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USER MANUAL
Operator & safety instructions
Inspection & maintenance instructions
2019-01-02
www.zepro.com
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 specifications....................................................................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
3
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
4
Value document
Value document
Remark!
Do not perform work on the lift without keeping a written
record within this document
WARNING
When servicing and repairing, no changes to the tail lift are
permitted and only original spare parts may be used
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 fulfilled it is also
necessary to use the tail lift according to this user manual.
5
Product approval
Declaration of conformity, manufacturer
ORIGINAL
(according to 2006/42 / EC, Annex 2A)
Type:
Serial no:
Technical file 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
Bispgården, Sweden
6
Product approval
Declaration of conformity, installation
The installer certifies at own responsibility that the tail lift as identifies 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 modifications is
approved by Zepro, this document is a confirmation that both the tail lift and installation
confirms to the following directive.
............................................................... ...........................................
Installers signature Date of installation
Installers stamp
7
8
Product approval
Post installation checks
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.
9
Product approval
Post installation checks
10
Product approval
Post installation checks
Under run bar. Tightness and moun-
11. ting position with regard to statutory
measures.
7
12
6 8 3
11
10
1
2
11
Product approval
Possible notes and action taken
Post installation check
12
Safety instructions
General safety
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 specific 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.
WARNING
Don’t use a damaged lift. Contact authorized workshop immediately
13
Safety instructions
General safety
Pay attention to the warning signs on the tail lift and the warnings contained in
this instruction.
NOTE! WARNING
Ensure that the area under and Only use the tail lift if the vehicle
around the tail lift is empty and is parked and the handbrake is
stays empty as long as the tail tightened so you are certain that the
lift is in use. vehicle doesn’t move during the use.
NOTE!
WARNING
Only one person is allowed to
The vehicle should be positioned
operate the tail lift at time.
so that operation of the tailgate lift
can take place without danger from
moving traffic
NOTE!
Only educated personnel is
allowed to use the lift. WARNING
Don’t let heavy loads fall down at the
platform.
NOTE!
In order to operate the tail lift,
only use control units that’s WARNING
approved by Zepro. Before the platform lowers or lifts you
must control and secure the load. All
to minimize the risk of falling load.
NOTE!
Always have full overseen of
WARNING
the working area when the lift
Despite the tail lift is equipped
is in use.
with a non-slip surface, precaution
must be taken at locomotion. Zepro
recommends to use non-slip footwear
NOTE! according to EN ISO 20345, 20346
Only use spare parts that’s and 20347.
approved by Zepro.
WARNING
Do not drive the vehicle if the platform
is loaded or open.
14
Safety instructions
Restricted area of use
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.
15
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 traffic.
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
16
Safety instructions
Warning and information signs
1
4
3
2
5
3
1. Warning flag
2. Working area
3. Loading diagram
7 4. Warning tape
6 5. Operating instruction
6. Danger of crushing
7. ( Optional) Function 3-button
sprial cable, with deactivation
button
17
Safety instructions
Technical safety
WARNING
The biggest risk for snips and catch injuries is in the danger zone between the
platform and body floor when the platform rises to body floor 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.
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.
18
Safety instructions
Hydraulic system safety
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 overflow valve as prevents that the tail lift can be
raised or tilted with an overload.
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.
User 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 fixed brackets below the body.
19
Safety instructions
User safety
The spiral cable control unit (remote) can be used from inside the vehicle standing
at least 300 mm from the floor-edge to prevent risk of foot injury.
Always use fixed 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.
20
Safety instructions
Loading diagram
Example on how the load weight changes when the distance to the body floors edge
increases.
NOTE!
Make it to a habit to control
the loading diagram and follow
the recommendations so you
maintain both your and the tail
lifts safety.
21
Technical specifications
Noice emmissions
22
Function, operation
Description function
The ZEPRO-lift is electro hydraulically The hydraulic system is protected with a
driven. An electric motor which gets its pressure regulator when lifting or tilting
power from the truck’s ordinary battery up. Note! This regulator does not prevent
drives a hydraulic pump which supplies oil overload at rest position or lowering.
to the working hydraulic cylinders.
