Zepro Z 2500-130 Series Page 38 Installation Instructions Manual Download | Manualshive

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Z 2500-130/150

38

Hydraulic unit and control card

www.zepro.com

8

Hydraulic unit and control card

The hydraulic unit and its control card are installed inside the lift’s frame. For access during installation,

maintenance and repair, for example, the protective cap needs to be dismantled and the hydraulic unit pulled

a little way out of the frame, see section "8.1 Accessing the hydraulic unit and control card" on page 39.

Image 65. Hydraulic unit and control card

CONTROL CARD

TANK CAP

MOTOR

OIL TANK

SOLENOID

VALVE HOUSING

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Summary of Contents for Z 2500-130 Series

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 75981TL 2020 01 24 Installation Instructions Tail Lift Z 2500 130 150 ...

Page 2: ......

Page 3: ... dimension 13 4 2 D dimension 13 4 3 A dimension 13 4 4 H dimension 13 5 Rear beam cut outs 15 6 Installation 16 6 1 Support frame 16 6 2 Control power cable 19 6 3 Control devices 20 6 4 Warning lighting foot controller 21 6 5 Main power cable 23 6 6 Installation of main fuse on vehicles without connection point 24 6 7 Cable lead through 25 6 8 Underrun protection 26 6 9 Armstops 28 6 10 Angle se...

Page 4: ...1 1 Sensor 53 11 2 Functional schematic drawing MA config 14 54 11 3 Restriction in use of control device 56 11 4 Quick opening activation zone 56 12 Functional description Z 2500 DA 57 12 1 Sensor 57 12 2 Functional schematic drawing config 16 58 12 3 Restriction in use of control device 60 12 4 Quick opening activation zone 60 13 Connection unit 61 13 1 Power save mode 61 13 2 Operating informat...

Page 5: ...ents 5 www zepro com 18 Specifications 75 18 1 Weights 75 18 2 Maximum power consumption Minimum recommended conductor cross sectional area 76 18 3 Battery maintenance 76 18 4 Loading diagram 77 18 5 Tightening torque 78 ...

Page 6: ...l injury or damage to the product and the surroundings mWARNING 1 2 Page navigation Each page in the installation instructions has a page header and a page footer containing the following information Chapter Product Page number Company name Page header The page header at the top of the page shows which chapter the visited page belongs to and what product the installation instructions apply to Chap...

Page 7: ...y the manufacturer This is a consequence of CE marking rules 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 recommended by the manufacturer To improve safety we supply decals fo...

Page 8: ...perties of the hydraulic fluid and the high viscosity index mean that the hydraulic system can be started in cold weather and runs reliably in fluctuating operating temperatures Our hydraulic fluid also provides excellent corrosion protection for the hydraulic system We also offer a biodegradable hydraulic fluid environmental fluid as an option product no 22235 1 litre made of a synthetic base oil...

Page 9: ...e the cylinder gaskets Boots hydraulic hoses and cables must not be painted coated as the solvent in the paint could damage the hoses cables and significantly im pair durability NOTE Image 1 Piston rods cylinder covers and boots must not be painted coated Image 2 Hydraulic hoses must not be painted coated Image 3 Cables must not be painted coated ...

Page 10: ...der and the following items subframe truck chassis beam for rear light number plate and the chassis bracket of the lift with a short overhang The final inspection must be carried out with the platform flat and tilted down 10 The clearance from the closest part of the cylinder must be at least 40 mm mWARNING The platform must not be tilted down more than 10 from the horizontal mWARNING min 40 mm 10...

Page 11: ...injury and damage If it is necessary to install other equipment check the vehicle manufacturer s body instructions and use the at tachment features on the vehicle mWARNING 2 5 Installation The platform must not be installed so it cannot reach ground level mWARNING Zepro tail lifts are only approved for installation with Zepro installation kits mWARNING All specified torque values apply for use wit...

