Zepro ZHZ 500, Installation Instruction

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 73161TL 2022 11 30 Installation Instruction Tail Lift ZHZ 500 600 850 ...

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Page 3: ... 4 Before installation 10 4 1 Calculating the installed dimensions 10 4 2 Temporary connection 11 5 Installation 13 5 1 Installing the lift 13 5 2 Installing the Platform 14 5 3 Installing the angle sensor 15 5 4 Installing the hydraulic unit 16 5 5 Control devices 17 6 Cable routing 18 6 1 General 18 6 2 Sizing electrical systems 19 6 3 Main power cable earth cable main fuse and main switch 21 6 ...

Page 4: ...tion 29 8 2 Fluid level check 29 9 Markings and decals 30 9 1 Load diagram 31 9 8 Work area 32 9 3 Driver s instructions 32 9 2 Identification plate 32 9 4 Danger area 33 9 5 Warning tape 33 9 6 Warning flags 33 9 7 CE marking 33 10 Testing and verification 34 10 1 Static test loading 34 10 2 Dynamic test loading 35 10 3 Testing safety functions 35 11 Specifications 36 11 1 Weights 36 11 2 Load ce...

Page 5: ...ing 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 information that may help the reader understand or perform a given operation 1 2 Technical support If technical support is needed please contact ZEPRO Tel 46 0 10 459 05 04 E mail zeprotech hiab com Always be r...

Page 6: ...aulic 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 Hydraulic systems with hydraulic oil tanks marked with a specification for the hydraulic oil are only permitted to be filled with the oil specified on the label 1...

Page 7: ...o 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 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 batt...

Page 8: ...closest part of the cylinder must be at least 40 mm Fig 6 The platform may not be tilted down more than 10º from the horizontal 2 2 Connection of third party equipment is forbidden m 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 damag...

Page 9: ...Main parts 9 www zepro com ZHZ 500 600 850 3 Main parts Platform Tilt cylinder Lift arm Support arm Frame Lift cylinder Link Step Fig 7 Overview ...

Page 10: ...ft needs to be installed under the vehicle body D dimension and the space between the lift arms in the upper position and the vehicle floor level A dimension 4 1 2 D dimension The D dimension is the space that the lift needs measured from the rear edge of the body to the front edge of the support frame in the direction of the vehicle Once the C dimension has been determined the D dimension can be ...

Page 11: ...available power supply con nection and CS on the relay card to simulate switch CS being on Remove the cable immediately after completed operation m WARNING Take great care while running the lift functions and make sure nothing gets pinched risk of personal injury and material damage Fig 8 Temporary connection 4 2 1 Battery maintenance When installing the lift when the lift is operated repeatedly t...

Page 12: ...f warning lights and the most commonly occurring controller CD Control Device models is shown below Possible controller models vary depending on lift model configuration and relevant market m WARNING Make sure the control relay is disconnected from power before connecting Connecting more than one controller to each connection is not permitted Risk of material damage Black C1 White Brown Up Yellow ...

Page 13: ...the platform NOTE Foldable platform requires more space 4 Tighten the mounting screws using a torque wrench Tightening torque 80 Nm Fig 9 Use the adjusting screws for adjusting the armstop Arm stop adjusting screw 25 mm Front hole pattern Rear hole pattern Art no Front hole pattern Rear hole pattern 72807TL 2 screws M12x35 mm 3 screws M12x35 mm 76013TL 2 screws M12x35 mm 3 screws M12x35 mm 73029TL...

Page 14: ...ush the shaft inwards until its flush with the platforms suface on the opposite side see Fig 13 1 5 Fit in the screw attached see Fig 13 2 to lock the platform shaft 6 Refit the cover 7 Attach the cylinder to the cylinder bracket and lock with locking pin see Fig 14 Fig 10 Remove the cover Fig 11 Push the shaft out off the platform Fig 12 Place the platform Fig 13 Fit in and lock the platform shaf...

Page 15: ...or with the connection cable pointing upvards and out on the bracket using the attached screws see Fig 16 4 Mount the cable among existing cables using cable ties Connection is described later in section 7 NOTE The cable must be installed sufficiently far from or be protected against sharp edges so that it cannot chafe or otherwise sustain damage that can lead to a short circuit or cable fire In g...

