Z/ZU 45/75-90/110 ZL/ZLU 45/75-90/110 ZN/ZNU 45/75-90/110

ZEPROTel.: +46 (0)10-459 05 00E-mail: [email protected] | zepro.com

54990TL2021-03-14

Installation Instructions

Tail LiftZ/ZU 45/75-90/110

ZL/ZLU 45/75-90/110ZN/ZNU 45/75-90/110

Z 45/75-90/110Contents

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Contents1 Introduction ...................................................................................................... 6

1.1 Important ................................................................................................ 61.1 CE marking ............................................................................................. 71.2 Product approval ................................................................................... 71.3 Hydraulic oil ............................................................................................ 71.4 Guarantee ............................................................................................... 71.2 Identification ........................................................................................... 8

2 Safety rules ....................................................................................................... 9

2.1 Repainting .............................................................................................. 92.2 Transport plug....................................................................................... 101.1 Moving parts - free movement .............................................................. 102.3 Third-party equipment must not be attached ........................................ 112.4 Installation ............................................................................................ 11

3 Assembly kits ................................................................................................. 12

4 Installation workflow ...................................................................................... 13

4.1 Installing support frame,standard ......................................................... 134.2 Assembling the support frame with the assembly kit ............................ 134.3 Electrical connections ........................................................................... 134.4 Installing the platform ........................................................................... 134.5 Installing cylinders ................................................................................ 134.6 Attaching decals ................................................................................... 13

5 Calculating the installed dimensions ........................................................... 14

5.1 C dimension ......................................................................................... 145.2 D dimension ......................................................................................... 145.3 A dimension .......................................................................................... 145.4 H dimension .......................................................................................... 14

6 Rear member cut-outs ................................................................................... 20

7 Installation ..................................................................................................... 21

7.1 Support frame ....................................................................................... 217.2 Control power cable .............................................................................. 237.3 Control devices ..................................................................................... 247.4 Warning lighting and Foot controls ....................................................... 257.5 Main power cable ................................................................................. 267.6 Cable grommet ..................................................................................... 297.7 Open platform alarm ............................................................................. 307.8 Underrun protection .............................................................................. 317.9 Armstops .............................................................................................. 357.10 Platform ................................................................................................ 367.11 Sealing strip (horizontal) ....................................................................... 377.12 Sealing strip (vertical) ........................................................................... 377.13 Sealing strip, integrated rubber strip ..................................................... 387.14 Angle sensor quick opening ................................................................. 397.15 Angle sensor for electronic autotilt (option) .......................................... 397.16 Purging the cylinders ............................................................................ 417.17 Transport lock ....................................................................................... 41

Z 45/75-90/110

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Contents

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8 Temporary operation of lift ............................................................................ 42

8.1 Connection ........................................................................................... 428.2 Operation .............................................................................................. 428.3 Disconnection ....................................................................................... 42

9 Hydraulic unit and control card .................................................................... 43

9.1 Summary .............................................................................................. 439.2 Hydraulic unit, installing ........................................................................ 449.3 Connecting hydraulic hoses ................................................................. 44

10 Electrical and hydraulic drawings ................................................................ 45

10.1 Z 45/75 ................................................................................................. 4510.2 Z 45/75, with hydraulic autotilt .............................................................. 4610.3 Connecting cabin switch and open platform alarm ............................... 4710.4 Connecting warning lighting and foot controls ...................................... 4810.5 Connecting control devices .................................................................. 49

11 Functional schematic drawing ....................................................................... 50

11.1 Sensor/Inputs ....................................................................................... 5011.2 Restriction in use of control device ....................................................... 5011.3 Functional schematic ............................................................................ 51

12 Connection unit .............................................................................................. 53

12.1 Power save mode ................................................................................. 5312.2 Operating information ........................................................................... 53

13 Marking ............................................................................................................ 59

13.1 Loading diagram ................................................................................... 6013.2 Identificationplate ................................................................................ 6113.3 Work area ............................................................................................ 6113.4 Warning tape ....................................................................................... 6113.5 Controller sticker ................................................................................... 6213.6 Danger area ......................................................................................... 6313.7 Warningflags ....................................................................................... 63

14 Lubrication and fluid level check .................................................................. 64

14.1 Lubrication ............................................................................................ 6414.2 Oil level check ...................................................................................... 64

15 Testing and verification ................................................................................. 65

15.1 Static load test ...................................................................................... 6515.2 Dynamic load test. ................................................................................ 6615.3 Test of safety functions ......................................................................... 67

16 Disassembly ................................................................................................... 68

Z 45/75-90/110Contents

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17 Specifications ................................................................................................ 69

17.1 Weights ................................................................................................ 6917.2 Maximum power consumption - Minimum recommended conductor cross sectional area ............................................................. 7017.3 Battery maintenance ............................................................................. 7117.4 Loading diagram ................................................................................... 7217.5 Tightening torque .................................................................................. 73

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Introduction

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1 Introduction

1.1 ImportantThe 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.

Take care. Risk of damage to the product.

NOTE.

Take extra care. Risk of personal injury or damage to the product and the surroundings.m WARNING!

Z 45/75-90/110Introduction

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1.1 CE markingZEPRO tail lifts for sale on the European market are CE marked (Conformité Européenne). The manufacturer guarantees that the product complies with the EU Machinery Directive.

Followtheinstallationinstructionscarefully.Modificationsnotapprovedinwritingbythemanufacturerarenotpermitted. Welding is not permitted.

1.2 Product approval Properly assembled, this product meets relevant requirements according to EN 1756-1:2001 + A1:2008.

1.3 Hydraulic oilIf the hydraulic oil needs to be replenished, only the oil recommended by ZEPRO is permitted to be used.

Hydraulicsystemswithhydraulicoiltankswithoutlabellingareonlypermittedtobefilledwithhighlyrefinedmineral oil (art. no. 21963, 1 litre).

Hydraulicsystemswithhydraulicoiltanksmarkedwithaspecificationforthehydraulicoilareonlypermittedtobefilledwiththeoilspecifiedonthelabel.

1.4 GuaranteeAfterinstallation,testingandverification,thetaillift’sdeliverycardmustberegisteredfortheguaranteetobevalid.

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Introduction

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1.2 Identification

E.g. Z 75 - 110 SA _ _ _ _ _ _ - _ _ _ _ _

Identification list

Z = Standard modelZL = Wide frame, wide lift armZN = Wide frame, narrow lift arm ZU = Standard model, 3 - part u protection ZLU = Wide frame, wide lift arm, 3 - part u protection ZNU = Wide frame, narrow lift arm, 3 - part u protection

Max. lifting capacity x 10 (kg)

Max lifting height x 10 (mm)

Cylinder model, S = Single operation Single speed Tilt Single operation Single speed Lift SA = Single operation Single speed Adjustable Tilt Single operation Single speed Lift

Z 45/75-90/110Safety rules

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2 Safety rules

2.1 Repainting

Piston rods and cylinder covers must not be painted. Painting could dam-age the cylinder gaskets.

Boots, hydraulic hoses and cables must not be painted/coated as the solvent in the paint could damage thehoses/cablesandsignificantlyimpair durability.

NOTE.

Image 1. Piston rods, cylinder covers and boots must not be painted/coated

Image 2. Hydraulic hoses must not be painted/coated

Image 3. Cables must not be painted/coated

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Safety rules

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2.2 Transport plug

When the lift is installed, the trans-port plug in the hydraulic unit must be removed and replaced with the normal tank cap supplied with the hydraulic unit.

NOTE.

54853

1.1 Moving parts - free move-ment

Whenthefinalinspection*takesplace,the space occupied by the moving cylinders must be cleared and made safe. There is a risk of collision be-tween the cylinder and the following items: subframe, truck chassis, beam for rear light (number plate) and the chassis bracket of the lift (with a short overhang).

*Thefinalinspectionmustbecarriedoutwiththeplatformflatandtilteddown10°. The clearance from the closest part of the cylinder must be at least 40 mm.

m WARNING!

The platform must not be tilted down more than max. 10° from horizontal when people are on the platform.

m WARNING!

min. 40 mm

10º

10º

Image 4. Replace the transport plug with the normal tank cap

Image 5. Clearance to the closest part of the cylinder must be at least 40 mm

Image 6. The platform must not be tilted down more than 10° from the horizontal

Z 45/75-90/110Safety rules

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2.3 Third-party equipment must not be attached

You must not attach third-party equipment (electric or hydraulic) to Zepro tail lifts. Attaching third-party equipment may interfere with the lift system and the safety functions. Risk of injury anddamage.Ifitisnecessarytoinstallotherequipment,checkthevehiclemanufacturer’sbody instructions and use the attachment features on the vehicle.

m WARNING!

2.4 Installation

The platform must not be installed so it cannot reach ground level.m WARNING!

Zepro tail lifts are only approved for installation with Zepro installation kits.m WARNING!

Allspecifiedtorquevaluesapplyforusewithascreworimpactwrenchwithtorquecontrol.Torquedistribu-tion max ± 5%.

NOTE!

