marking on the hydraulic tank indicates the type...

Страница 73: ...the platform Repeat the measurement of A B C D and verify that there has been no permanent deformation of the lift or its mounting 11 1 2 Drift Place a test load on the platform according to the tabl...

Страница 74: ...afety functions must be tested Check that the red light in the driver s cab is deactivated when the platform is completely closed against the body and conversely that it is activated when the platform...

Страница 75: ...the connection ramp 2 After ensuring that the battery is disconnected disconnect the main power cable and the control cable 3 Dismantle the hydraulic unit 4 Dismantle the tilt cylinder from the platfo...

Страница 76: ...list detailing a selection of components and their weight Complete lift chassis without platform Lift components included in complete lift chassis 130 kg Support frame 24 5 kg Lift arm 22 5 kg Platfo...

Страница 77: ...Specifications 77 www zepro com C ZHZ 500 600 alu platform 1200x1400 mm 13 2 Load centre C 150 C 300 C 450 TP1 mm 185 160 113 TP2 mm 500 kg 413 417 423 TP2 mm 600 kg 496 500 508 TP2 TP1 Max load...

Страница 78: ...s regarding the amount of power the lift can access from the existing battery NOTE 12 volt 24 volt Pump Motor unit 100 A 60 A Magnet hydr unit 4 2 A 0 7 A Magnet electrical hose rupture valve 1 5 A 0...

Страница 79: ...e lift When installing the lift and when carrying out servicing and repair work when the lift is operated repeatedly without the vehicle being started and used a battery charger must be used between o...

Страница 80: ...80 Specifications www zepro com 13 6 Loading diagram ZHZ 600 Fig 75 Loading diagram 13 7 Loading diagram ZHZ 500 Fig 76 Loading diagram...

Страница 81: ...Specifications 81 www zepro com...

Страница 82: ...ifts 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 o...

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