Zepro Z3N 75-100, Installation Instruction

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 74598TL 2022 11 30 Installation Instruction Tail Lift Z3N Z3NU 75 100 Z3NN Z3NNU 75 100 Z3NW Z3NWU 75 100...

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Page 3: ...9 3 2 Statutory dimensions 9 3 3 Calculating the installed dimensions 10 3 4 Z3N U 75 100 11 3 5 Z3NN U 75 100 12 3 6 Z3NW U 75 100 13 3 7 Temporary connection 14 4 Installation 17 4 1 Frame 17 4 2 Hy...

Page 4: ...9 1 Lubrication 46 9 2 Oil level check 46 10 Marking 47 10 1 Loading diagram 48 10 2 Identification plate 49 10 3 Work area 49 10 4 Warning tape 49 10 5 Controller sticker 50 10 6 Danger area 51 10 7...

Page 5: ...ening injury m CAUTION CAUTION indicates a potential hazard which if ignored may lead to minor injuries IMPORTANT IMPORTANT indicates a risk of equipment damage NOTE NOTE refers to additional informat...

Page 6: ...ed to be filled with highly refined mineral oil art no 21963 1 litre Hydraulic systems with hydraulic oil tanks marked with a specification for the hydraulic oil are only permitted to be filled with t...

Page 7: ...storage and how much power other components in the vehicle take from the battery After a period of storage the battery must always be charged fully before operating the lift When the lift is operated...

Page 8: ...res on the vehicle 2 3 Installation m WARNING Installation where the platform cannot reach ground level is prohibited m WARNING ZEPRO tail lifts are only approved for installation using ZEPRO assembly...

Page 9: ...ave at least dimensions of 95x50x3 mm corresponding to a minimum surface moment of inertia of 78 cm4 around the x axis See Image 7 If in doubt contact ZEPRO for support 3 2 Statutory dimensions Distan...

Page 10: ...there will be between the lift arms in the upper position and the vehicle floor level A dimension 3 3 2 D dimension The D dimension is the space the lift needs measured from the rear edge of the body...

Page 11: ...les 11 www zepro com Image 9 Installation dimensions for Z3N U 75 100 C A D R58 3 425 133 557 Approved 400 127 580 375 120 601 362 116 611 350 113 620 3 4 Z3N U 75 100 C 75 D max min A 1000 max Max 57...

Page 12: ...rules www zepro com Image 10 Installation dimensions for Z3NN U 75 100 C A D R58 3 463 133 607 Approved 438 127 630 413 120 651 400 116 661 388 113 670 3 5 Z3NN U 75 100 C 75 D max min A 1000 max Max...

Page 13: ...s 13 www zepro com Image 11 Installation dimensions for Z3NW U 75 100 380 155 A max 155 549 232 719 1080 1900 3 6 Z3NW U 75 100 C 75 D max min A 1000 max Max 545 166 14 C A D R58 3 455 133 607 Approve...

Page 14: ...S on the control card to simulate that the CS switch is turned on Remove the jumper immediately after completed operation m WARNING Take great care while running the lift functions and make sure nothi...

Page 15: ...i 1 Di 2 Di 3 Di 4 Di 5 Di 6 PA PA CSPWR CS B E C 2H1 B E C 2H2 B E C Lock B E C Lock U7 U6 U5 U4 U3 U5 U4 U2 U1 U0 Ctrl 6 Out In GND LLED Ctrl 5 Outputs Sensors o Brun B Gul E Bl C Bl 2H CD1 CD2 B C...

Page 16: ...from power before connecting Connecting more than one controller to each connection is not permitted Risk of material damage WL1 U7 U6 U5 U5 U4 U4 U3 U2 U1 U0 U0 U1 U2 U3 WL2 PA S5 S1 S4 S3 S2 S1 S5...

Page 17: ...Attach the mounting jig part no 74632TL f r Z3N 75 to the rear beam so that the respective midpoint corresponds Use clamps screws or spot weld 6 Place the lifting frame under the vehicle s frame and...

Page 18: ...Use supplied M10x25 50Nm 4 1 2 Hydraulic unit and hydraulic hoses The hydraulic unit is supplied with pre connected hydraulic hoses and electric cables 4 1 3 Hydraulic hoses A Oil return Tilt circuit...

