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Zepro ZHDN 2500-150, Installation Instructions Manual, Page: 8 / 58

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Zepro ZHDN 2500-150 Installation Instructions Manual Download Page 8

ZHDN 2500-150

8

Safety rules

www.zepro.com

2 

Safety rules

2.1 

Repainting

Piston rods and cylinder covers must 

not be painted. Painting could 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.

 

 

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

Summary of Contents for ZHDN 2500-150

Page 1: ...150 489550 Fax 0150 489551 E mail zepro zepro com Internet www z lyften se Factory Allévägen 4 840 73 BISPGÅRDEN SWEDEN Telephone 0696 17200 Fax 0696 17242 E mail info zepro com Internet www z lyften se 2016 07 07 75354TL INSTALLATION INSTRUCTIONS Z LYFTEN PRODUKTION AB ...

Page 2: ......

Page 3: ...nstalling cylinders 11 3 5 Attaching decals 11 4 Calculating the installed dimensions 12 4 1 C dimension 12 4 2 A dimension 12 4 3 H dimension 12 5 Adjusting the chassis brackets 14 5 1 Adjustment 14 6 Installation 15 6 1 Chassis brackets 15 6 2 Rear beam cut outs 15 6 3 Support frame 16 6 4 Control power cable 18 6 5 Control devices 18 6 6 Main power cable 19 6 7 Open platform alarm 20 6 8 Third ...

Page 4: ...evice 43 9 5 Sensor 44 9 6 Hydraulic unit 45 10 Marking and decals 46 10 1 Summary 46 10 2 Load diagram 47 10 3 Identification plate 47 10 4 Work area 47 10 5 Driver s instructions 48 10 6 Danger area 48 10 7 Warning tape 48 10 8 CE marking 49 10 9 Warning flags 49 11 Lubrication and fluid level check 50 11 1 Lubrication 50 11 2 Fluid level check 50 12 Testing and verification 51 12 1 Static load ...

Page 5: ...The piston rods of the hydraulic valves are treated by a method that provides a very long lifespan An integrated bypass valve protects the hydraulic system from overload when lifting and tilting up Note that the bypass valve does not prevent overload at rest position or during down movements The electricity supply is from the normal vehicle battery The control power is taken from the central elect...

Page 6: ...he driver s instruction manual when using the control device and its functions 1 4 Hydraulic fluid A tail lift must work just as well in tropical heat as in the Arctic cold The heat is no problem for the fluid Cold on the other hand is a big challenge for hydraulic fluid That is why Z Lyften chose a hydraulic fuel that can cope with all these conditions Our hydraulic fluid product no 21963 1 litre...

Page 7: ...MA 1 5 Identification ZHD Standard model ZHDN Narrow frame Max lifting capacity x 1 kg Max lifting height 135 1340 mm Cylinder model MA Double acting Adjustable Tilt Single acting Single speed Lift DA Double acting Adjustable Tilt Double acting Single speed Lift ...

Page 8: ...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 impair 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 9: ...ylinder 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 Theclearancefromtheclosestpart of the cylinder must be at least 40 mm mWARNING The platform must not be tilted down more than 10º from the horizontal mWARNING min 40mm 10º...

Page 10: ...e 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 attachment features on the vehicle mWARNING Image 7 You must not attach third party equipment to Zepro tail lifts 2 5 Installation The platform must not be installed so it cannot reach ground level mWARNING Zepro tail lifts are only approved for ...

Page 11: ...he support frame Mounting the standard 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 the tilt cylinder Test running 3 5 Attaching dec...

Page 12: ...the upper position and the vehicle floor level A dimension 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 deter mined the D dimension can be obtained from the table 4 2 A dimension The A dimension is the space provided for the rear beam i e the space there...

Page 13: ...DN 2500 150 Calculating the installed dimensions 13 www zepro com 1094 719 1174 1200 1500 1870 2486 202 or 242 623 100 100 297 62 567 817 133 301 Image 9 Installed dimensions Image 10 Installed dimensions ...

Page 14: ...ket together see illustration below 2 Fit the two parts of the bracket in the correct position with the eight bolts and nuts If the chassis width is 1300 mm or more fit the lower part to the inside B of the upper part see illustration below If the chassis is narrower than 1300 mm fit the lower part to the outside A of the upper part see illustration below NOTE 3 Tighten the bolts using a torque wr...

Page 15: ... 3 Attach the clamp on the rear of the chassis bracket using the supplied washers and nuts 4 Tighten the bolts using a torque wrench Tightening torque 260 Nm Image 12 Fitting the chassis bracket 6 2 Rear beam cut outs It is often necessary to create cut outs in the rear beam to provide space for the platform arms when the platform is in the upper position The size of the cut outs depends on the ca...

