Related Manuals for Zepro Z 45-90
Summary of Contents for Zepro Z 45-90
- Page 1 Installation instructions Tail Lift Z/ZU 45/75-90/110 ZL/ZLU 45/75-90/110 ZN/ZNU 45/75-90/110 ZEPRO Tel.: +46 (0)10-459 05 00 Email: zeprotech@hiab.com zepro.com 54990TL 2022-07-04...
-
Page 3: Table Of Contents
Adjusting the tilt angle ................. 34 4.15 Transport lock ..................35 4.16 Controllers .................... 36 Cable routing ....................38 General ....................38 Sizing electrical systems ..............39 Main power cable, earth cable, main fuse and main switch ....41 www.zepro.com... - Page 4 Warning lighting and foot controls (TLC-B1) ........48 Warning lighting and foot controls (ZePRO1) ........49 Cabin switch and open platform alarm (TLC-B1) ......... 50 Cabin switch and open platform alarm (ZePRO) ........51 Electrical and hydraulic diagrams ..............52 Z 45/75 (TLC-B1) .................. 52 Z 45/75 (ZePRO1) ................
-
Page 5: Important Information
NOTE refers to additional information that may help the reader understand, or perform, a given operation. Technical support If technical support is needed, please contact ZEPRO. Phone: +46 (0)10-459 05 04, Email: zeprotech@hiab.com. Always be ready to state the production number of the tail lift to guarantee you receive the correct information. -
Page 6: Identification
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). -
Page 7: Repainting
When the lift is operated repeatedly without starting or using the vehicle during lift installation or carrying out service and repairs, use the battery charger between operations to maintain battery charge. IMPORTANT The battery charger must be disconnected when operating the lift. Risk of material damage. www.zepro.com... -
Page 8: Safety Rules
Image 6. The platform may not be tilted down more than 10º from the horizontal Connection of third-party equipment is forbidden WARNING! Connecting third-party equipment (electric or hydraulic) to Zepro tail lifts is forbidden. Connecting third-party equipment could interfere with the lift’s system 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 at- tachment features on the vehicle. -
Page 9: Connection Of Third-Party Equipment Is Forbidden
WARNING! You must not attach third-party equipment (electric or hydraulic) to Zepro tail lifts. Attaching third-party equipment may interfere with the lift system and its safety functions. Risk of personal injury and material damage. If necessary to install other equipment, check the vehicle manufacturer’s body instructions and use the attachment options on the vehicle. -
Page 10: Before Installation
Image 7. Cross section of vehi- inertia of 306 cm around the x-axis. See Image 7. If cle chassis frame beam in doubt, contact ZEPRO for support. WARNING! The dimensions above are the minimum permitted for the installation of underrun protection. The strength requirements for mounting the tail lift usually require larger dimensions. -
Page 11: Calculating The Installed Dimensions
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 depends on the C dimension 3.3.4 H dimension The H dimension is the height from the ground (unloaded) to the vehicle floor level. The H dimension must not be greater than the maximum lifting height of the lift. The platform must always be able to reach ground level. www.zepro.com... - Page 12 Installation dimensions Z/ZL/ZN 45/75 - 90/110 H 900/1100 max max 450/550 Lifting height 1100 mm Lifting height 900 mm 450 170 400 154 350 143 300 134 250 127 Image 9. Installation dimensions for lift models with lifting height 900/1100 mm www.zepro.com...
- Page 13 Lifting height 1100 mm Lifting height 900 mm R58:3 R58:3 450 170 400 154 Approved 350 143 Approved 310 134 250 127 *Approved * Approved when installing longer underrun brackets (available as option). Image 10. Installation dimensions for lift models with lifting height 900/1100 mm www.zepro.com...
- Page 14 550 - max 1110 318/418 1171 2100 (1900 min.) ZU-45-90, ZU-75-90 ZU-45-110, ZU-75-110 424 / 524* * Longer underrun brackets that give the size 524 mm are available as an option. These are needed to achieve approved dimensions according to R58:3, if the C dimension is < 310 mm. www.zepro.com...