The system is steered by electrical valves. The electric power is taken from the trucks
The hydraulic unit with all details is either ordinary battery. Current to the tail lifts
built into the lifts support frame or contained electrical motor is lead by a fuse which also
in a separate box. Both systems are easy has a function as main switch to the tail lift.
to reach for service and maintenance. The The fuse is located in a plastic box near the
”power pack” is easy to replace. trucks battery.
The platform is supported by the lift arm Control current is taken from the dash
which is very strong and rigid. The under board. When the control currents isolator
run bar is bolted to the lift arms or is directly switch is switched off, the lift is ”locked”.
attached to the support frame. The platform At all transport situations must the control
has a nonslip surface. current be broken.
To save current the control ought to be
The lift arm lifting work is done by lift switched off when the lift not is in use.
cylinders which have built in safety valves
for protection against hose breakage. The The lift can be operated from optional
cylinders are equipped with electric safety units connected in parallel. It can also be
valves, which are leak proof. These safety operated by remote control.
valves also act as a transport lock for the
platform. The electric motor is equipped with a
so-called ”thermo guard”, a thermostatic
The platform’s tilt function is also provided steered switch as break the solenoids
by cylinders with the same construction as manoeuvre circuit if the motor is
the lift cylinders. Lifting and tilting up speed overheated. When the motor has to cool
are fixed by the pump capacity, and it’s down the solenoid will work again.
naturally conformed to statutory velocity.
23
Function, operation
Overview components
PLATFORM
MOUNTING BRACKET
LIFT ARM
SUPPORT FRAME
TILT CYLINDER
BUMPER BAR
LIFT CYLINDER
3 PART
BUMPER BAR
24
Function, operation
Operating standard lift
WARNING
The vehicle should be positioned so that operation of the tailgate lift can take place
without danger from moving traffic
25
Function, operation
Operating standard lift, 3 buttons + turn switch
NOTE!
Ensure that the tail lifts working
area and periphery are clear.
1 UP
2 TILT
3 DOWN
4 TURN SWITCH
Lower
Activate the turn switch (4) and down
(3) button in mentioned order. The
FIXED CONTROL UNIT
constant flow valve gives the same speed
independent of the load.
3-button control unit + turn switch
3 button + turn switch is used to all
operating of the tail lift in order to avoid LOWER
crushing. 4+3
OPEN/
TILT DOWN
4+2+3 TILT DOWN
4+2+3
26
Function, operation
Operating standard lift, 3 buttons + turn switch
Tilt up
Activate the turn switch (4) tilt button (2) NOTE!
and up button (1) in mentioned order. The The platforms movement can
platform tilts up. If the load is to heavy or stop at anytime (if the push
placed to far back on the platform at tilt up, buttons are released) and in
the overflow valve opens. all positions because the push
buttons break the current to
respective function.
TILTING UP
4+2+1
NOTE!
Lift
The hydraulic system is
Activate the turn switch (4) and push up
protected against overload
button (1). If the load is to heavy the over
at lift and tilt up of a built in
flow valve opens.
overflow valve. Notice that this
valve doesn’t protect at resting
or lowering. This may under
LIFT
no circumstances be used for
4+1 overloading at lowering.
OPERATING INSTRUCTION
Close
Activate the turn switch (4) and push tilt (2) The tail lift can only be used by authorized
and up (1). The platform tilts up and close personnel.
against the body.
DO NOT OVERLOAD THE TAIL LIFT!
27
Function, operation
Operating slider, 5 buttons
NOTE!
Ensure that the tail lifts working
area and periphery are clear.
UP 1
TILT & WORK. P.
INDICATOR 2
DOWN 3
4 SLIDER OUT
5 SLIDER IN
Function, fixed control unit Slider in
Fold in the platform. Push red button (2)
Slider out and button 5 (arrow right) at which the
Push button 4 (arrow left) at which the tail platform takes transport position under
lift slides out from transport position. Fold body. The red button deactivates working
out the platform position indicator.
