Zepro ZS 150-135 Installation Instruction
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Zepro ZS 150-135 Installation Instruction

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Installation Instruction
ZEPRO
Tel.: +46 (0)10-459 05 00
E-mail: zeprotech@hiab.com
54273TL
2019-11-12
ZS/ZSS 150/200-135/155/175
|
zepro.com
ZD 150/200-155/175
ZT/ZTS 150/200/250-140
ZS/ZSS 250-135/155
Tail Lift

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Summary of Contents for Zepro ZS 150-135

  • Page 1 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 ZEPRO Tel.: +46 (0)10-459 05 00 E-mail: zeprotech@hiab.com zepro.com 54273TL 2019-11-12...

  • Page 3: Table Of Contents

    Contents 1. CE marking................... 2. General ..................3. Dimensions for installation ............4. Slider installation................. 5. Electrical installation..............6. Electric and hydraulic diagram ..........7. Functional schematic drawing ........... 8. Connection unit ................9. Accessories ................. 10. Important information ............... 11.

  • Page 4: Ce Marking

    1. CE marking Since 1/1/1995 ZEPRO tail lifts sold to the European Welding is not necessary unless specifically recom- market are stamped with a CE mark. This is the mended by the manufacturer. manufacturer's guarantee that the product conforms to the European Machinery Directive.

  • Page 5: General

    The hydraulic system is protected with a pressure range. ZEPRO oil (art.no 21963 for 1 litre) is made regulator when lifting or tilting up. of a highly refined mineral oil, the lubricant additive...
  • Page 6 2. General E.g. ZS - 150 - 135 ML Identification list, slider lifts _ _ - _ _ _ - _ _ _ _ _ ZS = Single folded platform, for truck installation, hydraulic motor placed above support frame. ZSS = Single folded platform, for truck installation, hydraulic motor placerad in front of support frame.
  • Page 7 2. General Max Power Consumption ZT/ZTS 150/200 (130 bar) 7000 12 volt 24 volt Pump - Motor Unit 245 A 125 A Magnet (hydraulic unit) 4,2 A 2,1 A Magnet (electric safety valve) 1,5 A 0,75 A Solenoid 1,5 A 0,85 A Cable area: Control cable...
  • Page 8 2. General Loading Diagram ZT/ZTS-150/200/250 ZS/ZSS/ZD-150/200/250...

  • Page 9: Dimensions For Installation

    3. Dimensions for installation Underrun Protection Try to install the slider profile in a position so that, when it is folded, the rear edge of the platform is in line with the rear edge of the vehicle 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.
  • Page 10 3. Dimensions for installation ZS-150/200/250-135 Sliderprofile length NOTE: If the cables are a limiting factor, be careful to check the overhang *max 630 Total Overhang O Slide profile P1 (mm) length (mm) - 600 1370 * at max frame width 1040 600 - 800 1590 1972...
  • Page 11 3. Dimensions for installation ZS-150/200/250-155 Sliderprofile length NOTE: If the cables are a limiting factor, be careful to check the overhang Total Overhang O Sliderprofile P1 (mm) length (mm) *max 630 - 700 1590 700 - 1700 1500 / 2000 kg 2500 kg * at max frame width 1040 1005...
  • Page 12 3. Dimensions for installation ZS-150/200-175 Sliderprofile length NOTE: If the cables are a limiting factor, be careful to check the overhang Total Overhang O *max 630 Sliderprofile P1 (mm) length (mm) - 700 1590 700 - 1700 1500 / 2000 kg 2500 kg * at max frame width 1040 1005...
  • Page 13 3. Dimensions for installation ZSS-150/200/250-135 Sliderprofile length NOTE: If the cables or valve system are a limiting factor, be careful to check the overhang. *max 840 *max 565 Total Overhang O Slide profile P1 (mm) length (mm) - 550 1370 *at max frame width1040 550 - 700 1590...
  • Page 14 3. Dimensions for installation ZSS-150/200/250-155 Sliderprofile length NOTE: If the cables or valve system are a limiting factor, be careful to check the overhang. *max 840 Total Overhang O *max 565 Slide profile P1 (mm) length (mm) - 600 1590 *at max frame width1040 600 - 800 1700...
  • Page 15 3. Dimensions for installation ZSS-150/200-175 Slide profile length NOTE: If the cables or valve system are a limiting factor, be careful to check the overhang. *max 840 *max 565 Total Overhang O NOTE: If the cables are a limiting factor, be careful to check the overhang Sliderprofile P1 (mm)
  • Page 16 3. Dimensions for installation ZD-150/200-155 Slide profile length 1095 NOTE: If the cables are a limiting factor, be careful to check the overhang *max 630 Total overhang O 1500 / 2000 kg * at max frame width 1040 1972 1250 max 900 min 750 176.5 1314...
  • Page 17 3. Dimensions for installation ZD-150/200-175 Slide profile length 1215 NOTE: If the cables are a limiting factor, be careful to check the overhang *max 630 Total overhang O 1500 / 2000 kg * at max frame width 1040 1350 1972 max 900 min 750 176.5 1314...
  • Page 18 3. Dimensions for installation ZT-150/200/250-140 Slide profile length 1590 NOTE: If the cables are a limiting factor, be careful to check the overhang *max 750 Total overhang O 2044 1060 * at max frame width 1300 1974 1005 1849 1740 1740 1774 min 1200 - max 1300...
  • Page 19 3. Dimensions for installation ZTS-150/200/250-140 Slide profile length 1590 NOTE: If the cables or valve system are a limiting factor, be careful to check the overhang. 1096 Total Overhang O *max 980 *max 705 1916 * at max frame width 1300 1916 1740 1845...

