Zepro ZHD 1500 User manual

74584TL
2018-01-03
www.zepro.com
USER MANUAL
Operator & safety instructions
Inspection & maintenance instructions
USER MANUAL IN ORIGINAL
This manual must be kept in the glove
compartment in the truck at which
the tail lift is installed

3
Table of contents
User Manual
Value document...................................................................................5
Value document............................................................................5
Product approval.................................................................................6
Declaration of conformity, manufacturer.......................................6
Declaration of conformity, installation...........................................7
Post installation checks ................................................................9
Possible notes and action taken
Post installation check................................................................12
Safety instructions ............................................................................13
General safety ............................................................................13
Restricted area of use ................................................................15
Safety for third party ...................................................................15
Working area ..............................................................................16
Warning and information signs ...................................................17
Technical safety..........................................................................18
Hydraulic system safety .............................................................19
User safety .................................................................................19
Loading diagram.........................................................................21
Technical specications ...................................................................22
Noice emmissions ......................................................................22
Remote Diagnostics System ......................................................22
Function, operation...........................................................................23
Description function....................................................................23
Overview components................................................................24
Operating standard lift ................................................................25
Operating standard lift, 3 buttons + turn switch..........................26
Operating slider, 5 buttons .........................................................28
Operating standard lift, 4 buttons ............................................... 30
Operating slider, 6 buttons .........................................................32
Operating, slider SZF/SZFT .......................................................34
Operating, ZR.............................................................................36
Operating, foot control unit .........................................................38
Operating, spiral cable control unit.............................................39
Special handling................................................................................40
Cargo transfer - truck to truck / truck to trailer............................40
Adjusting the platform to the dock ..............................................41
Maximum tilt down angle............................................................41
Using the platform as a ramp for forklifts and
heavy pallet jacks .......................................................................42
If you have damaged your ZEPRO tail lift ..................................42
The CONCEALED overload .......................................................43
Table of Contents Continued on next page!

4
Table of contents
Service and maintenace....................................................................44
Think of the lift! ...........................................................................44
Safety information ......................................................................45
General information service .......................................................45
Daily safety device check list......................................................46
Once a week control of wear parts.............................................46
Lubrication..................................................................................47
Hydraulic oil / Hydraulic cleanliness ...........................................49
Service protocol L-Service Year 1 ..............................................50
Service protocol L-Service Year 2 ..............................................52
Service protocol XL-Service Year 3............................................54
Service protocol L-Service (Annual) Year...................................56
Service protocol XL-Service (Every 3rd Year) Year....... .............58
Trouble shooting ...............................................................................60
Trouble shooting for operator .....................................................60

5
The user manual must always be kept in the vehicle:
• in order to check validity at CE marking
• in order to prove possible warranty.
• in order to overview service and changes through the years.
If the number of pages for check and action taken isn’t enough, copies can be made for
addition to this manual.
Value document
NOTE!
Non-compliance with the above is only permitted with
expressed written permission from the manufacturer. If
this is not followed the CE marking ceases to be valid and
hence the responsibility for the safety level of the product
is transferred to those who have carried out the change.
In order for the safety requirements to be fullled it is also
necessary to use the tail lift according to this user manual.
WARNING
When servicing and repairing, no changes to the tail lift are
permitted and only original spare parts may be used
Remark!
Do not perform work on the lift without keeping a written
record within this document
Value document

6
Product approval
Complies with all applicable provisions of:
hereby declares that the tail lift
ZEPRO, Z-Lyften Produktion AB
Allévägen 4, 844 41 Bispgården
SWEDEN
Machinery Directive 2006 / 42 / EC
Serial no:
Type:
Place for sticker
ORIGINAL
(according to 2006/42 / EC, Annex 2A)
We:
also complies with all applicable provisions of:
EMC Directive 2004 / 108 / EC
Design and manufacture Standard EN 1756-1
Technical le in accordance with Directive 2006/42 / EC, Annex VII A is compiled by:
Name: Tomas Blomberg
Address: ZEPRO, Z-Lyften Produktion AB
Allévägen 4, 844 41 Bispgården
SWEDEN
This declaration is drawn up by:
Namn: Tomas Blomberg
Position: Factory Manager Date:
Bispgården, Sweden
Declaration of conformity, manufacturer

7
Product approval
Declaration of conformity, installation
Installers stamp
The installer certies that:
- installation has been carried out according to Zepros instructions.
- post installation check has been performed.
...........................................
...............................................................
Date of installation
Installers signature
The installer certies at own responsibility that the tail lift as identies at page 6 in this
manual has been installed according to instructions from Zepro and that post installation
check has been performed. In addition all vehicle manufacturer guidelines for auxiliary
equipment have been adhered to.
When Zepros installation instructions has been followed and possible modications is
approved by Zepro, this document is a conrmation that both the tail lift and installation
conrms to the following directive.
Machinery Directive 2006 / 42 / EC

