Zepro ZHZ 500-850, Installation Instruction

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 73161TL 2020 06 02 Installation Instruction Tail Lift ZHZ 500 600 850...

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Page 3: ...ers 11 4 5 Attaching decals 11 5 Calculating the installed dimensions 12 5 1 C dimension 12 5 2 D dimension 12 5 3 H dimension 12 6 Installation kits 13 7 Installation 15 7 1 Installation of installat...

Page 4: ...rea 70 9 7 Warning tape 70 9 8 Warning flags 71 9 9 CE marking 71 10 Lubrication and fluid level check 72 10 1 Lubrication 72 10 2 Fluid level check 72 11 Testing and verification 73 11 1 Static test...

Page 5: ...tion instructions and are intended to draw your attention to circumstances potentially causing unwanted situations near misses personal injury or damage to the product etc Take care Risk of damage to...

Page 6: ...n using the control device and its functions 1 3 Hydraulic fluid Our tail lift must work just as well in tropical heat as in the Arctic cold The heat is no problem for the fluid The cold on the other...

Page 7: ...www zepro com 1 4 Identification Max lifting capacity x 1 kg Max lifting height 850 850 mm Cylinder model MA Double acting adjustable tilt Single acting lift Identification list E g 600 850 MA _ _ _ _...

Page 8: ...age the cylinder seals Boots hydraulic hoses and cables must not be painted coated as the solvent in the paint could damage the hoses cables and significantly impair their durability NOTE Fig 1 Piston...

Page 9: ...k chassis member for rear lights number plate and the lift s chassis bracket with short overhangs Final inspection must be performed with the platform by the vehicle floor and tilted down 10 The clear...

Page 10: ...5 Installation The lift s platform must not be installed so that it cannot reach ground level Zepro s tail lifts are only approved for installation with Zepro s installation kits The lift s capacity m...

Page 11: ...tall the hydraulic hoses Add hydraulic oil in the hydraulic oil tank 4 2 Electrical connection Install the control devices Install the control devices cables Install the main power cable 4 3 Installin...

Page 12: ...eeds 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 5 2 D dimension The D dimension is the space t...

Page 13: ...5 Mercedes Sprinter 2018 3 5t RWD L 3665 24 9 kg 73167TL 7 1 6 Mercedes Sprinter 2018 5t RWD L 4325 Vehicle lenght 6967 17 6 kg 76796TL 7 1 7 Mercedes Sprinter 2006 2016 5t RWD L 4325 Vehicle lenght...

Page 14: ...D 15 5 Kg 78012TL 7 1 18 Mercedes Sprinter 2018 5t RWD L 4325 15 2 Kg 78128TL 7 1 19 Mercedes Sprinter 2018 3 5t RWD L 3665 26 8 kg 78130TL 7 1 20 Mercedes Sprinter 2018 3 5t RWD L 4325 15 2 Kg 78160T...

Page 15: ...ut tightening Installation play between chassis bracket and the lift s dimen sions 997 mm may not exceed 2 mm 4 When installing a folding platform slide the chassis bracket 20 mm to the left to avoid...

Page 16: ...height difference between the lift arm and the floor of the body to ap prox 25 mm Then adjust the lift so it is as close to the rear doors as possible Fig 12 Adjust the lift so it is as close to the...

Page 17: ...r 1 x M10 nyloc nut 1 x Spacer 20 mm Tightening torque 50 Nm 1 x M14x1 5 screw L 30 1 x Square washer Tightening torque 120 Nm 2 x M10x85 screws 1 x Washer 1 x M10 nyloc nut Tightening torque 50 Nm 2...

Page 18: ...M10 x 55 x 1 25 22765TL Sexkantskruv fing ngad Hexagon head screw 4 12 Z50404 72794TL Distans 20 mm Distance 20 mm 6 11 1 DIN 125 A 13 20181TL Bricka Plain washer 4 10 1 DIN 985 M10 20170TL Sexkantsm...

Page 19: ...Sexkantskruv Hexagon head screw 2 14 5 ISO 7089 10 140 HV 20184TL Bricka Plain washer 8 13 8 DIN 960 M10 x 55 x 1 25 22765TL Sexkantskruv fing ngad Hexagon head screw 4 12 Z50404 72794TL Distans 20 mm...

Page 20: ...with rustproof ing agent 3 Check that the supplied spacer tubes fit in the frame If necessary drill the holes to 20 5 so that the spacers can be installed Apply rustproofing agent See Fig 15 4 Install...