Page 12: ...ligning the support frame Mounting chassis brackets Detaching the mounting jig 3 2 Electrical connections Installing the control devices Installing the control device cables Installing the main power cable 3 3 Installing the platform Installing the platform Installing seals and end stops Installing the armstops 3 4 Installing cylinders Adjusting tilt cylinder Test running 3 5 Attaching decals ...

Page 13: ... space there will be between the lift arms in the upper position and the vehicle floor level A dimension 4 2 D dimension The D dimension is the space the lift needs measured from the rear edge of the body to the front edge of the support frame in the direction of the vehicle Once the C dimension is determined the D dimension can be obtained from the table 4 3 A dimension The A dimension is the spa...

Page 14: ...728 520 172 773 470 160 812 420 150 844 370 142 871 330 136 890 max 1300 690 220 214 194 C A 40 D C A D 715 211 736 680 197 777 630 182 828 580 170 871 530 159 909 480 151 941 430 143 969 360 134 1002 max 1500 785 220 214 194 C A 40 D Image 9 ZAEHD 150 200 1524 1010 min 750 max 930 1509 1966 2411 34 35 62 100 385 350 133 301 617 817 ...

Page 15: ...tion The size of the cut outs depends on the calculated installed dimension A see illustration below 1 Measure and mark the location and depth of the cut outs on the rear beam The two cut outs must be centred on the rear beam i e both cut outs must be an equal distance from the mid point of the beam 2 Cut along the markings 3 Grind away any burrs or sharp edges Image 10 Rear beam cut outs 994 245 ...

Page 16: ...s to the eye of the jig Use the steel platform s normal bolts 7 The support frame should be positioned as high as possible within the specified C dimension Adjust the frame to the ideal height under the chassis A car jack is useful The frame must be positioned parallel with the floor of the vehicle body and must not be in contact with the vehicle chassis there must be a few millimetres of play If ...

Page 17: ...e outer holes of each bracket Use M14x45 bolts and install the associ ated washer and nut on the inside of the vehicle chassis Installation must be performed with at least 6 bolts in the outer holes The bolt that was installed initially in the slot shaped hole may not be included in this figure If necessary this bolt can now be moved to one of the outer holes see illustra tion Then tighten the bol...

Page 18: ...e vehicle chassis for mounting bolts in each bracket s two upper round holes Use suitable bolts durability equivalent to M14 10 9 or higher and install the associated washer and nut on the inside of the vehicle chassis See Image 17 Tighten the bolts with a torque wrench Tightening torque Standard for selected screw Welding is not permitted on the chassis brackets Do not move the lift all the way t...

Page 19: ...otected with rubber grommets when it passes through beams or walls If there are quick connectors make sure they are effectively protected from moisture and dirt NOTE 2 Connect the control power cable to the cabin switch CS on the vehicle instrument panel Connect to the on board electrical system via a 10 A 24 V 15 A 12 V fuse according the customer s wishes See the connection diagram 9 5 Lift with...

Page 20: ...2 The distance between the vehicle s rear edge and the centre of the controllers must be 300 600 mm The distance between the controllers must be at least 260 mm See illustration 23 All cable inlets must be pointing downwards NOTE 3 The control device s cable is connected to the control card Image 19 Installing control de vice with two handed grip A controller must always be fitted on the side that...

Page 21: ...on Measure the distance A from the centre of the 1st boom shaft to the centre of the underrun protection see Image 24 3 Measure out the corresponding distance B on the 1st boom see Image 24 Image 21 Warning lighting and foot controller Image 22 Installing cabling Image 23 Installing cabling 6 4 Warning lighting foot controller Route the cable between the platform and the lift arm pipe so that it i...

Page 22: ...e cable through the cable grommet in the support frame See section 6 7 Cable lead through on page 25 6 Connect the cables to the control card see wiring diagram in section 9 4 Connecting warning light ing and foot controls on page 44 and section 9 7 Connecting control device on page 47 Make sure that the control card is disconnected from power before connecting peripheral equipment Risk of damage ...

