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Zepro ZHD 1500-135, Installation Instructions Manual

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Zepro ZHD 1500-135 Installation Instructions Manual Download Page 39

ZHD 1500/2000-135/155/175

Hydraulic unit and control card

39

www.zepro.com

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

U2

U1

U0

Ctrl 6

Ou

t

In Spk-

Spk+

I-

I+

CR

CT

Ctrl 5

Indication

Se appendix in

installation manual

Outputs

Sensor

s

Not in use

4

10

3A

Max. 12W

P

Pump unit

Tiltcylinder

NC 60bar

Key

Colour

1.

Yellow

2.

Blue

3.

Brown

4.

Black

5.

Green

6.

White

7.

Red

8.

Yellow

9.

Grey

10.

Orange

11.

Purple

12.

Pink

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

U2

U1

U0

Ctrl 6

Ou

t

In GN

D

LLE

D

Ctrl 5

Indication

Se appendix in

installation manual

Outputs

Sensor

s

Not in use

4

10

4

10

P

Pump unit

Tiltcylinder

NC 60bar

8A

12-24v

CS

8A

Max. 12W

Key

Colour

1.

Yellow

2.

Blue

3.

Brown

4.

Black

5.

Green

6.

White

7.

Red

8.

Yellow

9.

Grey

10.

Orange

11.

Purple

12.

Pink

9.7 

Connecting cabin switch and open platform alarm

9.8 

Alarm for open platform (trailer)

Summary of Contents for ZHD 1500-135

Page 1: ...N Telephone 46 0 150 489550 Fax 46 0 150 489551 E mail zepro zepro com Internet www zepro com Factory All v gen 4 844 41 BISPG RDEN SWEDEN Telephone 46 0 696 17200 Fax 46 0 696 17242 E mail info zepro...

Page 2: ......

Page 3: ...Installing cylinders 11 3 5 Attaching decals 11 4 Calculating the installed dimensions 12 4 1 C dimension 12 4 2 D dimension 12 4 3 A dimension 12 4 4 H dimension 12 5 Rear member cut outs 15 6 Instal...

Page 4: ...11 Connection unit 45 11 1 Power save mode 45 11 2 Operating information 45 12 Marking and decals 51 12 1 Summary 51 12 2 Load diagram 52 12 3 Identification plate 52 12 4 Work area 52 12 5 Driver s i...

Page 5: ...the installation instructions and are intended to draw your attention to circumstances that can potentially cause problems near misses personal injury and or damage to the product etc Take care Risk...

Page 6: ...ollow the driver s instruction manual when using the control device and its functions 1 3 Hydraulic fluid Our tail lift must work just as well in tropical heat as in the Arctic cold The heat is no pro...

Page 7: ..._ _ _ _ _ _ _ _ _ _ _ Identification list ZHD Standard model ZHDL Wide frame wide lift arm Max lifting capacity x 1 kg Max lifting height 135 1340 mm 155 1530 mm 175 1710 mm Cylinder model MA Double...

Page 8: ...d dam age 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 impair durability NOTE Fig 1 Pist...

Page 9: ...lowing items subframe truck chassis mem ber for rear lights number plate and the lift s chassis bracket with a short overhang The final inspection must be carried out with the platform at the vehicle...

Page 10: ...ay interfere with the lift system and the 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 attach...

Page 11: ...am Aligning 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 po...

Page 12: ...the 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 t...

Page 13: ...0 180 max 1340 220 max min C D A 610 620 197 570 669 182 520 721 163 470 764 144 420 800 126 360 835 104 815 D 40 A C 210 180 max 1530 220 max min C D A 715 680 229 680 725 212 630 781 194 580 828 179...

Page 14: ...ulating the installed dimensions www zepro com Fig 10 ZHD 1500 2000 Fig 11 ZHDL 1500 2000 Fig 12 ZHD ZHDL 1500 2000 1014 min 750 max 930 1435 2424 1515 1870 1246 min 982 max 1162 1669 2481 1749 2102 D...

Page 15: ...of the cut outs depends on the calcu lated installed dimension A see illustration below 1 Measure and mark the location and depth of the cut outs on the rear member The two cut outs must be centred o...

Page 16: ...port frame should be posi tioned as high as possible within the specified C dimension Adjust the frame to the ideal height under the chassis Aworkshop jack is useful The frame must be positioned paral...