  • Page 20: Slider Installation

    4. Slider installation Attention! Also refer to the truck manufacturer´s instructions for auxiliary equipment IMPORTANT: Finding the installation position of the slider is very simple if these instructions are follo- wed. The platform and lift arm combinations described on this page are optimised for minimum total over- hang (O), therefore always install the slide profile rear edge level with the rear edge of the vehicle frame or tow hook device so that the platform...
  • Page 21 4. Slider installation Single folding platform models ZS, ZSS, ZT, ZTS OVERHANG NECESSARY 81 mm ZS, ZT ZSS, ZTS 26 mm The following equation can be used to calculate the minimum overhang necessary for the installation of a slider. Distance forward of the beam (1) + Beam (2)+ Lift arm (3) + Fixed part of platform (5) - Liftarm/platform over- lap (4) Distance forward of the beam = 62 mm (ZS, ZT), 100 mm (ZSS, ZTS).
  • Page 22 4. Slider installation Geometry of sliding lift installation 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... ZS, ZSS, ZT, ZTS- models ZD- models then take time to read these instructions carefully and follow them!!!
  • Page 23 So the total platform length permissible is geometri- cally limited. ZEPRO will not sell you a platform combination that cannot fit, however, this serves as an explanation as to the limitation of platfom/ liftarm combinations available.
  • Page 24 4. Slider installation Geometry of sliding lift installation On this page diagrams show sliding lifts in- stalled with their slide profiles installed in the recom- mended position for short overhang model as far back as possible on the vehicle frames. 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...
  • Page 25 4. Slider installation ZT/ZTS-150/200/250 Suitable for installation on the following distances 165 - 400 110 - 150 If the stop at the slide profile rear end not is the same as platform- body, then you have to mount a 10-15 working position lock (art.
  • Page 26 4. Slider installation Mounting of working position lock If the lift has no working position lock and the stopping piece against the rear end of the sled profile does not match tothe lift’s working position (refer to page 23), the working position lock (art. no. 56280) must be mounted so that the distance between the bridge and the cabinet is correct.
  • Page 27 4. Slider installation ZS/ZSS/ZD-150/200/250 General The ZS sliders with single folding platforms and ZD sli- ders with double folding platforms are identical except for the addition of a roll arm on the ZD models to aid the folding out of the platform. The roll arm is installed at the factory.
  • Page 28 4. Slider installation ZS/ZSS/ZD-150/200/250 Holes 14.0mm min. 2 bolts min. 4 bolts Bolts M14 Hardness 10.9 Torque 95 Nm max 280 Nm NB. All holes except for those for the bolts through the slots should be drilled after test running the lift.
  • Page 29 4. Slider installation For fixed part of the aluminium platform , place the Hydraulic Automatic Tilt lift arm in its slot in the platform then push in the axle When hyd. auto-tilt is installed the angle sensor should bolts and fix them with the locking screws. Bolt the tilt be installed on the lift arm as in the diagram cylinders to the platform bracket (see pict.
  • Page 30 4. Slider installation Adjustment of tilt down angle. Pict. 10 Run the lift up so that the lift is at the floor level, see pict 9. Loosen the ring's lock screw (2). 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).
  • Page 31 4. Slider installation For ZD models ZD models with double folded 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.