- Page 15 750 - max 1410 1474 318/418 1000 2100 (1900 min.) ZLU-45-110, ZLU-75-110 ZLU-45-90, ZLU-75-90 424 / 524* * Longer underrun brackets that give the size 524 mm are available as an option. These are needed to achieve approved dimensions according to R58:3, if the C dimension is < 310 mm. www.zepro.com...
- Page 16 ZNU-45-110, ZNU-75-110 ZNU-45-90, ZNU-75-90 424 / 524* * Longer underrun brackets that give the size 524 mm are avail- able as an option. These will be required to obtain approved dimensions according to R58:3, if the C dimension is < 310 mm. www.zepro.com...
-
Page 17: Rear Beam Cut-Outs
3. Remove any burrs and sharp edges. A max Image 11. Z-45-110, Z-75-110, Z-45-90, Z-75-90 ZU-45-110, ZU-75-110, ZU-45-90, ZU-75-90 A max 1060 Image 12. ZL-45-90, ZL-75-90, ZL-45-110, ZL-75-110 ZLU-45-90, ZLU-75-90, ZLU-45-110, ZLU-75-110 A max Image 13. ZN-45-90, ZN-75-90, ZN-45-110, ZN-75-110 ZNU-45-90, ZNU-75-90, ZNU-45-110, ZNU-75-110 www.zepro.com... -
Page 18: Temporary Connection
When installing the lift, when the lift is operated repeatedly, the battery charger must be used between opera- tions to maintain the battery charge level. IMPORTANT! The battery charger must not be connected when operating the lift. Risk of material damage. www.zepro.com... -
Page 19: Connecting The Control Device To The Zepro1 Control Card
Lock Spiral Di 3 Ai 2 Black (+) Lock Di 2 White (-)* Ctrl 5 Di 1 Ctrl 4 Ai 1 Spiral Ai 2 Brown Brun B Lock Gul E Yellow Blå Blue * Blå 2H Blue 2H Black (+) * applies to controllers with heating only www.zepro.com... -
Page 20: Connecting The Control Device To The Tlc-B1 Relay Card
Blue Black White Brown Yellow Down Blue Tilt Pink Black White ( )* Tilt Brown Down Yellow Down WL1 U7 U6 U5 U5 U4 U4 U3 U2 U1 U0 Blue Tilt * applies to controllers with heating only Down Ctrl 1 Tilt Down Tilt Down www.zepro.com... -
Page 21: Installation
Installation Z 45/75-90/110 Installation NOTE! Also consult the vehicle manufacturer’s body instructions and the Zepro Operator’s manual before installation. WARNING! Zepro tail lifts are only approved for installation with Zepro assembly kits. Hydraulic unit Constant flow valve, tilt Control card Oil tank Tank cap... - Page 22 Image 17. Assembly of hydrau- ing strap before installation. lic unit on support frame. 3. Check whether the hydraulic tank is fitted with a sealed transport plug. In this case, replace it with the regular tank cap supplied. 54853 Image 18. Where necessary, replace the transport plug with a regular tank cap www.zepro.com...
-
Page 23: Support Frame
Use the M14x35 Image 21. Mounting jig. See table on the bolts supplied. Install without tightening. next page for part number. Image 22. Fit the lower part of the chas- sis bracket on the support frame. www.zepro.com... - Page 24 15. Remove the mounting jig. For other chassis brackets, see the respective directions. At least 4 bolts 6 bolts M14x45 10.9 (120 Nm) M14X35 8.8 (120 Nm) At least 4 bolts M14x45 8.8 (120 Nm) Image 25. Fitting the chassis bracket. www.zepro.com...