Page 21: ...HZ 600 Ford Transit V3 5 This drawing is property of Z Lyften Produktion AB and is loaned subject to return upon demand It is not to be reproduced or used directly or indirectly in any way detrimental...

Page 22: ...lose to the exhaust mounting as possible See Fig 16 4 Cut the towing eyelet as close to the mount as possible See Fig 17 5 Cut the left mounting bracket for the bumper by approx 200 mm See Fig 18 6 Ch...

Page 23: ...sis brack ets and bumper brackets 7 Install the chassis brackets and the bumper brackets with the supplied 5 x M12x110 screws M12 nyloc nuts and washers Tighten with the aid of a torque wrench See Fig...

Page 24: ...rance Surface finish Welding Mont sats ZHZ 600 Ford tran 2014 2014 06 24 TC 1 3 MJ TC 10 2 Z52993 74914TL A3 1 1 EN ISO 13920 A Z Lyften Produktion AB Drawn TC A CARGOTEC BRAND Used on Mounting kit ZH...

Page 25: ...3 If needed cut the exhaust pipe to avoid interference with the lift chassis 4 Cut the towing eyelet as close to the mount as possible see Fig 20 5 Install the chassis brackets and the bumper bracket...

Page 26: ...c king Hex Nut 18 3 Z53064 2 75017TL Ram f ste ZHZ 600 V Frame bracket ZHZ 600 L 1 2 Z53064 1 75016TL Ram f ste ZHZ 600 H Frame bracket ZHZ 600 R 1 1 Rev Drawing nr Stock nr Title Description Qty Item...

Page 27: ...illed hole See Fig 22 3 Install the chassis bracket on the outside and the base plate on the inside of the vehicle s frame Use 1 x M10x90 screw M10 nyloc nut washer and spacer Tighten with the aid of...

Page 28: ...m Satsen passar f ljande modeller Generation 906 2006 VW Crafter MB Sprinter Vans 3 5 t med hjulbas 4325 verh ng 1615 2015 Kit fits the following models Generation 906 2006 VW Crafter MB Sprinter Vans...

Page 29: ...rews Fig 26 Install outer and inner chassis brackets in the vehicle chassis Use four M12x100 screws Fig 25 Install the spacer tubes 4 Drill a 12 5 hole in the frame from the outside and inside using t...

Page 30: ...agningsmoment f r skruv och mutter Tightening torque for screws and nuts M12 80Nm Satsen passar f ljande modeller Generation 906 2006 VW Crafter MB Sprinter Vans 3 5 t med hjulbas 3665 verh ng 1240 Ki...

Page 31: ...x 90 22305TL Sexkantskruv M10 Screw M10 2 5 Z41759 01 63242TL Distansr r Spacer 2 4 ISO 7089 10 140 HV 20184TL Bricka Plain washer 2 3 Z54326 2 76795TL Ramf ste V Mounting bracket L 1 2 Z54326 1 7679...

Page 32: ...M12 21980TL Mutter M6MF M12 Loc king Nut M12 8 4 ISO 4014 M12 x 110 22304TL Sexkantsskruv Hexagon head screw 8 3 Z54329 1 76799TL Ramf ste H Bracket R 1 2 Z54329 2 76800TL Ramf ste V Bracket L 1 1 Dr...

Page 33: ...and one reinforcement plate see Fig 28 Tightening torque 80 Nm It may be necessary to create a cut out in the bumper NOTE 3 Drill up the holes on the vehicle chassis inside to 15 mm so that the spacer...

Page 34: ...Nut M12 18 4 Z54199 76594TL F rst rkning insida Crafter 2017 Reinforcement pl Crafter 2017 2 3 Z54282 2 76743TL Ramf ste ZHZ 600 Crafter 2017 V Mount br ZHZ600 Crafter 2017 L 1 2 Z54282 1 76742TL Ramf...

Page 35: ...acket in the ve hicle chassis use excisting holes Use four M12x110 screws and one reinforcement plate see Fig 30 Tightening torque 80 Nm It may be necessary to create a cut out in the bumper NOTE 3 Dr...

Page 36: ...Z54199 76594TL F rst rkning insida Crafter 2017 Reinforcement pl Crafter 2017 2 4 Z54473 77090TL Distans bricka Spacer 2 3 Z54476 2 77130TL Ramf ste ZHZ 600 V nster Mount br ZHZ 600 Left 1 2 Z54476 1...

Page 37: ...5 5 ISO 7089 12 140HV 20181 Bricka Plain washer 26 4 5 ISO 7089 10 140 HV 20184 Bricka Plain washer 4 3 A Z52558 2 74481TL Ramf ste v nster Mounting bracket left 1 2 A Z52558 1 74480TL Ramf ste Renau...