Page 17: ...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 i...

Page 18: ...in the 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...

Page 19: ...rough the cable lead through and connected to the control card Min 260 mm 6 3 Control power cable See also the trailer manufacturer s electrical instructions NOTE 1 Route the control power cable from...

Page 20: ...ll a radius as this can cause dam age to the cable In general care must be taken when laying all the cables in order to obtain a longer cable service life and to reduce the risk of un necessary stoppa...

Page 21: ...see illustrations They must also be far enough away from the edges so they cannot chafe Make sure that when fitted to the chassis and other vehicle parts the cables do not chafe against edges etc In...

Page 22: ...6 5 2 Statutory dimensions on page 23 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 ch...

Page 23: ...Max 375 mm See illustration The underrun protection may be placed further back and lower NOTE Horizontal distance from the outer edge of the member to the outside of the wheel Max 100 mm See illustra...

Page 24: ...nstalling on the right arm the sensor s cable input must be facing downwards NOTE Fig 33 Fit end stops between the lift arms and the rear member of the vehicle floor 6 8 Sealing strip horizontal The t...

Page 25: ...the platform is fitted also lubricate all bearings via normal grease nip ples see section 13 Lubrication and fluid level check on page 55 NOTE 3 Fit the platform to the arms using the supplied shafts...

Page 26: ...NOTE 3 Loosen the three lock screws on the cylinder fitted to the platform See illustration Lock screws 3 pcs Out In Fig 39 Adjusting the tilt angle Fig 40 The platform underhang A varies ac cording t...

Page 27: ...e tilt cylinder aligns with the attach ment on the platform See Fig 43 The max length of both cylinders must be adjusted equally to avoid unwanted breakout forces mWARNING 7 Fit the other tilting cyli...

Page 28: ...ck screws of the ad justing collar using a torque wrench Tightening torque 3 5 Nm After finishing the adjustment make sure the distance between the adjusting collar and the end of the thread is no mor...

Page 29: ...ift up so that the platform reaches the vehicle floor Fig 47 2 Loosen the lock screw of the end stop 2 Screw the end stop all the way back towards the platform 3 Fig 48 3 Tilt the platform down to max...

Page 30: ...urged by rais ing the platform fully against the vehicle body and then tilting all the way down 6 12 Transport lock Electric hose rupture valves serve as locks for the platform The lock opens automati...

Page 31: ...D and 12 24 V to the lift See also section 16 2 Maximum power consumption Minimum recommended conductor cross sectional area on page 60 3 Insert a jumper between CSPWR and CS to simulate a cabin switc...

Page 32: ...unit and control card www zepro com OIL TANK TANK CAP VALVE BODY MOTOR SOLENOID V1 V3 V2 CONTROL CARD 8 Hydraulic unit and control card The hydraulic unit is built into the lift s frame The control c...

Page 33: ...tle Material Dimension Datum Date Vikt Weigh kg Skala Scale Konstr Designer Kontr Checked by Godk Approved by Artikelnr Stock nr Ritningsnr Drawing nr Blad Sheet Format Size Revision F r denna ritning...

Page 34: ...ecified All measures intends finished product Alla m tt avser f rdig produkt Ben mning Title Material Dimension Datum Date Vikt Weigh kg Skala Scale Konstr Designer Kontr Checked by Godk Approved by A...

Page 35: ...Material Dimension Datum Date Vikt Weigh kg Skala Scale Konstr Designer Kontr Checked by Godk Approved by Artikelnr Stock nr Ritningsnr Drawing nr Blad Sheet Format Size Revision F r denna ritning g l...

Page 36: ...specified All measures intends finished product Alla m tt avser f rdig produkt Ben mning Title Material Dimension Datum Date Vikt Weigh kg Skala Scale Konstr Designer Kontr Checked by Godk Approved b...

Page 37: ...duced or used directly or indirectly in any way detrimental to the interest of Z Lyften Produktion AB Material Dimension Revision 1 1 ZEPRO B 2012 11 12 6698 ME MB CL C 2013 03 06 6763 TH CL CL D 2013...

Page 38: ...Lyften Produktion AB and is loaned subject to return upon demand It is not to be reproduced or used directly or indirectly in any way detrimental to the interest of Z Lyften Produktion AB Material Di...

