Related Manuals for Zepro Z3NW 75-100
Summarization of Contents
Important Information
Attention!
Explains warning signs like WARNING!, CAUTION!, IMPORTANT!, NOTE! for potential hazards.
Technical Support
Provides contact details for technical support and emphasizes providing the production number.
Identification
Details the meaning of model codes (ZN, Z3NU, etc.) and dimensions.
CE Marking
States that ZEPRO tail lifts are CE marked and comply with EU Machinery Directive.
Product Approval
Mentions compliance with EN 1756-1:2001 + A1:2008.
Hydraulic Oil
Specifies approved hydraulic oils for replenishment and filling.
Guarantee
Outlines warranty conditions, including assembly by approved bodybuilders.
Repainting
Warns against painting piston rods, cylinder covers, boots, hoses, and cables due to potential damage.
Battery Maintenance
Advises disconnecting the lift from the battery when storing for long periods and charging before use.
Safety Rules
Moving Parts - Free Movement
Specifies minimum clearance for moving cylinders and platform tilt angle limits.
Connection of Third-Party Equipment is Forbidden
Prohibits connecting third-party equipment to prevent interference with lift systems and safety functions.
Installation Safety
States installation prohibition if platform cannot reach ground level and approved installation methods.
Before Installation
Vehicle Chassis Requirements
Details required vehicle chassis specifications for mounting the tail lift, including frame beam dimensions.
Statutory Dimensions
Lists maximum allowed distances for underrun protection and ground clearance relative to the vehicle.
Calculating Installed Dimensions
Explains how to calculate key installation dimensions like C, D, A, and H from tables.
Z3N(U) 75-100 Installation Dimensions
Provides specific installation dimensions and diagrams for Z3N(U) 75-100 models.
Z3NN(U) 75-100 Installation Dimensions
Provides specific installation dimensions and diagrams for Z3NN(U) 75-100 models.
Z3NW(U) 75-100 Installation Dimensions
Provides specific installation dimensions and diagrams for Z3NW(U) 75-100 models.
Temporary Connection
Details how to temporarily connect the lift for testing functions with different control cards.
Battery Maintenance During Installation
Reiterates battery maintenance advice, especially when the lift is operated repeatedly.
ZePRO1 Control Card Connection
Provides wiring diagrams for connecting control devices to the ZePRO1 control card.
TLC-B1 Relay Card Connection
Provides wiring diagrams for connecting control devices to the TLC-B1 relay card.
Installation
Frame Mounting
Details the steps for mounting the lift frame to the vehicle chassis, including measurement and attachment.
Hydraulic Unit Attachment
Instructions for mounting the hydraulic unit on the lifting frame using specified bolts.
Hydraulic Unit and Hoses
Notes that the hydraulic unit comes with pre-connected hoses and cables.
Hydraulic Hose Identification
Identifies hose functions: A for oil return Tilt circuit, B for pressure to lift and tilt circuit.
Hydraulic Unit Detailed View
Provides a detailed diagram of the hydraulic unit, identifying key components.
Lift Platform and Sealing Strip Installation
Details steps for fitting the lift platform, lubricating bushings, and attaching tilt cylinders.
Horizontal Sealing Strip
Instructions for fitting horizontal sealing strips using self-tapping screws and drill holes.
Vertical Sealing Strip
Instructions for attaching vertical sealing strip tracks and fitting the rubber strip.
Integrated Rubber Sealing Strip
Details steps for fitting integrated rubber sealing strips, including stop profiles and armstops.
Fast Opening Angle Sensor Installation
Instructions for installing the fast opening angle sensor using supplied screws.
Electronic Autotilt Angle Sensor Installation
Instructions for installing the electronic autotilt angle sensor using supplied rivets.
Tilt Cylinder Adjustment
Explains how to adjust the tilt cylinder for proper platform fit, including loosening lock nuts and refitting bellows.
Cylinder Purging
Instructions for purging lift cylinders by lowering the platform and for tilt cylinders by closing against the body.
Underrun Protection Installation
Details the installation of underrun protection, including screwing brackets and aluminum profiles with specific torque values.
Controller Installation
Instructions for installing the primary controller, emphasizing placement away from traffic and specific distances.
Controller CD 1 Installation
Details fitting controllers, ensuring operator safety, and maintaining specific distances between the rear edge and controllers.
Cable Routing
General Cable Routing Principles
Emphasizes correct component sizing, assembly accuracy, and proper cable routing for reliability and safety.
