Related Manuals for Zepro ZHZ 500-850
Summary of Contents for Zepro ZHZ 500-850
- Page 1 Installation Instruction Tail Lift ZHZ 500/600-850 ZEPRO Tel.: +46 (0)10-459 05 00 E-mail: zeprotech@hiab.com zepro.com 73161TL 2020-06-02...
-
Page 3: Table Of Contents
7.10 Installation of license plate light ............60 7.11 Installation of connection ramp ............. 61 7.12 Armstops ....................61 7.13 Platform stop ..................61 7.14 Adjustment of tilt cylinder ..............62 7.15 Purging the cylinders ................63 7.16 Transport lock ..................63 www.zepro.com... - Page 4 Minimum recommended conductor cross sectional area ....78 13.4 Maximum power consumption – Minimum recommended conductor cross sectional area ....79 13.5 Battery maintenance ................79 13.7 Loading diagram ZHZ 500 ..............80 13.6 Loading diagram ZHZ 600 ..............80 www.zepro.com...
-
Page 5: Introduction
NOTE. Take care. Risk of damage to the product. WARNING! Take extra care. Risk of personal injury or damage to the product and the surroundings. www.zepro.com... -
Page 6: Ce Marking
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 hand, places considerable demands on the hydraulic fluid. Zepro has therefore selected hydraulic fluids that can cope with all of these demands. 1.3.1 Highly refined mineral oil (product no. 21963, 1 litre) Contains zinc-free wear-preventing additives and provides extremely good wear protection. -
Page 7: Identification
600 - 850 MA _ _ _ - _ _ _ - _ _ _ _ _ Max. lifting capacity x 1 (kg) Max. lifting height -850 = 850 mm Cylinder model, MA = Double-acting adjustable tilt Single-acting lift www.zepro.com... -
Page 8: Safety Rules
Boots, hydraulic hoses and cables boots must not be painted/coated must not be painted/coated, as the solvent in the paint could damage the hoses/cables and significantly impair their durability. Fig 2. Hydraulic hoses must not be painted/coated Fig 3. Cables must not be painted/coated www.zepro.com... -
Page 9: Transport Plug
.40 mm WARNING! The lift platform must not be tilted down more than max. 10° from horizontal when people are on the platform. 10° Fig 6. The lift platform must not be tilted down more than max. 10° from horizontal. www.zepro.com... -
Page 10: Attaching Third-Party Equipment Is Prohibited
Attaching third-party equipment is prohibited WARNING! Third-party equipment (both electrical and hydraulic) must not be attached to Zepro’s tail lifts. Attaching third-party equipment may interfere with the lift’s systems and its safety functions. Risk of injury and damage. If it is necessary to install other equipment, check the vehicle manufacturer’s body instructions and use the vehicle’s attachment features. -
Page 11: Installation Workflow
Install the control devices’ cables • Install the main power cable Installing the platform • Install the platform • Test functions and installation Installing cylinders • Adjusting tilt cylinder • Install the connecting ramp • Test operation Attaching decals www.zepro.com... -
Page 12: Calculating The Installed Dimensions
(in the direction of the vehicle). Once the C-dimension has been determined, the D-dimension can be obtained from the table. H-dimension The H-dimension is the height from ground (unloaded) to the vehicle floor level. The H-dimension must not be greater than the lift’s maximum lifting height. The lift’s platform must always be able to reach ground level. www.zepro.com... -
Page 13: Installation Kits
5t RWD, L= 4325, Vehicle lenght= 6945 Sprinter 2006-2016 5t RWD, L= 4325, Vehicle lenght= 6945 7.1.15 Mercedes Sprinter 2018- 5t RWD, L=3665 24,5 Kg 76801TL Mercedes Sprinter 2016-2017 5t RWD, L=3665 Crafter 2016-2016 5t RWD, L=3665 7.1.16 Crafter 2017- 3,5t RWD 14 kg 77132TL www.zepro.com... - Page 14 3,5t RWD, L= 4325 15,2 Kg 78160TL 7.1.22 Iveco Daily 2014 L=3520 11,7 kg 77523TL 7.1.23 Iveco Daily 2014 L= 4100 12,5 kg 78229TL wheelbase rear overhang FWD= front wheel drive RWD= rear wheel drive AWD= four wheel drive www.zepro.com...