-
Page 25: Lift Platform
2. Lubricate the metal bushings on the upper bear- ing of the arms. Make sure the small holes on the inside of the bushings are filled with grease. Use Zepro lubricant or equivalent. NOTE! Carefully lubricate the metal bushings on the upper bearing of the arms. Make sure the small holes are filled with grease. -
Page 26: Open Platform Alarm
When installing autotilt, mount the angle sensor onto the lift arm, see Image 28. NOTE! When installing on the left arm, the sensor’s cable input must be facing upwards. When installing on the right arm, the sensor’s cable input must be facing downwards. Image 28. Installing the angle sensor www.zepro.com... -
Page 27: Angle Sensor For 2-Hand Operation
2. Route the cables of the angle sensors and install together with cable ties as shown below. Check that the cable is not stretched or otherwise at risk of being damaged while the platform is in motion. 320 mm Image 30. Installing the IFM angle sensor www.zepro.com... -
Page 28: Underrun Protection
25 mm. See Image 32. • Each of the individual parts of the underrun protection must have a surface area of at least 350 cm . See Image 31. Max 25 mm Max 25 mm Image 32. Statutory dimensions www.zepro.com... - Page 29 M12x30 8.8 (90 Nm) part of the brackets is installed a long way in. M12x30 8.8 (90 Nm) Image 35. Installing brackets onto frame. www.zepro.com...
- Page 30 Tightening torque 25 Nm. NOTE! When installing on ZLU 45/75-90/110, more pow- erful brackets are used for the internal aluminium rail compared to other models. Image 36. Installing aluminium profiles. M8x20 8.8 (25 Nm) Image 37. Installing aluminium profiles. www.zepro.com...
-
Page 31: Arm Stops
, there may be special instructions for arm stops in the separate assembly directions for the assembly kit. WARNING! Welding on the lift arm is not permitted. Image 39. Use Loctite 243 or equivalent on the fixing screws www.zepro.com... -
Page 32: Sealing Strip (Horizontal), Surface-Mounted Rubber Strip
Fit the rubber strip in the track. Secure the rubber strips by swaging the tracks together at the bottom. NOTE! If an upper edge seal is being fitted, it must be mitred 45° to the vertical strips. Image 41. Installing a sealing strip www.zepro.com... -
Page 33: Sealing Strip, Integrated Rubber Strip
Image 42. Install screw, Image 43. Install- Image 44. Screw on nut arm stop ing the arm stops the stop profile Image 45. Mount Image 46. Lock the rubber strip Image 47. Fix the arm stop the rubber strip www.zepro.com... -
Page 34: Adjusting The Tilt Angle
Image 48. Adjusting the fit to the vehicle body side sealings. On vehicle bodies with rear doors, the platform is adjusted so that it stops in a verti- cal position with a sufficient gap between platform and doors. Image 49. Adjusting the fit to the vehicle body www.zepro.com... -
Page 35: Transport Lock
156 ±5 Electric hose rupture valves serve as locks for the platform. The lock opens automatically if the down function is actuated from the controller. The valves are check valves that let fluid into the cylinders but not out before they are actuated by the flow from the lowering valve. The platform is therefore hydrauli- cally locked during transport. www.zepro.com... -
Page 36: Controllers
The cable must be protected by rubber grommets when it passes through beams or walls. Cables must be installed sufficiently far from, or be protected against, sharp edges so they cannot chafe or otherwise sustain damage that could lead to a short-circuit and cable fires. Take care not to bend cables with too tight a radius as this can cause damage. 300-600 mm. Image 52. Installing controllers WARNING! The primary controller must always be fitted on the side that is facing away from moving traffic. Fitting in any other way involves increased risk of injury. Image 53. Installing controllers www.zepro.com... - Page 37 3. Any additional controllers can be installed in an optional location. 4. Run the controller cabling to the tail lift cable grom- met. Connection is described later in section 6. Image 54. Installing control- ler CD 1 with two-handed grip. www.zepro.com...
-
Page 38: Cable Routing
Take care not to bend cables to too tight a radius as this can cause damage. Image 55. Protect the cable against sharp edges and use cable grommets Image 56. Always use shrink hose over the cable connection when fitting cable terminals www.zepro.com... -
Page 39: Sizing Electrical Systems
Some vehicle models do not fully charge the battery. It may therefore be necessary to switch to a battery and sometimes also to a charger with a larger capacity. Image 57. Battery capacity and definition of the length of the earth and main power cables www.zepro.com... - Page 40 (I Some vehicle models have restrictions regarding the amount of power the lift can access from the existing battery. Image 58. Maximum power consumption Z75 - Minimum recommended conductor cross sectional area www.zepro.com...