Page 19: ...NU Z3NN Z3NNU Z3NW Z3NWU 75 100 Installation 19 www zepro com 4 2 Hydraulic unit with circuit card detailed image Image 19 Hydraulic unit FILLER CAP VALVE U1 CIRCUIT CARD CHASSIS WITH TANK SOLENOID S...

Page 20: ...NOTE Carefully lubricate the metal bushings on the upper bearing of the arms Make sure the small holes are filled with grease After installation of the platform the same bearings are also lubrica ted...

Page 21: ...fitting the top edge seal 4 3 2 Sealing strip horizontal surface mounted rubber strip The track is fitted using the self tapping screws supplied 1 Check that the distance between the vehicle floor and...

Page 22: ...nut onto the armstop and assemble them onto the stop profile 6 Place the armstop according to the position of the lift arm and secure by tightening its screws 7 Screw the stop profile into the pre dri...

Page 23: ...le sensor is installed according to illustration Secure with supplied screws Use 5 2mm drill 4 3 6 Electronic autotilt angle sensor Angle sensor is installed according to illustration Secure with supp...

Page 24: ...orm is lowered To ensure that the locking nut is fixed in the set posi tion it is recommended that it is locked with Loctite 243 or equivalent NOTE Max adjustment distance is 30 mm Do not exceed this...

Page 25: ...ting holes Use 2 M12x45 on each side 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...

Page 26: ...when running cables to get longer life for the cables and to reduce the risk of unnecessary downtime The cable must not be fastened to brake lines or the vehicle s normal electrical system The cable m...

Page 27: ...d tail lift and their working area 2 The distance between the vehicle s rear edge and the centre of the controllers must be 300 600 mm The distance between the controllers must be at least 260 mm See...

Page 28: ...connection must be made primarily to the negative terminal of the battery Alternatively another well protected earthing point which will not increase the voltage drop can be used The earthing point mu...

Page 29: ...g battery 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 NOTE Make sure the lift has ac...

Page 30: ...on connect the earth cable to the quick connector 4 Route connect the tail lift earth cable to the negative terminal of the battery or to a well protected earthing point When installing without main s...

Page 31: ...in switch and controller cables on the underside of the arm and fasten with cable ties 5 Pull the main power cable from the main switch to the fuse box battery plus pole Prepare the cable with a cable...

Page 32: ...cting peripheral equipment Risk of damage m WARNING Ensure that the angle sensor is fitted with the cable input in the same direction as the one that was removed Route the cables between the platform...

Page 33: ...be undone 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 cab...

Page 34: ...nnected from power before connecting Connecting more than one controller to each connection is not permitted Risk of material damage WL1 U7 U6 U5 U5 U4 U4 U3 U2 U1 U0 U0 U1 U2 U3 WL2 PA S5 S1 S4 S3 S2...

Page 35: ...1 Di 2 Di 3 Di 4 Di 5 Di 6 PA PA CSPWR CS B E C 2H1 B E C 2H2 B E C Lock B E C Lock U7 U6 U5 U4 U3 U5 U4 U2 U1 U0 Ctrl 6 Out In GND LLED Ctrl 5 Outputs Sensors o Brun B Gul E Bl C Bl 2H CD1 CD2 B C 2...

Page 36: ...intends finished product Title Material Dimension Date Weigh kg Scale Designer Checked by Approved by Stock nr Drawing nr Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish...

Page 37: ...itning r Z Lyftens egendom och skyddad enligt internationellt g llande lag f r copyright och f r ej utan Z Lyftens skriftliga medgivande kopieras delges eller obeh rigen anv ndas This drawing is prope...

Page 38: ...n ZEPRO El hydraulschema E H Schematic Larm f r ppen brygga Detection open Platform Z55598 79037TL 2021 09 23 MB ME MB MK B A2 1 1 Z Lyften Produktion AB 4 11 11 4 10 Connection for Truck Connection f...

Page 39: ...lschema E H Schematic Larm f r ppen brygga Detection open Platform Z54870 77752TL 2018 11 21 MB OE MB MK A A2 1 1 Z Lyften Produktion AB Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Control Power Sensor P...

Page 40: ...Z3N Z3NU Z3NN Z3NNU Z3NW Z3NWU 75 100 40 Connection www zepro com 6 2 7 Open platform alarm Applies when installing with main switch 4 11...

Page 41: ...main power cable 3 to the fuse box positive terminal see Image 54 Image 54 6 Screw tight the cable connections and fuse with the knob 4 Install the cables at 90 or 180 from each other Install the fuse...