-
Page 15: Installation
2 x M12x35 screws. Use 3 x M12x35 screws to screws to the left of the cut-out. the right of the cut-out in the chassis bracket and 2 x M12x35 screws to the left of the cut-out. See Fig 10. www.zepro.com... - Page 16 "7.3 Installing the Platform" on page 5 x M12x35 screws 5 x M12 M6MF nuts Tightening torque: 80 Nm Fig 12. Adjust the lift so it is as close to the rear doors as possible. Fig 13. Overview. www.zepro.com...
- Page 17 2 x M10x85 screws 1 x Washer 1 x M10 nyloc nut Tightening torque:50 Nm 2 x M12x35 screws 1 x Washer 1 x M12 nyloc nut 1 x spacer 6 mm Tightening torque: 80 Nm Fig 14. Overview, diagonally from below www.zepro.com...
- Page 18 Installation 7.1.1.1 Assembly 72807TL www.zepro.com...
- Page 19 Installation 7.1.1.2 Assembly 76013TL www.zepro.com...
- Page 20 See Fig 15. Tightening torque 80 Nm Install the lift, see "7.2 Installing the lift" on page 50. Install the platform, see "7.3 Install- ing the Platform" on page 51. www.zepro.com...
- Page 21 Installation 7.1.2.1 Assembly 73029TL www.zepro.com...
- Page 22 Ø 20.5 so that the spacers can be installed. Apply rustproofing agent. Fig 17. Cut the towing eyelet in line with the edge of the bumper bracket. Fig 18. Cut the left chassis bracket for the bumper by approx. 200 mm. www.zepro.com...
- Page 23 Install the lift, see section "7.2 Installing the lift" on page 50. Install the platform, se section "7.3 Installing the Platform" on page 51. 1 x Washer plate 2 x Spacer tubes Fig 19. Installation of chassis brack- ets and bumper brackets. www.zepro.com...
- Page 24 Installation 7.1.3.1 Assembly 74914TL www.zepro.com...
- Page 25 See Fig 21. Tightening torque 80 Nm. Install the lift, see "7.2 Installing the lift" on page 50. Install the platform, see "7.3 Install- ing the Platform" on page 51. Fig 21. Installation of chassis brack- ets and bumper brackets. www.zepro.com...
- Page 26 Installation 7.1.4.1 Assembly 75018TL www.zepro.com...
- Page 27 M12 M6MF nyloc nut. Tighten with the aid of a torque wrench. Tightening torque 80 Nm Install the lift, see "7.2 Installing the lift" on page 50. Install the platform, see "7.3 Install- ing the Platform" on page 51. www.zepro.com...
- Page 28 Installation 7.1.5.1 Assembly 73169TL www.zepro.com...
- Page 29 Install the lift, see "7.2 Installing the lift" on page 50. Install the platform, see "7.3 Install- ing the Platform" on page 51. Fig 27. Install a total of 9 x M12x100 screws through the frame as well as M12 M6MF nyloc nuts. 80 Nm. www.zepro.com...
- Page 30 Installation 7.1.6.1 Assembly 73167TL www.zepro.com...
- Page 31 Installation 7.1.7 VW Crafter, MB Sprinter 4325 (part no. 76796TL) Models from 2006 7.1.7.1 Assembly 76796TL www.zepro.com...
- Page 32 Installation 7.1.8 VW Crafter, MB Sprinter 3665 (part no. 76801TL) Models from 2006 7.1.8.1 Assembly 76796TL www.zepro.com...
