HIAB ZEPRO Z 15 Technical Manual
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HIAB ZEPRO Z 15 Technical Manual

HIAB ZEPRO Z 15 Technical Manual

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ZEPRO
Tel.: +46 (0)10-459 05 00
Email: zeprotech@hiab.com
79873TL
2024-05-20
Technical Manual
|
zepro.com
Z 15/20

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Summary of Contents for HIAB ZEPRO Z 15

  • Page 1 Technical Manual Z 15/20 ZEPRO Tel.: +46 (0)10-459 05 00 Email: zeprotech@hiab.com zepro.com 79873TL 2024-05-20...

  • Page 3: Table Of Contents

    Contents Contents Product overview ................... 4 1.1 Product variants and identification ............4 Accessing the card and the haydralic unit ..........10 Battery and cable requirements ............... 12 Control card ....................13 Relay card ....................13 Connection card ..................16 Functional descriptions and schematics ............22 Mechanical safety valves .................

  • Page 4: Product Overview

    Product overview Product overview Product variants and identification 1.1.1 The type sign The Z 15/20 product family is available in a number of different variants with varying levels of function- ality. The control systems, cylinder configurations, available control units and sensors can vary between the variants. It is therefore crucial to first identify the variant at hand to be able to find the correct tech- nical information for it. The first step in the process of identifying the variant is locating the type sign and reading the informa- tion in the tail lift type-field. The location of the typesign varies between different tail lift models but it is always riveted onto the support beam of the lift with the most common location being shown on the figure below.
  • Page 5 Product overview 1.1.2 Main components All variants of the Z 15/20 model family consist of the main components shown in the figure below. Most of these components are self-explanatory and will not be explained in-depth in this document. The Rear Underrun Protection Device is not required in some markets. www.zepro.com...
  • Page 6 Product overview 1.1.3 Hydraulic unit overview The hydraulic unit consists of the major components shown in the picture below. Explanations follow in the upcoming subchapters. Motor solenoid A motor solenoid is a type of electromagnetic device that uses a current flow through a helical wire (coil or magnet) inside it to create a magnetic field which moves an armature at the centre of the coil. The magnetic field is created when there is a current passing through the minor (smaller) terminals of the device, one of which is connected to an output pin on the control card, in this case to the Relay Card, and the other to a ground point on the motor. The movement of the armature is used to create a connection between the two major (larger) terminals on the device, one of which is connected to the battery (+) and the other to the power terminal on the motor.
  • Page 7 Product overview Pump A hydraulic pump is a mechanical device that converts mechanical power into hydraulic power that can be used to move a load. When the pump operates, it creates a vacuum at the pump inlet, which sucks liquid from the oil tank into the pump where, by mechanical action, it is forced through the outlet at a certain pressure and flow rate.
  • Page 8 Product overview Oil tank The oil tank is the main oil reservoir of the system. It is where stored oil is sucked into the pump from and returned to during operation. It is refilled by the filling cap on the top. There are markings on the outside of the tank showing the minimum and maximum levels for the oil which may not be exceeded. Refer to the users manual on how to check oil level.
  • Page 9 The cylinder interconnects the lift and tilt paths of the hydraulic system and shifts oil between them to achieve the desired auto tilt functionality. For more details on the Auto Tilt Functionality, a separate document titled “Technical manual - Hydraulic auto-tilt”. Please contact zeprotech@hiab.com for assistance. www.zepro.com...

  • Page 10: Accessing The Card And The Haydralic Unit

    Product overview Accessing the card and the haydralic unit The Relay Card and the Hydraulic Unit are housed inside the main support frame of the tail lift right side when facing the Tail lift standing at the rear. They are accessed by unlocking the lock on the top and bottom of the support frame and pulling the tray out from the support frame.
  • Page 11 Product overview 1.2.1 Control cards The control card converts the inputs from the user and the sensors into outputs to the motor solenoid and the valves which accomplish the desired motion. The Z 15/20 is equipped with a relay card with three relays that acts as the primary control card.