8

9
Product approval
The following checks should be made to ensure that the tail lift has been correctly and
safely installed. These checks should be carried out by the installer after the tail lift and
vehicle have been prepared by him for regular operation.
Checks (2, 3, 4, 5, 9, 11 och 15 if available).
1. Lift, tilt and lowering with xed
control unit.
2. Lift, tilt and lowering with other
control unit(s). Option.
3. Function and possible worn bearings
on roll-stop. Option.
4. Function of locking mechanism.
Option
5. Sealing strips and horizontal guide.
Option.
Post installation checks

10
6. Oil leakage at hydraulic hoses,
couplings and hydraulic units.
7. Oil level, see instructions at hydraulic
unit.
8.
Ground connection between tail
lift and vehicle frame. See also
manufacturers electric instructions.
9. Function of control unit heating ele-
ment. Option.
10. Function of drivers main switch.
Product approval
Post installation checks

11
11.
Under run bar. Tightness and moun-
ting position with regard to statutory
measures.
12. Tightness at all bolts at the tail lift.
13. Greasing (see page 46).
14. Load testing the tail lift (see
instruction in installation instruction).
15.
Test of safety functions and possible
accessory (see instruction in
installation instruction).
1
2
5
3
6
4
8
7
9
10
11
12
16. Free movement of hydraulic hoses.
Product approval
Post installation checks

12
Possible notes and action taken
Post installation check
Pos Action taken
Product approval

13
This manual contains useful information about your Zepro lift: Technical description of
equipment and function of these, technical safeguard, safety instructions for operators,
everything according to: En 1756-1: English standard: Vehicles - Safety requirements
for tail lifts for mounting on wheeled vehicles.
The manual must be kept in the vehicle on which the tail lift is placed and be used as a
guide for safety and maneuvering.
For safety of the operator and third party must the tail lift only be used by educated
persons who can and understand the content of this manual. Operators which hasn’t the
above knowledge constitute a big risk for them selves, assistant at loading and unloading,
and third party.
A tail lift is used to lift or lower heavy load, this may cause injuries if the safety instruction in
this manual isn’t followed.
Operator
Before allowing the operator to use the lift he should be thoroughly conversant with the lift’s
functions and usage according to the following:
1. During any phase of operation the lift must never, either whilst stationary or during up
or down movements, be loaded with more than the given maximum for that particular
lift. See loading diagram.
2. The centre of gravity of the maximum load should not be placed further back than the
loading diagram for the specic lift admits.
3. Nobody but the operator must operate the lift.
4. The lowering and lifting speed must not exceed 0.15 m per second = 1.5m per 10
seconds. The tilt down speed may not exceed 10°/second from transport position
to work position.
5. Beware of the risk of trapping parts of the body between lift and truck body when
lifting and closing. Keep feet clear from the front edge of the platform.
6. Carry out a daily control and always check the lift’s parts and correct function
after accidents.
NOTE!
It is the employers responsibility to ensure that the operator is conversant
with all safety risks associated with the use of the lift, according to Directive
2009/104 / EC. The operators attention should also be drawn to the permitted
loads allowed.
Safety instructions
General safety
WARNING
Don’t use a damaged lift. Contact authorized workshop immediately

14
NOTE!
Ensure that the area under and
around the tail lift is empty and
stays empty as long as the tail
lift is in use.
NOTE!
Only one person is allowed to
operate the tail lift at time.
NOTE!
Only educated personnel is
allowed to use the lift.
NOTE!
In order to operate the tail lift,
only use control units that’s
approved by Zepro.
NOTE!
Always have full overseen of
the working area when the lift
is in use.
NOTE!
Only use spare parts that’s
approved by Zepro.
Safety instructions
General safety
WARNING
Only use the tail lift if the vehicle
is parked and the handbrake is
tightened so you are certain that the
vehicle doesn’t move during the use.
WARNING
Don’t let heavy loads fall down at the
platform.
WARNING
Before the platform lowers or lifts you
must control and secure the load. All
to minimize the risk of falling load.
WARNING
Despite the tail lift is equipped
with a non-slip surface, precaution
must be taken at locomotion. Zepro
recommends to use non-slip footwear
according to EN ISO 20345, 20346
and 20347.
WARNING
Do not drive the vehicle if the platform
is loaded or open.
Pay attention to the warning signs on the tail lift and the warnings contained in
this instruction.
WARNING
The vehicle should be positioned
so that operation of the tailgate lift
can take place without danger from
moving trafc