- Page 33 M10x90, nut, washer and spacer.. Tightening torque 50 Nm. Install the lift, see "7.2 Installing the Fig 28. Installing the chassis bracket lift" on page 50. Install the platform, see "7.3 Instal- ling the Platform" on page 51. Fig 29. Mounted chassis bracket www.zepro.com...
- Page 34 Installation 7.1.9.1 Assembly 76745TL www.zepro.com...
- Page 35 M10x90, nut, washer and spacer. Tightening torque 50 Nm. Install the lift, see "7.2 Installing the Fig 30. Installing the chassis bracket lift" on page 50. Install the platform, see "7.3 Instal- ling the Platform" on page 51. Fig 31. Mounted chassis bracket www.zepro.com...
- Page 36 Installation 7.1.10.1 Assembly 77132TL www.zepro.com...
- Page 37 Installation 7.1.11 Renault, Open, Nissan (part no. 74451TL) Models before 2010 7.1.11.1 Assembly 74451TL www.zepro.com...
- Page 38 Installation 7.1.12 Renault, Open, Nissan (part no. 74452TL) FWD, Models from 2010 7.1.12.1 Assembly 74452TL www.zepro.com...
- Page 39 Installation 7.1.13 Renault, Open, Nissan (part no. 75236TL) Models from 2010 7.1.13.1 Assembly 75236TL www.zepro.com...
- Page 40 Installation 7.1.14 Sprinter/Crafter (part. no. 76796TL) 7.1.14.1 Assembly 76796TL www.zepro.com...
- Page 41 Installation 7.1.15 Sprinter/Crafter (part. no. 76801TL) 7.1.15.1 Assembly 76801TL www.zepro.com...
- Page 42 Installation 7.1.16 Sprinter/Crafter (part. no. 77132TL) 7.1.16.1 Assembly 77132TL www.zepro.com...
- Page 43 Installation 7.1.17 Sprinter (part. no. 77833TL) 7.1.17.1 Assembly 77833TL www.zepro.com...
- Page 44 Installation 7.1.18 Sprinter (part. no. 78012TL) 7.1.18.1 Assembly 78012TL www.zepro.com...
- Page 45 Installation 7.1.19 Sprinter (part. no. 78128TL) 7.1.19.1 Assembly 78128TL www.zepro.com...
- Page 46 Installation 7.1.20 Sprinter (part. no. 78130TL) 7.1.20.1 Assembly 78130TL www.zepro.com...
- Page 47 Installation 7.1.21 Sprinter (part. no. 78160TL) 7.1.21.1 Assembly 78160TL www.zepro.com...
- Page 48 Installation 7.1.22 Iveco Daily (part. no. 77523TL) 7.1.22.1 Assembly 77523TL www.zepro.com...
- Page 49 Installation 7.1.23 Iveco Daily (part. no. 78229TL) 7.1.23.1 Assembly 78229TL www.zepro.com...