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Assembly kits

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TRUCK

MAKE MODEL VERSION OTHER COMPLETE WEIGHT ART. NO.Citroen Jumper to & inc. 2006 34.1 kg 53672TL Jumper from 2007- 29.8 kg 56095TL Jumper L1-L4 from 2007- 30 kg 57336TL Jumper L4 from 2007- 16 kg 57337TLFiat Ducato to & inc. 2006 34.1 kg 53672TL Ducato from 2007- 29.8 kg 56095TL Ducato L1-L4 from 2007- 30 kg 57336TL Ducato L4 from 2007- 16 kg 57337TLFord Transit 260/300/330/350 to & inc. 2013 extension 14.3 kg 53646TL Transit 260/300/330/350 to & inc. 2013 10.8 kg 53649TL Transit L1/L2/L3 from 2014- 10.8 kg 53649TL Transit L4 from 2014- 14.3 kg 53649TL Iveco Daily 35/45/50 13.8 kg 53642TL Daily 35/45/50 For pull 20 kg 56418TL

M-B Sprinter 300 series L=3000 (EH) 9.3 kg 53648TL 906 300 series L=3250 (EH) 8.2 kg 56784TL 300 series L=3550 (EH) 9.3 kg 53648TL 300 series L=3550 (EH) 7.1 kg 53645TL 906 300 series L=3665 (EH, DH) 7.0 kg 53932TL 300 series L=4025 (EH,DH) 8.2 kg 53643TL 906 300 series L=4325 (EH, DH) 8.6 kg 53926TL 400 series L=3550 (EH,DH) 6.8 kg 53647TL 400 series L=4025 (EH,DH) 12 kg 53644TL 500 series L=3665 9.3 kg 53898TL 500 series L=4325 10.5 kg 56015TL 600 series L=4025 8.7 kg 53941TL 907 L=3665 7,1 kg 53932TL 907 L=3665 double wheel 9,8 kg 53898TL 907 L= 4325 8,7 kg 53926TL 907 L=4325 double wheel 10,5 kg 56015TL 910 All versions 12,5 kg 77747TL

Nissan NV 400 from 2010- 15.6 kg 57378TL

Peugeot Boxer to & inc. 2006 34.1 kg 53672TL Boxer L1-L4 from 2007- 29.8 kg 56095TL Boxer L1-L4 from 2007- 30 kg 57336TL Boxer L4 from 2007- 16 kg 57337TL

Renault Mascot L=3630 LO 13.8 kg 53642TL Mascot L=3630 NO 13.8 kg 53642TL Mascot L=4130 13.8 kg 53642TL Mascot L=4630 13.8 kg 53642TL Renault Master from 2010- 15.6 kg 57378TL Opel Movano from 2010- 15.6 kg 57378TL

VW Crafter 28/35 L=3250 (EH) 8.2 kg 56784TL Crafter 28/35 L=3665 (EH, DH) 7.0 kg 53932TL Crafter 28/35 L=4325 (EH, DH) 8.6 kg 53926TL Crafter 50 L=3665 9.3 kg 53898TL Crafter 50 L=4325 10.5 kg 56015TL Crafter L3 from 2017 7,6 kg 76758TL Crafter L3 from 2017 double wheel 10,6 kg 77666TL Crafter L4 from 2017 double wheel 10,6 kg 77666TL Crafter L4 from 2017 single wheel 8,9 kg 76759TL

VW T6 L4 Double cab 14,5 kg 53646TL T6 Spare wheel carrier 30,4 kg 75119TL T6 Floby cabin 59,6 kg 75124TL

Toyota Dyna 100 & 150 8.9 kg 56233TL Dyna 200 8.7 kg 57411TL

Universal 6.9 kg 53642TL Universal 15.6 kg 53650TLUniversal 8.7 kg 57411TL

3 Assembly kits

Z 45/75-90/110Installationworkflow

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4 Installation workflow

4.1 Installing support frame,standard• Calculating the installed dimensions• Attaching the mounting jig to the rear beam• Aligning the support frame • Mounting chassis brackets • Detaching the mounting jig

4.2 Assembling the support frame with the assembly kit• Calculating the installed dimensions• Attaching the mounting jig to the rear beam• Mounting chassis brackets • Detaching the mounting jig

4.3 Electrical connections• Installing the control devices• Installing the control device cables• Installing the main power cable

4.4 Installing the platform• Installing the platform• Installing seals and end stops• Installing the armstops

4.5 Installing cylinders• Adjusting tilt cylinder• Test running

4.6 Attaching decals

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Calculating the installed dimensions

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5 Calculating the installed dimensionsFor easier installation it is useful to calculate and specify the necessary dimensions in advance. DeterminetheCdimensionfirst,thenobtaintheotherdimensionsfromtherelevanttable.Youshould try to place the lift as high as possiblewithin the specifiedCdimension in the table.

The chassis bracket is in 2 parts and must be screwed together above thesupportframe.Thisaffectsthedimension between the lift frame and vehicle chassis. Take this into ac-count when calculating the installed dimension, C dimension.

NOTE!

5.1 C dimension TheCdimensionisthedistancebetweenthetopofthesupportframeandthevehiclefloorlevel.This dimension governs how far the lift needs to be installed under the vehicle body (D dimension) andthespacetherewillbebetweentheliftarmsintheupperpositionandthevehiclefloorlevel(A dimension).

5.2 D dimension The D dimension is the space 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 is determined, the D dimension can be obtained from the table.

5.3 A dimensionThe A dimension is the space provided for the rear member, i.e. the space there will be between theliftarmandthevehiclefloorwiththeliftintheraisedposition.TheAdimensionisdependenton the C dimension

5.4 H dimensionTheHdimensionistheheightfromtheground(unloaded)tothevehiclefloorlevel.TheHdimen-sion must not be greater that the maximum lifting height of the lift. The platform must always be able to reach ground level.

~70 mm

Z 45/75-90/110Calculating the installed dimensions

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Image 7. Installation dimensions for lift models with lifting height 900/1100 mm

Lifting height 900 mm

C A D450 170 384400 154 444350 143 490300 134 526250 127 554


C A D550 186 432500 168 498450 155 549400 145 590350 137 624310 131 652250 124 675

171

C

75D

maxmin

A

max 450/550

H 900/1100 max

Installation dimensions Z/ZL/ZN 45/75 - 90/110

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Image 8. Installation dimensions for lift models with lifting height 900/1100 mm


C A D R58:3450 170 384

Approved400 154 444350 143 490310 134 526

250 127 554 *Approved

* Approved when installing longer underrun brackets (available as option).


C A D R58:3550 186 432

Approved

500 168 498450 155 549400 145 590350 137 624310 131 652

250 124 675

171

C

75D

maxmin

A

max 450/550

H 900/1100 max

Installation dimensions ZU/ZLU/ZNU 45/75 - 90/110


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ZU-45-110, ZU-75-110, ZU-45-90, ZU-75-90

Z-45-90, Z-45-110, Z-75-90, Z-75-110

ZU-45-110, ZU-75-110

250

183

72

122

1410

min 550 - max 1110

1410

2100 (1900 min.)700 500

min 550 - max 1110

4591171

500

318/418

524

250

183

72

122

ZU-45-90, ZU-75-90250

183

72

122

424/524*

* Longerunderrunbracketsthatgivethesize524mm are available as an option. These are needed to achieve approved dimensions according to R58:3, if the C dimension is < 310 mm.

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ZLU-45-90, ZLU-75-90, ZLU-45-110, ZLU-75-110

ZL-45-90, ZL-45-110, ZL-75-90, ZL-75-110

ZLU-45-90, ZLU-75-90 ZLU-45-110, ZLU-75-110

250

18372

122

1720

min 750 - max 1410

1720

2100 (1900 min.)1000 350

min 750 - max 1410

7581474

350

318/418

250

183

72

122

424/524*524

250

183

72

122

* Longerunderrunbracketsthatgivethesize524mm are available as an option. These are needed to achieve approved dimensions according to R58:3, if the C dimension is < 310 mm.


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ZNU-45-90, ZNU-75-90, ZNU-45-110, ZNU-75-110

ZN-45-90, ZN-45-110, ZN-75-90, ZN-75-110

ZNU-45-90, ZNU-75-90 ZNU-45-110, ZNU-75-110

1280

1960 (1700 min.)

350 575

min 660 - max 1020

446446

575

318/418

250

183

72

122

424/524*524

250

183

72

122

250

18372

122

1280

min 660 - max 1020

* Longerunderrunbracketsthatgivethesize524mmareavail-able as an option. These are needed to achieve approved dimensions according to R58:3, if the C dimension is < 310 mm.

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Rear member cut-outs

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6 Rear member cut-outsIt is often necessary to create cut outs in the rear beam to provide space for the platform arms when the platform is in the upper position. The size of the cut outs depends on the calculated installed dimension “A”, see illustration below.

1. Measure and mark the location and depth of the cut outs on the rear beam. The two cut outs must be centred on the rear beam, i.e. both cut outs must be an equal distance from the mid-point of the beam.

