Zepro 78826TL User manual

78826TL - Owner's Manual, English translation
2023-08-08
Must be kept in the vehicle on which the tail lift is installed
OWNER'S MANUAL
INFORMATION FOR OWNERS AND USERS
Tail lift
SLIDER LIFT

3
Contents
1 Important information ..........................................................................5
1.1 Technical support ...................................................................................... 5
1.2 Location of the type plate.......................................................................... 5
1.3 Spare parts & accessories......................................................................... 6
1.4 Service ........................................................................................................ 6
1.5 Product discontinuation ............................................................................6
1.6 Warranty...................................................................................................... 6
1.7 REACH regulation.....................................................................................10
1.8 Information concerning the clause on remote diagnostics ..................10
1.9 Privacy ......................................................................................................11
1.10 Regular inspections .................................................................................11
1.11 Attention! ..................................................................................................12
2 Safety rules ........................................................................................13
2.1 General......................................................................................................13
2.2 Damage and malfunctions ......................................................................13
2.3 Max load ...................................................................................................14
2.4 Maintenance, repairs and service ...........................................................15
2.5 Modications............................................................................................15
2.6 Operation ..................................................................................................16
2.7 Intended use.............................................................................................18
2.8 Danger area ..............................................................................................18
2.9 Work area .................................................................................................19
2.10 Operator working position .......................................................................20
3 Design and Function ...........................................................................21
3.1 General......................................................................................................21
3.2 Frame .......................................................................................................21
3.3 Lift arm ...................................................................................................22
3.4 Platform....................................................................................................22
3.5 Sliderproles...........................................................................................22
3.6 Hydraulic system......................................................................................22
3.7 Control system .........................................................................................22
3.8 Cab and the main switch.........................................................................23
3.9 Timer.........................................................................................................23
3.10 Safety devices ..........................................................................................24
3.11 Controllers ................................................................................................25
3.12 Electric autotilt .........................................................................................27
3.13 Overheating protection ............................................................................28
4 Operation............................................................................................29
4.1 General......................................................................................................29
4.2 Max load ...................................................................................................30
4.3 Operator working position .......................................................................31
4.4 Working on the platform..........................................................................32
4.5 Loading and unloading from ground level..............................................34

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4.6 Loading and unloading with the platform on a loading dock .....................35
4.7 Moving load from one vehicle to another...............................................37
4.8 Wheel stop (accessory)...........................................................................38
4.9 Before use ................................................................................................42
4.10 After use ...................................................................................................42
4.11 Autotilt (Option)........................................................................................43
4.12 Fixed controller (CD20)............................................................................45
4.13 Operatingwiththexedcontroldevice(CD3)........................................49
4.14 Operating with the coiled cable control device (CD9) ...........................53
4.15 Operating with the coiled cable control device (CD10) .........................56
4.16 Operating with the foot operated control device (CD14).......................58
4.17 Operating with the radio control device (CD11).....................................60
5 Service and maintenance....................................................................63
5.1 Hydraulic oil..............................................................................................63
5.2 Before starting work ................................................................................64
5.3 Daily check ...............................................................................................65
5.4 Weekly check............................................................................................66
5.5 Lubrication................................................................................................67
5.6 Service ......................................................................................................68
6 Marking..............................................................................................69
6.1 Maximum load rating...............................................................................70
6.2 Identicationplate ..................................................................................71
6.3 Work area .................................................................................................71
6.4 Warning tape ...........................................................................................71
6.5 Control device sticker .............................................................................72
6.6 Danger area .............................................................................................74
6.7 Warningags...........................................................................................74
7 Troubleshooting .................................................................................75
8 Technical specifications .....................................................................76
8.1 Noise declaration ....................................................................................76
9 Product discontinuation......................................................................77
9.1 General......................................................................................................77
9.2 Applicable regulations and legislation....................................................77
10 Service record ....................................................................................79
11 Own remarks ......................................................................................91
12 Product approval ................................................................................92
13 Declaration of conformity ...................................................................93
14 Declaration of conformity during assembly.........................................94
15 Certificate of registration, delivery card..............................................94

