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Zepro Z 1500-135 User Manual

Zepro Z 1500-135
84 pages
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ZEPRO
Tel.: +46 (0)10-459 05 00
E-mail: zeprotech@hiab.com | zepro.com
75976TL
2021-03-10
Installation Instructions
Tail Lift
Z 1500/2000-135/155/175
ZL 1500/2000-135/155/175

Table of Contents

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Zepro Z 1500-135 Specifications

General IconGeneral
BrandZepro
ModelZ 1500-135
CategoryIndustrial Equipment
LanguageEnglish

Summary

Introduction and Compliance

CE Marking and Product Approval

CE marking compliance for European market and product approval according to EN standards.

Hydraulic Oil Requirements

Specifies approved hydraulic oil types and grades for the lift system.

Guarantee and Model Identification

Conditions for valid guarantee and explanation of model naming conventions.

Safety Rules and Precautions

Repainting and Material Protection

Guidelines on parts not to be painted to avoid damage to seals and cables.

Transport Plug and Safe Movement

Removing transport plug and ensuring safe movement clearance for cylinders.

Third-Party Equipment Restriction

Prohibition of attaching third-party equipment to the lift system to ensure safety.

Installation Workflow Steps

Support Frame Installation

Steps for calculating dimensions and installing the main support frame.

Electrical Connections

Procedures for connecting electrical components like control devices and cables.

Platform and Cylinder Installation

Steps for fitting the platform, seals, end stops, and cylinders.

Attaching Decals

Procedure for applying identification and safety decals.

Calculating Installed Dimensions

Key Dimension Definitions

Explains C, D, A, and H dimensions for lift installation planning.

Rear Member Cut-outs

Cut-out Procedure

Steps for creating necessary cut-outs in the rear beam for platform arms.

Detailed Installation Procedures

Support Frame Mounting

Detailed steps for mounting the support frame using jigs and chassis brackets.

Control Power Cable Routing

Instructions for routing the control power cable safely from cab to lift.

Control Device Installation

Guidelines for positioning and fitting control devices for operator safety.

Warning Lighting and Foot Controls

Cabling and routing for warning lights and foot controls.

Main Power Cable and Fuse Installation

Proper routing, protection of main power cable, and fuse box installation.

Cable Grommet and Underrun Protection

Using cable grommets and meeting underrun protection requirements.

Armstops, Angle Sensor, and Sealing Strips

Fitting armstops, installing angle sensor, and sealing strips.

Platform Fitting and Tilt Cylinder Adjustment

Lubricating and fitting the platform, adjusting tilt cylinders.

Downward Tilt Angle and Cylinder Boot Adjustments

Setting downward tilt angle and fitting cylinder boots.

Cylinder Purging and Transport Lock

Procedures for purging cylinders and the transport lock mechanism.

Temporary Lift Operation

Temporary Connection and Operation

Connecting the control card for temporary lift operation and safety warning.

Hydraulic Unit and Control Card

Accessing Hydraulic Unit and Control Card

Steps to access and service the hydraulic unit and control card.

Connecting the Controller

Routing and connecting the controller to the control card.

Electrical and Hydraulic Diagrams

MA Autotilt Model Diagram

Electrical and hydraulic diagram for MA Autotilt models.

MA Model Diagram

Electrical and hydraulic diagram for MA models.

DA Model Diagram

Electrical and hydraulic diagram for DA models.

Warning Lighting and Foot Controls Diagram

Diagram for connecting warning lights and foot controls.

Control Device Connections Diagram

Wiring diagrams for various control devices.

Functional Description: MA Autotilt

Sensors and Inputs

Table detailing sensors, inputs, and their functions for MA Autotilt.

Functional Schematic Drawing

Functional schematics for MA Autotilt lift with inclinometer.

Autotilt Function Details

Detailed explanation of the autotilt up and down functions.

Control Device Restrictions and Zones

Limitations on control device use and activation zones.

Functional Description: MA Model

Sensors and Inputs

Table detailing sensors, inputs, and their functions for MA models.

Functional Schematic Drawing

Functional schematics for MA models, including control device restrictions.

Control Device Restrictions and Zones

Limitations on control device use and activation zones.

Functional Description: DA Model

Sensors and Inputs

Table detailing sensors, inputs, and their functions for DA models.

Functional Schematic Drawing

Functional schematics for DA models, including control device restrictions.

Control Device Restrictions and Zones

Limitations on control device operation and activation zones.

Connection Unit Operations

Power Save Mode and Operating Information

Control card power save mode and explanation of display/LED indicators.

Information Codes

Interpretation of display codes for system status and configurations.

Fault Codes

Listing and explanation of fault codes for troubleshooting purposes.

Control Device Status and Supply Voltage

Control device status, locking, and recommended supply voltage ranges.

Markings and Labels

Loading Diagrams

Instructions for affixing load capacity diagrams on the vehicle body.

Identification Plate and Work Area Sticker

Details on the identification plate and work area sticker placement.

Warning Tape and Danger Area Sticker

Application of warning tape on platform edges and danger area sticker.

Controller Stickers

Guidelines for affixing controller identification stickers.

Lubrication and Fluid Level Check

Lubrication Points and Schedule

Identifies lubrication points and recommended service intervals.

Hydraulic Oil Level Check

Procedure for checking and topping up hydraulic fluid.

Testing and Verification Procedures

Static Load Test

Procedure for static load tests, including deformation and drift checks.

Dynamic Load Test

Testing lift operation with maximum load and overload conditions.

Safety Functions Verification

Verification of all safety functions of the tail lift.

Disassembly Instructions

Tail Lift Removal Procedure

Step-by-step instructions for removing the tail lift from a vehicle.

Specifications and Technical Data

Component Weights

List of weights for various lift components.

Power Consumption and Conductor Sizing

Electrical power requirements and recommended conductor sizes.

Battery Maintenance Guidelines

Guidelines for battery maintenance and charging.

Loading Diagrams

Graphical representation of load capacity limits.

Tightening Torques

Specifications for torque values for various fasteners.

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