2. Cut along the markings.

3. Grind away any burrs or sharp edges.

Image 9. Z-45-110, Z-75-110, Z-45-90, Z-75-90 ZU-45-110, ZU-75-110, ZU-45-90, ZU-75-90

Image 10. ZL-45-90, ZL-75-90, ZL-45-110, ZL-75-110 ZLU-45-90, ZLU-75-90, ZLU-45-110, ZLU-75-110

Image 11. ZN-45-90, ZN-75-90, ZN-45-110, ZN-75-110 ZNU-45-90, ZNU-75-90, ZNU-45-110, ZNU-75-110

750155

A max

155

1060155

A max

155

380155

A max

155

Z 45/75-90/110Installation

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7 Installation

Alsoconsult thevehiclemanufacturer’sbody in-structionsandZepro’s instructionbookletbeforeinstallation.

NOTE.

Zepro tail lifts are only approved for installation

with Zepro installation kits.

m WARNING!

7.1 Support frame1. Measure and mark the midpoint of the rear mem-

ber of the vehicle. Se Image 12.

2. Bolt or spot-weld the mounting jig to the rear beam, so that both mid-points are aligned.

3. Position the support frame under the vehicle chassis.

4. Temporarily connect the control card to enable the lift functions. See section...

5. Raise the lift arms to their highest position.

6. Attach the lift arms to the eye of the jig. Use the liftplatform’snormalbolts.

7. The support frame should be positioned as high as possiblewithinthespecifiedCdimension.Adjustthe frame to the ideal height under the chassis. A workshop jack is useful. The frame must be positioned parallelwith the floor of the vehiclebody and must not be in contact with the vehicle chassis; there must be a few millimetres of play. If necessary, adjust the angle of the arms by carefully operating the lift.

8. Fit the lower part of the chassis bracket on the support frame. Adjust its position on the frame ac-cording to the width of the vehicle chassis. Fasten with six bolts, twoangledwashersanda fixingplate placed inside the support frame. Use the M14x35 bolts supplied. Install without tightening.

Image 12. Measure and mark the midpoint of the rear member of the vehicle.

Image 13. Press, bolt or spot-weld the mounting jig to the rear beam

Image 14. Mounting jig

Image 15. Fit the lower part of the chas-sis bracket on the support frame.

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Installation

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9. Fit the upper part of the bracket onto the lower part. Installation must cover at least 6 holes of the row of holes on the lower bracket. Use the four M14x45 bolts supplied. Install without tightening. Se Image 16.

10. Check the C and D dimensions.

11. Align the chassis bracket on the vehicle chassis. Adjust these positions along the support frame if needed.

12. Drill 14 mm holes in the vehicle chassis, centred in the holes in the bracket.

13. Fasten the chassis bracket to the vehicle chassis. Use the M14x45 bolts supplied. Use at least 4 bolts in each chassis bracket. See Image 17 for location of bolts. Tightening torque 120 Nm.

14. Tighten the bolts that hold the two parts of the chas-sis bracket. Tightening torque 120 Nm.

15. Tighten the bolts that hold the chassis bracket to the support frame. Tightening torque 120 Nm.

Welding is not permitted on the chassis brackets.

Do not move the lift all the way to the armstops or with the platform fitted before all the bolts are fullytightened against the chassis.

Do not place the lift under load until:

· the correct number of bolts have been installed and torque-tightened.

· the vehicle body is installed to reinforce the truck chassis.

NOTE.

16. Remove the mounting jig.

For other chassis brackets, see the respective direc-tions.

Image 16. Fit the upper part of the bracket onto the lower part. Installation must cover at least 6 holes of the row of holes on the lower bracket.

1 2 3

Image 17. Fasten the chassis bracket to the ve-hicle chassis. Locations 1 and 2 are recommend-

ed, location 3 should be avoided if possible.

At least 4 bolts M14x45 10.9 (120 Nm)6 bolts

M14X35 8.8 (120 Nm)

At least 4 bolts M14x45 8.8 (120 Nm)

Image 18. Fitting the chassis bracket


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7.2 Control power cable

Seealsothevehiclemanufacturer’selectrical instructions.

NOTE.

1. I f the cont ro l power cab le is not pre-routed, e.g. VDHH, route the control pow-er cable from the driver ’s cab to the lift.

The cable must be protected with rubber grommets when it passes through members or walls. If there are quick connectors, make suretheyareeffectivelyprotectedfrommois-ture and dirt.

NOTE.

2. Connect the control power cable to the cabin switch (CS) on the vehicle instrument panel. Connect to the on-board electrical system via a 10 A (24 V), 15 A(12V)fuseaccordingthecustomer’swishes.Seethe connection diagram "10.3 Connecting cabin switch and open platform alarm" on page 47.

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Installation

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7.3 Control devicesIf the vehicle is equipped with two-handed grip this means that the operator must use both hands to be able to operate the loading platform, while this pro-tects the operator from pinch point injuries.

1. Fit the control devices in the desired locations. They must be positioned so that the operator is in the safest possible location and has a clear view of the load, the tail lift and the surrounding area.

2. The distance between the vehicle’s rear edgeand the centre of the controllers must be 300-600 mm. The distance between the controllers must be at least 260 mm. See illustration 18. All cable inlets must be pointing downwards.

NOTE.

3. The control device’s cable is connected to thecontrol card.

Image 19. Installing control de-vice with two-handed grip.

Acontrollermustalwaysbefittedonthesidethatisfacingawayfromtrafficinmotion.Ifthereisaneedforacon-trollerontheoppositeside,afurthercontrollermustthereforebefitted.Fittingontheothersideinvolvesincreasedrisk of injury.

m WARNING!

Image 20. Installing control device

Min. 260 mm.

300 - 600 mm.


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7.4 Warning lighting and Foot controls

If the tail lift is equipped with warning lighting and/or foot controls, their cabling must be routed and con-nected according to the following description.

1. Connect the supplied cable to the connector on the foot control/warning lighting cable, then route the cables and secure with cable ties according to Image 22.

2. Route the cable through the support frame's cable grommet. See section "7.6 Cable grommet" on page 29.

3. Connect the cables to the control card, see wiring diagram "10.4 Connecting warning light-ing and foot controls" on page 48 and section "10.5 Connecting control devices" on page 49.

Make sure that the control card is disconnected from power before connecting peripheral equipment. Risk of damage.

m WARNING!

Route the cables between the platform and the lift arm's pipe so that it is well protected when the platform hits the ground.

Leaveenough"slack"tothefirstcabletiesothat the cables is not at risk of being dam-aged when the lift is operated.

NOTE!

Image 21. Warning lighting and foot controls

Image 22. Installing cabling

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Installation

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7.5 Main power cable

7.5.1 Cable routing1. 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.

The cable must not be clamped to brake lines or the normal on-board electrical system.

The cable must be protected by rubber grommets when it passes through beams or walls, see Image 23.

Thecablemustbeinstalledsufficientlyfar from, or be protected against, sharp edges so that it cannot chafeorotherwisesustaindamagethatcanleadtoashortcircuitandcablefires.

Do not bend the cable with too small a radius as this can cause damage to the cable.

In general, care must be taken when routing all the cables in order to obtain a longer cable service life and to reduce the risk of unnecessary stoppages.

NOTE!

The fuse box must be located in a well protected position as close to the battery as possible.

NOTE.

2. Checkthatthehydraulicunitiseffectivelyearthed.Certaincommercialvehiclemanufacturersprovide

special earth connection points.

3. Connect the main power cable to the hydraulic unit, see "10 Electrical and hydraulic drawings" on page 45

Image 23. Protect the cable against sharp edges and use cable grommets


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7.5.2 Installation of main fuse on vehicles with M8 connection point (+)

Wheninstallingthemainpowercable,thefuse,150A(24V)or250(12V),mustbeinstalledonthevehicle’scon-nectionpoint(+).Thisistoprotecttheelectricalsystemfromdamageandriskoffireintheeventofashortcircuit.

1. Place the fuse on the connection point and connect the main power cable, see Image 24. 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 the knob.

The knob must lie against and centre the cable clip so that it does not come into contact with the bolt. Incorrectinstallationcancausethefusetomalfunction.Riskoffireintheeventofashortcircuit,seeIm-age 25 and Image 26.

WARNING!

Image 24. Install fuse and con-nect main current cable

Image 25. Correct installation Image 26. Incorrect installation

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Installation

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7.5.3 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.

1. Screw the fuse box into position with the following bolts (2 x M4x25) + washers and nuts, see Image 27.

2. Connect the main power cable to the connection point and place the fuse on top, see Image 28:1 and Image 28:2.

3. Connectacablefromthebattery’spositiveterminal,seeImage 28:3.

4. Screw the cable connections and fuse into place with the knob. Install the cables at 90° or 180° from each other. Install the fuse at right angles to the cables, see Image 28.

The knob must lie against and centre the cable clip so that it does not come into contact with the bolt. Incorrectinstallationcancausethefusetomalfunction.Riskoffireintheeventofashortcircuit,seeIm-age 29 and Image 30.

WARNING!

5. Install the fuse box cover, see Image 31.

Image 27. Screw the fuse holder into place

Image 28. Place fuse and connect wiring

Image 29. Correct installation Image 30. Incorrect installation Image 31. Cover fuse box

1

2

3

4


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7.6 Cable grommetInordertoinstall/dismantle/adjustcablesinthecablegrommet,thefiveboltshavetobeundone.