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1 Important information
Before using the ZEPRO tail lift, you must read and understand the contents of this manual
and especially the sections describing safety.
The owner’s manual is primarily intended to inform you about the tail lift’s functions and
characteristics and how to use it in the best way. It also contains important safety and
maintenance information and describes any problems that might occur during operation.
Always keep the owner's manual in the vehicle, as the need for important information
regarding operation, safety and maintenance may be necessary.
Informationaboutourproductsisalsoavailableonourwebsite.Youcanndusat
www.zepro.com.
Allinformation,images,illustrationsandspecicationsarebasedontheproductinformation
available when this manual was printed. Images and illustrations contained in the Instructions
for use are generic and not intended to be exact depictions of various parts of the product.
We reserve the right to make changes to the product without prior notice.
1.1 Technical support
If technical support is required, contact your nearest service workshop.
Always quote the tail lift’s serial number to make sure you receive the correct information.
The serial number is found on the rating plate located on the tail lift frame.
1.2 Location of the type plate
The type plate is positioned on the tail lift frame. The location differs from model to model.
Figure 1. Location on a
tail lift with a max load
lower than 1000 Kg
Figure 2. Location on a tail
lift with a max load equal to
or greater than 1000 Kg.
Figure 3. Type plate
Important information

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1.3 Spare parts & accessories
If spare parts or accessories are required, contact your nearest service workshop.
1.4 Service
If service is required, contact your nearest service workshop.
1.5 Product discontinuation
For information on product discontinuation, see section ”9 Product discontinuation” on
page 77.
1.6 Warranty
1.6.1 Warranty period
The tail lift comes with a 24-month warranty valid from the ex-works delivery date.
If the tail lift is stored before being put into service or delivered to the end customer, the
warranty period may be extended by a period corresponding to the storage period, but
not more than 6 months, i.e. the warranty is valid for a maximum of 30 months from the
factory delivery date.
Spare parts are supplied with a 24-month warranty from the ex works delivery date.
When storing spare parts before installation on the tail lift, the warranty period may be
extended by a period corresponding to the storage period, but not more than 6 months, i.e.
the warranty is valid for a maximum of 30 months from the factory delivery date. The spare
parts warranty is subject to proof of purchase.
Important information

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1.6.2 Warranty conditions
ZEPRO warranty rights are only valid if the following conditions are met:
• Claims are made within the normal warranty period.
• The delivery card is completed in C-care before the guarantee application is completed.
• Installation was carried out in accordance with ZEPRO installation instructions and
also by a ZEPRO-approved superstructure builder.
• Delivery acceptance inspection was carried out in accordance with ZEPRO’s instruc-
tionsandcertiedinthisowner'smanual.Seesection”14Declarationofconformity
during assembly” on page 94.
• The annual service was carried out according to ZEPRO’s instructions and by a
ZEPRO-approved service workshop. Service must be noted in the service record. See
section ”10 Service record” on page 79.
• Warranty work may only be carried out by ZEPRO-approved workshops.
There is information on our website about service workshops and distributors by country.
If no service workshop information is available, contact your distributor for information.
Warranty rights cannot be exercised in countries where there is no distributor.
1.6.3 Warranty compensation:
Tail lift
Following an approved tail lift claim during the ordinary warranty period, the warranty will
cover material and labour costs for the person performing the warranty work.
Spare Parts
Following an approved part claim within the ordinary warranty period, the warranty will cover
material costs for the person performing the warranty work. The warranty on parts does not
cover labour costs.
1.6.4 The warranty covers:
Factory and material defects on:
• Zepro original parts found to be defective.
• Zepro original spare parts found to be defective.
• Zepro original accessories found to be missing.
Important information

