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...
Properly assembled, this product meets relevant requirements according to EN 1756-1:2001 + A1:2008. Hydraulic oil If the hydraulic oil needs to be replenished, only the oil recommended by ZEPRO is permitted to be used. Hydraulic systems with hydraulic oil tanks without labelling are only permitted to be filled with highly refined mineral oil (art. no. 21963, 1 litre).
Max. lifting height -135 = 1340 mm -155 = 1530 mm -175 = 1710 mm Cylinder model, MA = Double acting Adjustable Tilt Single acting Single speed Lift DA = Double acting Adjustable Tilt Double acting Single speed Lift www.zepro.com...
Image 1. Piston rods, cylinder covers solvent in the paint could damage and boots must not be painted/coated the hoses/cables and significantly impair durability. Image 2. Hydraulic hoses must not be painted/coated Image 3. Cables must not be painted/coated www.zepro.com...
40 mm. WARNING! The platform must not be tilted down more than max. 10° from horizontal 10º when people are on the platform. Image 6. The platform must not be tilted down more than 10° from the horizontal www.zepro.com...
Third-party equipment must not be attached WARNING! You must not attach third-party equipment (electric or hydraulic) to Zepro tail lifts. Attach- ing third-party equipment may interfere with the lift system and the safety functions. Risk of injury and damage. If it is necessary to install other equipment, check the vehicle manufac- turer’s body instructions and use the attachment features on the vehicle.
Installing the control device cables • Installing the main power cable Installing the platform • Installing the platform • Installing seals and end stops • Installing the armstops Installing cylinders • Adjusting tilt cylinder • Test running Attaching decals www.zepro.com...
The A dimension is the space provided for the rear member, i.e. the space there will be between the lift arm and the vehicle floor with the lift in the raised position. The A dimension is dependent on the C dimension H dimension The H dimension is the height from the ground (unloaded) to the vehicle floor level. The H dimension must not be greater that the maximum lifting height of the lift. The platform must always be able to reach ground level. www.zepro.com...
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Installation workflow Z 1500/2000-135/155/175 Image 7. Z 1500/2000-135 715 680 680 725 630 781 580 828 530 869 480 904 430 934 Image 8. Z 1500/2000-155 515 1023 465 1051 Image 9. Z 1500/2000-175 www.zepro.com...
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Installation workflow Z 1500/2000-135/155/175 1435 1014 min. 750 - max. 930 1515 1870 2424 Image 10. Z 1500/2000 1669 1246 min. 982 - max. 1162 1749 2102 2481 Image 11. ZL 1500/2000 617-817 Image 12. Z/ZL 1500/2000 www.zepro.com...
WARNING! Image 15. Measure and mark the midpoint of the rear member of the vehicle. Zepro tail lifts are only approved for installation with Zepro installation kits. Support frame 1. Measure and mark the midpoint of the rear member of the vehicle. See "Image 15. Measure and mark the midpoint of the rear member of the vehicle."...
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M14x45 10.9 Then tighten the bolts with a torque wrench. 120 Nm Tightening torque: 120 Nm. 15. Remove the mounting jig. Image 20. Install the chassis bracket with at least six M14x45 10.9 bolts www.zepro.com...
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Do not place the lift under load until: · the correct number of bolts have been in- stalled and torque-tightened. · the vehicle body is installed to reinforce the truck chassis. 20. Remove the mounting jig. www.zepro.com...
(CS) on the vehicle instrument panel. Connect to the on-board electrical system via a 10 A (24 V), 15 A (12 V) fuse according the customer’s wishes. See the connection diagram "9.5 Connecting cabin switch and open platform alarm" on page 48. www.zepro.com...
All cable inlets must be pointing downwards. 3. The control device’s cable is connected to the control card. 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 fur- ther controller must therefore be fitted. Fitting on the other side involves increased risk of injury. Image 24. Installing control device www.zepro.com...
