Zepro Z 10 Installation Instructions Manual
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Zepro Z 10 Installation Instructions Manual

Tail lift
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Installation Instructions
ZEPRO
Tel.: +46 (0)10-459 05 00
E-mail: zeprotech@hiab.com
55757TL
2021-03-26
|
zepro.com
Tail Lift
Z 10/15/20

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Summary of Contents for Zepro Z 10

  • Page 1 Installation Instructions Tail Lift Z 10/15/20 ZEPRO Tel.: +46 (0)10-459 05 00 E-mail: zeprotech@hiab.com zepro.com 55757TL 2021-03-26...

  • Page 3: Table Of Contents

    Contents Z 10/15/20 Contents Introduction ...................... 5 Important ....................5 marking ..................... 6 Product approval ................... 6 Hydraulic oil .................... 6 Guarantee ....................6 1.6 Identification ................... 7 Safety rules ....................... 8 Repainting ....................8 Transport plug..................9 Moving parts - free movement ..............9 Third-party equipment must not be attached ........
  • Page 4 Z 10/15/20 Electrical and hydraulic drawings..............35 Z 10/15/20 .................... 35 Z 10/15/20 hydraulic autotilt ..............36 Connection to circuit board, 4 – button operation ......... 37 Connecting Open Platform Alarm ............38 Connecting warning lighting and foot controls ........39 Connecting controllers ................

  • Page 5: Introduction

    Introduction Z 10/15/20 Introduction Important The following “warning markings” appear in the installation instructions and are intended to draw your atten- tion to circumstances potentially causing unwanted situations, near misses, personal injury or damage to the product, etc. NOTE. Take care. Risk of damage to the product.

  • Page 6: Ce Marking

    Properly assembled, this product meets relevant requirements according to EN 1756-1:2001 + A1:2008. Hydraulic If the hydraulic 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).

  • Page 7: Identification

    Introduction Z 10/15/20 Identification E.g. 15 - 130 _ _ _ _ _ _ - _ _ _ _ _ Z = Standard model ZL = Wide frame, wide 1st boom Max. lifting capacity x 1 (kg) Max. lifting height -130 = 1300 mm...

  • Page 8: Safety Rules

    Safety rules Z 10/15/20 Safety rules Repainting NOTE. Piston rods and cylinder covers must not be painted. Painting could damage the cylinder gaskets. Boots, hydraulic hoses and cables must not be painted as the solvent in the paint could damage Image 1.

  • Page 9: Transport Plug

    Safety rules Z 10/15/20 54853 Transport plug NOTE. When the lift is installed, the transport plug in the hydraulic unit must be removed and replaced with the normal tank cap supplied with the hydraulic unit. Image 4. Replace the transport...

  • Page 10: Third-Party Equipment Must Not Be Attached

    Third-party equipment must not be attached WARNING! You must not attach equipment (electric or hydraulic) to Zepro tail lifts that has not been approved. Attaching unapproved equipment may interfere with the lift system and its safety functions. Risk of injury and damage. If it is necessary to install other equipment, check the vehicle manufacturer’s body instructions and use the attachment features on the vehicle.

  • Page 11: Installation Workflow

    Installation workflow Z 10/15/20 Installation workflow Installing the support frame • Calculating the installed dimensions • Attaching the mounting jig to the rear beam • Aligning the support frame • Mounting chassis brackets • Detaching the mounting jig Electrical connections •...

  • Page 12: Calculating The Installed Dimensions

    Calculating the installed dimensions Z 10/15/20 Calculating the installed dimensions For easier installation, it is useful to calculate and specify the necessary dimensions in advance. Determine the C dimension first, then obtain the other dimensions from the relevant table. You should try to place the lift as high as possible within the specified C dimension in the table. C dimension The C dimension is the distance between the top of the support frame and the vehicle floor level. This dimen- sion governs how far the lift needs to be installed under the vehicle body (D dimension) and the space there will be between the 1st booms in the upper position and the vehicle floor level (A dimension).
  • Page 13 Calculating the installed dimensions Z 10/15/20 685 max Image 7. Z 10/15/20 - 130 785 max Image 8. Z 10/15/20 - 150 www.zepro.com...
  • Page 14 Calculating the installed dimensions Z 10/15/20 1836 min. 740 - max. 930 2425 Image 9. Z 10/15/20 617-817 Image 10. Z 10/15/20 www.zepro.com...