-
Page 41: Main Power Cable, Earth Cable, Main Fuse And Main Switch
6. Route the main power cable from the tail lift to the fuse box/battery plus terminal. Prepare the cable with a cable terminal and shrink hose without connecting. Connection is described later in section 6. Image 59. Connection to the bat- Image 60. Connection to the fuse box tery's positive terminal www.zepro.com... - Page 42 The positive cable to the battery and main fuse is connected later in Section , after the cable has been routed/installed. Image 62. Installation of main Image 61. Installation of main switch on universal bracket switch to CD 19 controller Drainage Image 63. Main power switch www.zepro.com...
-
Page 43: Open Platform Alarm
Open platform alarm ZEPRO recommends the installation of an alarm for open platform. This can be in the form of warning light in the cab or when mounted on a trailer, a lamp mounted on the outside of the body, visible in the rear view mirror from the driver's cab. -
Page 44: Control Power Cable
1st boom’s pipe, so they are well protected when the platform hits the ground. Image 64. Warning lighting and foot controls Leave enough slack to the first cable tie to avoid the risk of damage to the cable during lift operations. Image 65. Installing cabling www.zepro.com... -
Page 45: Connection
2. Connect the relevant controller. See Section 6.4 - 6.5. 3. Where applicable, connect the warning lights. See Section 6.6 - 6.7. 4. Where appropriate, plug in cab switch (CS) and open platform alarm. See Section 6.8 - 6.9. After connection 1. When all cables are suitably located in the cable grommet, tighten the five screws; see Image 66. Tightening torque: 5 Nm. www.zepro.com... -
Page 46: Connecting The Control Device To The Zepro1 Control Card
2H Black (+) CD12 CD14 For connection of foot controls and warning lights, see electrical diagram in Section Brown Brown CD11 CD10 Yellow Yellow Brown Blue Yellow Blue Grey Lock Black (+) White (-) Black (+) Black (+) White (-)* White (-)* www.zepro.com... -
Page 47: Connecting The Controller To The Tlc-B1 Relay Card
WL1 U7 U6 U5 U5 U4 U4 U3 U2 U1 U0 Yellow Down CD14 Down Down Ctrl 1 Tilt Down For connection of foot controls and warning Ctrl 2 Tilt lights, see electrical diagram in Section Ctrl 3 Down * applies to controllers with heating only www.zepro.com... -
Page 48: Warning Lighting And Foot Controls (Tlc-B1)
Warning lighting and foot controls (TLC-B1) Signal is required on relay card input S3 for the warning light to work. Depending on the model, this can be done by connecting angle sensors between S3 and S3+ or with jumper Gnd. Sig.(+) Down www.zepro.com... -
Page 49: Warning Lighting And Foot Controls (Zepro1)
Connection Z 45/75-90/110 Warning lighting and foot controls (ZePRO1) www.zepro.com... -
Page 50: Cabin Switch And Open Platform Alarm (Tlc-B1)
Connection Z 45/75-90/110 Cabin switch and open platform alarm (TLC-B1) www.zepro.com... -
Page 51: Cabin Switch And Open Platform Alarm (Zepro)
Connection Z 45/75-90/110 Cabin switch and open platform alarm (ZePRO) www.zepro.com... -
Page 52: Electrical And Hydraulic Diagrams
Electrical and hydraulic diagrams Z 45/75-90/110 Electrical and hydraulic diagrams Z 45/75 (TLC-B1) www.zepro.com... -
Page 53: Z 45/75 (Zepro1)
Electrical and hydraulic diagrams Z 45/75-90/110 Z 45/75 (ZePRO1) www.zepro.com... -
Page 54: Z 45/75 With Electric Autotilt (Tlc-B1)
Electrical and hydraulic diagrams Z 45/75-90/110 Z 45/75 with electric Autotilt (TLC-B1) www.zepro.com... -
Page 55: Z 45/75, With Hydraulic Autotilt (Zepro1)
Electrical and hydraulic diagrams Z 45/75-90/110 Z 45/75, with hydraulic autotilt (ZePRO1) www.zepro.com... -