Route the cable between the platform and the lift arm pipe so that it is well protected when the platform hits the ground. The quick connector must be positioned in such a way that it does not conflict with the underrun protec- tion while the 1st boom is in motion. Leave enough "slack" to the first cable tie so that the cable is not at risk of being damaged when the lift is operated. Image 26. Installing cabling Image 27. Installing cabling www.zepro.com...
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6. Connect the cables to the control card, see wiring diagram in section "9.4 Connecting warning lighting and foot controls" on page 46 and section "9.6 Connecting control devices" on page 49. WARNING! Make sure that the control card is disconnected from power before connecting peripheral equipment. Risk of damage. Image 28. Quick connector location www.zepro.com...
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 "9 Electrical and hydraulic diagrams" on page 43. Image 29. Protect the cable against sharp edges and use cable grommets www.zepro.com...
4. Install the cable grommet’s protective cover with the three supplied bolts, see Image 35. Tightening torque: 8 Nm Image 36. Cable grommet's five screws 350 mm. Image 37. The outer sheathing on cable connected to the control card must be stripped 350 mm. www.zepro.com...
Image 38. The cross-secton of the frame beam 220x70x4 mm, corresponding to a surface moment of inertia of 937cm4 around the x-axis. See illustration. If in doubt, contact ZEPRO for support. WARNING! The above dimensions are the minimum permit- ted for the installation of underrun protection.
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25 mm. See Image 41. Each of the individual parts of the underrun protec- tion must have a surface area of at least 350 cm See Image 41. Min. Area: 350 cm Max 25 mm Max 25 mm Image 41. Statutory dimensions www.zepro.com...
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If necessary, tap carefully with a rubber Image 44. Fit the member end caps hammer. 2x M12x100 8.8 80 Nm 2x M12x80 8.8 2x M12x100 8.8 80 Nm 80 Nm 2x M12x80 8.8 80 Nm Image 45. Installing underrun protection www.zepro.com...
When installing on Image 47. The angle sensor allows autotilt function the right arm, the sensor’s cable input must be when the angle of the lift arm is horizontal or lower. facing downwards. Left Right Image 48. Installing the angle sensor www.zepro.com...
1. Fit the tracks with countersunk screws, rivets or by spot welding. 2. Fit the rubber strip to the track. Image 49. Installing a sealing strip 3. Secure the rubber strips by swaging the tracks together at the bottom. NOTE. To fit an upper edge seal, create a 45° mitre against the vertical strips. www.zepro.com...
Ensure that the small holes on the inside of the bushings are filled with grease. NOTE! Lubricate the bushings See Image 50. Use Zepro lubricant or the equivalent. NOTE. Image 50. Carefully lubricate the metal bushings Carefully lubricate the metal bushings on the upper bearing of the arms. Ensure that the small holes are filled with grease. After the...
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2. Tilt up and move both tilt cylinders all the way up. NOTE. Lock screws, 3 Adjustment must always take place with full pcs. hydraulic pressure in the tilt cylinders. 3. Loosen the three lock screws on the cylinder fit- Image 55. Adjusting the tilt angle www.zepro.com...
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Tighten the bolts using a torque wrench. Tightening torque: 80 Nm. 8. Adjust the two cylinders alternately so that the platform meets the vehicle body, see Image 56 (B). Image 58. Fitting the tilt cylinder to the platform www.zepro.com...
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30 mm. Image 59. Adjusting the tilt angle 10. Fit the cylinder boots. Image 60. ~ 10 mm Lift model 1500/2000-135 180 ±5 1500/2000-155 300 ±5 1500/2000-175 420 ±5 Image 60. Installing boots www.zepro.com...
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2. Install the angle sensor/Inclinometern on the platform using the included screws, nuts and washers and secure the cable with cable ties, see Image 63 and Image 64. Image 61. Angle sensor and mounting Image 62. Inclinometer and mounting Image 63. Installing the angle sensor Image 64. Installing the Inclinometer www.zepro.com...
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5. Tighten the lock screw in the end stop (5). See il- lustration. Image 66. The tightening torque for lock screws is 3-5 Nm Test all functions. Adjusting collar Lock screw Bolt End stop Washer Image 67. Tilt cylinder www.zepro.com...