Page 42: ...pretation unless otherwise specified All measures intends finished product Alla m tt avser f rdig produkt Ben mning Title Material Dimension Datum Date Vikt Weigh kg Skala Scale Konstr Designer Kontr...

Page 43: ...r Drawing nr Blad Sheet Format Size Revision F r denna ritning g ller IS0 toleranser SMS ritregler Toleranser Tolerance Ytj mnhet Surface finish Svets Welding 1 1 Ritad Drawn A HIAB brand part of Carg...

Page 44: ...ss otherwise specified All measures intends finished product Alla m tt avser f rdig produkt Ben mning Title Material Dimension Datum Date Vikt Weigh kg Skala Scale Konstr Designer Kontr Checked by God...

Page 45: ...Drawing nr Blad Sheet Format Size Revision F r denna ritning g ller IS0 toleranser SMS ritregler Toleranser Tolerance Ytj mnhet Surface finish Svets Welding 1 1 Ritad Drawn A HIAB brand part of Cargot...

Page 46: ...at upper bearing 2 Lift cylinder at lower bearing 7 Right tilt cylinder at upper bearing 3 Left tilt cylinder at lower bearing 8 Lift arm right side at upper bearing 4 Lift arm left side at upper bear...

Page 47: ...9 V cuandolatensi nesbaja NB S lolaunidadde controlprincipalfunciona Emergency closingwhenvoltag eislow NB Onlythemaincont rolunitisfunctional N dst ngning vidl gvolt OBS Endast huvudman verdonet ranv...

Page 48: ...o com 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 f...

Page 49: ...g information Type of lift Max permitted load in kg Production number Year of manufacture Address and tel no of manufacturer Country of manufacture Type number for approved underrun protection RUPD Ty...

Page 50: ...iab com 77661TL 2020 03 04 10 5 Controller sticker Affix the controller sticker next to the relevant controller The stickers are available in standard versions and in reversed version for affixing on...

Page 51: ...r on the inside of the vehicle body next to the hand control unit 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...

Page 52: ...there has been no deformation of the lift or its fixing 11 1 2 Drift Place a test load on the platform according to the table The tail lift must be at the same level and angle as the vehicle floor Lea...

Page 53: ...g to the table for the respective tail lift model and lifting capacity The test load should be 1 25 x the lift model s max load Check that the lift gate cannot lift the load when the up function is sw...

Page 54: ...he tail cannot be operated when the main current fuse is removed where applicable That the overflow valve is activated when the lift is run up to the floor level or arm stops That the tail lift cannot...

Page 55: ...rom the platform and rest the cylinders on the ground 3 Run the tilting cylinders to their minimum stroke limit to remove pressure from the circuit 4 Dismantle the axles Knock them out with a hammer a...

Page 56: ...75 100 112 kg Z3NN 75 100 99 kg Z3NNU 75 100 111 kg Z3NW 75 100 101 kg Z3NWU 75 100 113 kg Aluminium platforms Alu platform 1200x2160 mm 54 kg Alu platform 1450x2160 mm 61 kg Alu platform 1600x2160 mm...

Page 57: ...WU 75 100 Specifications 57 www zepro com TpX GgY C CgX CgY C 13 2 Center of gravity Z3N Z3NU Max Load 750kg C TpX TpY 425 1119 445 400 1142 422 375 1161 398 350 1179 374 C TpX TpY 425 448 443 400 460...

Page 58: ...U 75 100 58 Specifications www zepro com 13 3 Center of gravity Z3NW Z3NWU CgX CgY CgX CgY C Max Load 750kg C C TpX TpY 455 1169 475 430 1192 452 405 1211 428 380 1229 404 C TpX TpY 455 498 473 430 51...

Page 59: ...NWU 75 100 Specifications 59 www zepro com 13 4 Center of gravity Z3NN U CgX CgY CgX CgY C Max Load 750kg C C TpX TpY 463 1169 483 438 1192 460 413 1211 463 388 1229 412 C TpX TpY 463 498 481 438 510...

Page 60: ...Z3N Z3NU Z3NN Z3NNU Z3NW Z3NWU 75 100 60 Specifications www zepro com Image 73 Loading diagram 13 5 Loading diagram...

Page 61: ...3NWU 75 100 Specifications 61 www zepro com 13 6 Tightening torque All specified torque values apply for use with a screw or impact wrench with torque control Torque distribution max 5 NOTE M8 25Nm M1...

Page 62: ...ifts 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 o...