Zepro ZHZ 500-850 User manual

ZEPRO
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E-mail: [email protected] |zepro.com
73161TL
2020-06-02
Installation Instruction
Tail Lift
ZHZ 500/600-850

Contents
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Contents
1 Introduction ..................................................................................................... 5
1.1 Important ................................................................................................ 5
1.2 CE marking ............................................................................................ 6
1.3 Hydraulicuid ......................................................................................... 6
1.4 Identication ........................................................................................... 7
2 Safety rules ....................................................................................................... 8
2.1 Repainting .............................................................................................. 8
2.2 Transport plug......................................................................................... 9
2.3 Moving parts – free movement ............................................................... 9
2.4 Attaching third-party equipment is prohibited ....................................... 10
2.5 Installation ............................................................................................ 10
3 Main parts ....................................................................................................... 10
4 Installation workflow...................................................................................... 11
4.1 Installing the support frame .................................................................. 11
4.2 Electrical connection............................................................................. 11
4.3 Installing the platform ........................................................................... 11
4.4 Installing cylinders ................................................................................ 11
4.5 Attaching decals ................................................................................... 11
5 Calculating the installed dimensions ........................................................... 12
5.1 C-dimension ........................................................................................ 12
5.2 D-dimension ........................................................................................ 12
5.3 H-dimension ......................................................................................... 12
6 Installation kits ............................................................................................... 13
7 Installation ...................................................................................................... 15
7.1 Installation of installation kit.................................................................. 15
7.2 Installing the lift............................................................................ 50
7.3 Installing the Platform ........................................................................... 51
7.4 Installing the angle sensor.................................................................... 52
7.5 Installing the hydraulic unit ................................................................... 53
7.6 Control devices..................................................................................... 54
7.7 Connection box..................................................................................... 55
7.8 Control power cable.............................................................................. 56
7.9 Main power cable ................................................................................. 57
7.10 Installation of license plate light............................................................ 60
7.11 Installation of connection ramp............................................................. 61
7.12 Armstops .............................................................................................. 61
7.13 Platform stop ....................................................................................... 61
7.14 Adjustment of tilt cylinder...................................................................... 62
7.15 Purging the cylinders ............................................................................ 63
7.16 Transport lock ....................................................................................... 63

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Contents
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8 Electrical and hydraulic drawings................................................................. 64
8.1 ZHZ-600-850 MAConnection to circuit board....................................... 64
8.2 Connection to circuit board 4 – button operation.................................. 65
8.3 Connection of cab switch and alarm for open platform ........................ 66
8.4 Connection of control device ................................................................ 67
9 Markings and decals ...................................................................................... 68
9.1 Overview............................................................................................... 68
9.2 Load diagram........................................................................................ 69
9.3 Identicationplate............................................................................... 69
9.4 Work area ............................................................................................ 69
9.5 Driver’s instructions .............................................................................. 70
9.6 Danger area ......................................................................................... 70
9.7 Warning tape ....................................................................................... 70
9.8 Warningags....................................................................................... 71
9.9 CE marking........................................................................................... 71
10 Lubrication and fluid level check.................................................................. 72
10.1 Lubrication ............................................................................................ 72
10.2 Fluid level check ................................................................................... 72
11 Testing and verification ................................................................................. 73
11.1 Static test loading ................................................................................. 73
11.2 Dynamic test loading. ........................................................................... 74
11.3 Testing safety functions ........................................................................ 74
12 Dismantling..................................................................................................... 75
13 Specifications ................................................................................................ 76
13.1 Weights ................................................................................................ 76
13.2 Load centre........................................................................................... 77
13.3 Maximum power consumption –
Minimum recommended conductor cross sectional area................... 78
13.4 Maximum power consumption –
Minimum recommended conductor cross sectional area................... 79
13.5 Battery maintenance............................................................................. 79
13.7 Loading diagram ZHZ 500.................................................................... 80
13.6 Loading diagram ZHZ 600.................................................................... 80

Introduction
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1 Introduction
1.1 Important
The following “warning markings” appear in the installation instructions and are intended to draw
your attention to circumstances potentially causing unwanted situations, near misses, personal
injury or damage to the product, etc.
Take care. Risk of damage to the product.
NOTE.
Take extra care. Risk of personal injury or damage to the product and the surroundings.
mWARNING!