1. Loosenthefivescrewsonthecablegrommet,seeImage 30. Cables can now be installed/removed/adjusted in the grommet. On installation, the cable must be installed together with existing cabling with cable ties.

2. Whenallcablesarecorrectlylocatedinthecablegrommet,tightenthefivebolts. Tightening torque: 5 Nm.

Image 32. Cable grommet's five screws

Hydraulic Unit 5915

Z 45/75-90/110

30

Installation

www.zepro.com

7.7 Open platform alarmTheliftcanbefittedwithanopenplatformalarm.Thealarmcomprisesawarninglampthatcomesonwhenthe starter key is switched on if the platform is not pressed against the rear posts.

The device comprises:• Pressure monitor located on one of the tilting cylinder valve blocks

• Cable up to the instrument panel (not provided by Zepro)

• Inline fuse

• Warning lamp 12 and 24 volt

Test running1. Turntheignitionkeywhentheplatformistiltedupandpressedfirmlyagainstthevehiclebody.Thelamp

mustbeoff.Tilttheplatformafewdegreesfromthevertical.Thelampshouldthencomeon.

2. Leavetheplatforminthelastpositionandturnofftheignition.Thelampshouldgooff.Turntheignitionback on and the lamp should come on again.

3. Firmlyclosetheplatform.Thelampshouldgooff.


31www.zepro.com

Max 550 mm

Max 328 mm.

Image 33. Cross section of vehi-cle chassis’ frame beam

X140

70

3(x2)

Y

7.8 Underrun protection

7.8.1 Vehicle chassis requirementsIn order to comply with the applicable underrun protection standards, there are requirements for the vehicle chassis on which the rear tail lift is mounted.The moment of inertia in a cross-section on the current frame beam is not permitted to be less than 306 cm4. Forthisreason,theframebeam’scross-sectionshallhave at least dimensions of 140x70x3 mm, correspond-ing to a minimum surface moment of inertia of 306 cm4 around the x-axis. See Image 33. If in doubt, contact ZEPRO for support.

7.8.2 Statutory dimensions• Distance between the beam and the ground when the vehicle is unloaded: Max. 550 mm.• Horizontal distance from the outermost part of the platform to the underrun protection: Max 328 mm. See

Image 34.

The underrun protection may be placed further back and lower.

NOTE!

Image 34. Statutory dimensions

The above dimensions are the minimum per-mitted for the installation of underrun protec-tion. The strength requirements for mounting the tail lift usually require larger dimensions.

m WARNING!

Z 45/75-90/110

32

Installation

www.zepro.com

0-100 mm

Max 25 mmMax 25 mm

Min. Area: 350 cm2

• Horizontal distance from the outer edge of the beam to the outside of the wheel: Max 100 mm. See Image 35.

• The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm. See Image 36.

• Each of the individual parts of the underrun protection must have a surface area of at least 350 cm2. See Image 35.




33www.zepro.com

7.8.3 InstallationTest the position of the underrun protection with-out tightening the bolts to check that the statutory dimensions are obtained. Adjust if necessary then tighten the bolts with a torque wrench. See "7.8.2 Statutory dimensions" on page 31.

1. Hang the four U protection brackets on the lift frame by inserting the projecting parts into the end ofthefixingprofiles.

2. Check that the statutory measurements are kept. See "7.8.2 Statutory dimensions" on page 31.

3. Fasten the outer brackets with two M12x30 (8.8) bolts each, including support plate. The bolts are inserted from inside the frame and outwards. Remove the frame end plugs so as to reach the fastening points for the outer brackets. Tightening torque 90 Nm.

4. Fasten the inner brackets with two M12x30 (8.8) bolts each. The bolts are inserted from inside the frame and outwards. There are openings on the underside of the frame to allow access to the fas-tening points, right in front of the inner brackets. Tightening torque 90 Nm.

Check carefully that there is no risk of the outer part of each bracket colliding with any part of the cylinders whenusingthelift’sfunctions.Inparticular,checkinrelationtothecylinders’hoseconnections,espe-cially when the outer part of the brackets is installed a long way in.

m WARNING!

Image 37. Installing underrun protection

Image 38. Installing underrun protection

max 25 mmmax 25 mm

M12x30 8.8 (90 Nm)

M12x30 8.8 (90 Nm)

Image 39. Installing brackets onto frame.

Z 45/75-90/110

34

Installation

www.zepro.com

M8x20 8.8 (25 Nm)

Image 40. Installing aluminium profiles.

Image 41. Installing aluminium profiles.

5. Fasten the aluminium profileswith twoM8x20(8.8) bolts each. The head of the bolt is threaded in the aluminium rail and the rail is fitted andscrewed into the bracket. Tightening torque 25 Nm.

When installing on ZLU 45/75-90/110, more powerful brackets are used for the internal aluminium rail ,compared to other models.

NOTE!


35www.zepro.com

7.9 ArmstopsArmstops are not included in standard equipment. Can be ordered separately, art. no. 53450 for Z/ZU/ZL/ZLU and art. no. 53869 for ZN/ZNU models.

1. Fit armstops as high up as possible on the lift arm. Ensure that the adjustment screws have a good contact area against the rear member of the vehicle floor.Ifneeded,fitastopontherearmembersoasto create a stable contact surface for the armstop.

2. Adjust with the adjustment screws, so that both armstops contact the rear member/stop at the same time.

When installing armstops, add Loctite 243, or similar, on the fastening screws, See Image 43.

m WARNING!

If an assembly kit has been used for assembling the support frame , there may be special instruc-tions for armstops in the separate assembly direc-tions for the assembly kit.

NOTE!

It is not permitted to perform welding in the lift arm.m WARNING!

Image 42. Fit end stops between the lift arms and the rear member of the vehicle floor

*

min - m

ax

100 m

m

Image 43. Add Loctite, or simi-lar, on the fastening screws

Z 45/75-90/110

36

Installation

www.zepro.com

F

Vehiclefloorlevel

Type Flat 30 mm

F (mm) 75

7.10 Platform1. Check that all included components are clean,

cleaning them where necessary.

2. Lubricate the metal bushings on the upper bear-ing of the arms. Ensure that the small holes on the inside of the bushings are filled with grease. Use Zepro lubricant or the equivalent.

Carefully lubricate the metal bushings on the upper bearing of the arms. Ensure that the small holesarefilledwithgrease.Aftertheplatformisfitted,alsolubricateallbearingsvianormalgrease nipples, see section "14 Lubrication and fluidlevelcheck"onpage64.

NOTE.

3. Fit the platform to the arms and fasten the tilt cylinders to the platform. Use the shafts and lock-ing nuts provided. Tightening torque: 25 Nm. Thetiltcylindersshouldbeadjustedbeforefix-

ing to the platform.

NOTE!

4. Test the lift by carefully raising it to the vehicle 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 45.

The platform underhang (F) varies according to platform type, and this should be taken into accountwhenfittingtheupperseal.

NOTE!

Image 44. Fit the platform with the shafts and locking nuts provided.

Image 45. Fitting the platform to the arms


37www.zepro.com

7.11 Sealing strip (horizontal)Thetrackisfittedusingtheself-tappingscrewsprovided.

1. Check that thedistancebetween thebodyfloorand the platform is 38 - 40 mm.

2. Mark where to drill holes for the self-tapping screws.

3. Drill holes (Ø 7.2 mm) for the screws.

4. Fit the horizontal stop strip (steel or aluminium).

5. Fit the rubber strip to the track.

7.12 Sealing strip (vertical)6. Check that thedistancebetween thebodyfloor

and the platform is 38 - 40 mm.

7. Fit the tracks with countersunk screws, rivets or by spot welding.

8. Fit the rubber strip to the track.

9. Secure the rubber strips by swaging the tracks together at the bottom.

Tofitanupperedgeseal,createa45°mitreagainst the vertical strips.

NOTE.

Image 46. Check that the distance between the body floor and the platform is 38 - 40 mm.

38 - 40 mm 38 - 40 mm

Image 47. Installing a sealing strip

Z 45/75-90/110

38

Installation

www.zepro.com

7.13 Sealing strip, integrated rubber strip1. Check that the distance between the vehicle bed and the platform is 38 - 40 mm, see Image 46.

2. Measureoutandcutthestopprofileandrubbertrimtothedesiredlength.

3. Mark where to drill holes for the self-tapping screws.

4. Drill holes (Ø 7.2 mm) for the screws.

5. Fitthescrewandnutontothearmstopandassemblethemontothestopprofile,seeImage 48 and Image 49.

6. Place the armstop according to the position of the 1st boom and secure by tightening its screws, see Im-age 53.

7. Screwthestopprofileintothepre-drilledholes,seeImage 50

8. Insertandinstalltherubberstripinthestopprofile,seeImage 51.

9. Secure the rubber strip with the associated screw, see Image 52.

Rubber strip

Stopprofile

Armstop

Image 48. Install screw, nut armstop

Image 49. Install the armstops Image 50. Screw tight the stop profile

Image 51. Fit the rubber strip Image 52. Secure the rubber strip

Image 53. Secure the armstop


39www.zepro.com

7.14 Angle sensor quick opening1. Mount the angle sensor as shown below, se Image 54.

2. Secue with attached screws, use Ø5,2 mm drill.

Ensure that the sensor is mounted in such a way that its cable connection ends down, see Image 54.