Page 23: ... that it cannot chafe or otherwise sustain damage that can lead to a short circuit and cable fires Do not bend the cable with too small a radius as this can cause damage to the cable In general care must be taken when routing all the cables in order to obtain a longer cable service life and to reduce the risk of unnecessary stoppages NOTE The fuse box must be located in a well protected position a...

Page 24: ...age 27 2 3 Connect a cable from the battery s positive terminal see Image 27 3 4 Screw the cable connections and fuse into place with the knob Install the cables at 90 or 180 from each other Install the fuse at right angles to the cables see Image 27 The knob must lie against and centre the cable clip so that it does not come into contact with the bolt Incorrect installation can cause the fuse to ...

Page 25: ...able grommet see Image 32 Cables can now be installed removed adjusted in the grommet On installation the cable must be installed together with existing cabling with cable ties Ensure the length of the cable is sufficient for moving the control card The outer casing on cables connected to the control card must be stripped 350 mm see Image 33 3 When all cables are correctly located in the cable lea...

Page 26: ...tatutory dimensions on page 27 Check carefully that there is no risk of the outer part of each bracket colliding with any part of the cylinders when using the lift s functions In particular check in relation to the cylinders hose connections especially when the outer part of the brackets is installed a long way in mWARNING Use the correct bolts M12x80 Assemble without tight ening the bolts See Ima...

Page 27: ...Max 375 mm See Image 38 The underrun protection may be placed further back and lower NOTE Horizontal distance from the outer edge of the beam to the outside of the wheel Max 100 mm See Image 39 The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm See Image 40 Each of the individual parts of the underrun protection must have a surface area...

Page 28: ...ched at the same time as high up the lift arm as possible Installation must take place against the vehicle body It is not permitted to perform welding in the lift arm Installation must take place against the vehicle body m WARNING 6 10 Angle sensor If the lift is fitted with electronic autotilt install the angle sensor on the 1st boom see Image 42 The angle sensor allows autotilt function when the...

Page 29: ...pping screws 2 Drill holes Ø 7 2 mm for the screws 3 Fit the horizontal stop strip steel or aluminium 4 Fit the rubber strip to the track 6 12 Sealing strip vertical 1 Fit the tracks with contersunk screws rivets or by spot welding 2 Fit the rubber strip to the track 3 Secure the rubber strips by swaging the tracks together at the bottom To fit an upper edge seal create a 45 mitre against the vert...

Page 30: ...the platform is fitted lubricate all bearings via normal grease nipples see section 15 Lubrication and fluid level check on page 71 NOTE 3 Fit the platform to the arms using the supplied shafts and screws Tighten the bolts using a torque wrench Tightening torque 80 Nm 4 Fit one of the tilt cylinders to the platform Use the supplied shaft and support wheel Make sure the cylinders are installed with...

Page 31: ... at the bottom where they are secured with hose clips 2 Tilt up and move both tilt cylinders all the way up Adjustment must always take place with full hy draulic pressure in the tilt cylinders NOTE 3 Loosen the three lock screws on the cylinder fitted to the platform see illustration Lock screws 3 pcs Out In Image 48 Adjusting the tilt angle Image 49 The platform underhang A varies ac cording to ...

Page 32: ...cylinderaligns with the attachment on the platform See Image 52 The max length of both cylinders must be adjusted equally to avoid unwanted breakout forces mWARNING 7 Fit the other tilt cylinder to the platform mount ing Use the supplied shaft and support wheel Make sure the cylinders are installed with the grease nipples facing up NOTE 8 Tighten the bolts using a torque wrench Tightening torque 8...

Page 33: ...ots 10 Tighten the lock screws of the adjusting collar using a torque wrench Tightening torque 3 5 Nm After finishing the adjustment make sure the distance between the adjust ing collar and the end of the thread is no more than 30 mm mWARNING 11 Fit the cylinder boots Image 55 Lift model A 2500 130 142 5 2500 150 252 5 ...

Page 34: ...nd Image 57 The angle sensor must be installed with the cable in place according toImage 56 NOTE 2 Install the angle sensor Inclinometern on the platform using the included screws nuts and washers and secure the cable with cable ties see Image 58 and Image 59 Image 56 Angle sensor and mounting Image 57 Inclinometer and mounting Image 58 Installing the angle sensor Image 59 Installing the Inclinome...