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Introduction
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1.2 CE marking
Z-Lyften’s tail lifts on sale on the European market have been CE marked (CE stands for Conformité
Européenne) since 1 January 1995. The manufacturer guarantees that the product complies with
the EC Machinery Directive.
The aim of the EC Machinery Directive is to increase the safety of products throughout Europe.
There are some basic general rules that have to be following when installing Z-Lyften lifts.
Follow the installation instructions. If it is not possible to follow the installation instructions or if
modicationsarenecessary,themodicationshavetobeapprovedbythemanufacturer.Thisis
a consequence of CE marking regulations. The manufacturer is unable to certify compliance with
the Machinery Directive if the product is subsequently changed without its knowledge or approval.
To retain a valid CE marking for the product, it is essential to contact Z-Lyften.
Welding is not necessary except where recoended by the manufacturer.
To improve safety, we have enclosed decals for the lift that are easy to understand, regardless of
the language. Make sure these decals are attached so that the information they contain can be
seen by the lift operator.
Position control device so that it provides the operator with the safest possible working position,
as well as a clear view of the load, tail lift and working area. Follow the driver’s instruction manual
when using the control device and its functions.
1.3 Hydraulic uid
Our tail lift must work just as well in tropical heat as in the Arctic cold. The heat is no problem
fortheuid.Thecold,ontheotherhand,placesconsiderabledemandsonthehydraulicuid.
Zeprohasthereforeselectedhydraulicuidsthatcancopewithallofthesedemands.
1.3.1 Highly rened mineral oil (product no. 21963, 1 litre)
Contains zinc-free wear-preventing additives and provides extremely good wear protection.
Thehydraulicuid’sspeciallow-temperaturepropertiesandthehighviscosityindexmeanthat
the hydraulic system can be started in extreme cold, as well as delivering reliable operation in
uctuatingoperatingtemperatures.Theuidalsoprovidesthehydraulicsystemwithexcellent
protection against corrosion.
1.3.2 Biodegradable hydraulic uid (product no. 22235, 1 litre)
Asanoption,wealsoo󰀨erabiodegradablehydraulicuid(environmentaluid)madeupofa
syntheticbaseoilcalledpolyalphaolen,whichisbiodegradable.Thebaseoildeliversoutstand-
ingpropertiesatlowandhightemperatures.Theuidremainsliquiddowntotemperaturesas
low as -50°C. Its oxidation stability is extremely good, resulting in a long service life with longer
changeintervalsasaresult.Theuidiseasytopumpthankstogoodlteringandairseparation
properties, together with a low density. This minimises the risk of cavitation and foaming. Con-
tact us for more information.
ATFuidorHFuidmaynotbeusedwithZ-Lyften.Theseuidsa󰀨ecttherubberingaskets
and seals and shorten the service life.
NOTE!

Introduction
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1.4 Identication
Max. lifting capacity x 1 (kg)
Max. lifting height -850 = 850 mm
Cylinder model, MA = Double-acting adjustable tilt
Single-acting lift
Identication list E.g. - 600 - 850 MA
_ _ _ - _ _ _ - _ _ _ _ _

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Safety rules
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2 Safety rules
2.1 Repainting
Piston rods and cylinder covers must
not be painted. Painting these com-
ponents could damage the cylinder
seals.
Boots, hydraulic hoses and cables
must not be painted/coated, as the
solvent in the paint could damage the
hoses/cablesandsignicantlyimpair
their durability.
NOTE.
Fig 1. Piston rods, cylinder covers and
boots must not be painted/coated
Fig 2. Hydraulic hoses must not be painted/coated
Fig 3. Cables must not be painted/coated

Safety rules
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2.2 Transport plug
When installing a lift, the transport
plug in the hydraulic unit must be re-
moved and replaced with the normal
tank cap supplied with the hydraulic
unit.
NOTE.
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5
3
2.3 Moving parts – free move-
ment
During nal inspection*, the space
occupied by the moving cylinders
must be cleared and made safe.
There is a risk of collision between
cylinder and the following items:
subframe, truck chassis, member
for rear lights (number plate) and
the lift’s chassis bracket (with short
overhangs).
*Finalinspectionmustbeperformed
withtheplatformbythevehicleoor
and tilted down 10°. The clearance to
the nearest part of the cylinder must
be at least .40 mm
mWARNING!
The lift platform must not be tilted
down more than max. 10° from
horizontal when people are on the
platform.
mWARNING!
min. 40 mm
10°
10°
Fig 4. Replace the transport plug
with the normal tank cap
Fig 5. The clearance to the nearest part of
the cylinder must be at least 40 mm.
Fig 6. The lift platform must not be tilted down
more than max. 10° from horizontal.

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Main parts
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2.4 Attaching third-party equipment is prohibited
Third-party equipment (both electrical and hydraulic) must not be attached to Zepro’s tail lifts.
Attaching third-party equipment may interfere with the lift’s systems and its safety functions.
Risk of injury and damage. If it is necessary to install other equipment, check the vehicle
manufacturer’s body instructions and use the vehicle’s attachment features.
mWARNING!
2.5 Installation
The lift's platform must not be installed so that it cannot reach ground level.
Zepro’s tail lifts are only approved for installation with Zepro’s installation kits.
The lift’s capacity must NOT exceed the capacity approved by the vehicle manufacturer.
Take great care during test operation before adjusting the tilt cylinder to ensure that the vehicle
body is not damaged. Make sure that the tilt cylinder is adjusted in such a way that the platform
does not catch on the vehicle body when the platform is tilted up fully.
mWARNING!
3 Main parts
Platform
Tilt cylinder
Lift arm
Support arm
Frame
Lift cylinder
Link
Step
Fig 7. Overview