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Zepro Z3NU 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 Z3NU 75-100 Specifications

General IconGeneral
BrandZepro
ModelZ3NU 75-100
CategoryLifting Systems
LanguageEnglish

Summary

Important Information and Safety

Warning Symbols Explained

Details warning signs used in instructions for potential hazards and damage.

Safety Rules for Operation

Clearance for Moving Parts

Ensures safe clearance around moving cylinders and platform tilt limits.

Third-Party Equipment Prohibition

Prohibits connecting external equipment to prevent system interference and ensure safety.

Installation Safety Precautions

Highlights safety requirements for installation, including ground level access and approved kits.

Pre-Installation Requirements

Vehicle Chassis Strength

Specifies chassis requirements, including frame beam dimensions and moment of inertia for mounting.

Electrical Connections and Control

ZePRO1 Control Card Wiring

Illustrates connections for control devices (CD15, CD1, CD2) to the ZePRO1 control card.

TLC-B1 Relay Card Wiring

Shows connections for controllers (CD19, CD1, CD4) and warning lights to the TLC-B1 relay card.

Installation Steps and Components

Frame Mounting

Instructions for mounting the lift to the vehicle chassis, including measurements and jig use.

Hydraulic Unit Attachment (Z3N/Z3NW)

Details on mounting the hydraulic unit onto the lifting frame for specific models.

Platform Fitting and Sealing

Steps for fitting the platform to the arms, lubricating bushings, and attaching tilt cylinders.

Underrun Protection Installation

Instructions for installing the underrun protection, including bracket and aluminum profiles.

Controller Placement

Guidelines for installing primary and additional controllers on the vehicle, considering traffic safety.

Cable Routing and Management

General Cable Routing Principles

General principles for cable routing, emphasizing reliability, proper connections, and protection.

Electrical System Sizing

Guidance on sizing electrical systems, battery capacity, and cable cross-sections for reliability.

Main Power and Earth Wiring

Procedure for installing main power, earth cables, fuse, and main switch, with options for different setups.

Main Power Switch Installation

Instructions for mounting and connecting the main power switch, including drainage direction.

Connections and Wiring Diagrams

TLC-B1 Control Device Connection

Diagrams for connecting control devices and warning lights to the TLC-B1 relay card.

Powering Up the Tail Lift

Initial Power-Up Sequence

Steps for connecting power, installing fuses, and activating switches to power up the tail lift.

Electrical and Hydraulic Schematics

Maintenance: Lubrication and Fluids

Testing and Verification Procedures

Static Load Testing

Procedure for static load testing, including deformation and drift checks under load.

Dynamic Load Testing

Details dynamic load testing procedures, including tests with max load and overload.

Safety Function Verification

Checks to verify that all tail lift functions and safety features operate correctly.

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