Related Manuals for Zepro Z3N 75-100
Summary of Contents for Zepro Z3N 75-100
- Page 1 Installation Instruction Tail Lift Z3N / Z3NU 75-100 Z3NN / Z3NNU 75-100 Z3NW / Z3NWU 75-100 ZEPRO Tel.: +46 (0)10-459 05 00 E-mail: zeprotech@hiab.com zepro.com 74598TL 2022-11-30...
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Page 3: Table Of Contents
Main power cable, earth cable, main fuse and main switch ....30 Control power cable ................32 Open platform alarm ................32 Warning lighting and Foot controls ............32 Connection ...................... 33 Cable grommet ..................33 Connection ................... 34 Powering up the tail lift .................. 41 www.zepro.com... - Page 4 13.1 Weights ....................56 13.2 Center of gravity Z3N / Z3NU ............... 57 13.3 Center of gravity Z3NW / Z3NWU ............58 Z3NN(U) ............. 59 13.4 Center of gravity 13.5 Loading diagram ................... 60 13.6 Tightening torque .................. 61 www.zepro.com...
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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. Tel: +46 (0)10-459 05 04, E-mail: zeprotech@hiab.com. Always be ready to state the tail lift’s production number to guarantee you receive the correct information. The production number is given on the identification plate located on the tail lift frame. -
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
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 attachment features on the vehicle. -
Page 9: Before Installation
95x50x3 mm, corresponding to a minimum surface moment of inertia of 78 cm around Image 7. Cross section of vehicle chassis’ frame beam the x-axis. See Image 7. If in doubt, contact ZEPRO for support. WARNING! The above dimensions are the minimum per- mitted for the installation of underrun protec- tion. -
Page 10: 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 is dependent 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 dimen- sion 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... -
Page 11: Z3N(U) 75-100
Safety rules Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 Z3N(U) 75-100 R58:3 425 133 400 127 Approved 375 120 362 116 350 113 Max 575 1900 A max Image 9. Installation dimensions for Z3N(U) 75-100 www.zepro.com... -
Page 12: Z3Nn(U) 75-100
Safety rules Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 Z3NN(U) 75-100 R58:3 463 133 438 127 Approved 413 120 400 116 Max 537 388 113 1900 A max Image 10. Installation dimensions for Z3NN(U) 75-100 www.zepro.com... -
Page 13: Z3Nw(U) 75-100
Safety rules Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 Z3NW(U) 75-100 R58:3 455 133 430 127 Approved 405 120 392 116 380 113 Max 545 1080 1900 A max Image 11. Installation dimensions for Z3NW(U) 75-100 www.zepro.com... -
Page 14: 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 15 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 16 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...
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Page 17: Installation
4 M14x45 10.9 (120 Nm) per side. NOTE! Use washers on both sides of the fastening!. Image 15. Adjust the frame to the ideal height under the frame. A car jack is a good tool. www.zepro.com... - Page 18 4.1.3 Hydraulic hoses A = Oil return Tilt circuit. B = ressure to lift and tilt circuit. Image 17. Hydraulic unit Image 18. A = Oil return Tilt circuit. B = ressure to lift and tilt circuit. www.zepro.com...
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Page 19: Hydraulic Unit With Circuit Card, Detailed Image
Installation Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 Hydraulic unit with circuit card, detailed image VALVE FILLER CAP CIRCUIT CARD CHASSIS SOLENOID MOTOR WITH TANK Image 19. Hydraulic unit www.zepro.com... -
Page 20: Installation Lift Platform And Sealing Strip
2. Lubricate the metal bushings on the upper be- aring 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 21 4. Secure the rubber strips by swaging the tracks the vehicle floor and the platform is 75 mm. together at the bottom. NOTE! If an upper edge seal is being fitted, it must be mitred 45° to the vertical strips. Image 23. Installing a sealing strip www.zepro.com...
- Page 22 Stop profile Image 24. Stop profile, overview Image 25. Install Image 26. Install the armstops Image 27. Screw tight screw, nut armstop the stop profile Image 28. Image 29. Secure Image 30. Secure the armstop Fit the rubber strip the rubber strip www.zepro.com...