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The warranty does not apply in the case of:
• Damage caused by electrical overload:
Damagetoelectricalpartscausedbyinsucientbatterycapacity,e.g.Insucient
installedbatterycapacityand/orinsucientbatterychargeinrelationtotheamount
of lift use.
• Damage caused by hydraulic overload:
Damage to lift parts caused by tampering with the hydraulic system
• Damage caused by mechanical overload:
Damage to lift parts caused by overloading or external force.
• Wear parts:
e.g.supportwheels,bearings,shafts,wornordamagedpaint,warningags,stickers,
batteries, rubber bellows, seals between the tail lift and vehicle.
• Service and maintenance related:
Measures of a purely service and maintenance character. Replacing fuses, adjusting
hydraulic pressure, adjusting tilt cylinders, adjusting torque. Hydraulic components
contaminated by dirty hydraulic oil. Dissonance caused by neglected maintenance
(lubrication).
• Incorrect installation:
Damage caused by incorrect installation. Claims for this type of damage must be
submitted to the tail lift seller or installer, or to the service workshop that installed the
spare part.
• External equipment:
Damage caused by external equipment or materials not approved by ZEPRO. For ex-
ample, equipment connected to the tail lift electrical system. Parts that have previous-
ly been repaired without Z-lyften’s consent.
• Parts that have been disassembled:
For example, motors, cylinders, solenoids, pressure switches, valves and similar parts.
• Corrosion:
Surface corrosion on standard fasteners or on components with damaged surface treatment.
Important information

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• External costs:
Emergency actions, on-call, travel expenses, vehicle hire, lost income, damage to goods.
• Missing parts:
Ifmultiplepartsaresubmittedwithaclaimapplication,partsthathavenoidentied
defects covered by the warranty will not be replaced. Example: An electrical hose rup-
ture valve is found to be faulty and the valve and solenoid are both submitted; howe-
ver, only the part that has a defect covered by the warranty will be replaced.
• Transportation costs:
Transportation costs for returned goods (claims). The claimant is liable for transporta-
tion costs for returned goods (claims).
• Painted-over parts:
Hoses, piston rods, control devices, cables and similar. Parts where the ID plate has
beenpaintedoverandmakingidenticationimpossible.
Important information

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1.7 REACH regulation
All tail lifts produced by Z-lyften Produktion AB comply with Regulation (EC) No 1907/2006
of the European Parliament and of the Council of 18 December 2006, aka the REACH
regulation.
All accessories supplied by Z-lyften Produktion AB comply with the reach regulation.
All suppliers engaged by Z-lyften Produktion AB are contractually bound to comply with
the REACH regulation, which is a basic requirement in Z-lyften Produktion AB’s supplier
development program.
1.8 Information concerning the clause on remote diagnostics
ZEPRO, or a third party designated by ZEPRO, shall at all times have the right to (i) install,
maintain and dismantle a remote diagnostics device in and from the Products; and (ii)
access, send, receive, collect, store, copy, aggregate, combine with other information, pro-
cess, make available, further develop and use any and all information and data gathered
through the remote diagnostics device, including but not limited to, information concerning
equipment identity, e󰀩ciency, availability, downtime, operation, operating environment,
movement, condition, logon, location and similar information relating to the Products (the
“Information”). Such Information may be used for providing, delivering, optimizing, develo-
ping, servicing and o󰀨ering the Products or any related products, equipment, and services.
The Information may also be used for example for sales and marketing, ZEPRO’s internal
business and/or operating purposes as well as for regulatory, warranty and contract com-
pliance and for proactive maintenance and diagnostics. The Information may be shared to
ZEPRO’s group companies and to ZEPRO’s and its group companies’ dealers, subcont-
ractors, service providers and other business partners for the above described purposes.
Important information