  • Page 12: Battery And Cable Requirements

    Product overview Battery and cable requirements For proper function of the tail lift the electrical system needs to be sized per the following: Item Minimum battery capacity (I 180Ah 170Ah Minimum voltage during operation (U Cross sectional area of power cable, length up to 8m 35mm 35mm Cross sectional area of power cable, length 8-15m 50mm 35mm Cross sectional area of power cable, length over 15m Not possible 50mm The given cross sectional areas are valid for copper cables.

  • Page 13: Control Card

    Control card Control card Relay card 2.1.1 Overview An overview of the relay card is shown below. The following chapters contain in-depth information on the different sections of the card. www.zepro.com...
  • Page 14 Control card 2.1.2 Connection block The connection block on the right side of the card is used for control device input to the relay card. It con- sists of ten spade pins which are interconnected in couples to provide: • 2 x power supply spade pins used to send voltage into the control device.
  • Page 15 Control card 2.1.3 Relays The relay card has 3 electric mechanical relays, sometimes defined as K1, K2 and K3 in the documentation, used to control the lower, raise and tilt functions respectively. The relays have basic terminals identified as 30, 85, 86, 87 and 87a. Note that 87a is not used on this card. In its normal state, terminal 30 is connected to 87a. Black relays are 24vdc and Brown relays are 12vdc. Each relay has a coil between 85 and 86.

  • Page 16: Connection Card

    Control card Connection card 2.2.1 Overview The Connection Card consists of seven discrete blocks containing 3-6 connection points each and a LED strip with ten LED’s used to indicate active functions. The card is located in a separate white plastic box which is mounted on the vehicle close to the tail lift.
  • Page 17 Control card 2.2.2 Output block The output block is located on the far left of the card and consists of the following five connection points: • B: Outputs a raise-signal. • E: Outputs a lower-signal. • C: Outputs a tilt-signal. • Ground: Ground source for the card. • Power: Power source for the card. The output block is used to connect the Connection Card to the Relay Card. The connection is done using a five-conductor cable as shown below.
  • Page 18 Control card 2.2.4 2-hand control and angle sensor inputs Usage of the 2-hand control and sensor input blocks located on the right side of the card varies depending on the legal requirements of your local market. Without 2-hand control functionality In the most basic configuration, the 2H input is not used and the sensor-input is bridged as shown below.
  • Page 19 Control card The angle sensor is active when the angle of the platform is within 45 degrees of horizontal and platform tilting is allowed with all connected control devices. Basically the first 45 degrees of opening or the last 45 degrees when closing. i.e. when the platform angle exceeds 45 degrees from horizontal, the sensor is inactive and tilting is only allowed with a primary control device in combination with a one-button device Note that each of the two primary control devices have their own one-button device.
  • Page 20 Control card 2.2.6 Spiral input The spiral input block is used for the spiral cable control device sometimes referred to as CD9 (3 button) or CD10 (2 button) or remote hand held control. It can also be used for foot controls, CD14. The devices are connected as shown below. Note that some devices have fewer wires than shown. The block consists of six terminals: • B: Input for a Raise-signal. • E: Input for a Lower-signal. • C: Input for a Tilt-signal. •...
  • Page 21 Control card 2.2.7 Status LED’s Green LED’s Active LED indicates that the card has power and is active. This LED should never be OFF in normal circum- stances. Ctrl1, 2, Radio and Spiral Remote controllers These green LED’s indicate the status of the inputs from the two primary control devices, the radio and the spiral cable device. Each LED has three states: •...

