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Zepro Z3N 75-100 User Manual

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ZEPRO
Tel.: +46 (0)10-459 05 00
E-mail: zeprotech@hiab.com | zepro.com
74598TL
2022-11-30
Installation Instruction
Tail Lift
Z3N / Z3NU 75-100
Z3NN / Z3NNU 75-100
Z3NW / Z3NWU 75-100

Table of Contents

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Zepro Z3N 75-100 Specifications

General IconGeneral
BrandZepro
ModelZ3N 75-100
CategoryLifting Systems
LanguageEnglish

Summary

Important Information and Safety

Attention and Warnings

Explains various warning signs like WARNING!, CAUTION!, IMPORTANT!, and NOTE! used in the manual.

Technical Support and Contact

Provides contact details for ZePro technical support and how to request assistance.

Hydraulic Oil Requirements

Specifies the recommended hydraulic oil types permitted for use with ZePro tail lifts.

Battery Maintenance Guidelines

Details procedures for battery maintenance during storage and operation to prevent discharge.

Safety Rules for Operation

Moving Parts Clearance

Ensures safe operation by specifying clearance around moving cylinders and the platform.

Installation Safety Precautions

Highlights critical safety aspects during installation, such as platform ground clearance.

Pre-Installation Procedures

Vehicle Chassis Requirements

Details the necessary strength and dimensional requirements for the vehicle chassis.

Statutory Dimensions

Specifies legal dimensions for ground clearance and platform overhang.

Calculating Installed Dimensions

Guidance on determining key dimensions (C, D, A, H) for proper lift installation.

Model-Specific Installation Dimensions

Z3N(U) 75-100 Installation Dimensions

Provides specific installation measurements for the Z3N(U) 75-100 tail lift model.

Z3NN(U) 75-100 Installation Dimensions

Provides specific installation measurements for the Z3NN(U) 75-100 tail lift model.

Z3NW(U) 75-100 Installation Dimensions

Provides specific installation measurements for the Z3NW(U) 75-100 tail lift model.

Temporary Lift Operation

Temporary Connection Procedures

Instructions for temporarily connecting the lift to operate its functions during installation.

ZePRO1 Control Card Connection

Wiring guide for connecting control devices to the ZePRO1 control card.

TLC-B1 Relay Card Connection

Wiring guide for connecting control devices to the TLC-B1 relay card.

Installation Steps

Frame Mounting

Detailed steps for mounting the lift frame to the vehicle chassis.

Hydraulic Unit Installation

Guide for attaching the hydraulic unit and its hoses to the lifting frame.

Lift Platform and Sealing Strip

Instructions for fitting the lift platform and various sealing strips.

Underrun Protection Installation

Procedure for installing the underrun protection components onto the lift.

Controller Mounting

Guidelines for installing primary and additional controllers on the vehicle.

Cable Routing and Connection

General Cable Routing Principles

Essential guidelines for safe and reliable cable routing to prevent damage and ensure longevity.

Sizing Electrical Systems

Recommendations for sizing batteries, chargers, and cables for optimal system performance.

Main Power, Earth, Fuse, and Switch

Instructions for wiring main power cables, earth connections, fuses, and main switches.

Control Power Cable Routing

Guidance on routing the control power cable from the cab switch to the tail lift grommet.

Warning Lighting and Foot Controls

Instructions for routing and connecting cabling for warning lights and foot controls.

Electrical Connections

Cable Grommet Installation

Procedure for installing, dismantling, or adjusting cables within the hydraulic unit's cable grommet.

TLC-B1 Warning Light/Foot Control

Wiring diagram for warning lights and foot controllers connected to the TLC-B1 relay card.

ZePRO1 Warning Lights/Foot Controls

Wiring diagram for warning lights and foot controls connected to the ZePRO1 control card.

TLC-B1 Cab Switch & Alarm

Wiring schematic for cab switches and open platform alarms with TLC-B1.

ZePRO1 Cab Switch & Alarm

Wiring schematic for cab switches and open platform alarms with ZePRO1.

Powering Up the Tail Lift

Initial Power-Up Procedure

Step-by-step guide for connecting power and enabling the tail lift's main switch and cab switch.

Electrical and Hydraulic Diagrams

TLC-B1 Schematic (75-100 Models)

Electrical and hydraulic schematic for Z3N/Z3NN/Z3NW 75-100 models using TLC-B1.

ZePRO1 Schematic (75-100 Models)

Electrical and hydraulic schematic for Z3N/Z3NN/Z3NW 75-100 models using ZePRO1.

TLC-B1 Autotilt Schematic

Electrical and hydraulic schematic for autotilt functionality with TLC-B1.

ZePRO1 Autotilt Schematic

Electrical and hydraulic schematic for autotilt functionality with ZePRO1.

Lubrication and Fluid Checks

Lubrication Points and Frequency

Identifies all lubrication points and specifies the required greasing frequency.

Hydraulic Oil Level Check

Procedure for checking and topping up the hydraulic fluid level in the tank.

Product Markings

Loading Diagram Application

Guidance on affixing load diagrams near the primary controller for visibility.

Identification Plate Information

Details the specific information found on the tail lift's identification plate.

Controller Sticker Placement

Instructions for affixing controller stickers next to the relevant controller, including orientation.

Danger Area and Warning Flags

Placement guidelines for danger area stickers and warning flags for safety.

Testing and Verification Procedures

Static Load Test

Procedures for conducting static load tests to check for deformation and drift.

Dynamic Load Test

Methods for performing dynamic load tests with max load and overload conditions.

Safety Functions Testing

Verification steps for all tail lift safety functions, including lights, switches, and locks.

Disassembly Instructions

Tail Lift Removal Procedure

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

Specifications and Data

Component Weights

Lists the weights of various components for handling and safety considerations.

Center of Gravity Data

Provides center of gravity coordinates (TpX, TpY, CgX, CgY) for Z3N/Z3NU models.

Tightening Torque Values

Specifies torque values for various fastener sizes (M8 to M14) during installation.

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