Electric hose breakage valves serve as locks for the platform. The lock opens automatically if the down function is actuated from the control device. The valves are non-return valves that let fluid in from the cylinders but not out before they are actuated by the flow from the lowering valve. The platform is thus hydraulically locked during transport. www.zepro.com...
Ctrl 2 CSPWR Jumper Ctrl 6 Di 6 Ctrl 3 Di 5 Radio Di 4 Lock Di 3 Di 2 Ctrl 5 Di 1 Ctrl 4 Ai 1 Spiral Ai 2 Lock Image 69. Temporary connection of lift control card www.zepro.com...
"8.1 Accessing the hydraulic unit and control card" on page 41. OIL TANK TANK CAP VALVE HOUSING SOLENOID MOTOR CONTROL CARD Image 70. Hydraulic unit and control card www.zepro.com...
Image 71. The protective cap is se- Image 72. Release latch control card cured with two quick-release locks Image 73. Connection socket Image 74. Releasing hydraulic unit www.zepro.com...
5. Fold in and secure the control card, see section "8.1 Accessing the hydraulic unit and control card" on page 41. WARNING! Ensure that no cables are trapped or in any other way damaged when the control card is folded out or removed. Image 75. Installing cabling with cable ties www.zepro.com...
Electrical and hydraulic diagrams Z 1500/2000-135/155/175 Electrical and hydraulic diagrams Z 1500/2000 MA with electrical autotilt Config 14, Firmvare 9.8 or later www.zepro.com...
Electrical and hydraulic diagrams Z 1500/2000-135/155/175 Connecting warning lighting and foot controls 9.4.1 Lift with inclinometer www.zepro.com...
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Ctrl 2 CSPWR Green Ctrl 6 White Di 6 Di 5 Ctrl 3 Yellow Radio Di 4 Grey Lock Di 3 Orange Di 2 Ctrl 5 Purple Di 1 Ctrl 4 Pink Ai 2 Spiral Ai 1 Lock Hydraulic unit www.zepro.com...
Ai 1 CD14 B Spiral Ai 2 Black (+) Lock Blue CD11 Brown CD12 Yellow Blue Grey Lock Black (+) White (-) Brown Brown CD10 Yellow Yellow Blue Black (+) Black (+) (White (-), (White (-), if available) if available) www.zepro.com...
Signal to Cs usually comes from the cab switch. In individual cases, where the cab switch is not used, the (+) signal coming in to Cs is jumpered from (CS PWR) on nearby terminal. See also the electrical diagram: "9.1 Z 1500/2000 MA with electrical autotilt" on page 43. www.zepro.com...
15º Ctrl 5 -10º Ctrl 6 Ctrl 1 Ctrl 2 Ctrl 3 0° Lower* Ctrl 4 Ctrl 5 Ctrl 6 * Only required at start of travel; it is ignored after breakover of sensor until repositioned. ** 0.5 second delay of output signal. *** Not connected See also the electrical diagram: "9.1 Z 1500/2000 MA with electrical autotilt" on page 43. www.zepro.com...
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Ctrl 6 Does not af- Ctrl 1 fect function Ctrl 2 Ctrl 3 Close 0° Ctrl 4 Ctrl 5 Ctrl 6 * Only required at start of travel; it is ignored after breakover of sensor until repositioned. ** 0.5 second delay of output signal. *** Not connected See also the electrical diagram: "9.1 Z 1500/2000 MA with electrical autotilt" on page 43. www.zepro.com...
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The Auto Tilt function remembers the most recently set angle of the "Tilt-function", provided it is in the +/- 10 ° range. This angle can be changed at any time during the cycle described above using the "Tilt- function". See also the electrical diagram: "9.1 Z 1500/2000 MA with electrical autotilt" on page 43. www.zepro.com...
Ctrl 3, 4 & 6 Image 80. The use of controllers 3, 4 and 6 is limited by the platform angle 10.4 Quick opening - activation zone 90º 10º Image 81. Quick opening is active when the platform angle is approx. 90º-10º www.zepro.com...