Page 16: ... illustration 3 Position the support frame under the trailer chassis 4 Temporarily connect the control card to enable the lift functions see sec tion 7 Temporary operation of lift on page 30 5 Raise the lift arms to the highest position 6 Attach the lift arms to the eye of the jig Use the normal bolts of the steel Image 14 Measure and mark the mid point of the rear beam of the trailer Image 15 Bol...

Page 17: ...brackets on page 14 If necessary adjust the angle of the arms by carefully operating the lift 8 Fit the support frame to the trailer chassis using the clamps See illustration below Tighten the bolts using a torque wrench Tightening torque 180 Nm Welding is not permitted on the chassis brackets Do not move the lift all the way to the armstops or with the platform fitted before all the bolts are ful...

Page 18: ...2 V 15 A 12 V fuse according the customer s wishes See the connec tion diagram 8 5 Connecting cabin switch and open platform alarm on page 35 Image 17 Quick connectors must be well protected Image 18 Control devices 6 5 Control devices 1 Fit the control devices in the desired locations They must be positioned so that the operator is in the safest possible location and has a clear view of the load ...

Page 19: ...sk of unnecessary stoppages NOTE 6 6 Main power cable 1 Route the main power cable from the lift to the battery Pull the cable through the plastic casing The cable must not be tied to brake lines or the normal on board electrical system The ca ble must be protected with rubber grommets when it passes through beams or walls NOTE 2 Fit a 160 A 24 V or 250 A 12 V fuse to the main power cable from the...

Page 20: ... passes through beams or walls If there are quick connectors make sure they are effectively protected from moisture and dirt 6 7 2 Test running 1 Turn the ignition key when the platform is tilted up and pressed firmly against the vehicle body The lamp must be off 2 Tilt the platform a few degrees from the vertical The lamp must come on 3 Leave the platform in the last position and turn off the ign...

Page 21: ...ions Select the position that meets the statutory requirements Use the correct bolts M12x80 As semble without tightening the bolts See illustration The underrun protection may be placed further back and lower than the specified measure ments NOTE 3 Check that the installation meets the statutory requirements 4 Tighten all the bolts using a torque wrench Tightening torque 80 Nm 5 Fit the beam end c...

Page 22: ...to the underrun protection Max 375 mm See illustration Horizontal distance from the outer edge of the beam to the outside of the wheel Max 100 mm See illustration The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm See illustration Each of the individual parts of the underrun protection must have a surface area of at least 350 cm2 See il...

Page 23: ...oor 6 12 Sealing strip horizontal The track is fitted using the self tapping screws provided 1 Mark where to drill holes for the self tapping 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 13 Sealing strip vertical 1 Fit the tracks with contersunk screws rivets or by spot welding 2 Fit the rubber strip to the tr...

Page 24: ...he platform is fitted lubricate all bear ings via normal grease nipples see section 11 Lubrication and fluid level check on page 50 NOTE 3 Fit the platform to the arms using the supplied shafts and screws Tighten the bolts using a torque wrench Tightening torque 80 NOTE Lubricate the bushings Nm 4 Fit one of the tilt cylinders to the platform Use the supplied shaft as a support wheel Make sure the...

Page 25: ...Flat 40 mm A Max 40 mm Min 38 mm 6 14 1 Adjusting the tilt angle Do not adjust the cylinders before they are fitted to the platform The tilt cylinders are preset from the factory NOTE 1 Loosen the rubber bellows 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 hydraulic pressure in the tilt cylind...

Page 26: ...r see illustration 6 Loosen the three lock screws on the other tilt cylinder see illustration 7 Turn the adjusting collar so that the tilt cylinder aligns with the attach ment on the platform see illustra tion 8 Fit the other tilt cylinder to the platform Use the sup plied shaft as a support wheel Make sure the cylinders are installed with the grease nipples facing up NOTE Tighten the bolts using ...

Page 27: ...mage 42 Installing boots 10 Tighten the lock 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 adjust ing collar and the end of the thread is no more than 30 mm mWARNING 11 Fit the cylinder boots see Image 42 ...

Page 28: ...w the end stop all the way back towards the platform 3 See illustration 3 Tilt the platform down to max 10 degrees below the horizontal See illustration 4 Adjust the end stop all the way to the top of the cylinder 4 5 Tighten the lock screw in the end stop 5 See illustration The tightening torque for lock screws is between 3 5 Nm Test all functions The tilt angle of both cylinders must be adjusted...

Page 29: ...m against the vehicle body and then opening and tilting all the way down 6 16 Transport lock Electric hose breakage valves serve as locks for the platform The lock opens automatically if the down function is actuated from the control device The valves are non return valves that let in fluid from the cylinders but not out be fore they are actuated by the flow from the lowering valve The platform is...