SLIDER OUT
SLIDER IN
4
2+5
28
Function, operation
Operating slider, 5 buttons
NOTE!
Tilt up The hydraulic system is
Push tilt (2) and up (1) button in mentioned protected against overload
order. f the load is to heavy or placed to far at lift and tilt up of a built in
back on the platform at tilt up, the overflow overflow valve. Notice that this
valve opens. valve doesn’t protect at resting
or lowering. This may under
no circumstances be used for
TILT overloading at lowering.
UP
2+1
OPERATING INSTRUCTION
29
Function, operation
Operating standard lift, 4 buttons
NOTE!
Ensure that the tail lifts working
area and periphery are clear.
4
1
3
Lower
Use button (3) and button (4). The
constant flow valve gives the same speed
4-button control unit independent of the load.
4 button control is used to all operating of
the tail lift in order to avoid crushing.
AUTOMATIC
TILT DOWN
3+4
30
Function, operation
Operating standard lift, 4 buttons
Automatic Tilt up from the ground
Use buttons (1) and button (2). The NOTE!
platform tilts up to horizontal level, then it The platforms movement can
turns into normal lift function . If the load stop at anytime (if the push
is to heavy or placed to far back on the buttons are released) and in
platform at tilt up, the overflow valve opens. all positions because the push
buttons break the current to
respective function.
AUTOMATIC
TILTING UP
1+2
NOTE!
Lift
The hydraulic system is
Use buttons (1) and button (2). If the load
protected against overload
is to heavy the over flow valve opens.
at lift and tilt up of a built in
overflow valve. Notice that this
valve doesn’t protect at resting
or lowering. This may under
LIFT no circumstances be used for
1+2 overloading at lowering.
OPERATING INSTRUCTION
Close
Use buttons (1) and button (4). The The tail lift can only be used by authorized
platform tilts up and close against the body. personnel.
31
Function, operation
Operating slider, 6 buttons 5
NOTE! 1 3
Ensure that the tail lifts working
area and periphery are clear.
4
Function, control unit 2
Slider out
Push button 4 (arrow left) at which the tail
6
lift slides out from transport position. Fold
out the platform
Automatic Tilt down to the ground
Use button (2) and button (4). When
SLIDER OUT reaching the ground the platform
5 automatically tilts down.
LOWER
3
32
Function, operation
Operating slider, 6 buttons
Tilt up NOTE!
Push button (1) and button (4). If the load The platforms movement can
is to heavy or placed to far back on the stop at anytime (if the push
platform at tilt up, the overflow valve opens. buttons are released) and in
all positions because the push
buttons break the current to
TILT respective function.
UP
1+4
Lift NOTE!
Push button (1) and button (3). The platform The hydraulic system is
lifts with the same speed. If the load is to protected against overload
heavy the over flow valve opens. at lift and tilt up of a built in
overflow valve. Notice that this
valve doesn’t protect at resting
LIFT or lowering. This may under
1+3 no circumstances be used for
overloading at lowering.
33
Function, operation
Operating, slider SZF/SZFT
NOTE!
Ensure that the tail lifts working
area and periphery are clear.
UP 1
TILT & WORK. P.
INDICATOR 2
DOWN 3
4 SLIDER OUT
Function, fixed control unit 5 SLIDER IN
From working position: Lower
Push down button (3). The platform lowers
Lower to “slide out” position with the same speed. The constant flow
Push down button (3) until the platform has valve gives the same speed independent of
reached sufficient level to slide out. the load.
LOWER LOWER
3 3
Slider out
Push button (4). The platform slides out Lift
Push up button (1). The platform lifts with
the same speed. If the load is to heavy the
overflow valve opens.
SLIDER
OUT
4
LIFT
1
34
Function, operation
Operating slider SZF/SZFT NOTE!
Before loading/unloading Always lift up the platform
Fold out the ramps. against body floor before tilt
up/closing to transport position.
NOTE!
The platforms movement can
stop at anytime (if the push
After loading/unloading buttons are released) and in
Fold in the ramps. all positions because the push
buttons break the current to
respective function.
