Zepro Tail lift User manual

74584TL - Owner's Manual, English translation
2021-08-10
Must be kept in the vehicle on which the tail lift is installed
OWNER'S MANUAL
INFORMATION FOR OWNERS AND USERS
Tail lift
STANDARD LIFT

3
Contents
1 Important information ..........................................................................5
1.1 Technical support ...................................................................................... 5
1.2 Spare parts & accessories......................................................................... 6
1.3 Service ........................................................................................................ 6
1.4 Product discontinuation ............................................................................ 6
1.5 Warranty...................................................................................................... 6
1.6 REACH regulation.....................................................................................10
1.7 Information concerning the clause on remote diagnostics ..................10
1.8 Attention! ..................................................................................................11
2 Safety rules ........................................................................................12
2.1 General...................................................................................................... 12
2.2 Damage and malfunctions ......................................................................12
2.3 Max permissible load...............................................................................13
2.4 Maintenance, repairs and service ...........................................................14
2.5 Modications............................................................................................14
2.6 Operation ..................................................................................................15
2.7 Intended use.............................................................................................17
2.8 Danger area ..............................................................................................17
2.9 Work area .................................................................................................18
2.10 Operator working position .......................................................................19
3 Design and Function ...........................................................................20
3.1 General...................................................................................................... 20
3.2 Frame .......................................................................................................20
3.3 Lift arm ...................................................................................................21
3.4 Underrun protection ..............................................................................21
3.5 Platform....................................................................................................21
3.6 Hydraulic system......................................................................................21
3.7 Control system .........................................................................................21
3.8 Cab and the main switch .........................................................................22
3.9 Safety devices ..........................................................................................23
3.10 Controllers ................................................................................................24
3.11 Electric autotilt .........................................................................................26
3.12 Overheating protection ............................................................................27
4 Operation............................................................................................28
4.1 General...................................................................................................... 28
4.2 Max load ...................................................................................................29
4.3 Operator working position .......................................................................30
4.4 Working on the platform..........................................................................31
4.5 Loading and unloading with the platform on ground ............................33
4.6 Loading and unloading with the platform on a loading dock................34
4.7 Loading/unloading at loading dock with the
platform under the loading dock.............................................................36

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4.8 Moving load from one vehicle to another...............................................37
4.9 After use ...................................................................................................38
4.10 Operatingwiththexedcontroldevice(CD19) .....................................39
4.11 Fixedcontroldevices,standardlift(CD1) ..............................................41
4.12 Operatingwiththexedcontroldevice(CD4)........................................44
4.13 Operatingwiththecoiledcablecontroldevice(CD9) ...........................46
4.14 Operatingwiththecoiledcablecontroldevice(CD10) .........................49
4.15 Operatingwiththefootoperatedcontroldevice(CD14).......................51
4.16 Operatingwiththeradiocontroldevice(CD11).....................................53
4.17 Controldevice,2-buttonwithswitch(CD17)..........................................56
4.18 Controldevice,3-buttonwithswitch(CD18)..........................................58
5 Service and maintenance....................................................................61
5.1 Hydraulic oil..............................................................................................61
5.2 Before starting work ................................................................................62
5.3 Daily checks .............................................................................................63
5.4 Weekly checks..........................................................................................64
5.5 Lubrication................................................................................................65
5.6 Service ......................................................................................................66
6 Marking..............................................................................................67
6.1 Maximum load rating...............................................................................68
6.2 Identicationplate ..................................................................................69
6.3 Work area .................................................................................................69
6.4 Warning tape ...........................................................................................69
6.5 Control device sticker .............................................................................70
6.6 Danger area .............................................................................................72
6.7 Warningags...........................................................................................72
7 Troubleshooting .................................................................................73
8 Technical specifications .....................................................................74
8.1 Noise declaration ....................................................................................74
9 Product discontinuation......................................................................75
9.1 General...................................................................................................... 75
9.2 Applicable regulations and legislation....................................................75
10 Service record ....................................................................................76
11 Own remarks ......................................................................................88
12 Product approval ................................................................................90
13 Declaration of conformity during assembly.........................................91
14 Certificate of registration, delivery card..............................................91

5
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.
Figure 1. Identification plate
Important information

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1.2 Spare parts & accessories
If spare parts or accessories are required, contact your nearest service workshop.
1.3 Service
If service is required, contact your nearest service workshop.
1.4 Product discontinuation
For information on product discontinuation, see section “9 Product discontinuation” on page 75.
1.5 Warranty
1.5.1 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 facto-
ry 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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1.5.2 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“13Declarationofconformity
during assembly” on page 91.
• 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 76.
• 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.
Warranty rights cannot be exercised in countries where there is no distributor.
1.5.3 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.
1.5.4 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 hy-
draulic pressure, adjusting tilt cylinders, adjusting torque. Hydraulic components contam-
inated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; however,
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,makingidenticationimpossible.
Important information

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1.6 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.
1.7 Information concerning the clause on remote diagnostics
ZEPRO always has the right to:
install, maintain and remove remote diagnostic tools or similar sensor-based connectivity
(“connectivity”)inandfromequipment
have access to, send, receive, collect, store and use all information and data collected
throughconnectivity,includingbutnotlimitedtoinformationoneciency,availability,
downtime, operation, operating environment, movement, condition, logins, locations and
similardetailsoftheequipment(“information”).Suchinformationmaybeusedtooptimise
the equipment or related equipment or services, and for ZEPRO's internal activities and/
or operations. ZEPRO is responsible for complying with all applicable laws and regulations
regarding such information.
The customer/user must not remove, disable or interfere in any way with connectivity or
the information. Intellectual property rights or other rights of ownership and disposal over
the connectivity functions and information and all further development thereof are, and at
all times remain, the exclusive property of ZEPRO.
Important information

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1.8 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, life-threatening
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 these instruc-
tions for use 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 permissible 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 spec-
i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.
Max. 2000 Kg
mm
Max. 750 mm
Max. 1000 mm
Max. 1500 mm
2000 Kg
1500 Kg
1000 Kg
750 1000 1500
500
Figure 2. 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-threat-
ening 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 these
instructions for use 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-threatening 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 work-
ing 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
65977TL 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 these instructions for use may also render the
product warranty invalid.
2.8 Danger area
mWARNING!
The hazard area is the area in which the tail lift moves during operation. Under no circumstanc-
es 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 tail lift operation 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 insta-
bility, 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.

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Design and Function
3 Design and Function
3.1 General
The ZEPRO tail lift consists of a number of main components, namely the frame, lift arms,
platform and chassis bracket. The tail lift is operated electro-hydraulically. A hydraulic
pump powered by the vehicle's ordinary battery supplies hydraulic oil to the actuating
hydraulic cylinders. The hydraulic system is controlled by the control system, which is
operated by control devices.
3.2 Frame
The frame constitutes the tail lift’s chassis to which other components such as the chassis
brackets, lift arms and hydraulic units are mounted.
Overview
Platform
Lift arm Frame
Underrun protection