Page 30: ...nnection 1 Connect a suitable control device to the control card see illustration below The number of available functions varies depending on the lift model 2 Connect an earth connection GND to the control card see illustration below 3 Connect 12 24 V to the control card protected with a 15 A fuse see illustration below 4 Insert a jumper between CSPWR and CS to simulate a cabin switch CS in the ON...

Page 31: ...t Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El Hydraulschema E H Schematic ZHDN 2500 EAtilt c13 ZHDN 2500 EAtilt c13 Z53533 75529TL 2016 07 04 MB MB PS PS A2 1 1 Z Lyften Produktion AB t 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 ...

Page 32: ...specified All measures intends finished product Title Material Dimension Date Weigh kg Scale Designer Checked by Approved by Stock nr Drawing nr Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El Hydraulschema E H Schematic ZHDN 2500 Sensors ZHDN 2500 Sensors Z53535 75531TL 2016 07 04 MB MB PS PS A2 1 1 Z Lyften Produkt...

Page 33: ...2H2 B E C Lock B E C Lock U7 U6 U5 U4 U3 U5 U4 U2 U1 U0 Ctrl 6 Out In GND Spk LLED Spk I I CR CT Ctrl 5 Indication Se appendix in installation manual Outputs Sensors Not in use 2 3 Knappsdon 2 3 Button Control 10 2 8 3 2 8 3 2 8 3 4 4 4 6 6 3 Ctrl 1 Ctrl 2 2 3 Knappsdon 2 3 Button Control Slädmanöverdons anslutning Sledcontroller connection Ctrl 4 Spiralmanöverdon Spiral cable controller Anslutnin...

Page 34: ... U4 U3 U5 U4 U2 U1 U0 Ctrl 6 Out In GND Spk LLED Spk I I CR CT Ctrl 5 Indication Se appendix in installation manual Outputs Sensors Not in use 2 3 Knappsdon 2 3 Button Control 10 2 8 3 2 8 3 2 8 3 4 4 4 6 6 7 Man don 1 Ctrl 1 Man don 2 Ctrl 2 2 3 Knappsdon 2 3 Button Control Slädmanöverdons anslutning Sledcontroller connection Man don 4 Ctrl 4 Spiralmanöverdon Spiral cable controller Anslutningsta...

Page 35: ...ical and hydraulic drawing Connect a 3 A fuse between the circuit board and the pressure sensor 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 Out In Spk Spk I I CR CT Ctrl 5 Indication Se appendix in installation manual Outputs Se...

Page 36: ...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 indicates Active input button s on control device pressed LED 2 indicates Active output lift in operation Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Control Power Sensor Power Ground IN OUT Ai 2 Ai...

Page 37: ...ce The control devices are symbolised by the figures 1 7 1 Fixed control device 1 including two hand button 2h1 2 Fixed control device 2 including two hand button 2h2 3 Radio control device External 4 Coil control device 5 Truck slider control device 6 Radio control device internal module 7 CS cabin switch Once a button has been released the control system for the current control device is locked ...

Page 38: ...ice the control system is locked for 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 receives the voltage again when the CS cabin switch is switched ...

Page 39: ...off the system will browse through a list containing the five latest faults detected before the display goes off Fault codes Identification Code 1 Code 2 Code 3 Information Other L Low battery voltage 07 35 Voltage measured H High battery voltage 07 35 Voltage measured E Control device locked 1 Fixed control device 1 incl two hand button 2h1 if they are monitored 2 Fixed control device 2 incl two ...

Page 40: ...ample of sequence of fault codes Output No 3 short circuited 9 1 3 Supply voltage A supply voltage of between 8 0V and 15 0V is regarded by the unit as correct for a 12V system A supply voltage of between 18 0V and 29 0V is regarded by the unit as correct for a 24V sys tem All functions on the unit cease when the supply voltage is less than 7 0V If the supply voltage then rises to more than 7 0V f...

Page 41: ...ts the angle of the platform if it is angled down when it is to be lowered This is done to reduce the risk of the load sliding off the platform leading to material damage and personal injury With Electrical Autotilt the platform adjusts itself to a horizontal position not with a fixed angle in relation to the vehicle Most ZHDN2500 150 can have Electrical Autotilt retrofitted Contact our sales staf...

Page 42: ... E Coil U0 U1 U3 U5 45º 90º 0º 10º Raise Manual B Di6 U0 U2 Without autotilt Di6 jumpered Raise B Di2 Di6 U0 U2 With autotilt Di6 NOT jump ered Raise Autotilt up B Di2 Di6 U0 U3 Tilt up B C Di3 or B C 2H U0 U3 Tilting up to approximately 45º 45º 90º 0º 10º Close B C 2H U0 U3 Close against vehicle body 45º 90º 0º 10º Quick opening C E To angle sen sor The angle sensor is activated for tilt down ope...