NOTE!
The hydraulic system is
protected against overload
at lift and tilt up of a built in
To transport position: overflow valve. Notice that this
Slider in valve doesn’t protect at resting
Push button 5. The platform slides in. or lowering. This may under
no circumstances be used for
overloading at lowering.
NOTE!
Ensure that the tail lifts working
area and periphery are clear.
1UP
FIXED
2TILT
CONTROL UNIT 3DOWN
LOWER
3 LOWER
3
Tilt down
Fold out the platform by means of Push tilt (2) and down button (3) in
manhandle. The platform is ”double folded” mentioned order. The platform tilts
down against ground. Also here gives
the constant flow valve the same speed
independent of the load.
TILT DOWN
2+3
36
Function, operation
Operating, ZR
NOTE!
Always lift up the platform
against body floor before tilt
up/closing to transport position.
Tilt up
Push tilt (2) and up (1) button in mentioned
order. The platform tilts up to horizontal NOTE!
position. If the load is to heavy or placed The platforms movement can
to far back on the platform at tilt up, the stop at anytime (if the push
overflow valve opens. buttons are released) and in
all positions because the push
TILT UP buttons break the current to
2+1 respective function.
NOTE!
Lift The hydraulic system is
Push up button (1) The platform lifts with protected against overload
the same speed. If the load is to heavy the at lift and tilt up of a built in
over flow valve opens. overflow valve. Notice that this
valve doesn’t protect at resting
or lowering. This may under
LIFT no circumstances be used for
1 overloading at lowering.
OPERATING INSTRUCTION
Fold in the platform by means of The tail lift can only be used by authorized
manhandle. (Double folding) personnel.
NOTE!
Ensure that the tail lifts working
area and periphery are clear.
1 1
2
2
3 3
Lower Lower
Push neutral (1) and down (3) button. The Push neutral (3) and down (2) button. The
platform lowers with the same speed. The platform lowers with the same speed. The
constant flow valve gives the same speed constant flow valve gives the same speed
independent of the load. independent of the load.
LOWER LOWER
1+3 3+2
Lift Lift
Push neutral (1) and up (2) button. The Push neutral (3) and up (1) button. The
platform lifts with the same speed. If the platform lifts with the same speed. If the
load is to heavy the over flow valve opens. load is to heavy the over flow valve opens.
LIFT LIFT
1+2 3+1
38
Function, operation
Operating, spiral cable control unit
Tilt down
Push tilt (2) and down button (3) in
mentioned order. The platform tilts
NOTE!
down against ground. Also here gives
Opening and closing function is
the constant flow valve the same speed
only allowed with fixed control
independent of the load.
units.
TILT DOWN
2+3
1 UPP
2 VIPP
3 NER Tilt up
Push tilt (2) and up (1) button in mentioned
order. The platform tilts up to horizontal
position. If the load is to heavy or placed
to far back on the platform at tilt up, the
overflow valve opens.
Lower
Push down button (3). The platform lowers
with the same speed. The constant flow Lift
valve gives the same speed independent of Push up button (1) The platform lifts with
the load. the same speed. If the load is to heavy the
over flow valve opens.
SÄNKA
3 LIFT
1
39
Special handling
Cargo transfer - truck to truck / truck to trailer
When several tons heavy load is to be transferred from one truck to another, it means large
overload, especially if the platforms are long.
Maximum transfer weight = Taillift loading capacity x 0,5
Use the platform of the truck to be loaded as a ramp. The platform can be
raised or tilted up, but not lowered or tilted down without activating the control units.
Note !! Maximum transfer weight is taillft loading capacity x 0,5.
For example, on a 2000kg taillift, allowed transfer weight is 1000kg.
The tip of the platform should be kept clear in all loading situations
40
Special handling
Adjusting the platform to the dock
Before you unload each article onto the dock use the control unit to tilt down. Make sure
that the platform overlaps sufficiently (min 150 mm) and have a secure and solid resting
position. lt’s safer for the driver, the customer and his cargo.
min 150 mm
Lastkaj
41
Special handling
Using the platform as a ramp for forklifts and
heavy pallet jacks
The platform can not withstand truck driving without special locks.