Page 35: ...he platform mWARNING 1 Raise the lift to the vehicle floor Image 6045 2 Loosen the lock screw of the end stop 2 Screw the end stop all the way back towards the platform 3 Image 61 3 Tilt the platform down to max 10 below the hori zontal Image 60 4 Adjust the end stop all the way to the top of the cylinder 4 Image 61 5 Tighten the lock screw in the end stop 5 See illustration Image 61 The tightenin...

Page 36: ...y against the vehicle body and then tilting all the way down 6 15 Transport lock Electric hose breakage valves serve as locks for the platform The lock opens automatically if the down func tion is actuated from the control device The valves are non return valves that let fluid in from the cylinders but not out before they are actuated by the flow from the lowering valve The platform is thus hydrau...

Page 37: ...Connect a suitable control device to the control card see illustration below The number of available func tions varies depending on the lift model 2 Connect an earth connection GND and 12 24V to the lift see Image 52 See also section 18 2 Maximum power consumption Minimum recommended conductor cross sectional area on page 76 3 Insert a jumper between CSPWR and CS to simulate a cabin switch CS in t...

Page 38: ... the lift s frame For access during installation maintenance and repair for example the protective cap needs to be dismantled and the hydraulic unit pulled a little way out of the frame see section 8 1 Accessing the hydraulic unit and control card on page 39 Image 65 Hydraulic unit and control card CONTROL CARD TANK CAP MOTOR OIL TANK SOLENOID VALVE HOUSING ...

Page 39: ... unit see Image 68 4 Release the hydraulic unit by unscrewing the wing nut and corresponding screw C see Image 69 and pull out the hydraulic unit until the tank cap can be accessed see Image 65 on page 38 Reinstall in reverse order Ensure that no cables are trapped or in any other way damaged when the control card is folded out or removed Do not pull out the hydraulic unit more than necessary make...

Page 40: ...see section 9 7 Connecting control device on page 47 Make sure that the control card is disconnected from power before connecting peripheral equipment Risk of damage m WARNING 4 Route the cabling on the reverse of the control card and secure with cable ties see Image 70 5 Fold in and secure the control card see section 8 1 Accessing the hydraulic unit and control card on page 39 Ensure that no cab...

Page 41: ...erance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Z2500 EATilt C14 Z2500 EATiltC14 Z54831 77651TL 2018 10 05 MB OE MB MK A A2 1 1 Z Lyften Produktion AB t GND GND GND GND GND GND 6 6 6 6 11 4 3 5 8 2 8 2 GND Indikerar jordanslutningar koppla dessa till någon av styrkortets jordpunkter Indicates ground connection connect these to ground connection...

Page 42: ...e finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Z2500 C14 Z2500 C14 Z53838 75914TL 2016 10 25 MB MB ME PS C A2 1 1 Z Lyften Produktion AB t GND GND GND GND GND GND 6 6 6 6 11 4 4 3 5 8 2 8 2 GND Indikerar jordanslutningar koppla dessa till någon av styrkortets jordpunkter Indicates ground connection connect these to ground connection on controlcard GND 7 4 ...

Page 43: ...ace finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Z1500 2000 Dvx4 C16 Z1500 2000 Dvx4 C16 Z53857 75938TL 2016 10 31 MB MB PS PS C A2 1 1 Z Lyften Produktion AB t GND GND GND GND GND GND 6 6 6 6 11 4 4 3 5 8 2 8 2 GND Indikerar jordanslutningar koppla dessa till någon av styrkortets jordpunkter Indicates ground connection connect these to ground connection o...

Page 44: ...A HIAB brand part of Cargotec Corporation Samm Used on 1 1 2 2 3 3 4 4 5 5 6 6 A B C D Denna ritning är Z Lyftens egendom och skyddad enligt internationellt gällande lag för copyright och får ej utan Z Lyftens skriftliga medgivande kopieras delges eller obehörigen användas This drawing is property of Z Lyften Produktion AB and is loaned subject to return upon demand It is not to be reproduced or u...