OBSERVERA!

Image 54. Mounting angle sensor

~ 45º

7.15 Angle sensor for electronic autotilt (option)

When installing electronic autotilt, install the angle sensor on the lift arm, see Image 55.

Wheninstallingontheleftarm,thesensor’scableinput must be facing upwards.

Wheninstallingontherightarm,thesensor’scableinput must be facing downwards.

NOTE.

Image 55. Installing the angle sensor

Z 45/75-90/110

40

Installation

www.zepro.com

7.15.1 Adjusting the tilt angle

Donotadjustthecylindersbeforetheyarefittedto the platform. The tilt cylinders are preset from the factory.

NOTE.

1. Loosen the rubber bellows at the bottom where they are secured with hose clips.

2. Tilt up and move both tilt cylinders all the way up.

Adjustment must always take place with full hydraulic pressure in the tilt cylinders.

NOTE.

3. Undo the locking nut.

4. Turn the pushrod so that the platform comes into the desired position. For vehicle bodies without rear doors the platform is adjusted against the side sealings. For vehicle bodies with rear doors the platform is adjusted so that it stops in a verti-calpositionwithasufficientgapbetweenplatformand doors.

Out

In

Body without rear doors.With side seals. Body with rear doors.

+

Image 56. Adjusting the fit with the vehicle body

Image 57. Adjusting the fit with the vehicle body


41www.zepro.com

5. After adjustment, tighten the locking nut. To ensurethatthelockingnutisfixedinthesetposition it is recommended that it is locked with Loctite 243 or equivalent. Tightening torque: 80 Nm.

Afterfinishing theadjustment,makesure thedistance between the adjusting collar and the end of the thread is no more than 30 mm.

m WARNING!

6. Fit the cylinder boots.

Max. 30 mm

A

Image 58. Afterfinishingtheadjustment,makesure the distance between the adjusting collar and

the end of the thread is no more than 30 mm.

Lift model A

45/75-90 73 ±5

45/75-110 156 ±5

7.16 Purging the cylindersPurge the lift cylinders by fully lowering the platform a few times. You may have to lift the truck to fully lower the platform.

The tilt cylinders can be purged by raising the plat-form fully against the vehicle body and then tilting all the way down.

Fluid may need to be topped up when purging the hydraulic system.

NOTE

7.17 Transport lockFor all CE marked lifts with 1000 kg lifting capacity or more, platforms are supplied without mechanical locks. Otherwise, the transport lock for steel plat-formsisfittedontherightside.

Electric hose breakage valves serve as locks for the platform. The lock opens automatically if the down function is actuated from the control device. The valvesarenon-returnvalvesthatletfluidinfromthecylinders but not out before they are actuated by the flowfromtheloweringvalve.Theplatformisthus hydraulically locked during transport.

Image 59. Installing boots.

Z 45/75-90/110

42

Temporary operation of lift

www.zepro.com

8 Temporary operation of liftWhen the lift is installed, it is sometimes necessary to operate the lift functions in order to change the posi-tion of the cylinders and the lift arms. To do this, the lift control card can be connected temporarily to run thefunctions.Toaccessthelift’scontrolcard,seesection"9Hydraulicunitandcontrolcard"onpage43

The battery charger must not be connected when operating the lift. Risk of damage.

With this connection, closing against the vehicle body does not work.

NOTE.

8.1 Connection1. Connect a suitable control device to the control card, see illustration below. The number of available func-

tions varies depending on the lift model.

2. Connect an earth connection (GND) and +12/24 V to the lift. See also section "17.2 Maximum power con-sumption - Minimum recommended conductor cross sectional area" on page 70.

3. Insert a jumper between CSPWR and CS to simulate a cabin switch CS in the ON position, see Image 60.

8.2 OperationUse the control device to operate the lift functions.

Take great care when running the lift functions and make sure nothing is trapped. There is a risk of injury and damage.

m WARNING!

8.3 Disconnection1. Remove the jumper between CSPWR and CS.

2. Disconnect +12-24 V from the platform.

3. Disconnect the earth connection from the platform.

4. Disconnect the control device from the control card.

Ctrl 4Spiral

Ctrl 3Radio

Ctrl 2

Ctrl 1

Con

trl P

ower Sensor Power

Gro

und

IN OUT

Ai 2Ai 1Di 1Di 2Di 3Di 4Di 5Di 6

PA-PA+

CSPWRCS

+

BEC2H1

BEC2H2

BECLock

BECLock

U7

U6

U5

U4

U3

U5

U4

U2

U1

U0

Ctrl 6

Out In GN

DLL

EDCtrl 5

Outputs

Sen

sors

UpDownTilt

Control voltage

Image 60. Temporary connection of lift control card

Jumper

2H

Z 45/75-90/110Hydraulic unit and control card

43www.zepro.com

9 Hydraulic unit and control card

9.1 Summary

Image 61. Overview Hydraulic Unit

Motor

Solenoid (s)

Oil Tank Tank Cap

Valve housing

Constantflowvalve, tilt cylinderControl Card

U1 Valve, lower

U2 Valve, lift cylinder

U3 Valve, tilt cylinder

Z 45/75-90/110

44

Hydraulic unit and control card

www.zepro.com

250~70

9.2 Hydraulic unit, installingThe hydraulic unit may be supplied with hydraulic hoses and electrical cables connected or without pre-connection.

1. When installing the unit the tensioning strap for transport is removed. The tensioning strap is not to be used for fastening the plastic hood.

2. Install the unit on the support frame (see Image 63.) or on the vehicle chassis according to the il-lustration (See Image 64.).

9.3 Connecting hydraulic hosesThe hydraulic hoses are connected according to Image 65. Ensure that the hoses are properly con-nected. P2 Lift circuit, P3 Tilt circuit and T Tank/return.

Image 62. Remove the tension-ing strap before installation.

Image 63. Assembly of hydrau-lic unit on support frame.

Image 64. Assembly of hydrau-lic unit on vehicle chassis.

Image 65. Connecting hydraulic hoses P2 Lift circuit, P3 Tilt circuit and T Tank/return.

P3 P2 T

Z 45/75-90/110Electrical and hydraulic drawings

45www.zepro.com

10 Electrical and hydraulic drawings

10.1 Z 45/751 1

2 2

3 3

4 4

5 5

6 6

ABCD

Denna ritning är Z-Lyftens egendom och skyddad enligt internationellt gällande lag för copyrightoch får ej utan Z-Lyftens skriftliga medgivande kopieras, delges eller obehörigen användas.

This drawing is property of Z-Lyften Produktion AB and is loaned subject to return upon demand. It is notto be reproduced or used directly or indirectly in any way detrimental to the interest of Z-Lyften Produktion AB.

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Z 45/75-90/110

46

Electrical and hydraulic drawings

www.zepro.com

10.2 Z 45/75, with hydraulic autotilt1 1

2 2

3 3

4 4

5 5

6 6

ABCD



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47www.zepro.com

10.3 Connecting cabin switch and open platform alarm

1 1

2 2

3 3

4 4

5 5

6 6

ABCD



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Z 45/75-90/110

48

Electrical and hydraulic drawings

www.zepro.com

10.4 Connecting warning lighting and foot controls

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PA-

PA+

CSP

WR CS

+

B E C 2H1

B E C 2H2 B E C Lo

ck

B E C Lock

U7U6U5

U4

U3

U5

U4

U2U1U0

Ctrl

6

OutInGND/Spk-

LLED/Spk+

Ctrl

5

Indi

catio

nSe

app

endi

x in

inst

alla

tion

man

ual

Out

puts

Sensors

B20

20-1

1-20

7908

DN

-M

K


49www.zepro.com

Ctrl 4Spiral

Ctrl 3Radio

Ctrl 2

Ctrl 1

Con

trl P

ower Sensor Power

Gro

und

IN OUT


PA-PA+

CSPWRCS

+

BEC2H1

BEC2H2

BECLock

BECLock

U7

U6

U5

U4

U3

U5

U4

U2

U1

U0

Ctrl 6

Out In GN

DLL

ED

Ctrl 5

Outputs

Sens

ors

CD11

Brown B Yellow E Blue C *Blue 2H

CD1, CD2

BC

2H1 2H2

2H

E

CD4

BC

2H

E

Black (+)

Black (+)

2H Black (+)

Black (+)

Black (+)

Black (+)

(White (-), if avail-able)

(White (-), if available)

White (-)

CD14 ABS E

CD14 BBS E Black (+)

CD12

Ctrl 4Spiral

Ctrl 3Radio

Ctrl 2

Ctrl 1

Con

trl P

ower Sensor Power

Gro

und

IN OUT


PA-PA+

CSPWRCS

+

BEC2H1

BEC2H2

BECLock

BECLock

U7

U6

U5

U4

U3

U5

U4

U2

U1

U0

Ctrl 6

Out In GN

DLL

EDCtrl 5

Outputs

Sen

sors

White (-) must be con-nected to the connec-tions marked “Ground”.