  • Page 22: Functional Descriptions And Schematics

    Functional descriptions and schematics Functional descriptions and schematics Mechanical safety valves 3.1.1 Relay card only (Most basic variant) Overview The Z 15/20 with mechanical safety valves and no Connection Card is a variant which uses a simple hydraulic system based on two electrically operated valves located at the valve block above the pump/ motor-assembly and four mechanical safety valves, one on each cylinder.
  • Page 23 Functional descriptions and schematics Z15/20 Function: Open/ tilt down Description: Platform tilt down including opening from fully closed against body Control input: Down (E) + Tilt (C) Sensor input: None required for function. www.zepro.com...
  • Page 24 Functional descriptions and schematics Z15/20 Function: lower Description: Vertical platform lowering. Control input: Down (E) Sensor input: K1 (V1) www.zepro.com...
  • Page 25 Functional descriptions and schematics Z15/20 Function: raise Description: Vertical platform raising. Control input: Up B Sensor input: K2 (Motor solenoid) www.zepro.com...
  • Page 26 Functional descriptions and schematics Z15/20 Function: tilt up, close Description: Platform tilt up including against the box body Control input: Up (B) + Tilt (C) Sensor input: K2 (Motor solenoid) + K3 (V2) www.zepro.com...
  • Page 27 Functional descriptions and schematics 3.1.2 Relay Card with Connection card (mechanical safety valves) Overview The Z 15/20 with mechanical safety valves and a connection card is a variant which uses a simple hydraulic system based on two electrically operated valves located at the valve block above the pump/motor-assembly and four mechanical safety valves, one at each cylinder. The electrically operated valves are controlled by the relay card and direct flow to or from the tilt or lift cylinders, depending on which function is active.
  • Page 28 Functional descriptions and schematics Z15/20 Function: open Description: Platform opening from fully closed against box body to horizontal. Control input: Safety button (2H) + Down (E) + Tilt (C) Sensor input: Inactive angle sensor (doesn't send voltage to card) enables the safety button requirement in the initial 45° of opening Active output: K1 (V1) + K3 (V2) www.zepro.com...
  • Page 29 Functional descriptions and schematics Z15/20 Function: lower Description: Vertical platform lowering. Control input: Down (E) Sensor input: Function not affected by sensor Active output: K1 (V1) www.zepro.com...
  • Page 30 Functional descriptions and schematics Z15/20 Function: tilt down Description: Tilting down within +45/-10 degrees from horizontal. Control input: Down (E) + Tilt (C) Sensor input: Active angle sensor (sensor is sending voltage to card) disables safety button requirement when the platform is within 45° from horizontal Active output: K1 (V1) + K3 (V2) www.zepro.com...
  • Page 31 Functional descriptions and schematics Z15/20 Function: tilt up Description: Platform tilt up or closing Control input: Up (B) + Tilt (C) Sensor input: Active angle sensor (sensor is sending voltage to card) disables safety button requirement when the platform is within 45° from horizontal Active output: K2 (Motor solenoid) + K3 (V2) www.zepro.com...
  • Page 32 Functional descriptions and schematics Z15/20 Function: raise Description: Vertical platform raising. Control input: Up (B) Sensor input: Function not affected by sensor Active output: K2 (Motor solenoid) www.zepro.com...
  • Page 33 Functional descriptions and schematics Z15/20 Function: close Description: Closing fully against the box body. Control input: Safety button (2H) + Up (B) + Tilt (C) Sensor input: Inactive angle sensor (doesn't send voltage to card) enables the safety button requirement in the last 45° of closing Active output: K2 (Motor solenoid) + K3 (V2) www.zepro.com...
  • Page 34 Functional descriptions and schematics 3.1.3 Schematic www.zepro.com...