Sizing Electrical Systems
Guides on ensuring sufficient battery and charger capacity and using appropriate cable cross-sectional areas.
Main Power, Earth, Fuse, and Switch
Instructions for mounting main switches, routing main power and earth cables, and connecting to fuse boxes or battery terminals.
Main Power Switch Mounting
Details mounting the main switch, connecting cables, and routing them, emphasizing downward drainage.
Control Power Cable Routing
Instructions for routing control current cables from cab switches to the tail lift cable grommet.
Open Platform Alarm Installation
Recommends installing an open platform alarm (warning light or lamp) and routing lamp cables.
Warning Lighting and Foot Controls Cabling
Details cabling for warning lights and foot controls, including sensor replacement and routing between platform and pipe.
Connection
Cable Grommet Procedure
Instructions for installing, dismantling, and adjusting cables in the cable grommet on the hydraulic unit.
TLC-B1 Relay Card Connection
Provides wiring diagrams for connecting control devices and warning lights to the TLC-B1 relay card.
ZePRO1 Control Card Connection
Provides wiring diagrams for connecting control devices to the ZePRO1 control card.
TLC-B1 Warning Light and Foot Controller
Shows signal requirement for warning light on relay card input S3 and wiring for foot control and warning lights.
ZePRO1 Warning Lights and Foot Controls
Shows wiring for foot control and warning lights for the ZePRO1 control card.
TLC-B1 Cab Switch and Open Platform Alarm
Details connections for truck and trailer for cab switch and open platform alarm using TLC-B1.
ZePRO1 Cab Switch and Open Platform Alarm
Details connections for truck and trailer for cab switch and open platform alarm using ZePRO1.
Open Platform Alarm (Main Switch)
Shows the circuit for an open platform alarm when installing with a main switch.
Electrical and Hydraulic Drawings
TLC-B1 System Schematics
Presents the electrical and hydraulic schematic for TLC-B1 systems.
ZePRO1 System Schematics
Presents the electrical and hydraulic schematic for ZePRO1 systems.
TLC-B1 Electrical Autotilt Schematics
Shows the electrical and hydraulic schematic for TLC-B1 systems with electrical autotilt.
ZePRO1 Electrical Autotilt Schematics
Shows the electrical and hydraulic schematic for ZePRO1 systems with electrical autotilt.
Lubrication and Fluid Level Check
Lubrication Points
Lists all lubrication points on the lift that require greasing during installation and regular maintenance.
Oil Level Check
Instructs on checking and topping up hydraulic fluid levels, specifying fluid types and product numbers.
Marking
Loading Diagram
Instructs to affix load diagrams near the primary controller and in a visible position on the vehicle body.
Identification Plate
Explains the location and content of the identification plate for easy identification of the lift.
Work Area Sticker
Instructs to affix the work area sticker clearly visible on the rear of the vehicle.
Warning Tape Application
Details affixing warning tape along platform edge strips to mark edges in the lowered position.
Controller Sticker Placement
Guides on affixing controller stickers next to relevant controllers, ensuring correct orientation for vehicle/lift image.
Danger Area Sticker
Instructs to affix the danger area sticker on the inside of the vehicle body next to the hand control unit.
Warning Flags Attachment
Details attaching warning flags to the platform edges to ensure they don't come loose when lowered.
Testing and Verification
Static Load Test Procedures
Details procedures for static load testing, including deformation checks and drift verification.
Dynamic Load Test Procedures
Outlines procedures for dynamic load testing, including tests with max load and overload.
Safety Functions Test
Lists safety functions to be tested, such as red light behaviour, cabin switch operation, and sticker installation.
Specifications
Component Weights
Provides weights for complete lift chassis, aluminium platforms, lift components, and accessories.
Center of Gravity Z3N / Z3NU
Shows diagrams and tables for the center of gravity calculations for Z3N and Z3NU models.
Center of Gravity Z3NW / Z3NWU
Shows diagrams and tables for the center of gravity calculations for Z3NW and Z3NWU models.
Center of Gravity Z3NN(U)
Shows diagrams and tables for the center of gravity calculations for Z3NN(U) models.
Loading Diagram
Displays a loading diagram for a maximum load of 750 kg, showing load capacity versus center of gravity distance.
Tightening Torque Specifications
Lists specified torque values for various bolt sizes (M8, M10, M12, M14) for installation.
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