Page 16: ...th regular tank cap before removing plugs in A and B 5 4 1 Connection of hydraulic hoses to hydraulic unit Return side tilt cylinder A Pressure side lift tilt cylinder B Fig 17 Return side tilt cylinder A Pressure side lift tilt cylinder B 5 5 Installation of license plate light Connect the license plate light to the vehicles ordinary lights cabeling Follow the manufacturer s recommendations Fig 1...

Page 17: ...ft Adjust with the adjustment screws so that both arm stops contact the lift arms at the same time NOTE On some vehicle models the space can be so confined that the lift has to be lowered in order for the adjusting screws to be accessible If so measure the need for adjustment first 5 8 Platform stop Applies only to folding platform When the lift platform is folded up and closed against the vehicle...

Page 18: ...ng torque 80 Nm Fig 22 The tilt cylinder can be adjusted so that the lift platform stops in the verti cal position behind the rear doors Fig 23 Undo the locking nut Fig 24 Turn the piston rod clockwise to angle down the platform or anti clock wise to angle up the platform Fig 25 The maximum permitted ad justing distance is 30 mm m WARNING Take great care during test operation before adjusting the ...

Page 19: ...e the lift cylinders by lowering the platform all the way to the ground a few times It may be necessary to raise the truck to allow the platform to be lowered completely Purge the tilt cylinders by tilting the platform all the way up to the vehicle body and then all the way down ...

Page 20: ...n the controllers must be at least 260 mm See Fig 26 3 Any additional controllers can be installed in an optional location 4 Run the controller cabling to the tail lift cable grommet Connection is described later in section 7 Fig 26 Installing control devices for two handed grip Min 260 mm 300 600 mm Fig 27 Installing control device m WARNING A controller must always be fitted on the side that is ...

Page 21: ... controllers with two handed grip are to be con nected a connection box must be fitted 1 Install the connection box in an appropriate location 2 When fitting the drainage tube must be facing downwards see Fig 28 3 Connection is described later in section 7 Fig 28 Connection box Connection box Drainage tube Circuit board Cover ...

Page 22: ...nnection 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 must be so well protected that increased voltage drop due to oxidation over time can be eliminated Risk of material damage Warranty rights do not apply to material damage caused by insufficient earthing A...

Page 23: ...a pacity Imin Some vehicle models have restrictions regarding the amount of power the lift can access from the existing battery 12 volt 24 volt Pump Motor unit 100 A 60 A Magnet hydr unit 4 2 A 0 7 A Magnet electrical hose rupture valve 1 5 A 0 75 A Solenoid 1 8 A 0 9 A Minimum recommended conductor cross sectional area copper cables positive and negative cables Control cable 1 5 mm2 1 5 mm2 Suppl...

Page 24: ...d conductor cross sectional area copper cables positive and negative cables Control cable 1 5 mm2 1 5 mm2 Supply line L 8 m 35 mm2 35 mm2 Supply line L 8 15m 35 mm2 35 mm2 Supply line L 15 m 35 mm2 Battery Min capacity Imin 140 Ah 110 Ah Min voltage during operation Umin when lifting 9 volt 18 volt NOTE Ensure that the lift has access to the minimum recommended power ca pacity Imin Some vehicle mo...

Page 25: ...ct 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 switch 5 On tail lifts with cable mounted quick connector for its main power connect the main power cable to the quick connector 6 Route the main power cable from the tail lift to the fuse box battery plus ter...

Page 26: ...ting cabling using cable ties Fig 35 The cable grommet s five screws 7 2 Connection 1 Run the cabling through the grommet 2 Connect the relevant controller See section 7 4 When connecting more than 3 controllers or 2 controllers with two handed grip connect via connection card See section 7 5 3 Where applicable connect the angle sensor See Section 8 1 4 Where applicable connect cab switch CS and o...

Page 27: ...ning lights and the most commonly occurring controller CD Control Device models is shown below Possible controller models vary depending on lift model configuration and relevant market m WARNING Make sure the control relay is disconnected from power before connecting Connecting more than one controller to each connection is not permitted Risk of material damage Black C1 White Brown Up Yellow Down ...

