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Zepro Z 150-135 Installation Instruction

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Z-LYFTEN PRODUKTION AB
INSTALLATION INSTRUCTION
Z/ZL 150/200-135/155/175
Sales
Mossvägen 8, 641 49 KATRINEHOLM, SWEDEN
Telephone:
+46 150 - 489550
Telefax:
+46 150 - 489551
E-mail:
zepro@zepro.com
Internet:
www.zepro.com
Z/ZL 250-135/155
Factory
Allévägen 4, 840 73 BISPGÅRDEN, SWEDEN
Telephone:
+46 696 - 17200
Telefax:
+46 696 - 17242
E-mail:
info@zepro.com
Internet:
www.zepro.com
54245TL
2016-09-06

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Summary of Contents for Zepro Z 150-135

  • Page 1 Mossvägen 8, 641 49 KATRINEHOLM, SWEDEN Allévägen 4, 840 73 BISPGÅRDEN, SWEDEN Telephone: +46 150 - 489550 Telephone: +46 696 - 17200 Telefax: +46 150 - 489551 Telefax: +46 696 - 17242 E-mail: zepro@zepro.com E-mail: info@zepro.com Internet: www.zepro.com Internet: www.zepro.com...

  • Page 3: Table Of Contents

    Contents 1. CE marking................4 2. General ..................5 3. Dimensions for installation ............ 10 4. Installation support frame ............12 5. Electrical installtion..............13 6. Electrical and hydraulic diagram ........... 15 7. Connection unit ............... 20 8. Installation, miscellaneous ............. 27 9.

  • Page 4: Ce Marking

    1. CE marking Since 1/1/1995 ZEPRO tail lifts sold to the European Welding is not allowed 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 cylinder piston rods are treated with carbon range. ZEPRO oil (art.no 21963 for 1 litre) is made nitriding which gives them very long life. of a highly refined mineral oil, the lubricant additive...
  • Page 6 The following are the ranges of weights for various heavy components. Cpl. Lift chassis (without platform) Lift components (part of cpl. lift chassis). Z 150-135 350 kg Support frame Z 150/200/250 86 kg...
  • Page 7 2. General Centre of gravity Max load Z-150/200-135, steel platform 2000x2540 mm C = 330 C = 470 C = 610 (mm) (mm) 1500 kg (mm) 2000 kg (mm) 2500 kg Z-150/200-155, steel platform 2000x2540 mm C = 360 C = 580 C = 715 (mm) (mm) 1500 kg...
  • Page 8 2. General Max Power Consumption Z/ZL-150/200/250 (200 bar) 7000 12 volt 24 volt Pump - Motor Unit 245 A 135 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 1,5 mm...
  • Page 9 2. General Loading Diagram...

  • Page 10: Dimensions For Installation

    3. Dimensions for installation Z/ZL 150/200/250-135 A = C / 3 - 20 * without support wheels Z/ZL 150/200/250-155 A = C / 3 - 20 * without support wheels Z/ZL 150/200-175 1026 1054 1085 A = C / 3 - 20 * without support wheels...
  • Page 11 3. Dimensions for installation Z 150-195 1040 1080 1120 1150 1180 1206 1230 A = C / 3 - 20 * without support wheels Z 150/200/250 1432 1014 min 750 - max 930 1477 617-817 1820 2400 A max ZL 150/200/250 1664 1246 min 982 - max 1162...

  • Page 12: Installation Support Frame

    4. Installation support frame Attention! Also refer to the truck manufacturer´s instructions for auxiliary equipment If it is difficult to get the support frame into its right posi- Preparation/support frame tion, loosen a hydraulic hose from one lift cylinder to let oil 1.

  • Page 13: Electrical Installtion

    5. Electrical installation Install control units at suitable places, but the posi- If you have a spiral cable unit, its cable colours are tion of the control unit should ensure that the ope- different (see electric diagram): rator has a good view of the load, the working area If you want an electrically heated spiral cable unit and the loading area, whilst maintaining a safe you can order a 5-part cable (spare-part no 21303).
  • Page 14 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 15: Electrical And Hydraulic Diagram

    6. Electric and hydraulic diagram Z/ZL-150/200/250 MA...
  • Page 16 6. Electric and hydraulic diagram Z/ZL-150/200/250 DA...
  • Page 17 6. Electric and hydraulic diagram Z/ZL-150/200/250 MA, with hydraulic Auto-tilt...
  • Page 18 Pump Unit Tiltcylinder Control Power 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 mirror The light must be of amber color.
  • Page 19 6. Electric and hydraulic diagram 4-button control unit 3-button control unit with main switch and selector switch 3-button control unit 3-button remote control unit with spiral cable...