  • Page 35: Electrical Safety Valves

    Functional descriptions and schematics Electrical safety valves 3.2.1 Relay card only Overview The Z 15/20 with electrical safety valves and no connection card is a variant which uses a hydraulic system based on four electrically operated valves and two mechanical safety valves. Two electrically operated valves, V1 and V2, located at the valve block above the pump/motor-assembly are used to direct flow to or from the tilt or lift cylinders, depending on which function is active.
  • Page 36 Functional descriptions and schematics Z15/20 Function: open, tilt down Description: Platform tilt down including opening from fully closed against body Control input: Down (E) + Tilt (C) Active output: K1 (V1, V4, V5) + K3 (V2). Note: no flow through V4 due to shifted V2 www.zepro.com...
  • Page 37 Functional descriptions and schematics Z15/20 Function: lower Description: Vertical platform lowering. Control input: Down (E) Active output: K1 (V1, V4, V5). Note: no flow through V5 due to unshifted V2 www.zepro.com...
  • Page 38 Functional descriptions and schematics Z15/20 Function: raise Description: Vertical platform raising. Control input: Up (B) Active output: K2 (Motor solenoid) www.zepro.com...
  • Page 39 Functional descriptions and schematics Z15/20 Function: Tilt up, close Description: Platform tilt up including closing against the box body Control input: Down (E) + Tilt (C) Active output: K2 (Motor solenoid) + K3 (V2) www.zepro.com...
  • Page 40 Functional descriptions and schematics 3.2.2 Relay car with Connection card Overview The Z 15/20 with electrical safety valves and no connection card is a variant which uses a hydraulic system based on four electrically operated valves and two mechanical safety valves. Two electrically operated valves, V1 and V2, located at the valve block above the pump/motor-assembly are used to direct flow to or from the tilt or lift cylinders, depending on which function is active.
  • Page 41 Functional descriptions and schematics Z15/20 Function: open Description: Platform opening from fully closed against box body to horizontal. Control input: Safety button (2H) + Down (E) + Tilt (C) Sensor input: Inactive angle sensor (doesn't send voltage to card) enables the safety button requirement in the initial 45° of opening Active output: K1 (V1, V4, V5) + K3 (V2). Note: no flow through V4 due to shifted V2 www.zepro.com...
  • Page 42 Functional descriptions and schematics Z15/20 Function: lower Description: Vertical platform lowering. Control input: Down (E) Sensor input: Function not affected by sensor Active output: K1 (V1, V4, V5). Note: no flow through V5 due to unshifted www.zepro.com...
  • Page 43 Functional descriptions and schematics Z5/20 Function: tilt down Description: Tilting down within +45/-10 degrees from horizontal. Control input: Down (E) + Tilt (C) Sensor input: Active angle sensor (sensor is sending voltage to card) disables safety button requirement when the platform is within 45° from horizontal Active output: K1 (V1, V4, V5) + K3 (V2). Note: no flow through V4 due to shifted V2 www.zepro.com...
  • Page 44 Functional descriptions and schematics Z15/20 Function: tilt up Description: Tilting up within +45/-10 degrees from horizontal. Control input: Up (B) + Tilt (C) Sensor input: Active angle sensor (sensor is sending voltage to card) disables safety button requirement when the platform is within 45° from horizontal Active output: K2 (Motor solenoid) + K3 (V2) www.zepro.com...
  • Page 45 Functional descriptions and schematics Z15/20 Function: raise Description: Vertical platform raising. Control input: Up (B) Sensor input: Function not affected by sensor Active output: K2 (Motor solenoid) www.zepro.com...
  • Page 46 Functional descriptions and schematics Z15/20 Function: close Description: Closing fully against the box body. Control input: Safety button (2H) + Up (B) + Tilt (C) Sensor input: Inactive angle sensor (doesn't send voltage to card) enables the safety button requirement in the last 45° of closing Active output: K2 (Motor solenoid) + K3 (V2) www.zepro.com...
  • Page 47 Functional descriptions and schematics 3.2.3 Schematic www.zepro.com...

  • Page 48: Troubleshooting

    Troubleshooting Troubleshooting Causes of malfunction There are three categories of issues that can lead to a malfunctioning tail lift: electrical, hydraulic and mechani- cal. Electrical issues are fairly common and include but are not limited to damaged wiring, sensors, magnets and solenoids.
  • Page 49 Troubleshooting in its closed position. Make sure the magnet on the valve is properly connected to the down-output on the Relay Card and to the earth point on the card. If the magnet is properly connected and the problem remains, use a multimeter to measure the resistance within the magnet.
  • Page 51 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...

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