  • Page 32: Electrical Installation

    5. Electrical installation 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.
  • Page 33 5. Electrical installation Please refer to the instructions for electrical If you have a spiral cable unit, its cable colours are installation regarding ancilliary equipment from different (see electric diagram): your vehicle supplier. If you want an electrically heated spiral cable Install control units at suitable places, but the posi- unit you can order a 5 - part cable (spare-part no tion of the control unit should ensure that the ope-...
  • Page 34 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 safety. If it's really important for you to make such installations please check with the vehicle manufacturers installation instructions and use the trucks capabilities.

  • Page 35: Electric And Hydraulic Diagram

    6. Electric and hydraulic diagram ZS/ZD/ZSS/ZT/ZTS-150/200/250 ML...
  • Page 36 6. Electric and hydraulic diagram ZS/ZD/ZSS/ZT/ZTS-150/200/250 DL...
  • Page 37 6. Electric and hydraulic diagram ZS/ZD/ZSS/ZT/ZTS-150/200/250 ML, with hydraulic Auto-Tilt...
  • Page 38 6. Electric and hydraulic diagram Cabin switch, Alarm for open platform Liftcylinder Tiltcylinder Sensor Power Not in use Outputs NC 60bar Pump unit Pumpunit Ctrl 1 IN OUT Indication Se appendix in installation manual Ctrl 2 CSPWR 12-24v Ctrl 6 Di 6 Di 5 Ctrl 3...
  • Page 39 6. Electric and hydraulic diagram 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. Lift cylinder NC 60bar Pump unit...
  • Page 40 Lock Purple Pink 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.
  • Page 41 6. Electric and hydraulic diagram Connecting control device The most commonly occurring control device (CD) models are shown below. Possible control device models vary depending on lift model, configuration and relevant market. Black (+) (White (-), if available B: 1+3 C+B: 1+4 E: 2+4 C+E: 2+3...

  • Page 42: Functional Schematic Drawing

    7. Functional schematic drawing ZS/ZD/ZT/ZTSZSS 150-200 (Config 1) Function Input signal Input signal Output Comment Control Illustration high low (0V) signal device Ctrl 1 Ctrl 2 U1+U2+U4 Ctrl 3 Ctrl 4 Ctrl 6 Lower Ctrl 1 Ctrl 2 E+Di3* Autotilt down Ctrl 3 U1+U2+U4+U5 90º...
  • Page 43 7. Functional schematic drawing Function Input signal Input signal Output Comment Control Illustration high low (0V) signal device Ctrl 5 Slider out U0+U1+U6 Ctrl 6 Platform is folded out manually Platform is folded in manually Ctrl 5 U0+U1+U7 Normal Ctrl 6 Slider in Ctrl 5 C+In+Di1*...
  • Page 44 7. Functional schematic drawing ZS/ZD/ZT/ZTSZSS 150-200 (Config 3) Function Input Input Output Comment Control Illustration signal signal signal device high (0V) Ctrl 1 Ctrl 2 Lower U0+U1+U2+U4 Ctrl 3 Ctrl 4 90º Ctrl 1 45º Ctrl 2 Tilt down U0+U1+U3+U5 Ctrl 3 Ctrl 4 0º...
  • Page 45 7. Functional schematic drawing Function Input Input Output Comment Control Illustration signal signal signal device high (0V) Ctrl 5 Slider out U0+U1+U6 Ctrl 6 Platform is folded in manually Platform is folded in manually Ctrl 5 U0+U1+U7 Normal Ctrl 6 Slider in Ctrl 5 C+In+Di1*...