Page 39: ...2 Blue 3 Brown 4 Black 5 Green 6 White 7 Red 8 Yellow 9 Grey 10 Orange 11 Purple 12 Pink 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...

Page 40: ...CD2 B C 2H1 2H2 2H E CD4 B C 2H E Black 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 Con...

Page 41: ...3 U1 U2 U4 Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 Ctrl 6 2 E Di3 U1 U2 U4 U5 Autotilt down Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 Ctrl 6 10 0 Tilt down C E Di2 U0 U1 U3 U5 Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 Ctrl 6 45 90 0 10 Rais...

Page 42: ...platform alarm Pressure sensor for falling pressure connected to side of tilt cylinder In the actuated state returns the connection signal to Di4 and resulting in output signal at Pa Also phase signal...

Page 43: ...2 Ctrl 3 Ctrl 4 Raise B Di5 U0 U2 Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 Tilt up Close B C Di5 U0 U3 Ctrl 1 Ctrl 2 Ctrl 3 Ctrl 4 45 0 10 90 Open 1 C E 2H U0 U1 U3 U5 Open from vehicle body down to about 45 Ctrl...

Page 44: ...platform alarm Pressure sensor for falling pressure connected to side of tilt cylinder In the actuated state returns the connection signal to Di4 and resulting in output signal at Pa Also phase signal...

Page 45: ...LEDS These display current operating informa tion In the event of any operational disturbances fault codes are displayed to facilitate troubleshooting The display indicates Active control device Faul...

Page 46: ...L 5 Slider lift control device 6 CTRL 6 Radio control device internal module 7 CS CS cabin switch Once a button has been released the control system for the current control device is locked for a whil...

Page 47: ...l 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 press...

Page 48: ...nly the fault code for the fault with the highest priority will be shown automatically The display is prioritised in the order in the table below L H E F and A To see all current faults press and hold...

Page 49: ...reset automatically if the function in ques tion is running function verified Displayed only af ter the respective output U0 U7 has been active A Internal fault 0 Any measurement faults are reg ister...

Page 50: ...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 is blocked 11 2 4 Supply voltage The figur...

Page 51: ...ow NB Onlythemaincontrolunitisfunctional N dst ngningvidl gvolt OBS Endast huvudman verdonet ranv ndbart NotsteuerungbeiUnterspannung ACHTUNG Notsteuerungistnurmitder Hauptsteuerungm glich Fermetured...

Page 52: ...o that any drivers parking behind the vehicle know that 5 m clear ance is needed for the platform to open and that sufficient space should be left for loading and unloading 12 3 Identification plate T...

Page 53: ...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 12 7 Warning tape Warning tape is pr...

Page 54: ...where 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 12 9 CE marking The marking below represents the Fig 62 CE...

Page 55: ...lift cylinder at lower bearing 5 Left tilt cylinder at lower bearing 6 Lift arm left side at lower bearing 7 Left tilt cylinder at upper bearing 8 Right tilt cylinder at upper bearing 9 Lift arm righ...

Page 56: ...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 14 1 2 Drift Place a test load on the platform accordi...

Page 57: ...ust be tested 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...

Page 58: ...he platform and rest the cylinders on the ground 3 Run the tilting cylinders to their minimum stroke limit to remove pressure from the circuit 4 Dismantle the axles Knock them out with a hammer and su...

Page 59: ...rm ZHD 1500 2000 175 61 kg ZHDL 1500 155 362 kg Lift arm ZHDL 1500 2000 175 63 kg ZHDL 1500 175 378 kg 3 part underrun protection complete ZHD ZHDL 56 kg ZHDL 2000 135 355 kg Complete chassis bracket...

Page 60: ...re recommended to disconnect the lift from the bat tery via the main switch or by releasing the lift s main fuse in order to reduce the risk of the bat tery discharging The length of time the vehicle...

Page 61: ...ZHD 1500 2000 135 155 175 Specifications 61 www zepro com Fig 66 Loading diagram 16 4 Loading diagram...

Page 62: ...ZHD 1500 2000 135 155 175 62 Specifications www zepro com Fig 67 Tightening torque 16 5 Tightening torque 280 Nm 280 Nm 80 Nm 280 Nm 120 Nm...

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