Page 45: ... 4 Di 5 Di 6 PA PA CSPWR CS B E C 2H1 B E C 2H2 B E C Lock B E C Lock U7 U6 U5 U4 U3 U5 U4 U2 U1 U0 Ctrl 6 Out In GND LLED Ctrl 5 Outputs Sensors 4 2 3 Sig Gnd 2 2 4 4 2 4 2 4 3 6 8 5 Fotmanöverdon Varningsbelysning Brygga S Signal D Ner U Upp Vinkelgivare Brygga 45 Säkring 2 3A Pos Färg 1 Gul Grön 2 Blå 3 Brun 4 Svart 5 Grön 6 Vit 7 Röd 8 Gul 9 Grå 10 Orange 11 Lila 12 Rosa Säkring 2 3A Hydraulag...

Page 46: ...finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Larm för öppen brygga Detection open Platform Z54870 77752TL 2018 11 21 MB OE MB MK A2 1 1 Z Lyften Produktion AB Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Control Power Sensor Power Ground IN OUT Ai 1 Ai 2 Di 1 Di 2 Di 3 Di 4 Di 5 Di 6 PA PA CSPWR CS B E C 2H1 B E C 2H2 B E C Lock B E C Lock U7 U6 U5 U4 U3 U5 U4...

Page 47: ...ck Black 2H Black Black Black Black White if avail able White if available White CD14 A B S E CD14 B B S E Black CD12 Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Contr l Power Sensor Power Ground IN OUT Ai 2 Ai 1 Di 1 Di 2 Di 3 Di 4 Di 5 Di 6 PA PA CSPWR CS B E C 2H1 B E C 2H2 B E C Lock B E C Lock U7 U6 U5 U4 U3 U5 U4 U2 U1 U0 Ctrl 6 Out In GND LLED Ctrl 5 Outputs Sensors White must be con nected to...

Page 48: ...r For Autotilt safety function Di2 Not used in this configuration Di3 Not used in this configuration Di4 Tilting cylinder Open platform alarm Pressure switch for falling pressure connected to side of tilting cylinder In its actuated state returns the connection signal to Di4 resulting in output signal at Pa At the same time signal is sent on Pa 60 Bar NC Di5 Lift cylinder Pressure switch For autot...

Page 49: ...p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 Quick opening is activated p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 10º 10º 3 C E p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 0 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 15º 10º Lower 1 E p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 0 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p...

Page 50: ...rl 4 p Ctrl 5 p Ctrl 6 10º 0º 2 B p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 0 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 Tilt up B C p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 0 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 45º 10º Close B C 2H 0 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 p Ctrl 1 p Ctrl 2 p Ctrl 3 ...

Page 51: ...t up down and opening closing Ctrl 1 2 Ctrl 3 4 6 Image 71 The use of controllers 3 4 and 6 is limited by the platform angle 10 4 Quick Opening Zone Image 72 Quick opening is active when the plat form angle is approx 90º 10º 90º 10º See also the electrical diagram 9 1 Z2500 130 150 MA with electrical autotilt on page 41 ...

Page 52: ...ctivate the warning lights and foot controls 45º 10 6 Inclinometer voltage The voltage on the inclinometer output varies with inclinometer angle Below are some examples of different angles and approximate voltages 0º 45º 90º 1 8V 2 5V 3 2V Image 74 Approximate voltage at various angles 2 5V 3 2V 1 8V See also the electrical diagram 9 1 Z2500 130 150 MA with electrical autotilt on page 41 ...

Page 53: ...wo hand button 2H together with the primary control device in order to continue to maintain the tilt up function Di4 Tilting cylinder Open platform alarm Pressure switch for falling pressure connected to side of tilting cylinder In its actuated state returns the connection signal to Di4 resulting in output signal at Pa At the same time signal is sent on Pa 60 Bar NC Di5 Not used in this configurat...