  • Page 15: Rear Member Cut-Outs

    2. Cut along the markings. 3. Grind away any burrs or sharp edges. A max 1030 Image 11. Z 10/15/20 www.zepro.com...

  • Page 16: Installation

    Image 13. Image 13. Bolt or spot-weld the mounting jig to the rear member part. no. 51724TL for Z 10/15/20 Position the support frame under the vehicle frame. 4. Raise the 1st booms to their highest position.
  • Page 17 Installation Z 10/15/20 When installing on chassis with pre-drilled holes, go directly to point 16. 9. Install the U-profile with associated washers and nuts, but do not tighten these. Screw the bolts al- ternately until the U-profile is aligned in contact with the frame, see "Image 15. Install the U-profile with associated washers and nuts" on page 16. 35 mm 10.
  • Page 18 Installation Z 10/15/20 When installing on chassis with pre-drilled holes 16. Bolt the brackets securely on the outside of the vehicle chassis. Install in the slot-shaped holes with at least 6 screws. Use suitable bolts (dura- bility equivalent to M14 10.9 or higher) and install the associated washer and nut on the inside of the vehicle chassis.

  • Page 19: Control Power Cable

    Installation Z 10/15/20 Control power cable NOTE. See also the relevant vehicle manufacturer’s electrical instructions 1. If the control power cable is not pre-routed, e.g. VDHH, route the control power cable from the driver’s cab to the lift. NOTE. The cable must be protected with rubber grom- mets when it passes through beams or walls.

  • Page 20: Controllers

    Installation Z 10/15/20 Controllers If the vehicle is equipped with two-handed grip, it means that the operator must use both hands to be 300 - 600 mm able to operate the loading platform, while it protects the operator from pinch and crush injuries.

  • Page 21: Warning Lighting/Foot Controls

    Installation Z 10/15/20 Warning lighting/foot con- trols S: Signal U: Up If the tail lift is equipped with warning lighting/foot D: Down controls, their cabling must be routed and connected according to the following description. 1. Connect the supplied cable to the foot control/ warning lighting cable on the platform.
  • Page 22 Installation Z 10/15/20 3. Route the cable along the 1st boom and fix with cable ties according to Image 25. Then route the cable to the hydraulic unit along the front of the support frame and fix it together with the existing cabling with cable ties. NOTE. Route the cable between the platform and the lift arm's pipe so that it is well protected when the platform hits the ground.

  • Page 23: Main Power Cable

    Installation Z 10/15/20 Main power cable 6.5.1 Cable routing 1. Route the main power cable from the lift to the battery. Route the cable through a plastic casing and ensure it is not clamped to the brake line or the vehicle's existing electrical system. NOTE! The cable must not be clamped to brake lines or the normal on-board electrical system.

  • Page 24: Installation Of Main Fuse On Vehicles Without Connection Point

    Installation Z 10/15/20 Installation of main fuse on vehicles without connection point On vehicles without connection point, the following fuse box with fuse, 150A (24V) or 250A (12V) must be installed. The fuse box must be positioned well-protected as close to the battery as possible.

  • Page 25: Underrun Protection

    220x70x4 mm, corresponding to a surface moment of Image 32. The cross-secton of the frame beam inertia of 937cm4 around the x-axis. See illustration. If in doubt, contact ZEPRO for support. WARNING! The above dimensions are the minimum permit- ted for the installation of underrun protection.
  • Page 26 Installation Z 10/15/20 Horizontal distance from the outer edge of the beam to the outside of the wheel: Max 100 mm. See Image 34. 0-100 mm. Image 34. Statutory dimensions The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm.
  • Page 27 Installation Z 10/15/20 6.7.3 Installation Test the position of the underrun protection without tightening the bolts to check that the statutory dimensions are obtained. Adjust if necessary and then tighten the bolts with a torque wrench. 1. Fit the inner part of each bracket at one of four heights.

  • Page 28: Armstops

    Installation Z 10/15/20 Armstops Fit end stops between the 1st booms and the rear beam of the vehicle floor. The left and right end stops must be reached at the same time, as high up the 1st boom as possible. Installation must take place against the vehicle body. WARNING! Image 40. Fit end stops between the 1st booms...