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1.9 Privacy
For administrative purposes relating to the warranty program and in order to full the obliga-
tions under the contract and the law, and to manage the customer relationship, the Seller,
and ZEPRO Group as the manufacturer of the Products, is required to collect and pro-
cess information regarding the Customer, which may include personal data of the contact
persons and other possible representatives and employees of the Customer. Information
collected may also be used, among other things, to satisfy requests made by the Customer,
to inform the Customer about new products and services, as well as for other promotional
or marketing purposes. The information may be shared within the ZEPRO Group of com-
panies and its associated companies, and ZEPRO ’s authorised dealers, distributors and
service workshops, and other companies providing services for the Customer’s benet for
the above described purposes. ZEPRO Group may also receive and use of the information
provided to ZEPRO Group through ZEPRO ’s authorised dealer and service network (such
as from the authorised ZEPRO distributor or dealer from whom the Customer has purcha-
sed the Product).
A more detailed description of how ZEPRO processes personal data is available in
ZEPRO’s privacy policy (https://hiab.com/en/privacy-policy). The ZEPRO Privacy Policy
applies to the processing of personal data by ZEPRO Group of companies. Please note
that in case you have purchased the Product from a ZEPRO distributor or dealer, personal
data may be further processed by the seller of the Product. In such case, please refer to
the applicable policies of the seller of the Product.
1.10 Regular inspections
Rules and regulations concerning regular tail lift inspections differ from country to country.
Failure to carry out inspections in compliance with national legislation may lead to penalty
charges and a prohibition on the use of the tail lift. Find out the regular inspection require-
ments applicable to your tail lift and make sure you meet them.
Important information

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1.11 Attention!
The Instructions for use contain the following warning signs. They are intended to alert you
to conditions that could cause problems, incidents, injury, and/or damage to the product, etc.
mWARNING!
WARNING indicates a potential hazard, which if ignored may lead to serious, fatal injury.
mCAUTION!
CAUTION indicates a potential hazard, which if ignored, may lead to minor injuries.
IMPORTANT!
IMPORTANT indicates a risk of equipment damage.
NOTE!
NOTE! refers to additional information that may help the reader understand, or perform, a
given operation.
Important information

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2 Safety rules
2.1 General
Because the tail lift is used for handling heavy loads, extra care must be taken when using
it. It is important that you read and follow the instructions and safety regulations in this
manual before using the tail lift. Improper use may result in injury, or damage to the tail lift
andthevehicletowhichitistted.
NOTE!
ZEPRO is not liable for any injury to persons or damage to property that may result from failure
of the operator or other person to comply with the recommendations, warnings and instruc-
tions set forth in these instructions for use.
2.2 Damage and malfunctions
If in any situation you feel the tail lift and its various functions are not behaving as expected, or
if you suspect something is wrong, discontinue use as soon as possible, switch off the main
power supply to the tail lift and contact your authorised dealer for assistance without delay.
Safety rules

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2.3 Max load
Undernocircumstancesmaytheliftbeburdenedwithmoreweightthanthespecied
maximum load. Under no circumstances may the max load centre be placed further out on
theplatformthantheloadcentredistancespeciedforthetaillift.
Information about the max permissible platform load and the load centre distance for max
loadisshownonstickersaxedtothetailliftorvehicle.
mWARNING!
Under no circumstances is it permitted to load the platform with loads greater than those spe-
ciedonthestickers.Excessiveloadcancausestructuraldamage.Riskofmaterialdamage
and life-threatening injury.
Example: This tail lift has a maximum load of 2000 kg when the load’s centre of gravity is no more than
750 mm from the edge of the vehicle oor. If the load’s centre of gravity is placed 1500 mm from the edge
of the vehicle oor, max permissible weight decreases to 1000 kg.
Sticker, max permissible load 2000 kg. Load centre distance 750 mm.
Safety rules

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2.4 Maintenance, repairs and service
Onlyperformtheserviceandmaintenanceproceduresspeciedinthismanual.
Allotherservice,repairs,modicationsoractionsonthetailliftandthevitalsystemsofits
accessories must be carried out by an authorised workshop.
When working on the tail lift, switch off the main power supply.
Use only spare parts and accessories approved or recommended by ZEPRO. Any other use
may lead to changes that impair tail lift function and safety. This may also render your tail
lift warranty invalid.
2.5 Modications
ModicationsnotdescribedorapprovedbyZEPROmaynotbemade.Suchmodications
may entail an increased risk of accidents, a negative impact on product life and render the
product warranty invalid.
mWARNING!
Modications to the tail lift may affect safety. In the case of deviations from the documented
CE-marked tail lift, the CE-marking will cease to apply. Risk of material damage and life-threate-
ning injury.
Safety rules