CD9BCE

Black (+)(White (-), if available)

CD10B

E

Black (+)(White (-), if available)

Brown BYellow EBlue CGreen 2H

Brown BYellow EBlue CBlue 2H

Brown BYellow E

Brown BYellow EBlue CGrey Lock

Brown BYellow EBlue C

Brown BYellow E

Red BBlue E

Only 1 control device/connection may be connected.

NOTE.

10.5 Connecting control devicesThe most commonly occurring control device (CD) models are shown below. Possible control device models varydependingonliftmodel,configurationandrelevantmarket.

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Functional schematic drawing

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11 Functional schematic drawing

11.1 Sensor/Inputs

Name Position (Standard) Function Description

Di1 Not used on this lift model and must not be connected.

Di2 Platform Angle sensor Non-actuated Di2 disables Tilt up with the secondary control device so that the operator has to use the two-hand button (2H) along with the primary control device in order to continue to maintain the tilt up function.

Di3 Lift arm Angle sensor For autotilt, safety function.

Di4 Tilt cylinder Open platform alarm

Pressure sensor for falling pressure connected to +side of tilt cylinder. In the actuated state, returns the connection signal (+) to Di4 and resulting in output signal (-) at Pa-. Also phase (+) signal out at Pa+.



Cs Cabin Activation No signal in at Cs results in blocked control device terminals. Signal to Cs usually comes from the cabin switch.

2H Control devices Two-hand button

Activated in connection with opening and closing of vehicle body. Used for Quick opening.

11.2 Restriction in use of control device(Tilt up/down and opening/closing)

Image 66. Use of radio control device limited by the platform angle

Ctrl 1, 2 & 4 Ctrl 1, 2, 3, 4 & 6

Z 45/75-90/110Functional schematic drawing

51www.zepro.com

11.3 Functional schematic

Function

Input signal Output signal Comment Controller IllustrationHigh Low (0v)

Open

1

CE2HDi6

p Di1 p Di2 p Di3 p Di4 p Di5 p Di6

p U0 p U1 p U2 p U3 p U4 p U5p U6p U7

Open from vehicle body down to about 45º

p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6

45º90º

0º-10º

2DEDi6


p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7


45º

0º-10º

90º

Lower

1 E




2 EDi3*



Autotilt down


-10º0º

Tilt down

CEDi2Di6




45º90º

0º-10º

* Onlyrequiredatstartofmotion;afterchangeofsensor,itisignoreduntilare-runtakesplace.

Z 45/75-90/110

52

Functional schematic drawing

www.zepro.com

Function

Input signal Output signal Comment Controller IllustrationHigh Low (0v)

Raise

B



Autotilt up


-10º0º

B




Tilt up 1BCDi2



Tilting up to approxi-mately 45º


45º90º

0º-10º

CloseBC2H



Close against vehicle body


45º90º

0º-10º

* Onlyrequiredatstartofmotion;afterchangeofsensor,itisignoreduntilare-runtakesplace.

Z 45/75-90/110Connection unit

53www.zepro.com

12 Connection unit

12.1 Power save modeIf the control card is not used for a certain amount of time, it goes into power save mode. For 5 or 20 minutes dependingonwhichmodethecontrolcardisinandwhetherCSisonoroff.Pressanycontrolbuttonforapprox. 0.5 seconds to “wake up” the control card again.

12.2 Operating informationAllthelift’sfunctionsarecontrolledandmonitoredthroughthecontrolcard,whichisequippedwithanalpha-numericaldisplaywithaflashinglightand2redLEDS.Thesedisplaycurrentoperatinginformation.Intheevent of any operational disturbances, fault codes are displayed to facilitate troubleshooting.The display indicates:

- Active control device- Fault display- Programconfiguration- Sensors’currentstatus

Flashing light indicates:- Supply voltage- Off:Nosupplyvoltage- On: Supply voltage available but CS (cabin switch) is not active.- Flashing: CS (cabin switch) is active, the system is awaiting input signal.

LED 1 indicates: - Active input, button(s) on control device pressed.

LED 2 indicates:- Active output (approved input signal from control device and sensors), the lift is operated.

Image 67. The control card is equipped with an alphanumerical display with a flashing light and 2 red LEDS

DisplayFlashing light

LED 2LED 1

Z 45/75-90/110

54

Connection unit

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12.2.1 Information codesCodesareshownonthedisplayinasequence.Firstaletterforidentificationofinformation,fol-lowedbyfiguresorsegmentsforfurtherinformationandthenendingwithapause:

WhentheCS(cabinswitch)isswitchedon,thecurrentprogramconfiguration(P)isdisplayedfirst,followedbyconfigurationnumber. The number of volts detected is then displayed and, after this, the current software version (J), followed by version number.

As long as no control device is used, a scrolling sequence is then displayed, with sensor indication (C), followed by 0-6 segments showing which sensors have a signal.

When a control device is used, the control device being used (1-7) is displayed, followed by which button has been pressed, segments B, C, E or X (X symbolises the 4th button on the respective controldevice(2h1forfixedcontroldevice1,2h2forfixedcontroldevice2, lockknobforradiocontrol device and coil control device).

Thecontroldevicesaresymbolisedbythefigures1-7

Control card con-nection

Recommended control device

1 CTRL 1 Fixed control device 1, including two-hand button 2h1


3 CTRL 3 Radio control device, External

4 CTRL 4 Coil control device

5 CTRL 5 Slider lift control device

6 CTRL 6 Radio control device, internal module

7 CS CS (cabin switch)

Once a button has been released, the control system for the current control device is locked for a while to ensure that no other person operates the lift from another control device. During the periodthecontrolsystemislockedforthecurrentcontroldevice,itsnumber(1-7)willflashonthedisplay. This primarily applies to radio and coil control devices, as other control devices have such a short locking period that there is hardly time to see the indication.

Ctrl 4 can be equipped with a locking function. Once the control device has been used, the control systemislockeduntilitisunlockedmanuallyfromtherespectivecontroldevice’sdeactivationbutton.

The radio control device is also equipped with a locking function. The control system can then be locked/unlocked via the remote control lock button. On certain models, the status of the lock is indicated by LED which lights when the lock is activated. In the event of a fault in the remote control,unlockingcanbeperformedbyturningthecontrolpower(CS)Off/On.

On certain remote control models, the lift locks again as soon as a button on the remote control is pushedwhentheliftisunlockedbythecontrolpower(CS)beingswitchedOff/On.

Theliftremainslockedifitlosespowerandisthenstartedupagain,andthenumber6flashesonthecontrolcard’sdisplay.Unlockingisperformedasdescribedabove.

NOTE.


55www.zepro.com

Information codes

Identification Code 1 Code 2

Code 3 Information Other

P (Program

configuration)

00–99 Cancelledconfiguration

- Dividers

12/24 Number of volts detected

J Software version

01–99 _ 1-9 Version number

1-6 (Fixed light)Active control device

while operating

1-6Fixed light (1-6) displays active control device during operation.

B C

E X

In

Out

Segment B, C, E or X.

Segments B, C, E or X are illuminated depending on which button is pressed X= 2H and Lock.

1-7 (Flashing) The control device to which the control system is locked for a while after com-pleted operation.

1-7

Control device to which the control system is locked. This primarily applies to radio and coil control devices, as other control devices have such a short locking period that there is no time to see the indication.Thenumberwillstopflashingwhenoneof the current control device’s buttons arepressed.If the control card has been without voltage and receives the voltage again when the CS (cabinswitch)isswitchedon,“7”willflashon the display and the control card is locked untiltheOff/OnontheCSisoperated.1-6 = Ctrl 1-6

7 = CS

C Sensor indication

Segment

1-6 segments indicate sensors.On - signal in.Off-nosignal in. 0V.(See electrical and hydraulics diagrams for information about the location of the sensors).

Di1 Di3

Di6 Di4

Di2

Di5

Example of sequence of information codes:Programconfiguration:01,Voltagedetected:12V,Softwareversion:09

Example of sequence with sensor indication:Sensor indication: C, Detected sensor: Di1

Example of sequence with control device indication:Control device: 2, Detected button: B

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Connection unit

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12.2.2 Fault codesIf a fault arises, the fault code is shown in the display in the form of a letter for identifying the fault, followed by numbers and/or number segments for further information, followed by sensor indica-tion (C) in accordance with the previous page.

In fault codes E, F and U, the numbers (1-9) show which control device/output the fault code refers to.

Control card con-nection

Recommended control device



3 CTRL 3 Radio control device, External

4 CTRL 4 Coil control device

5 CTRL 5 Slider lift control device

6 CTRL 6 Radio control device, internal module

7 CS CS (cabin switch)

8 Control Power

9 Sensor Power

If the system discovers several faults, only the fault code for the fault with the highest priority will be shown automatically. The display is prioritised in the order in the table below, L/H, E, F, and A. To see all current faults, press and hold in button C on the control device.

WhentheCSisswitchedoff,thesystemwillbrowsethroughalistcontainingthefivemostrecentfaultsdetectedbeforethedisplaygoesoffafterapprox.5minutes,thecontrolcardthengoesinto power save mode.