15
Restricted area of use
Safety instructions
A tail lift has the sole purpose of aiding
the loading and unloading of vehicles,
thus, preventing the operator from making
unnecessary physical efforts.
Under no circumstances must a tail lift be
used to scoop objects or material up from
the ground or drive objects in the ground
using the platform or other parts of the tail
lift as driving tools.
I.E. the platform or other parts of the lift
are´t allowed to use as working tool for
other than intended use.
A tail lift is only meant to be used when the
function is satisfactory. If there is any doubt
concerning the tail lifts functionality call for
or visit an authorized workshop.
When the tail lift is in use the operator must
be aware of that all in nearby risks injuries.
The tail lift is delivered with a working area
decal as clearly show at which distance
other vehicles is allowed to park.
Ensure that other vehicles doesn’t park
closer than 5 m from the edge of the body.
Pay special attention to that no kids or
animals set foot on working area when the
tail lift is in use.
Instability in heavy loads can give injuries
at people.
The working area must always be free from
persons and things. Al to avoid damages if
loads should fall of.
Uneducated personnel can never be
allowed to operate the tail lift.
Safety for third party

16
Safety instructions
Working area
The control units are located in such a way, so they will give:
• A good oversee over the working area and the surroundings.
• A safe position in proportion to passing trafc.
NB!
Dangerzone: The area in which the platform is moving. This area may under no
circumstances set foot on when the tail lift is in use.
Working area: The area outside the platform where the operator may stand when the lift is
in use. If anyone else than the operator set foot on this area when the tail lift is in use must
all up or down movement cease immediately.
Area outside working area: The operator must be observant at the surroundings in order
to detect potential danger.
Danger zone
Working area

17
Safety instructions
Warning and information signs
1. Warning ag
2. Working area
3. Loading diagram
4. Warning tape
5. Operating instruction
6. Danger of crushing
7. (Optional) Function 3-button
sprial cable, with deactivation
button
2
3
3
4
5
6
1
7

18
Mechanical safety valves
Unlike electrical safety valves as protect at
leakage, these protect the tail lift against
plummeting at hose breakage.
Control unit
3-button control + turn switch is used at all
opening/down tilting/lowering and closing/
up tilting/lifting movements to avoid catch
injuries. This means that the turn switch
must be activated together with normal
buttons in order to the above movement is
to be carried out.
Warning ags & warning light
To mark ”platform out” there is warning
ags and warning lights at platforms,
mounted as alerts the surroundings during
the tail lifts movement. The ags have
reectors to enable good visibility at all
times, thus ensuring safe work in the
evenings and nights.
Main fuse
In order to prevent electrical overload of
circuits and the consequent risk of re
a 150A (24V) or 250A (12V) has been
integrated into the electrical circuit.
Safety instructions
Technical safety
Your ZEPRO tail lift is equipped with safety
devices to prevent accidents.
Electric safety
Electric safety valves are one-way valves
which allow oil to ow into the cylinders
but not out from them, provided that all the
control buttons are released and no current
activates the magnets on the valves. In
the event of a leakage, the platform is
supported by the oil which is trapped
securely in the cylinder by the safety valve.
ZEPRO supplies one such valve on the
tilt cylinder circuit and one on lift cylinder
circuit so that both circuits are protected.
NOTE! Some safety valves require that the
current activates the magnet at both the
inow and outow from the cylinder.
WARNING
The biggest risk for snips and catch injuries is in the danger zone between the
platform and body oor when the platform rises to body oor level and when
the platform closes against the body. A person who rides with the goods at the
platform must keep back feet and other parts of the body from this danger zone.
WARNING
The electrical safety valve locks
the hydraulic oil inside the
cylinder as long as its magnet
is not activated by a control
button.

19
NOTE!
The operator isn’t allowed to make any changes or adjustments of parts
belonging to the hydraulic system. If anything of the above has to be done,
this must be carried out by an authorized workshop.
Safety instructions
The hydraulic system at Zepro tail lifts works under high pressure (up to 200 bar) and shall
be maintained continuously in order to function at a reliable and safe way.
All hydraulic units are equipped with an overow valve as prevents that the tail lift can be
raised or tilted with an overload.
Hydraulic system safety
The tail lift is equipped with a control unit.
The control units must be approved by Zepro and must be mounted at the same time as
the tail lift is mounted at the truck.
Control units can also be mounted at xed brackets below the body.
User safety

20
Safety instructions
User safety
The spiral cable control unit (remote) can be used from inside the vehicle standing
at least 300 mm from the oor-edge to prevent risk of foot injury.
Always use xed control units at opening and closing of the tail lift. In order to avoid
crush damages at operators, this person must always pay attention to the positioning
of the feet in order to avoid the danger zone between body and the platform.