  • Page 20: Connection Unit

    7. Connection unit Operating information All the lift's functions are controlled and monitored through the connection unit and its circuit board. The circuit board is equipped with an alphanumerical display with a flashing light and 2 red LEDS. These display current operating information.
  • Page 21 7. 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 22 7. Connection unit Information codes Code Code Identification Code 1 Information Other 00–99 Cancelled configuration (Program Dividers configuration) 12/24 Number of volts detected Version number 01–99 Software version Fixed light (1-7) displays active control 1.-7 (Fixed light) device during operation. Active control device while operating Segments B, C, E or X are illuminated de-...
  • Page 23 7. 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 accord- ance with the previous page.
  • Page 24 7. 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 automatically if the battery voltage becomes correct.
  • Page 25 7. Connection unit Function schema (also refer to corresponding. el & hyd. diag.) Z/ZL-150/200/250 MA Z/ZL-150/200/250 MA, with hydraulic Auto-tilt (config 1, art. no. 34301TL) Function Signal in Signal Out Notes Lift U0+U2 Lower U1+U2+U4 Lower E+Di3 U1+U2+U4+U5 Tilt up U0+U3 Tilt down U0+U1+U3+U5...
  • Page 26 7. Connection unit, hydraulic unit VENTILHUS VALVE BODY VENTIL GEHAUSE TANKLOCK FILLER CAP TANKDECKEL TANKLÅDA CHASSIS WITH TANK ÖLTANK SOLENOID SWITCH MAGNETSCHELTER MOTOR KRETSKORT CIRCUIT CARD GETRUCTE SCHALTUNG KOPPLINGSENHET CONNECTION UNIT KOPPLUNGS EINHEIT...

  • Page 27: Installation, Miscellaneous

    8. Installation, continued Installation of adjustable 3 parts bumper bar Install the bumper bar temporarily. Check that it is positioned within applicable dimensions. Max 550 mm between bar and ground when vehicle is unloaded. Maximum 375 mm horizontally from the outermost part of the lift platform to the bumper bar.
  • Page 28 8. Installation, continued Installation of platform Max 40 mm, Min 38 mm Install platform onto the lift arms and tilt cylinders to the platform. Use axles and support wheels provided (280 Nm). pict 10. Pict. 12 Tighten all nuts (see section 4). Weld the square shaped washers to the brackets.
  • Page 29 Pict. 14 Transport lock For CE marked lifts with 1000kg max lifting capacity and over ZEPRO provides platforms without trans- port lock. For other lifts transport lock are installed on the platforms right side. Electric safety valves can serve as transport locks for platforms.
  • Page 30 Art. no. 54599 3. Turn the adjusment collar (spanner width 50mm) as seen from above, as per pict 17 (Zepro tool 54600), alternately the right cylinder and then left one, so that the platform fits exactly to the body as Locking nut per pict B.
  • Page 31 8. Installation, continued Adjustment of tilt down angle. NB. To obtain the correct function after adjustment, it is necessary to first follow the procedure on previous Pict. 21 page which describes the adjustment of the 90º tilt angle up against the body. Run the lift up so that the lift is at the floor level, see pict 20.

  • Page 32: Important Information

    9. 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 54853 54853 damage the seals/gaskets).

  • Page 33: Markings, Positioning Of Decals On Lift

    10. Markings, decals (see pictures on next page) An operating instructions decal should be placed next to the main control unit. A danger zone decal, warning of the danger area between the platform and the vehicle bed is to be The loading diagram plates should be placed near affixed on the inside of the vehicle body near to the the control unit and in a clearly visible position on...
  • Page 34 10. Markings, decals...

  • Page 35: Post Installation Maintenance

    11. Maintenance Grease all bearings and platform locks with LE lubricant 4622 or equivalent. Greasing at least 8 times / year Right tiltcylinder, lower bearing. Right liftcylinder, lower bearing. Liftarm right side, lower bearing. Left liftcylinder, lower bearing. Left tiltcylinder, lower bearing. Liftarm left side, lower bearing.

  • Page 36: Testing The Lift

    12. Load testing the tail lift Static loading (Test load 1,25 x tail lift loading Testing and verification of the tail lift. capacity). For tail lifts with load centre of 600 mm Carried out in accordance with the installation in- struction and delivery check list.
  • Page 37 12. Load testing the tail 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 38: Dismantling

    13. 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.

This manual is also suitable for:

Z 150-155Z 150-175Z 150-195Z 200-135Z 200-155Z 200-175 ... Show all

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