Note! Forklift locks can only be used on taillifts with steel platforms and loading
capacity 1500 - 2500kg.
If you install forklift locks, you can drive with a max 3,0 ton forklift including load
over the platform.
Lock the platform at bed level using the forklift locks. Secure the rear wheels.
If you unload the vehicle, tilt the platform down to compensate for changes in the bed
height, always make sure that the platform overlaps sufficiently (min 150 mm) and have
a secure and solid resting position.
42
Special handling
The CONCEALED overload
You can’t overload the ZEPRO-lift when lifting or tilting up. The pressure relief valve will
prevent it. At lowering or at ”resting platform” is however the overload unlimited.
The ZEPRO-lift needs maintenance to give trouble-free service. Grease and control
regularly. Also check that all details are not damaged: Hoses, cylinder covers etc.
Follow the maintenance instructions and the inspection record.
Remark!
When necessary...
Bleeding the cylinders
Lift cylinders:
Lower the platform a few times. You may have to lift the truck to fully lower the
platform.
Tilt cylinders:
Close the platform up against the vehicle body and then opening and tilting all
the way down.
NOTE!
Lubrication
Lubricate the lift according to instructions page 46.
For lubricating points, see the lubrication instruction IE-0101
NOTE!
Hydraulic oil
Check the oil level. Use Zepro oil or equivalent, if not available,
please contact us.
Change the oil once a year. Water and dirt can prevent the lift from working
properly. See service instructions IE-0102 for oil change.
44
Service and maintenance
Safety information
The following are the manufacturer’s recommendations for inspection and service
frequencies. Take the time to adhere to them and you could prolong the life of your tail lift.
Failure to follow these guidelines could result in dangerous faults arising thus increasing
the risk of accidents.
1. Daily safety device check list
2. Once a week control of wear parts.
3. Greasing
4. Service station maintenance*.
* The service should be carried out one time per year (L-service) at Zepro approved
service stations (or Zepro agents). After maintenance or repair service protocol must be
completed and signed.
Zepro also recommend XL service every 3rd year. The XL-service includes L-service and
replacement of parts that are included in the service kit.
Year 1 L-Service
Year 2 L-Service
Year 3 XL-Service
Year 4 L-Service
Year 5 L-Service
Year 6 XL-Service
45
Service and maintenance
Daily safety device check list
1. Before use each day check that all safety devices are securely fixed and clearly visible
eg. flags with reflector strips, warning decals, signs (Working area and loading diagram
for all control units and platform).
2. Check for damage to hoses. Oil leakage.
3. Check for cracks and correct fastening of lift arm, mounting brackets and bolt
connections between tail lift and frame.
4. Check electric wires and connections.
5. Check electric safety valves and fuse.
6. Check cylinder covers for cracks.
7. If any details are damaged or missing contact your agent who will arrange for
rapid delivery of spare parts.
(5 & 6 if available)
46
Service and maintenance
Lubrication
Which grease can I use?
Zepro recommend an acid-free lithium-complex grease with a high quality paraffin base oil
as ground. The grease must meet ASTM D 4950, SAE J310 and NLGI (grade 2) GC-LB
specification as well be classed EP (extreme pressure).
Graphite grease should not be used.
* At demounting of hydraulic system, the working areas must be well cleaned from dirt in all
shapes.
* All components must be well cleaned before demounting.
*Unless hydraulic system should be mounted right away after demounting, the details must
be kept in such a way that they don’t expose to unnecessary contamination.
* At oil change, be sure that filler tank are well cleaned outside and well cleaned strainer is
used while filling up.
* Filler cap must be dried of before removing.
* Rags and papers made of non fluffing materials must be used when working areas and
tools are cleaned.
* Paste-up grease must be avoided. If there are needs for lubrication, use hydraulic oil.
* At oil change, Zepro original oil or similar must be used:
Alternative oils:
* NOTE! ATF and HF oils should not be used unless permission from Zepro.