- Page 23 Angle sensor is installed according to illustration. Secure with supplied screws. Use Ø5.2mm drill. Image 31. Fast opening angle sensor 4.3.6 Electronic autotilt angle sensor Angle sensor is installed according to illustration. Secure with supplied rivets. Use Ø5 drill. Image 32. Electronic autotilt angle sensor www.zepro.com...
- Page 24 With side seals. 1. Detach the rubber bellows. 2. Loosen the lock nut (Zepro tool 54598) Turn push rod clockwise or anti-clockwise depending on the desired adjustment. See illustration. Adjustment clockwise, the platform is lowered.
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Page 25: Underrun Protection
Tightening torque 80 Nm. 2. Screw each aluminium profile in place with 2 bolts M8x40 (8.8) each. Tightening torque 25 Nm. Place the head of the screw into the aluminium rail’s groove and fit into the bracket and screw tight. Check that the statutory measurements are kept. See section 3.2. In addition, check the space for any tow bars and draw bars. M8x40 8.8 (25 Nm) M12x45 8.8 (80 Nm) Image 39. Installing underrun protection www.zepro.com... -
Page 26: Controllers
Take care not to bend cables with too tight a radius as this can cause damage. 300-600 mm. Image 40. 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 41. Installing controllers www.zepro.com... - Page 27 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 42. Installing control- ler CD 1 with two-handed grip. www.zepro.com...
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Page 28: Cable Routing
Take care not to bend cables to too tight a radius as this can cause damage. Image 43. Protect the cable against sharp edges and use cable grommets Image 44. Always use shrink hose over the cable connection when fitting cable terminals www.zepro.com... -
Page 29: 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 45. Battery capacity and definition of the length of the earth and main power cables www.zepro.com... -
Page 30: 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 46. Connection to the bat- Image 47. Connection to the fuse box tery's positive terminal www.zepro.com... - Page 31 The positive cable to the battery and main fuse is connected later in Section , after the cable has been routed/installed. Image 49. Installation of main Image 48. Installation of main switch on universal bracket switch to CD 19 controller Drainage Image 50. Main power switch www.zepro.com...
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Page 32: Control Power Cable
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 33: Connection
1. Loosen the five screws on the cable grommet, see Image 53. Cables can now be installed/removed/adjusted in the grommet. On installation, the cable must be installed together with existing cabling with cable ties. 2. When all cables are correctly located in the cable grommet, tighten the five bolts. Tightening torque: 5 Nm. Hydraulic Unit 5910 Image 53. Cable grommet's five screws www.zepro.com... -
Page 34: Connection
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 35 Lock Di 2 White (-)* Ctrl 5 Di 1 Ctrl 4 Ai 1 Spiral Ai 2 Brun B Brown Lock Gul E Yellow Blå Blue * Blå 2H Blue 2H Black (+) * applies to controllers with heating only www.zepro.com...
- Page 36 Warning light and foot controller (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 37 Connection Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 6.2.4 Warning lights and foot controls (ZePRO1) www.zepro.com...
- Page 38 Connection Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 6.2.5 Cab switch and open platform alarm (TLC-B1) Applies when installing without main switch www.zepro.com...
- Page 39 Connection Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 6.2.6 Cab switch and open platform alarm (ZePRO1) Applies when installing without main switch www.zepro.com...
- Page 40 Connection Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 6.2.7 Open platform alarm Applies when installing with main switch www.zepro.com...