  • Page 29: Platform

    Note. Lubricate the bushings NOTE. Maximum load capability of aluminium platforms is at 600 mm as standard. On Z 10 and Z15, the marking can be moved to 750 mm (see "9.1 Image 42. Make sure the ini- Loading diagram" on page 42).
  • Page 30 Installation Z 10/15/20 5. Test the lift by carefully raising it to the vehicle Max. 40 mm, Min. 38 mm floor level and tilting it to the vertical position. Check the position in relation to the rear beam and side posts of the vehicle. See Image 44. 6. The platform underhang (A), see Image 45, var- ies according to platform type and this should be taken into account when fitting the upper seal.
  • Page 31 3. Turn the nut (pos. 4, see Image 47) to adjust Image 46. Adjusting the fit to the vehicle body cylinder length and position on the platform. Use ZEPRO tool part no. 59693 (60 mm). Always adjust both cylinders. 4. Unscrew the lock screws (pos. 5, 6, 7, see Image 48).
  • Page 32 4. Tilt the platform down to max. 10 degrees below the horizontal, see Image 52. 5. Tighten the lock screw in the end stop (5). See Image 51. Zepro recommends securing the screws with Loctite 243 or equivalent. Test all functions.

  • Page 33: Purging The Cylinders

    Installation Z 10/15/20 6.12 Purging the cylinders Purge the lift cylinders by fully lowering the platform a few times. You may have to lift the truck to fully lower the platform. The tilting cylinders can be purged by raising the platform fully against the vehicle body and then tilt- ing all the way down.

  • Page 34: Hydraulic Unit

    Hydraulic unit Z 10/15/20 Hydraulic unit The lift’s hydraulic unit is installed inside the lift’s frame. For access during installation, maintenance and repair, for example, the hydraulic unit needs to be pulled a little way out of the frame. Function Input Output signal Comment signal Tilt down V1+V2+V4+V5+K1+K3 Tilt down E+PS1 V1+V4+V5+K1 Hydraulic autotilt Lower...

  • Page 35: Electrical And Hydraulic Drawings

    Electrical and hydraulic drawings Z 10/15/20 8 Electrical and hydraulic drawings Z 10/15/20 www.zepro.com...

  • Page 36: Z 10/15/20 Hydraulic Autotilt

    Electrical and hydraulic drawings Z 10/15/20 Z 10/15/20 hydraulic autotilt www.zepro.com...

  • Page 37: Connection To Circuit Board, 4 - Button Operation

    Electrical and hydraulic drawings Z 10/15/20 Connection to circuit board, 4 – button operation Control Power Pos. Colour Yellow/Green Blue Brown Black Green White Yellow Grey Orange Purple Pink www.zepro.com...

  • Page 38: Connecting Open Platform Alarm

    Electrical and hydraulic drawings Z 10/15/20 Connecting Open Platform Alarm Vinklegivare Pos. Colour Yellow/Green Blue Brown Black Green White Yellow Grey Orange Purple Pink www.zepro.com...

  • Page 39: Connecting Warning Lighting And Foot Controls

    Electrical and hydraulic drawings Z 10/15/20 Connecting warning lighting and foot controls S: Signal U: Up D: Down 6 4 3 8 3 2 4 6 4 3 8 Pos. Colour Yellow/Green Blue Brown Black Green White Yellow Grey Orange...

  • Page 40: Connecting Controllers

    When installing a controller without locking function, it connects directly to the relay board, see wiring diagram in "8.1 Z 10/15/20" on page 35. When installing a controller with locking function or when installing several controllers, a connection card is used, see wiring diagram in "8.3 Connection to circuit board, 4 –...

  • Page 41: Marking

    Marking Z 10/15/20 Marking Below, an overview of the location of the different markings is shown. Image of marking and further informa- tion can be found under the each subchapter for subsequent pages. Image 53. Overview of labelling www.zepro.com...

  • Page 42: Loading Diagram

    Marking Z 10/15/20 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 54. Load diagram for load capacity 1000 kg, centre of gravity distance 750 mm. Image 55. Load diagram for load capacity 1500 kg, centre of gravity distance 750 mm.

  • Page 43: Identification Plate

    Marking Z 10/15/20 Identification plate The identification plate is fixed on to the tail lift’s frame. Affix the corresponding sticker version of the identification plate, preferably by the cab door post to facilitate identification. The identification plate contains the following infor- mation: • Type of lift • Max. permitted load in kg Image 57. Identification plate • Production number • Year of manufacture • Address and tel. no. of manufacturer •...

  • Page 44: Controller Sticker

    Marking Z 10/15/20 Controller sticker Affix the controller sticker next to the relevant controller. The stickers are available in standard versions and in reversed version (Option) for affixing on the opposite side of the vehicle. Make sure the stickers are affixed so the image of the vehicle/tail lift on the sticker is in the same direction as the vehicle on which it is affixed. Image 62. Standard mounting Image 63. Reversed mounting Controller Sticker (Stand- Sticker ard) (Reversed) CD 1,2,9 55053TL* 55054TL* CD 4 55055TL 55056TL CD 10 77661TL 77662TL * The sticker section for 2-hand operation is delivered on the same backing paper and has to www.hiab.com...