Page 56: Lubrication And Oil Level Check
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. Oil level check Check the fluid level in the tank during maintenance, 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 (1 litre). Image 67. Lubrication points www.zepro.com... -
Page 57: Marking
Marking Z 45/75-90/110 Marking Below, an overview of the location of the different markings is shown. Image of markings and additional infor- mation can be found under the relevant subchapter for the following pages. Image 68. Overview of labelling www.zepro.com... -
Page 58: Loading Diagram
Z 45/75-90/110 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 69. Load diagram for load capacity 450 kg, load centre distance 600 mm. Image 70. Load diagram for load capacity 750 Kg, load centre distance 600 mm. www.zepro.com... -
Page 59: Identification Plate
Affix the sticker clearly visible on the rear of the vehicle. Image 72. Work area Warning tape Affixed along the platform edge strips to mark the plat- form edges in its lowered position. The location of the warning tape often coincides with the outline marking, in which case the warning tape may be omitted. Image 73. Warning tape www.zepro.com... -
Page 60: Controller Sticker
For applications without 2-hand operation, this Image 76. Control device sticker for CD 1, 2, 9 part of the sticker is discarded. www.hiab.com www.hiab.com 77661TL 2020-03-04 55055TL 2020-03-04 Image 77. Control device sticker for CD 10 Image 78. Control device sticker for CD 4 www.zepro.com... -
Page 61: Danger Area
65977TL 2020-05-14 Image 79. Danger area 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 fixing tracks together to secure the warning flags. Image 80. Warning flags www.zepro.com... -
Page 62: Testing And Verification
750 mm. Capacity Load 1000 kg Load 1500 kg Distance on platform (L) 1000 kg 940 mm 1500 kg 1410 mm 940 mm 2000 kg 1875 mm 1250 mm 2500 kg 2340 mm 1560 mm www.zepro.com... -
Page 63: Dynamic Load Test
Distance on platform (L) 450 kg 600 mm 500 kg 600 mm 700 kg 800 mm 750 kg 900 mm 1000 kg 1200 mm 600 mm 1500 kg 1800 mm 900 mm 2000 kg 1200 mm 2500 kg 1500 mm www.zepro.com... -
Page 64: Test Of Safety Functions
That there is a “max. load” marking on the platform and it is correctly positioned according to the loading diagram for the tail lift model concerned. • That warning flags and reflectors are fitted and fulfil their function correctly. • That all safety and operating stickers are affixed in their respective positions. • 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 cab. • That the CE declaration of conformity has been completed. www.zepro.com... -
Page 65: Registration
Registration Z 45/75-90/110 Registration For the tail lift’s guarantee to be valid, the delivery card must be registered in C-care (www.c-office.com). The bodybuilder is responsible for registration in C-care and must certify in the intended location in tail lift's instruc- tion manual that it has been registered. www.zepro.com... -
Page 66: Specifications
Alu. platform 1600x2210 mm 66 kg Other lift components Alu. platform 1600x2060 mm 62 kg Towing hitch kit Z/ZU 22.0 kg Alu. platform 1600x1980 mm 60 kg Towing hitch kit ZN/ZNU 23.9 kg Towing hitch kit ZL/ZLU 25.5 kg www.zepro.com... -
Page 67: Tightening Torque
Specifications Z 45/75-90/110 12.2 Tightening torque NOTE! All specified tightening torques apply when using torque wrench or screw/nut runner with torque control. Torque spread max ±5%. Image 82. Tightening torque www.zepro.com... - Page 68 BUILT TO PERFORM Zepro, Del and Waltco are Hiab trade marks 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...