Page 38: ...2 140HV 20181 Bricka Plain washer 26 4 1 ISO 4017 M12 x 45 22213 Sexkantskruv Six head screw 16 3 Z52562 1 74485TL Ramf ste h ger Mount bracket right 1 2 Z52562 2 74486TL Ramf ste v nster Mount bracke...

Page 39: ...28 4 Z52563 74483TL Distans pl t Spacer plate 2 3 A Z53235 1 75234TL Ramf ste ZHZ H Mounting bracket ZHZ R 1 2 A Z53235 2 75235TL Ramf ste ZHZ V Mounting bracket ZHZ L 1 1 Rev Drawing nr Stock nr Titl...

Page 40: ...22304TL Sexkantsskruv Hexagon head screw 8 6 ISO 4014 M10 x 100 21190TL Sexkantskruv Hexagon head screw 2 5 Z41759 01 63242TL Distansr r Spacer 2 4 ISO 7089 10 140 HV 20184TL Bricka Plain washer 2 3...

Page 41: ...TL Mutter M6MF M12 Loc king Nut M12 8 4 ISO 4014 M12 x 110 22304TL Sexkantsskruv Hexagon head screw 8 3 Z54329 1 76799TL Ramf ste H Bracket R 1 2 Z54329 2 76800TL Ramf ste V Bracket L 1 1 Drawing nr S...

Page 42: ...agon head screw 10 5 Z54199 76594TL F rst rkning insida Crafter 2017 Reinforcement pl Crafter 2017 2 4 Z54473 77090TL Distans bricka Spacer 2 3 Z54476 2 77130TL Ramf ste ZHZ 600 V nster Mount br ZHZ 6...

Page 43: ...Reinforcement plate 2 4 1 ISO 4014 M12 x 100 21597TL Sexkantskruv Hexagon head screw 8 3 ISO 7043 M12 21980TL Mutter M6MF M12 Loc king Nut M12 8 2 Z54910 77832TL Ramf ste pl t Mounting bracket 2 1 Rev...

Page 44: ...tsmutter M12 Loc king Hex Nut 4 3 5 ISO 4017 M12 x 35 21311TL Sexkantskruv Hexagon head screw 4 2 ISO 7043 M12 21980TL Mutter M6MF M12 Loc king Nut M12 8 1 Rev Drawing nr Stock nr Title Description Qt...

Page 45: ...1759 01 63242TL Distansr r Spacer 2 6 ISO 7043 M12 21980TL Mutter M6MF M12 Loc king Nut M12 8 5 8 ISO 4014 M12 x 110 22304TL Sexkantsskruv Hexagon head screw 8 4 Z47217 53925TL F rst rkning insida Rei...

Page 46: ...nr Title Description Qty Item All defined tightening torques applies when use of torque wrench or nut runners with torque control torque spread max 5 Tightening torque requirements M12 80 Nm Passar S...

Page 47: ...king Hex Nut 10 8 1 DIN 125 A 13 20181TL Bricka Plain washer 10 7 5 ISO 7089 10 140 HV 20184TL Bricka Plain washer 2 6 1 DIN 985 M10 20170TL Sexkantsmutter Hex Nut 2 5 8 ISO 4014 M10 x 100 21190TL Se...

Page 48: ...ZHZ 600 Reinforcment plate ZHZ 600 2 3 Z54736 2 77520TL Ramf ste ZHZ 600 left Mounting Br ZHZ 600 left 1 2 Z54736 1 77521TL Ramf ste ZHZ 600 h ger Mounting Br ZHZ 600 right 1 1 Rev Drawing nr Stock n...

Page 49: ...exkantskruv Hexagon head screw 12 1 Rev Drawing nr Stock nr Title Description Qty Item Tightening torque requirements M12 80 Nm All defined tightening torques applies when use of torque wrench or nut...

Page 50: ...ires more space NOTE 4 Tighten the mounting screws using a torque wrench Tightening torque 80 Nm Fig 32 Mounting and adjustment of the lift Art no Hole pattern front Hole pattern rear 72807TL 2 screws...

Page 51: ...haft inwards until its flush with the platforms suface on the opposite side see Fig 36 1 5 Fit in the screw attached see Fig 36 2 to lock the platform shaft 6 Refit the cover 7 Attach the cylinder to...

Page 52: ...using the at tached screws see Fig 39 4 Mount the cable among existing cables using cable ties and connect to the 4 button operation circuit board See section 8 2 Connection to circuit board 4 button...