Page 54: ...º down to approx 45º Quick opening is activated p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 89º 15º 45º 0º 10º 2 C E p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 Opens the body from inside p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 89º 15º 45º 0º 10º Lower E p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 p Ctrl 1 p Ct...

Page 55: ... p Di6 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 Tilt up B C Di3 p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 ilting up to approxi mately 45º p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 45º 90º 0º 10º Closing B C 2H p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 Close against v...

Page 56: ... 3 4 and 6 is limited by the platform angle 11 4 Quick opening activation zone Image 76 Quick opening can be activated when the platform angle is 90º 45º If the control buttons are kept pressed the quick opening function is active down to 10 90º 45º Ctrl 1 2 Ctrl 4 Ctrl 3 4 6 See also the electrical diagram 9 2 Z2500 130 150 MA on page 42 ...

Page 57: ...wo hand button 2H together with the primary control device in order to continue to maintain the tilt up function Di4 Tilting cylinder Open platform alarm Pressure switch for falling pressure connected to side of tilting cylinder In its actuated state returns the connection signal to Di4 resulting in output signal at Pa At the same time signal is sent on Pa 60 Bar NC Di5 Not used in this configurat...

Page 58: ...89º 15º 45º 0º 10º 2 C E p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 Opens from inside the body p Ctrl 1 p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 89º 15º 45º 0º 10º Lower 1 E p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 2 E Di6 p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 p U0 p...

Page 59: ... 6 2 B Di6 p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 Manual up replaces raise 1 and 2 with jumpered Di6 p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 Tilt up B C Di3 p Di1 p Di2 p Di3 p Di4 p Di5 p Di6 p U0 p U1 p U2 p U3 p U4 p U5 p U6 p U7 Tilting up to approxi mately 45º p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 45º 90º 0º 10º Closing B C 2H...

Page 60: ... 3 4 and 6 is limited by the platform angle 12 4 Quick opening activation zone Image 78 Quick opening can be activated when the platform angle is 90º 45º If the control buttons are kept pressed the quick opening function is active down to 10 90º 10º Ctrl 1 2 Ctrl 4 Ctrl 3 4 6 See also the electrical diagram 9 3 Z2500 130 150 DA on page 43 ...

Page 61: ...t of any operational disturbances fault codes are displayed to facilitate troubleshooting The display indicates Active control device Fault display Program configuration Sensors current status The flashing light indicates Supply voltage Off No supply voltage On Supply voltage available but CS cabin switch is not active Flashing CS cabin switch is active the system is awaiting input signal LED 1 in...

Page 62: ...he current control device is locked for a while to ensure that no other person operates the lift from another control device During the period the control system is locked for the current control device its number 1 7 will flash on the display This primarily applies to radio and coil control devices as other control devices have such a short locking period that there is hardly time to see the indi...

Page 63: ... a while after com pleted operation 1 7 Control device for which the control sys tem is locked This primarily applies to radio and coil control devices as other control devices have such a short locking period that there is no time to see the indication The number will stop flashing when one of the current control device s buttons are pressed If the control card has been without voltage and receiv...

Page 64: ...rnal module 7 CS cabin switch 8 Control Power 9 Sensor Power If the system discovers several faults only the fault code for the fault with the highest priority will be shown auto matically The display is prioritised in the order in the table below L H E F U and A To see all faults press and hold in button C on the control device The system will then browse through the list so that all faults detec...

Page 65: ...evice 5 Truck slider control device 6 Radio control device internal module 7 CS cabin switch Segment Segments B C E or X are illumi nated depending on which button signal has locked the control device F Output short circuit ed high current 0 9 Which output has short circuited has high current 1 7 Control device displayed only after the re spective output function has been active 8 Control power 9 ...

Page 66: ...he control device in question see the list in section 13 2 2 Fault codes on page 64 Example Control device 2 is blocked the LED on the coil control device then flashes twice goes out for a mo ment flashes twice again etc Coil control device s LED Fixed light The coil control device is active Extinguished weak glim mer The coil control device is not active Flashing One of the other control devices ...