Inclinometer - voltage The voltage on the inclinometer output varies with inclinometer angle. Below are some examples of different angles and approximate voltages. ~3,2V ~3.2V 90º ~2.5V ~2,5V 45º ~1,8V 0º ~1.8V Image 83. Approximate voltage at various angles See also the electrical diagram: "9.1 Z 1500/2000 MA with electrical autotilt" on page 43. www.zepro.com...
Cs is jumpered from (CS PWR) on nearby terminal. Controller Two-hand but- Activated in connection with opening and closing of vehicle body. Used for quick opening. See also the electrical diagram: "9.2 Z 1500/2000 MA" on page 44. www.zepro.com...
Ctrl 3 15º inside Ctrl 4 0º Ctrl 5 -10º Ctrl 6 Ctrl 1 Ctrl 2 Ctrl 3 Lower Ctrl 4 Ctrl 5 Ctrl 6 * Only required at start of travel; it is ignored after breakover of sensor until repositioned. ** 0.2 second delay of output signal. See also the electrical diagram: "9.2 Z 1500/2000 MA" on page 44. www.zepro.com...
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Ctrl 5 Ctrl 6 Ctrl 1 90º Ctrl 2 45º Close against vehicle Ctrl 3 Closing body. Ctrl 4 0º -10º Ctrl 5 Ctrl 6 * Only required at start of travel; it is ignored after breakover of sensor until repositioned. ** 0.2 second delay of output signal. See also the electrical diagram: "9.2 Z 1500/2000 MA" on page 44. www.zepro.com...
Quick opening can be activated when the platform angle is 90º-45º. If the control buttons are kept pressed, the quick-opening function is active down to -10 °. See also the electrical diagram: "9.2 Z 1500/2000 MA" on page 44. www.zepro.com...
Cs is jumpered from (CS PWR) on nearby terminal. Controller Two-hand but- Activated in connection with opening and closing of vehicle body. Used for quick opening. See also the electrical diagram: "9.3 Z 1500/2000 DA" on page 45. www.zepro.com...
Ctrl 6 Lower Ctrl 1 Ctrl 2 Manual down, replaces Ctrl 3 lower 1 and 2 with Ctrl 4 jumpered Di6. Ctrl 5 Ctrl 6 * Only required at start of travel; it is ignored after breakover of sensor until repositioned. ** 0.2 second delay of output signal. See also the electrical diagram: "9.3 Z 1500/2000 DA" on page 45. www.zepro.com...
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Ctrl 6 Ctrl 1 90º Ctrl 1 45º Ctrl 2 Close against vehicle Closing Ctrl 3 body. 0º Ctrl 4 -10º Ctrl 5 Ctrl 6 * Only required at start of travel; it is ignored after breakover of sensor until repositioned. ** 0.2 second delay of output signal. See also the electrical diagram: "9.3 Z 1500/2000 DA" on page 45. www.zepro.com...
Quick opening can be activated when the platform angle is 90º-45º. If the control buttons are kept pressed, the quick-opening function is active down to -10 °. See also the electrical diagram: "9.3 Z 1500/2000 DA" on page 45. www.zepro.com...
Active output (approved input signal from control device and sensors), the lift is operated. LED 1 LED 2 Display Flashing light Image 88. The control card is equipped with an alphanumerical display with a flashing light and 2 red LEDS www.zepro.com...
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In the event of a fault in the remote control, unlocking can be performed by turning the control power (CS) Off/On. If the remote control is in the locked position and the lift has been unlocked by turning the control power (CS) Off/On, the lift will be locked again as soon as any button on the remote control is pressed. NOTE. The lift remains locked if it loses power and is then started up again, and the number 6 flashes on the con- trol card’s display. Unlocking is performed as described above. www.zepro.com...
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CS (cabin switch) is switched on, “7” will flash on the display and the control card is locked until the Off/On on the CS is operated. 1-6 = Ctrl 1-6 = CS 1-6 segments indicate sensors. Sensor indication On - signal in. Off - no signal in. 0V. Segment (See electrical and hydraulics diagrams for information about the location of the sensors). www.zepro.com...