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2.6 Operation
2.6.1 General
Because the tail lift is used for handling heavy loads, extra care must be taken when using
it. It is important that you read and follow the instructions and safety regulations in this
manual before using the tail lift. Improper use may result in injury, or damage to the tail lift
andthevehicletowhichitistted.
mWARNING!
Do not allow heavy loads to drop onto the platform. Risk of material damage and life-threate-
ning injury.
mWARNING!
Exercise caution when present or working on or in the immediate vicinity of the platform or tail
lift with respect to protruding parts and sharp edges. Never leave the tail lift with the platform
raised and extended. Risk of material damage and life-threatening injury.
mCAUTION!
ZEPRO is not liable for any injury to persons or damage to property that may result from failure
of the operator or other person to comply with the recommendations, warnings and instruc-
tions set forth in these instructions for use.
2.6.2 Working in the dark
mCAUTION!
Make sure the necessary and appropriate lighting is available when working in the dark. ZEPRO
recommendsttingthetailliftwithwarninglightsforworkinginpoorlylitareas.Riskofinjury.
Safety rules

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2.6.3 Working on the platform
mWARNING!
The greatest risk for cut and crush injuries is in the hazard area between the tail lift and the
vehicleoorwhentheliftisraisedtovehicleoorheight.Anyonestandingonthetailliftorthe
vehicleoormustkeeptheirfeetandotherpartsofthebodyawayfromthishazardareawhen
the tail lift is in operation. Risk of life-threatening injury.
mCAUTION!
To reduce the risk of foot injuries, wear safety shoes with protective steel toe-caps when wor-
king on the platform. Even though the platform has a non-slip surface, take care when transfer-
ring goods. ZEPRO recommends the use of anti-slip safety shoes with protective toecaps in
accordance with EN ISO 20345. Risk of injury.
mCAUTION!
Always be aware of the platform edges to avoid stepping off by mistake. Also be aware of the risk
oftripping,especiallyiftheplatformisttedwithwarninglightsorwheelstops.Riskofinjury.

www.hiab.com
55061TL 2020-05-14
min. 300 mm
min. 300 mm
Safety rules

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Safety rules
2.7 Intended use
mWARNING!
The tail lift may only be used for its intended purpose, i.e. the loading and unloading of goods, and
then only in accordance with the regulations contained in this owner's manual. No other type of
use is permitted as this may damage the tail lift and give rise to dangerous situations. Risk of
material damage and life-threatening injury.
Use of the tail lift in a manner not described in this manual may also render the product war-
ranty invalid.
2.8 Danger area
mWARNING!
The hazard area is the area in which the tail lift moves during operation. Under no circumstan-
ces may the operator or any other person enter this area when the tail lift is in operation. Risk
of material damage and life-threatening injury.
Danger area
Work area

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Safety rules
2.9 Work area
The operator must make sure that the working area behind the tail lift is free from persons and
every kind of object when the tail lift is used. The operator must also pay attention to the
surroundings beyond the working area to have good forewarning of approaching persons
or objects that may cause a hazardous situation. Negligent operation of a tail lift may entail
a risk of injury and material damage.
mWARNING!
Make sure other vehicles are parked no closer than 5 m from the rear of the vehicle.
Make sure the work area is clear of persons and objects. Be especially aware of children and animals.
Pay attention to the surroundings to have good forewarning of approaching persons or objects that
may cause a hazardous situation. Stop work immediately if unsure.
During loading and unloading, handle cargo as described in this manual. In the event of instability,
loads may move uncontrollably. Risk of material damage and life-threatening injury.
When handling loads with wheels, the tail lift platform must be equipped with roll stops. Risk
of material damage and life-threatening injury.
Danger area
Work area

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Safety rules
2.10 Operator working position
Alwayspositionthevehicletoallowtailliftoperationwithoutdangerfrompassingtrac.
Also make sure the work area is clear.
mWARNING!
Thevehiclemustbepositionedtoallowtailliftoperationwithoutdangerfrompassingtrac.
Risk of material damage and life-threatening injury.
mCAUTION!
Always make sure the work area is clear during platform operation. Risk of injury.