57www.zepro.com

Fault codes

Identification Code 1 Code 2 Code 3 Information Other

L Low battery voltage

07-35 Voltage measured

HHigh battery voltage

07-35 Voltage measured

E Control device

locked

1 Fixed control device 1, including two-hand button 2h1

2 Fixed control device 2, including two-hand button 2h2

3 Radio control device, external

4 Coil control device

5 Truck slider control device

6 Radio control device, internal module

7 CS (cabin switch)

Segment

Segments B, C, E or X are illuminated depending on which signal has locked the control device. X= 2H Lock.

B C

E X

In

OutF

Output short-circuit-ed/high current

0-9

Which output has short-circuited/has high current. Fault code is reset automatically if the function in question is running (function verified).

1-7 U0-U7, dis-played only a f t e r t h e respective output/function has been ac-tive.

8 Control power

9 Sensor power

Output not connect-ed/cable breakdown

0-7

Which output is not connected/has cable breakdown. Fault code is reset automatically if the function in question is running (functionverified).

Displayed only af-ter the respective output U0-U7 has been active.

A Internal fault 0- Any measurement faults are reg-

istered by the system.

Contact support if the lift does not function.

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Connection unit

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All fault codescanbe resetmanuallybyswitchingOn/Off theCS (cabinswitch). Fault codes F0-F7andU0-U7areresetautomaticallyifthefunctioninquestionisrunning(functionverified).Fault codes L and H are reset automatically if the battery voltage becomes correct. Fault code E is reset automatically if the control system has not received any signal from the relevant control device for 6 minutes.

Example of sequence of fault codes:Output No. 3 short-circuited.

12.2.3 Control devicesIf a control device button is held down for too long, the control device is blocked and cannot be used foranumberofminutes.FaultcodeEflashesonthedisplay.Thefaultisalsoindicatedonanon-active coil control device with a lock button, if this is connected to Ctrl 4. The LED on the coil control devicethenflashesthesamenumberoftimesasthenumberonthecontroldeviceinquestion,seethe list in section "12.2.2 Fault codes" on page 56.

Example:Controldevice2isblocked,theLEDonthecoilcontroldevicethenflashestwice,goesoutforamoment,flashestwiceagain,etc.

Coil control device’s LEDFixed light The coil control device is active

Extinguished (weak glim-mer)

The coil control device is not active

Flashing One of the other control devices is blocked

12.2.4 Supply voltageTheillustrationsbelowshowthedesiredsupplyvoltagefor12Vand24Vsystems.Specifiedvoltagerefers to voltage when the lift is operated. See also section "17.2 Maximum power consumption - Minimum recommended conductor cross sectional area" on page 70.

The lift is not working.The lift is working but is issuing a warning. This voltage range is only recommended for emergency operation.Theliftisworking,butthevoltagerangeoutsidethe‘heart-marked’areaisonlyrec-ommended for operation for short periods.The lift is working within the voltage range for optimum function and service life.

0V 36V

0-7V

8-15V

16-36V

12V 10-14V

0V 36V

0-16V

18-30V

32-36V

24V 20-28V

Z 45/75-90/110Marking

59www.zepro.com

7

8

12Vs s tem

1 5V1 6

18

24 V sys t em

29 V

cuando la tensión es baja.

¡NB! Sólo la unidad de

control principal funciona.

Emergency closing when voltage is low.

NB! Only the main control unit is functional.

Nödstängning vid låg volt. OBS! Endast

huvudmanöverdonet är användbart.

Notsteuerung bei Unterspannung.

ACHTUNG: Notsteuerung ist nur mit der

Hauptsteuerung möglich!

Fermeture d’urgence lorsque la tension est

trop faible. NB! Seule l’unité de commande

principal est fonctionnel.

Cierre de emergencia

y

www.zepro.com Phone +46 (0)150 48 95 50

76350TL 2017-02-02

Autotilt

Autotilt

Image 68. Overview of labelling

13 MarkingBelow,anoverviewofthelocationofthedifferentmarkingsisshown.Imageofmarkingandfurtherinformationcan be found under the each subchapter for subsequent pages.

13.1

13.5

13.3

13.4

13.5

13.6

13.7

Z 45/75-90/110

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Marking

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13.1 Loading diagramAffix 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 69. Load diagram for load capacity 450 kg, centre of gravity distance 600 mm.

Image 70. Load diagram for load capacity 750 kg, centre of gravity distance 600 mm.

Z 45/75-90/110Marking

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Image 71. Identification plate

Image 72. Work area

13.2 Identification plate Theidentificationplateisfixedontothetaillift’sframe.Affixthecorrespondingstickerversionoftheidentifica-tion plate, preferably by the cab door post to facilitate identification.

Theidentificationplatecontainsthefollowinginforma-tion:

• 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)• Type number for electromagnetic compatibility

(EMC)

13.3 Work area Affixthestickerclearlyvisibleontherearofthevehicle.

Image 73. Warning tape

13.4 Warning tape Affixedalongtheplatformedgestripstomarktheplat-form edges in its lowered position. The location of the warning tape often coincides with the contour marking, in which case the warning tape can be omitted.

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62

Marking

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Image 74. Controller sticker for CD 1, 2, 9

Controller Sticker (Stand-ard)

Sticker (Reversed)

CD 1,2,9 55053TL* 55054TL*CD 4 55055TL 55056TLCD 10 77661TL 77662TL

* Thestickersectionfor2-handoperationisdelivered on the same backing paper and has to beaffixediftheapplicationhas2-handoperation.For applications without 2-hand operation, this part of the sticker is discarded.

www.hiab.com 55053TL 2020-03-04

�

Image 75. Controller sticker for CD 10

www.hiab.com 77661TL 2020-03-04

�

13.5 Controller stickerAffixthecontrollerstickernexttotherelevantcontroller.Thestickersareavailableinstandardversionsandinreversedversion(Option)foraffixingontheoppositesideofthevehicle.Makesurethestickersareaffixedsotheimageofthevehicle/tailliftonthestickerisinthesamedirectionasthevehicleonwhichitisaffixed.

Image 76. Standard mounting Image 77. Reversed mounting

Image 78. Controller sticker for CD 4

www.hiab.com 55055TL 2020-03-04

�

Z 45/75-90/110Marking

63www.zepro.com

Image 79. Danger area

Image 80. Warning flags

13.6 Danger area If one is fitted, affix the sticker on the insideof thevehicle body next to the hand control unit.

13.7 Warning flags Attachwarningflagsascloseaspossibletothetopand edge of the platform, where there is no risk of them coming loose when the platform is lowered to the ground. Swage the tracks together to secure the warningflags.

�

www.hiab.com 65977TL 2020-05-14

min. 300 mm

min. 300 mm

Z 45/75-90/110

64

Lubricationandfluidlevelcheck

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Image 81. Lubrication points

14 Lubrication and fluid level checkThe following lubrication points must be greased on installation. They must then be lubricated at least 4 times a year.

14.1 Lubrication

Use LE lubricant 4622 or the equivalent.

NOTE.

1. Right tilt cylinder, at lower bearing.2. Right lift cylinder, at lower bearing.3. Lift arm right side, at lower bearing.4. Left lift cylinder, at lower bearing.5. Left tilt cylinder, at lower bearing.6. Lift arm left side, at lower bearing.7. Left tilt cylinder, at upper bearing.8. Right tilt cylinder, at upper bearing.9. Lift arm right side, at upper bearing.10. Right lift cylinder, at upper bearing.11. Left lift cylinder, at upper bearing.12. Lift arm left side, at upper bearing.

14.2 Oil level checkCheckthefluidlevelinthetankduringservice,topupifnecessary.Themarkingonthehydraulictankindi-catesthetypeofhydraulicfluidused.Mineralhydraulicfluid,productno.21963(1litre),orbiodegradablesyntheticfluid,productno.22235(1litre).

1

2

5 36 4 8

7

9

10

11

12

Z 45/75-90/110Testingandverification

65www.zepro.com

15 Testing and verificationTestingandverificationofthetaillifttakesplaceinaccordancewiththeinstallation/deliveryinspection.Verifythat the tail lift is suitable for the vehicle in question and for the intended use.

15.1 Static load test

15.1.1 DeformationPositionthetaillifthalfwayuptothevehiclefloorlevelandwiththeplatforminthehorizontalposition.Meas-ure dimensions A-B-C-D for comparison as illustrated.Place a test load on the platform according to the table for the respective tail lift model and lifting capacity.Remove the test load from the platform.RepeatthemeasurementofA-B-C-Dandverifythattherehasbeennodeformationoftheliftoritsfixing.

15.1.2 DriftPlace a test load on the platform according to the table. The tail lift must be at the same level and angle as thevehiclefloor.Leavethetestloadfor15minutes.Verify that the platform drift is no more than 15 mm on the vertical (points A and D) and 2º in terms of the angle.

15.1.3 Static load (Test load 1.25 x tail lift loading capacity). For lifts with a load centre of 600 mm.

Capacity Load 500 kg Load 1000 kgDistance out in platform (L)

450 kg (450 kg) 675 mm -500 kg 750 mm -700 kg 1050 mm -750 kg 1125 mm -

1000 kg 1450 mm 750 mm1500 kg 2250 mm 1125 mm2000 kg - 1550 mm2500 kg - 1875 mm

15.1.4 Static load (Test load 1.25 x tail lift loading capacity). For lifts with a load centre of 750 mm.


1000 kg 940 mm -1500 kg 1410 mm 940 mm2000 kg 1875 mm 1250 mm2500 kg 2340 mm 1560 mm

Z 45/75-90/110

66

Lubricationandfluidlevelcheck

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15.2 Dynamic load test.