-
Page 50: Installing The Lift
3 screws M12x35 mm 74451TL 2 screws M12x35 mm 2 screws M12x35 mm 74452TL 2 screws M12x35 mm 3 screws M12x35 mm 75236TL 2 screws M12x35 mm 3 screws M12x35 mm Fig 32. Mounting and adjustment of the lift www.zepro.com... -
Page 51: Installing The Platform
7. Attach the cylinder to the cylinder bracket and lock with locking pin, see Fig 37. Fig 33. Remove the cover Fig 35. Place the platform Fig 34. Push the shaft out off the platform Fig 37. Attach and lock the cylinder Fig 36. Fit in and lock the platform shaft www.zepro.com... -
Page 52: Installing The Angle Sensor
Fig 39. Attache the angle sensor In general, care must be taken whenever routing cables, in order to ensure a longer cable service life and to reduce the risk of unnecessary operational stoppages. Fig 40. Mounted angle sensor www.zepro.com... -
Page 53: Installing The Hydraulic Unit
The hydraulic unit can be installed hori- zontally or vertically. 7.5.1 Connection of hydraulic hoses to hydraulic unit Fig 41. Return side tilt cylinder (A), Return side tilt cylinder (A), Pressure side Pressure side lift/tilt cylinder (B). lift/tilt cylinder (B). www.zepro.com... -
Page 54: Control Devices
64. When mounting more control devices, the control devices shall be con- nected to the circuit board, see "8.2 Connection to circuit board 4 – button operation" on page 65. WARNING! A controller must always be fitted on the side that is facing away from traffic in motion. If there is a need for a controller on the opposite side, a further controller must therefore be fitted. Fitting on the other side involves increased risk of injury. Fig 43. Installing control device www.zepro.com... -
Page 55: Connection Box
3. Connect the controllers to the connection box and the connection box to the relay board, see "8.1 ZHZ- 600-850 MAConnection to circuit board" on page 64 and "8.2 Connection to circuit board 4 – button operation" on page 65. Connection box Circuit board Drainage tube Cover Fig 44. Connection box www.zepro.com... -
Page 56: Control Power Cable
2. Connect the control power cable to the cab switch (CS) on the vehicle’s instrument panel. Connect to the ve- hicle’s electrical system via 10 A (24 V), 15 A (12 V) fuse according to the customer’s wishes. www.zepro.com... -
Page 57: Main Power Cable
The fuse box must be located in a well protected position as close to the battery as possible. 2. Check that the hydraulic unit is effectively earthed. Certain commercial vehicle manufacturers provide special earth connection points. 3. Connect the main power cable to the hydraulic unit, see "8 Electrical and hydraulic drawings" on page 64. Fig 46. Protect the cable against sharp edg- es and use cable grommets www.zepro.com... - Page 58 The knob must lie against and centre the cable clip so that it does not come into contact with the bolt. Incorrect installation can cause the fuse to malfunction. Risk of fire in the event of a short circuit, see Fig 48 and Fig 49. Fig 47. Install fuse and connect main current cable Fig 48. Correct installation Fig 49. Incorrect installation www.zepro.com...
- Page 59 52 and Fig 53. Install the fuse box cover, see Fig 543. Fig 51. Place fuse and Fig 50. Screw the fuse connect wiring holder into place Fig 52. Correct installation Fig 53. Incorrect installation Fig 54. Cover fuse box www.zepro.com...
-
Page 60: Installation Of License Plate Light
Installation 7.10 Installation of license plate light Connect the license plate light to the vehicles ordinary lights cabeling. Follow the manufacturer’s recommendations. Vehicle lighting License plate light (+)12V Fig 55. Example of connecting the license plate light www.zepro.com... -
Page 61: Installation Of Connection Ramp
Platform stop (Applies only to folding platform) When the lift platform is folded up and closed against the vehicle body, the platform stop must automatically lock the various parts of the platform against each other. Fig 58. Platform stop www.zepro.com... -
Page 62: Adjustment Of Tilt Cylinder
3. After adjusting, tighten the locking nut. Tightening torque 80 Nm Fig 61. Turn the piston rod clockwise to angle down the platform or anti-clock- wise to angle up the platform. 30 mm Fig 62. The maximum permitted ad- justing distance is 30 mm www.zepro.com... -
Page 63: Purging The Cylinders
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. www.zepro.com... -
Page 64: Electrical And Hydraulic Drawings