Page 53: ...location for the hydraulic unit is on the wheel housing The unit is ideally secured with the supplied bracket The hydraulic unit can be installed hori zontally or vertically 7 5 1 Connection of hydra...

Page 54: ...ator is in the safest possible working position and has a clear view of the load the tail lift and its working area 2 The distance between the vehicle s rear edge and the centre of the controllers mus...

Page 55: ...location 2 When fitting the drainage tube must be facing downwards see Fig 44 3 Connect the controllers to the connection box and the connection box to the relay board see 8 1 ZHZ 600 850 MAConnectio...

Page 56: ...ntrol power cable from the driver s cab to the lift When passing through a mem ber or wall the cable must be protected by rubber grommets If there are any quick release connectors make sure these are...

Page 57: ...cannot chafe or otherwise sustain damage that can lead to a short circuit and cable fires Do not bend the cable with too small a radius as this can cause damage to the cable In general care must be ta...

Page 58: ...ion point and connect the main power cable see Fig 47 The following image showing the connection point is an example and may vary from vehicle to vehicle 2 Secure the fuse and main power cable with th...

Page 59: ...Fig 51 2 3 Connect a cable from the battery s positive terminal see Fig 51 3 4 Screw the cable connections and fuse into place with the knob Install the cables at 90 or 180 from each other Install the...

Page 60: ...tion of license plate light Connect the license plate light to the vehicles ordinary lights cabeling Follow the manufacturer s recommendations Fig 55 Example of connecting the license plate light Vehi...

Page 61: ...t with the adjustment screws so that both armstops contact the lift arms at the same time On some vehicle models the space can be so confined that the lift has to be lowered in order for the adjusting...

Page 62: ...e to angle down the platform or anti clockwise to angle up the platform Lock the lug in place using a suitable tool Adjust the tilt cylinder in horizontal position The maximum permitted adjust ing dis...

Page 63: ...st the vehicle body and then tilting it all the way down Oil may need to be filled during aera tion of cylinders NOTE 7 16 Transport lock Electric hose rupture valves serve as locks for the loading pl...

Page 64: ...y detrimental to the interest of Z Lyften Produktion AB D r annat ej anges Drawing interpretation unless otherwise specified All measures intends finished product Alla m tt avser f rdig produkt Ben mn...

Page 65: ...f r copyright och f r ej utan Z Lyftens skriftliga medgivande kopieras delges eller obeh rigen anv ndas This drawing is property of Z Lyften Produktion AB and is loaned subject to return upon demand I...

Page 66: ...66 Electrical and hydraulic drawings www zepro com 8 3 Connection of cab switch and alarm for open platform 10 4 10 4...

Page 67: ...elow Possible control device models vary depending on lift model configuration and relevant market Connect according to the table below and the electrical and hydraulic drawings see section 8 Electric...

Page 68: ...68 Markings and decals www zepro com 9 Markings and decals 9 1 Overview The illustrations below show the positions of the various decals...

Page 69: ...ers park ing behind the vehicle know that a 5 m clearance is required for the platform to open and that sufficient space should be left for loading and unloading 9 3 Identification plate The identific...

Page 70: ...he vehicle The decal must be attached to the inside of the vehicle body close to where the manual control device is installed 9 7 Warning tape The warning tape is ideally attached along the platform s...

Page 71: ...coming loose when the platform is lowered to the ground Swage the tracks together to secure the warning flags in place Fig 71 CE marking 9 9 CE marking The marking below represents the manufacturer s...

Page 72: ...h 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...

Page 73: ...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 11 1 2 Drift Place a test load on the platform according to the tabl...

Page 74: ...afety 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...

Page 75: ...the connection ramp 2 After ensuring that the battery is disconnected disconnect the main power cable and the control cable 3 Dismantle the hydraulic unit 4 Dismantle the tilt cylinder from the platfo...

Page 76: ...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 Platfo...

Page 77: ...Specifications 77 www zepro com 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 78: ...s regarding the amount of power the lift can access from the existing battery NOTE 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...

Page 79: ...e lift When installing the lift and when carrying out servicing and repair work when the lift is operated repeatedly without the vehicle being started and used a battery charger must be used between o...

Page 80: ...80 Specifications www zepro com 13 6 Loading diagram ZHZ 600 Fig 75 Loading diagram 13 7 Loading diagram ZHZ 500 Fig 76 Loading diagram...

Page 81: ...Specifications 81 www zepro com...

Page 82: ...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...