HF oils can contain additives and these can have negative effect on polyurethane, that
most of our cylinder sealing are made of. Also ATF oils can contain additives that affect
plastic and rubber materials negatively. The result may be cylinder leakage.
49
Service protocol L-Service Year 1
Reg.No:
50
Note: If comment is marked for any of the service points;
complete the task below
Service control.
(Mark the box for actions performed for each. service point.)
Service-
points Comments / Actions
Signature............................................... Signature..............................................
Date............................ Date............................
73014TL
51
Service protocol L-Service Year 2
Reg.No:
52
Note: If comment is marked for any of the service points;
complete the task below
Service control.
(Mark the box for actions performed for each. service point.)
Service-
points Comments / Actions
Signature............................................... Signature..............................................
Date............................ Date............................
73014TL
53
Service protocol XL-Service Year 3
Reg.No:
C=Check R=Replace L=Lubrication * If the lift has the equipment **If the service kit contains the detail
54
it
Note: If comment is marked for any of the service points;
complete the task below
Service control.
(Mark the box for actions performed for each. service point.)
Service-
points Comments / Actions
Signature............................................... Signature.............................................
Date............................ Date............................
73020TL
55
Service protocol L-Service (Annual) Year.......
Reg.No:
56
Note: If comment is marked for any of the service points;
complete the task below
Service control.
(Mark the box for actions performed for each. service point.)
Service-
points Comments / Actions
Signature............................................... Signature..............................................
Date............................ Date............................
73014TL
57
Service protocol XL-Service (Every 3rd Year) Year.......
Reg.No:
C=Check R=Replace L=Lubrication * If the lift has the equipment **If the service kit contains the detail
58
it
Note: If comment is marked for any of the service points;
complete the task below
Service control.
(Mark the box for actions performed for each. service point.)
Service-
points Comments / Actions
Signature............................................... Signature.............................................
Date............................ Date............................
73020TL
59
Trouble shooting
Trouble shooting for operator
For other faults, please contact service workshop
Lifting
Doesn’t lift, motor will not start Electrical fault Check fuses in truck cabin, taillift and
Solenoid is not activated mainfuse between lift and battery.
Check wiring / connections.
Doesn’t lift, solenoid activated Faulty solenoid or cable Check wiring / connections.
but motor does not start. between solenoid and
motor.
The lift does not lift the max. Bad connections. Check battery cables all connections
load. Motor stops. ( + ), ( - ).
The lift does not lift the max. The oil level is to low. Check oil level. Fill up oil if needed.
load. Motor keeps going. Bleed the system.
Lowering
Platform cannot be lowered, Electrical fault Check fuses in truck cabin, taillift and
nothing happens. No ”click” mainfuse between lift and battery.
from valves in hydraulic unit. Check wiring / connections.
60
Trouble shooting
Problem: Possible cause: Correction:
Slow lowering Oil is to thick Change to Zepro oil or eqvivalent
see page 47.
The lifts bearings are Check that the lift arm and cylinders
rough, ungreased or (piston rod) is undamaged. Lubricate
damaged. all bearings.
Tilting up
Platform does not tilt up. Motor The oil level is to low. Lower the platform to the ground, fill up
starts. oil to max level.
Platform does not tilt up. Motor Electrical fault Check wiring / connections.
will not start.
Tilting up is slow The oil level is to low. Check oil level. Fill up if needed
61
Trouble shooting
Problem: Possible cause: Correction:
Tilting down
Platform cannot be tilted down. Electrical fault Check fuses in truck cabin, taillift and
No ”click” from valves in mainfuse between lift and battery.
hydraulic unit. Check wiring / connections.
The lifts bearings are Check that the lift arm and cylinders
rough, ungreased or (piston rod) is undamaged. Lubricate
damaged. all bearings.
62
Notes
ZEPRO Sales / Importer
Manufacturer
Address: Telephone: Fax:
KATRINEHOLM Mossvägen 8, 0150 - 489550 0150 - 489551
Sales S-641 49 Katrineholm, SWEDEN
www.zepro.se
www.zepro.com