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If the system discovers several faults, only the fault code for the fault with the highest priority will be shown auto- matically. The display is prioritised in the order in the table below, L/H, E, F and A. When the CS is switched off, the system will browse through a list containing the five most recent faults de- tected before the display goes off after approx. 5 minutes, the control card then goes into power save mode. www.zepro.com...
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Displayed only af- ed/cable breakdown has cable breakdown. Fault ter the respective code is reset automatically if the output U0-U7 has function in question is running been active. (function verified). Contact support if the lift does not Internal fault function. www.zepro.com...
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The lift is working, but the voltage range outside the ‘heart-marked’ area is only rec- ommended for operation for short periods. The lift is working within the voltage range for optimum function and service life. 8-15V 10-14V 0-7V 16-36V 18-30V 20-28V 0-16V 32-36V www.zepro.com...
Marking Z 1500/2000-135/155/175 Marking Below, an overview of the location of the different markings is shown. Image of marking and further informa- tion can be found under the each subchapter for subsequent pages. 14.1 14.4 14.3 14.5 14.5 14.6 14.7 Image 89. Overview of labelling www.zepro.com...
Loading diagram Affix the load diagrams for the appropriate lift model close to the primary controller and in a suitable clearly visible position on the vehicle body. Image 90. Load diagram for load capacity 1500 kg, centre of gravity distance 1000 mm. Image 91. Load diagram for load capacity 2000 kg, centre of gravity distance 1000 mm. www.zepro.com...
Image 93. Work area 14.4 Warning tape Affixed along the platform edge strips to mark the platform edges in its lowered position. The location of the warning tape often coincides with the contour marking, in which case the warning tape can be omitted. Image 94. Warning tape www.zepro.com...
Image 95. Controller sticker for CD 1, 2, 9 For applications without 2-hand operation, this part of the sticker is discarded. www.hiab.com www.hiab.com 77661TL 2020-03-04 55055TL 2020-03-04 Image 96. Controller sticker for CD 10 Image 99. Controller sticker for CD 4 www.zepro.com...
Image 100. Danger area 14.7 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 platform is lowered to the ground. Swage the tracks together to secure the warning flags. Image 101. Warning flags www.zepro.com...
9. Lift arm right side, at upper bearing. 10. Right lift cylinder, at upper bearing. 11. Left lift cylinder, at upper bearing. 12. Lift arm left side, at upper bearing. 15.2 Oil level check Check the fluid level in the tank during service, top up if necessary. The marking on the hydraulic tank indi- cates the type of hydraulic fluid used. Mineral hydraulic fluid, product no. 21963 (1 litre), or biodegradable synthetic fluid, product no. 22235 (1 litre). Image 102. Lubrication points www.zepro.com...
1000 mm Capacity Load 1500 kg Load 2000 kg Distance out in platform (L) 1500 kg 1250 mm 2000 kg 1625 mm 1250 mm Deformation Max. 15 mm Drift Max 2º Image 103. Testing and verification www.zepro.com...
That all safety and operating decals are installed in their respective position. • That the platform’s mechanical lock is functioning correctly (where applicable). • That the instructions for using the tail lift have been left in the driver’s cabin. • That the CE declaration of conformity has been completed. www.zepro.com...
9. Support the support frame from beneath, for example with a car jack. 10. Remove the support frame from the vehicle chassis by loosening the bolts and carefully lowering the support frame to the ground with a car jack. www.zepro.com...
The following is a list of selected components with their weight. Complete lift chassis (without platform) Lift components (included in complete lift chassis) Z 1500-135 315 kg Support frame Z 1500 69 kg...
When installing the lift and when carrying out service and repair work, when the lift is operated repeatedly without the vehicle being started and used, the 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...
Specifications Z 1500/2000-135/155/175 18.5 Tightening torque NOTE! All specified torque values apply for use with a screw or impact wrench with torque control. Torque distribution max ± 5%. 80 Nm 80 Nm 120 Nm 280 Nm 80 Nm Image 106. Tightening torque www.zepro.com...
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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...