  • Page 46: Connection Unit

    8. Connection unit Power save mode If the control card is not used for a certain amount of time, it goes into power save mode. Time with CS off = 5 min - CS on = 20 min. With CS on, press any control button for approx. 0,5 seconds to “wake up”...
  • Page 47 8. Connection unit Information codes Codes are shown on the display in a sequence. First a letter for identification of information, followed by figures or segments for further information and then ending with a pause: When the CS (cabin switch) is switched on, the current program configuration (P) is displayed first, followed by configuration number.
  • Page 48 8. Connection unit Information codes Code Code Code Identification Information Other 00–99 Cancelled configuration (Program Dividers configuration) 12/24 Number of volts detected 01–99 Version number Software version Fixed light (1-6) displays active control device 1-6 (Fixed light) during operation. Active control device while operating Segments B, C, E or X are illuminated depend- Segment...
  • Page 49 8. Connection unit Fault codes If a fault arises, the fault code is shown in the display in the form of a letter for identifying the fault, followed by numbers and/or number segments for further information, followed by sensor indication (C) in accordance with the previous page. In fault codes E, F and U, the numbers (1-9) show which control device/output the fault code refers to.
  • Page 50 8. Connection unit All fault codes can be reset manually by switching On/Off the CS (cabin switch) Fault codes F0-F7 and U0-U7 are reset automatically if the function in question is running (function verified). Fault codes L and H are reset automati- cally if the battery voltage becomes correct.
  • Page 51 8. Connection unit VENTILHUS VALVE BODY VENTIL GEHAUSE TANKLOCK FILLER CAP TANKDECKEL TANKLÅDA CHASSIE WITH TANK ÖLTANK SOLENOID SWITCH MAGNETSCHELTER MOTOR VENTIL, SLÄDRÖRELSE VALVE, SLIDE FUNCTIONS VENTIL, SCHIEBEFUNKTION KRETSKORT CIRCUIT CARD GETRUCTE SCHALTUNG KOPPLINGSENHET CONNECTION UNIT KOPPLUNGS EINHEIT...

  • Page 52: Accessories

    9. Accessories Working position indicator Slide out the lift, open the platform and lift to the floor height. Run the lift into the body, this is the working position. Fasten the stop plate when the red diode lamp lights up. The working position sensor is already installed at the factory, therefore only Alt.
  • Page 53 9. Accessories Working position indicator Test all functions: Working position function, slide out the lift, open the platform and lift 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.

  • Page 54: Important Information

    10. Important information Repainting Replace the transport plug NB. If the cylinders are to be repainted, ensure that the During installation the oil tank transport plug should be cylinder push rod and cover are not painted (this can removed and replaced damage the seals/gaskets).

  • Page 55: Markings, Positioning Of Decals On Lift

    11. Markings, decals The loading diagram plates should be placed near An operating instructions decal should be placed the control unit and in a clearly visible position on next to the main control unit. the platform. The plate clearly indicates the nominal loading and the diagram shows the A danger zone decal, warning of the danger area maximum permitted loading at different positions on...
  • Page 56 11. Markings, decals...

  • Page 57: Post Installation Maintenance

    12. Maintenance Grease all bearings and platform locks with LE lubricant 4622 or equivalent. Greasing at least 8 times / year Right tilt cylinder, lower bearing. Right lift cylinder, lower bearing. Lift arm right side, lower bearing. Left lift cylinder, lower bearing. Left tilt cylinder, lower bearing.

  • Page 58: Testing The Lift

    13. Testing the lift Testing and verification of the tail lift. Static loading (Test load 1,25 x tail lift loading Carried out in accordance with the installation in- capacity). For tail lifts with load centre of 600 mm struction and delivery check list. Capacity Load 500 kg Load 1000 kg...
  • Page 59 13. Testing the lift Dynamic load testing Test of safety functions Test with nominal load The tail lifts safety functions must be tested Place a test load on the platform according to the Check: table for the respective tail lift model and lifting capacity.

  • Page 60: Dismantling

    16. Dismantling 1. In the event of dismantling the tail lift from the ve- 10. Check that the battery is disconnected. Unscrew hicle, in the case of transferring it to another vehicle, the cable from the battery to the tail lift and all the for storage or for modification please follow these cables and wires between the hydraulic unit and the instructions.
  • Page 62 BUILT TO PERFORM Zepro, Del and Waltco are Hiab brands for tail 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...

This manual is also suitable for:

Zs 150-155Zs 150-175Zs 200-135Zs 200-155Zs 200-175Zss 200-135 ... Show all

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