Electrical and hydraulic drawings Electrical and hydraulic drawings ZHZ-600-850 MAConnection to circuit board www.zepro.com... -
Page 65: Connection To Circuit Board 4 - Button Operation
Färg/Colour/Farbe Gul / Grön, Yellow / Green, Gelb / Grün Blå / Blue / Blau Brun / Brown / Braun Svart / Black / Schwarz Grön / Green / Grün Vit / White / Weiß Röd / Red / Rot Gul / Yellow / Gelb Grå / Grey / Grau Orange / Orange / Orange www.zepro.com... -
Page 66: Connection Of Cab Switch And Alarm For Open Platform
Electrical and hydraulic drawings Connection of cab switch and alarm for open platform www.zepro.com... -
Page 67: Connection Of Control Device
Connect according to the table below and the electrical and hydraulic drawings, see section "8 Electrical and hydraulic drawings" on page 64 and 65.Connection of control. (2H) (2H) CD10 CD11* CD13* 1 2 3 Fig 63. Control device models www.zepro.com... -
Page 68: Markings And Decals
Markings and decals Markings and decals Overview The illustrations below show the positions of the various decals. www.zepro.com... -
Page 69: Load Diagram
A “work area” decal must be attached to the platform so that any drivers 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. Fig 66. Work area www.zepro.com... -
Page 70: Driver's Instructions
Markings and decals Driver’s instructions A driver’s instructions decal must be placed close to the fixed control device. Autotilt Autotilt www.zepro.com Phone +46 (0)150 48 95 50 76350TL 2017-02-02 Fig 67. Driver’s instructions Danger area A “danger area” decal warns about the danger zone between the platform and the rear edge of the vehicle. -
Page 71: Warning Flags
The marking below represents the manufacturer’s guarantee that the lift is designed and supplied in accordance Fig 71. CE marking with the requirements stipulated in the EC Machinery Directive. This is the customer’s guarantee of high quality and safety. www.zepro.com... -
Page 72: Lubrication And Fluid Level Check
Lubrication and fluid level check Lubrication and fluid level check 10.1 Lubrication 850 is equipped with 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 of hydraulic fluid used. Mineral hydraulic fluid, product no. 21963 (1 Litre), or biodegradable synthetic fluid, product no. 22235 (). www.zepro.com... -
Page 73: Testing And Verification
600 mm Capacity Load 250 kg Load 500 kg Distance out on the platform (L) 500 kg 1500 mm 750 mm 600 kg 1800 mm 900 mm Deformation Max. 15 mm Operation Max. 2° Fig 72. Testing and verification www.zepro.com... -
Page 74: Dynamic Test Loading
• that the platform’s mechanical locking device is working (where applicable). • that instructions for using the tail lift have been left in the cab. • that a CE declaration of conformity has been certified. www.zepro.com... -
Page 75: Dismantling
4. Dismantle the tilt cylinder from the platform. 5. Support the platform with a crane or similar equipment that can safely carry the weight of the platform (see weight information). 6. Dismantle the platform. 7. Dismantle the support frame. 8. Dismantle the chassis brackets. www.zepro.com... -
Page 76: Specifications
1600x1400 mm 64 kg Lift cylinder 5.6 kg Outer boom cylinder 7.2 kg Folding 1200x1400 mm 60 kg 1400x1400 mm 65 kg 1600x1400 mm 71 kg Half 1200x700 mm 40 kg 1400x700 mm 45 kg 1600x700 mm 51 kg www.zepro.com... -
Page 77: Load Centre
Specifications 13.2 Load centre Max. load ZHZ 500-600, alu. platform 1200x1400 mm C = 150 C = 300 C = 450 (mm) (mm) 500 kg (mm) 600 kg www.zepro.com... -
Page 78: Maximum Power Consumption - Minimum Recommended Conductor Cross Sectional Area
140 Ah 110 Ah the amount of power the Min. voltage during operation, U 9 volt 18 volt lift can access from the (when lifting) existing battery. Fig 73. Maximum power consumption – Minimum recommended conductor cross sectional area www.zepro.com... -
Page 79: Maximum Power Consumption - Minimum Recommended Conductor Cross Sectional Area
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 operations to maintain the battery’s charge level. NOTE. The battery charger must not be connected when operating the lift. Risk of damage. www.zepro.com... -
Page 80: Loading Diagram Zhz 500
Specifications 13.7 Loading diagram ZHZ 500 Fig 75. Loading diagram 13.6 Loading diagram ZHZ 600 Fig 76. Loading diagram www.zepro.com... - Page 81 Specifications www.zepro.com...
- Page 82 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...