  • Page 45: Danger Area

    Marking Z 10/15/20 Danger area If one is fitted, affix the sticker on the inside of the vehicle body next to the hand control unit. www.hiab.com 65977TL 2020-05-14 Image 65. Danger area 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 loose when the platform is lowered to the ground.

  • Page 46: Lubrication And Fluid Level Check

    Lubrication and fluid level check Z 10/15/20 Lubrication and fluid level check The following lubrication points must be greased on installation. They must then be lubricated at least 4 times a year. 10.1 Lubrication NOTE. Use LE lubricant 4622 or the equivalent. 1. Right tilting cylinder, at lower bearing.

  • Page 47: Testing And Verification

    Testing and verification Z 10/15/20 Testing and verification Testing and verification of the tail lift takes place in accordance with the installation/delivery inspection. Verify that the tail lift is suitable for the vehicle in question and for the intended use. 11.1 Static load test 11.1.1 Deformation • Position the tail lift half way up to the vehicle floor level and with the platform in the horizontal position. Measure dimensions A-B-C-D for comparison as illustrated in Image 68.
  • Page 48 Testing and verification Z 10/15/20 11.1.3 Static load (Test load 1.25 x tail lift loading capacity). For tail lifts with load centre of 1000 mm. Capacity Load 500 kg Load 1000 kg Distance on platform (L) 450 kg (450 kg) 675 mm...

  • Page 49: Dynamic Load Test

    Testing and verification Z 10/15/20 11.2 Dynamic load test. 11.2.1 Test with max. load • Place a test load on the platform according to the table (for the respective tail lift model/lifting capacity). • Check that the lift operates correctly in the normal range of movement, i.e. up, down, tilting at ground level and tilting at vehicle floor level.

  • Page 50: Test Of Safety Functions

    Testing and verification Z 10/15/20 11.3 Test of safety functions The tail lift safety functions must be tested. Check: • That the red light in the driver’s cab turns off when the platform is completely closed against the body and that it turns on when the platform is opened. • That the tail lift cannot be activated if the cab switch is in the off position. • That the tail lift cannot be activated when the main switch fuse is removed.

  • Page 51: Disassembly

    3. Run the tilting cylinders to their minimum stroke limit to remove pressure from the circuit. 4. Dismantle the side profiles from the platform. Loosen the grease nipples and lock screws in the platform pivots. Use the Zepro special tool for the platform pivots. Hammer outside with the sliding weight. 5. Follow the same procedures for the other side.

  • Page 52: Specifications

    Lift arm Z 10/15/20-150 49 kg Z-15-150 328 kg 3-part underrun protection complete Z/ZL 57 kg Z-20-130 317 kg Complete frame bracket Z 10/15/20 28 kg Z-20-150 330 kg Lift cylinder Z 10/15-130 11.4 kg each Lift cylinder Z 10/15-150 12.5 kg each...

  • Page 53: Maximum Power Consumption - Minimum Recommended Conductor Cross Sectional Area

    Specifications Z 10/15/20 13.2 Maximum power consumption - Minimum recommended conductor cross sectional area Z 10 (130 bar) Z 15/20 (170 bar) 7400 (170 bar) 7400 (130 bar) 24 Volt 24 Volt Pump - Motor unit 120 A Pump - Motor unit...

  • Page 54: Loading Diagram

    Loading diagram NOTE! The max. load marking on alu- minium platforms is located at 600 mm as standard. On Z 10 and Z15, the marking can be moved to 750 mm. Z 10 and Z 15 Z 20 Max load Image 70.

  • Page 55: Centres Of Gravity

    Specifications Z 10/15/20 13.5 Centres of gravity Max. load Z-15/20-130 steel platform 1700x2650 mm C = 285 C = 465 C = 615 (mm) (mm) 1500 kg (mm) 2000 kg Z-15/20-150, steel platform 1700x2650 mm C = 325 C = 515...

  • Page 56: Tightening Torque

    Specifications Z 10/15/20 13.6 Tightening torque NOTE! All specified torque values apply for use with a screw or impact wrench with torque control. Torque distribu- tion max ± 5%. 280 Nm 280 Nm 280 Nm 115 Nm 280 Nm 80 Nm Image 71. Tightening torque www.zepro.com...
  • Page 57 BUILT TO PERFORM Zepro, Del and Waltco are Hiab brands 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 increase the efficiency of...

This manual is also suitable for:

Z 15Z 20

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