Page 28: ...28 Connection www zepro com ZHZ 500 600 850 7 5 Connection card ...

Page 29: ...600 850 7 5 1 Scotchlok IMPORTANT When using Scotchlok make sure all cables are correctly positioned and use a suitable plier to acheev correct clamp connection Bad connection can cause mall function and material damage on the equippment ...

Page 30: ...c Larm för öppen 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 for Trailer Output fuse LED Powerpack QC U3 U2 U1 U0 Outputs MainFuse 15 A Power in U0 U1 U2 U3 U4 U5 U6 U7 WL1 PA WL2 S5 S4 S3 S2 S1 S5 S4 S3 S2 S1 CS CS PA VDHH Sensors User controls Ctrl1 Ctrl2 Ctrl3 Down 2H Out Down Down C1 C1 Up Til...

Page 31: ... any way detrimental to the interest of Z Lyften Produktion AB Där annat ej anges Drawing interpretation unless otherwise specified All measures intends finished product Alla mått avser färdig produkt Benämning Title Material Dimension Datum Date Vikt Weigh kg Skala Scale Konstr Designer Kontr Checked by Godk Approved by Artikelnr Stock nr Ritningsnr Drawing nr Blad Sheet Format Size Revision För ...

Page 32: ... power cable 3 to the fuse box positive terminal see Fig 36 Fig 37 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 at right angles to the cables see Fig 36 Fig 37 IMPORTANT The knob must bear against and centre the cable lug so that it does not come into contact with the screw Incorrect installation can cause the fuse to...

Page 33: ...ipped with slide bearings that must NOT be lubricated 10 2 Fluid level check Check the fluid level in the tank when performing servicing 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 biode gradable synthetic fluid product no 22235 ...

Page 34: ...0 600 850 11 Markings and decals 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 11 1 11 3 11 4 11 6 11 8 11 7 ...

Page 35: ...ZHZ 500 600 850 11 1 Load 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 Fig 41 Load diagram ZHZ 500 Fig 42 Load diagram ZHZ 600 ...

Page 36: ...untry of manufacture Type no for approved underrun protection RUPD Type no for electromagnetic compatibility EMC Corresponding identification plate in decal design preferably located on the cab door pillar for reliable identification 11 3 Work area A work area decal must be attached to the platform so that any drivers parking behind the vehicle know that a 5 m clearance is required for the platfor...

Page 37: ...tform and the rear edge of the vehicle The decal must be attached to the inside of the vehicle body close to where the manual control device is installed 11 7 Warning tape The warning tape is ideally attached along the plat form s edges to indicate the edges of the platform in the lowered position The location of the warning tape often coincides with the contour marking in which case the warning t...

Page 38: ...oad from the platform Repeat the measurement of A B C D and verify that there has been no permanent deformation of the lift or its mounting 12 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 Leave the test load for 15 minutes Verify that the platform drift is no more than 15 mm in the vertical direction point...

Page 39: ... lift s safety functions must be tested Check that the red light in the driver s cab is deactivated when the platform is completely closed against the body and conversely that it is activated when the platform is opened that the lift cannot be activated when the control switch in the cab is turned off that the lift cannot be activated when the main switch s fuse by the battery is tripped that the ...

Page 40: ...Below is a list detailing a selection of components and their weight Complete lift chassis without platform Lift components included in complete lift chassis 130 kg Support frame 24 5 kg Lift arm 22 5 kg Platforms Support arm 5 1 kg Whole Link 1 7 kg 1200x1400 mm 55 kg Step 9 7 kg 1400x1400 mm 58 kg Hydraulic unit 13 kg 1600x1400 mm 64 kg Lift cylinder 5 6 kg Outer boom cylinder 7 2 kg Folding 120...

Page 41: ...ifications 41 www zepro com ZHZ 500 600 850 C ZHZ 500 600 alu platform 1200x1400 mm 13 2 Load centre C 150 C 300 C 450 TP1 mm 185 160 113 TP2 mm 500 kg 413 417 423 TP2 mm 600 kg 496 500 508 TP2 TP1 Max load ...

Page 42: ...r 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 ...

Page 43: ...Registration 43 www zepro com ZHZ 500 600 850 ...

Page 44: ...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 our customers operations and to shape the future of intelligent load handling ...