Page 67: ...Z 2500 130 150 Marking and decals 67 www zepro com Image 80 Marking and decals 14 Marking and decals 14 1 Summary The illustrations below show the positions of the various decals ...

Page 68: ...ached to the platform so that any drivers parking behind the vehicle know that 5 m clearance is needed for the platform to open and that sufficient space should be left for loading and unloading 14 3 Identification plate The identification plate is fitted to the frame of the tail lift and contains the following information Type of lift Max permitted load in kg Production number Year of manufacture...

Page 69: ...ea decal warning about the danger zone between the platform and the rear edge of the vehicle The decal must be attached to the inside of the vehicle body where the hand control device is installed 14 7 Warning tape Warning tape can be affixed along the platform edging to mark the edges of the platform when in the extended position The location of the warning tape often coin cides with the contour ...

Page 70: ...e there is no risk of them coming loose when the platform is lowered to the ground Swage the tracks together to secure the warning flags Image 88 CE marking 14 9 CE marking The marking below represents the manufacturer s guarantee that the lift is designed and supplied in ac cordance with the EU Machinery Directive This is the customer s guarantee of high quality and safety ...

Page 71: ...ring Left tilt cylinder at lower bearing Lift arm left side at lower bearing Left tilt cylinder at upper bearing Right tilt cylinder at upper bearing Lift arm right side at upper bearing Right lift cylinder at upper bearing Left tilt cylinder at upper bearing Lift arm left side at upper bearing 15 2 Fluid level check Check the fluid level in the tank during service top up if necessary The marking ...

Page 72: ...ve tail lift model and lifting capacity Remove the test load from the platform Repeat the measurement of A B C D and verify that there has been no deformation of the lift or its fixing 16 1 2 Drift Place a test load on the platform according to the table The tail lift must be at the same level and angle as the vehicle floor Leave the test load for 15 minutes Verify that the platform drift is no mo...

Page 73: ...sted Check That the red light in the vehicle cabin turns off when the platform is completely closed against the body and that it turns on when the platform is opened where applicable That the tail lift will not operate if the cabin switch is in the off position That the tail lift cannot be operated with the main switch fuse near the battery blown That the overflow valve is activated when the lift ...

Page 74: ... the platform and rest the cylinders on the ground Run the tilt cylinders to their minimum stroke limit to remove pressure from the circuit Dismantle the axles Knock them out with a hammer and suitable drift Lift off the platform Raise the lift arms to their highest position Disconnect 12 24 V from the control card Disconnect all control devices from the control card Support the support frame from...

Page 75: ...t platform Steel platforms Z 2500 130 403 kg Steel platform 1700x2560 mm 313 kg Z 2500 150 422 kg Steel platform 2000x2560 mm 365 kg Lift components included in complete lift chassis Support frame Z 2500 116 kg Lift arm Z 2500 130 57 kg Lift arm Z 2500 150 63 5 kg 3 part underrun protection complete Z 2500 130 40 kg 3 part underrun protection complete Z 2500 150 45 kg Chassis bracket complete par ...

Page 76: ... from the battery via the main switch or by releasing the lift s main fuse in order to reduce the risk of the battery discharging The length of time the vehicle can be stored without the battery s charge level becoming too low depends on the condition of the battery the charge level before storage and how much power the vehicle s other components take from the battery After a period of storage the...

Page 77: ...Z 2500 130 150 Specifications 77 www zepro com Image 92 Loading diagram 18 4 Loading diagram ...

Page 78: ...cations www zepro com Image 93 Tightening torque 18 5 Tightening torque All specified torque values apply for use with a screw or impact wrench with torque control Torque distribution max 5 NOTE 80 Nm 80 Nm 120 Nm 280 Nm 80 Nm ...

Page 79: ......

Page 80: ...lifts Hiab is a world leading supplier of equipment intelligent services and digital solutions for on road load handling As an industry pioneer our company commitment is to increase the efficiency of our customers operations and to shape the future of intelligent load handling ...

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