15.2.1 Test with max. loadPlace a test load on the platform according to the table for the respective tail lift model and lifting capacity.Check that the lift operates correctly in the normal range of movement allowed, i.e. up, down, tilting at ground levelandtiltingatthevehiclefloorlevel.

15.2.2 Test with overloadPlace a test load on the platform according to the table for the respective tail lift model and lifting capacity.Thetestloadshouldbe1.25xtheliftmodel’smax.load.Verifythatthetailliftcannotlifttheloadwhentheup function is switched on (it may however by possible to tilt up the load).

15.2.3 Dynamic load (Test load 1.0 x tail lift loading capacity). For tail lifts with load centre of 600 mm


450 kg 600 mm -500 kg 600 mm -700 kg 800 mm -750 kg 900 mm -

1000 kg 1200 mm 600 mm1500 kg 1800 mm 900 mm2000 kg - 1200 mm2500 kg - 1500 mm

Image 82. Testing and verification

Max 2º

Max. 15 mmB

D

C

A B

DC

A

Vehiclefloorle

vel

Deformation

Drift

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15.2.4 Dynamic load (Test load 1.0 x tail lift loading capacity). For lifts with a load centre of 750 mm.


1000 kg 750 mm -1500 kg 1125 mm 750 mm2000 kg 1500 mm 1000 mm2500 kg 1875 mm 1250 mm

15.3 Test of safety functionsThe tail lift functions must be tested.Check:

• Thattheredlightinthevehiclecabinturnsoffwhentheplatformiscompletelyclosedagainst the body and that it turns on when the platform is opened (where applicable).

• Thatthetailliftcannotbeactivatedifthecabinswitchisintheoffposition.

• That the tail lift cannot be activated when the main switch fuse is removed (where applica-ble).

• Thattheoverflowvalveisactivatedwhentheliftisoperateduptothevehiclefloorlevelorend stops.

• That the tail lift cannot be lowered or tilted down if the electrical connector from the electric hose rupture valves is removed from the lift and tilt cylinders respectively.

• That there is a “max. load” marking on the platform and it is correctly positioned according to the loading diagram for the tail lift model concerned.

• Thatwarningflagsandreflectorsarefittedandfulfiltheirfunctioncorrectly.

• That all safety and operating decals are installed in their respective position.

• Thattheplatform’smechanicallockisfunctioningcorrectly(whereapplicable).

• Thattheinstructionsforusingthetaillifthavebeenleftinthedriver’scabin.

• That the CE declaration of conformity has been completed.

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Disassembly

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16 DisassemblyIf the tail lift has to be removed from the vehicle, for example to transfer it to another vehicle, for storage or formodification,pleasefollowtheseinstructions.

1. Support the platform with a crane or similar equipment that can safely carry the platform's weight (NB. weight info).

2. Dismantlethetiltcylinders’upperaxlefromtheplatformandrestthecylindersontheground.

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 and suitable drift.5. Liftofftheplatform.6. Raise the lift arms to their highest position.7. Disconnect +12-24 V from the control card.8. Disconnect all control devices from the control card.9. Support the support frame from beneath, for example with a car jack.10. Remove the support frame from the vehicle chassis by loosening the bolts and carefully

lowering the support frame to the ground with a car jack.

Z 45/75-90/110Specifications

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17 Specifications

17.1 Weights Many of the lift components are heavy, requiring the use of lifting equipment. Make sure the weight of the components does not exceed the maximum permitted load of the lifting equipment. The following is a list of selected components with their weight.

Complete lift chassis (without platform)

Lift components (included in complete lift chassis)

Z-45/75-90 130 kg Support frame Z/ZU 45/75 25.5 kgZ-45/75-110 136.5 kg Support frame ZL/ZLU 45/75 32.5 kgZL-45/75-90 141 kg Support frame ZN/ZNU 45/75 25.5 kgZL-45/75-110 146.5 kg Lift arm Z/ZU 45/75-90 20.0 kgZN-45/75-90 125 kg Lift arm Z/ZU 45/75-110 22.5 kgZN-45/75-110 131 kg Lift arm ZL/ZLU 45/75-90 23.5 kgZU-45/75-90 148 kg Lift arm ZL/ZLU 45/75-110 26.0 kgZU-45/75-110 154.5 kg Lift arm ZN/ZNU 45/75-90 17.0 kgZLU-45/75-90 159 kg Lift arm ZN/ZNU 45/75-110 19.0 kgZLU-45/75-110 164.5 kg Complete chassis bracket 4.2 kgZNU-45/75-90 139 kg Hydraulic unit 13.0 kg

ZNU-45/75-110 145 kg Lift cylinder -90 5.0 kg each

Lift cylinder -110 5.9 kg each 12.2 kg each

Aluminium platforms Tilt cylinder S -90 7.3 kg each

Level 30mm (PLALAS L) Tilt cylinder S -110 8.2 kg each

Aluminium platform 1200x2200 mm 54 kg Tilt cylinder SA -90 7.2 kg each

Aluminium platform 1450x2200 mm 63 kg Tilt cylinder SA -110 8.2 kg each

Aluminium platform 1600x2200 mm 68 kg U-protection cpl. ZU 20 kg

U-protection cpl. ZLU 20 kg

U-protection cpl. ZNU 16 kg

Other components

Towbar kit Z/ZU 22,0 kg

Towbar kit ZN/ZNU 23,9 kg

Towbar kit Z/ZU/ZL/ZLU 25,5 kg

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Specifications

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Image 83. Maximum power consumption Z45 - Minimum rec-ommended conductor cross sectional area

- +

- +

L

L

UminImin

Imin Umin

17.2 Maximum power consumption - Minimum recommended conductor cross sectional area

Z45 (110 bar)

5915 12 volt 24 volt

Pump - Motor unit 95 A 60 AMagnet (hydraulic unit) 1.4 A 0.7 AMagnet (electric safety valve) 1.5 A 0.75 ASolenoid 1.8 A 0.9 AMinimum recommended conductor cross sectional area (copper cables, plus and minus cables)Control cable 1.5 mm2 1.5 mm2

Supply cable, L < 8 m 25 mm2 25 mm2

Supply cable, L = 8 - 15 m 35 mm2 35 mm2

Supply cable, L > 15 m - 35 mm2

BatteryMin. capacity, Imin 140 Ah 110 AhMin. voltage during operation, Umin (at lift)

9 volt 18 Volt

Ensure that the lift has access to the minimum recommended power capacity (Imin). Some ve-hicles have restrictions regarding the amount of power the lift can access from the existing battery.

NOTE.


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17.3 Battery maintenanceWhen storing for longer than 1 week, you are recommended to disconnect the lift from the battery via the mainswitchorbyreleasingthelift’smainfuse,inordertoreducetheriskofthebatterydischarging.Thelengthoftimethevehiclecanbestoredwithoutthebattery’schargelevelbecomingtoolowdependsontheconditionofthebattery,thechargelevelbeforestorageandhowmuchpowerthevehicle’sothercomponentstake from the battery. After a period of storage, the battery must always be charged fully before operating the lift. When installing the lift and when carrying out service and repair work, when the lift is operated repeatedly without the vehicle being started and used, the battery charger must be used between operations to maintain thebattery’schargelevel.

The battery charger must not be connected when operating the lift. Risk of damage.

NOTE.

- +

- +

L

L

UminImin

Imin Umin

Z75 (150 bar)

5915 12 volt 24 volt

Pump - Motor unit 115 A 75 AMagnet (hydraulic unit) 1.4 A 0.7 AMagnet (electric safety valve) 1.5 A 0.75 ASolenoid 1.8 A 0.9 AMinimum recommended conductor cross sectional area (copper cables, plus and minus cables)Control cable 1.5 mm2 1.5 mm2

Supply cable, L < 8 m 25 mm2 25 mm2

Supply cable, L = 8 - 15 m 35 mm2 35 mm2

Supply cable, L > 15 m - 35 mm2

BatteryMin. capacity, Imin 140 Ah 110 AhMin. voltage during operation, Umin (at lift)

9 volt 18 Volt

Ensure that the lift has access to the minimum recommended power capacity (Imin). Some ve-hicles have restrictions regarding the amount of power the lift can access from the existing battery.

NOTE.

Image 84. Maximum power consumption Z75 - Minimum recommended conductor cross sectional area

Z 45/75-90/110

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Specifications

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Image 85. Loading diagram

17.4 Loading diagram


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Image 86. Tightening torque

17.5 Tightening torque

Allspecifiedtorquevaluesapplyforusewithascreworimpactwrenchwithtorquecontrol.Torque distribution max ± 5%.

NOTE!

www.zepro.se BUILT TO PERFORMZepro, 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 our customers' operations and to shape the future of intelligent load handling.

Z/ZU 45/75-90/110 ZL/ZLU 45/75-90/110 ZN/ZNU 45/75-90/110

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