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Page 41: Powering Up The Tail Lift
7. Install the fuse box cover. 8. Where fitted, set the main switch to the ON position. 9. Where fitted, set the cab switch to the ON position. Image 55. Connection to the bat- Image 54. Connection to the fuse box tery's positive terminal Image 56. Correct installation Image 57. Incorrect installation Image 58. Cover, fuse box www.zepro.com... -
Page 42: Electrical And Hydraulic Drawings
Electrical and hydraulic drawings Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 Electrical and hydraulic drawings Z3N(U), Z3NN(U), Z3NW(U) 75-100 (TLC-B1) www.zepro.com... -
Page 43: Z3N(U), Z3Nn(U), Z3Nw(U) 75-100 (Zepro1)
Electrical and hydraulic drawings Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 Z3N(U), Z3NN(U), Z3NW(U) 75-100 (ZePRO1) www.zepro.com... -
Page 44: Z3N(U), Z3Nn(U), Z3Nw(U) 75-100 Electrical Autotilt (Tlc-B1)
Electrical and hydraulic drawings Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 Z3N(U), Z3NN(U), Z3NW(U) 75-100 electrical autotilt (TLC-B1) www.zepro.com... -
Page 45: Z3N(U), Z3Nn(U), Z3Nw(U) 75-100 Electrical Autotilt (Zepro1)
Electrical and hydraulic drawings Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 Z3N(U), Z3NN(U), Z3NW(U) 75-100 electrical autotilt (ZePRO1) www.zepro.com... -
Page 46: Lubrication And Fluid Level Check
Lift arm right side, at upper bearing. Lift arm left side, at upper bearing. Lift arm right side, at lower bearing Left tilt cylinder, at upper bearing. 10. Lift arm left side, at lower bearing. 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 59. Lubrication points www.zepro.com... -
Page 47: Marking
Marking Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 Marking Below, an overview of the location of the different markings is shown. Image of marking and further information can be found under the each subchapter for subsequent pages. 10.4 10.5 10.1 10.7 10.5 10.5 10.6 Image 60. Overview of labelling www.zepro.com... -
Page 48: Loading Diagram
Marking Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 10.1 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 61. Load diagram for load capacity 750 kg, centre of gravity distance 600 mm. www.zepro.com... -
Page 49: Identification Plate
Image 63. Work area 10.4 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 contour marking, in which case the warning tape can be omitted. Image 64. Warning tape www.zepro.com... -
Page 50: Controller Sticker
For applications without 2-hand operation, this part of the sticker is discarded. www.hiab.com 55053TL 2020-03-04 Image 67. Controller sticker for CD 1, 2, 9 www.hiab.com www.hiab.com 77661TL 2020-03-04 55055TL 2020-03-04 Image 68. Controller sticker for CD 10 Image 69. Controller sticker for CD 4 www.zepro.com... -
Page 51: Danger Area
Image 70. Danger area 10.7 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 71. Warning flags www.zepro.com... -
Page 52: Testing And Verification
Static load (Test load 1.25 x tail lift loading capacity). For tail lifts with loadcentre of 750 mm Capacity Load 1000 kg Load 1500 kg Distance out in 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 53: Dynamic Load Test
Distance out in 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 54: Test Of Safety Functions
• That the warning flags are installed and fulfil their function correctly. • That all safety and operating stickers are installed in their respective position. • That the platform's mechanical lock functions correctly (where applicable). • That the Operator's Handbook has been left in the driver's cabin • That the declaration of CE conformity has been filled in (where applicable). www.zepro.com... -
Page 55: Disassembly
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 sup- port frame to the ground with a car jack. www.zepro.com... -
Page 56: Specifications
Some separate components of the lift must be manipulated by other lifting equipment during handling and therefore could represent hazards if their weights exceed the equipment's permitted load. The following are the ranges of weights for various heavy components. Complete Lift chassis (without platform and accessories) Z3N 75-100 100 kg Z3NU 75-100 112 kg... -
Page 57: Center Of Gravity Z3N / Z3Nu
Specifications Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 13.2 Center of gravity Z3N / Z3NU Max Load 750kg 1119 1142 1161 1179 www.zepro.com... -
Page 58: Center Of Gravity Z3Nw / Z3Nwu
Specifications Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 13.3 Center of gravity Z3NW / Z3NWU Max. Load 750kg 1169 1192 1211 1229 www.zepro.com... -
Page 59: Z3Nn(U)
Specifications Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 13.4 Center of gravity Z3NN(U) Max. Load 750kg 1169 1192 1211 1229 www.zepro.com... -
Page 60: Loading Diagram
Specifications Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 13.5 Loading diagram Image 73. Loading diagram www.zepro.com... -
Page 61: Tightening Torque
Specifications Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100 13.6 Tightening torque NOTE! All specified torque values apply for use with a screw or impact wrench with torque control. Torque distribution max ± 5%. - M8..25Nm. - M10..50Nm. - M12..80Nm. - M14..120Nm. www.zepro.com... - 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...