Page 43: ...se of control device 45º 90º 0º 10º 45º 90º 0º 10º 45º 90º 0º 10º Tilt up Tilt down Control device 1 2 Ctrl 1 2 Coil Ctrl 4 Control device 1 2 Ctrl 1 2 Radio Ctrl 3 6 Coil Ctrl 4 Radio Ctrl 3 6 Image 48 Use of radio and coil control device limited by the platform angle ...

Page 44: ...t signal at Pa Also phase signal out at Pa Di5 Lift cylinder Pressure sen sor fitted to lift cylinder Pressure sensor for increased pressure connected to side of lift cylinder In the actuated state returns the connection signal to Di5 and resulting in output signal at Pa Also phase signal out at Pa Di6 Control card Jumper Jumper to deactivate autotilt functions Cs Cabin Activation No signal in at ...

Page 45: ...ZHDN 2500 150 Connection unit 45 www zepro com TANK TANK CAP VALVE BODY MOTOR SOLENOID V1 V3 V2 CIRCUIT BOARD CONNECTION UNIT 9 6 Hydraulic unit Image 49 Hydraulic unit Image 50 Connection unit ...

Page 46: ...ble NB Seule l unité de commande principal est fonctionnel Cierre de emergencia y 7 8 1 2V s stem 1 5 V 1 6 1 8 24Vsyst em 2 9 V cuandolatensiónesbaja NB Sólolaunidadde controlprincipalfunciona Emergencyclosingwhenvoltageislow NB Onlythemaincontrolunitisfunctional Nödstängningvidlågvolt OBS Endast huvudmanöverdonetäranvändbart NotsteuerungbeiUnterspannung ACHTUNG Notsteuerungistnurmitder Hauptsteu...

Page 47: ...hed to the platform so 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 10 3 Identification plate The identification plate is fitted to the frame of the tail lift and contains the fol lowing information Type of lift Max permitted load in kg Production number Year of manufacture...

Page 48: ...ose to the fixed control device 10 6 Danger area A danger area 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 10 7 Warning tape Warning tape is preferably attached along the platform edge strips to mark the platform edges in the lowered posi tion 55056 ...

Page 49: ...nd supplied in accordance with the Machinery Directive This the customer s guarantee of high quality and safety Image 59 Warning flags 10 9 Warning flags Attach warning flags as close as possible to the top and edge of the platform 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 ...

Page 50: ...lower bearing 4 Left 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 right side at upper bearing 10 Right lift cylinder at upper bearing 11 Left lift cylinder at upper bearing 12 Lift arm left side at upper bearing 11 2 Fluid level check Check the fluid...

Page 51: ...ce a test load on the platform according to the table for the respective 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 12 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 Leav...

Page 52: ...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 when the main switch fuse is removed where applica ble That the overflow valve is activated when the lift...

Page 53: ...e cylinders on the ground 3 Run the tilt cylinders to their minimum stroke limit to remove pressure from the circuit 4 Remove the lock screws in the platform axles 5 Remove the axles by knocking them our with a hammer and suitable drift 6 Lift off the platform 7 Raise the lift arms to the highest position 8 Disconnect 12 24 V from the control card 9 Disconnect all control devices from the control ...

Page 54: ...omplete lift chassis without platform Lift components included in complete lift chassis ZHDN 2500 150 340 kg Support frame ZHDN 2500 89 kg Lit arm ZHDN 2500 150 53 kg Steel platforms 3 part underrun protection complete ZHDN 56 kg Steel platform 2000x2540 mm 335 kg Complete chassis bracket ZHDN 32 kg Lift cylinder ZHDN 2500 150 9 5 kg each Aluminium platforms Flat 40 mm Tilt cylinder ZHDN 2500 150 ...

Page 55: ...fications 55 www zepro com Image 62 Centre of gravity TP2 40 C TP1 ZHDN 2500 150 steel platform 2000x2560 mm C 360 C 485 C 610 TP1 mm 170 138 88 TP2 mm 1500 kg 824 833 848 TP2 mm 2000 kg 864 872 883 14 2 Centre of gravity ...

Page 56: ...y valve 1 5 A 0 75 A Solenoid 1 8 A 0 9 A Minimum recommended conductor cross sectional area copper cables plus and minus cables Control cable 1 5 mm2 1 5 mm2 Supply cable L 8m 35 mm2 35 mm2 Supply cable L 8 15m 50 mm2 35 mm2 Supply cable L 15m 50 mm2 Battery Min capacity Imin 180 Ah 170 Ah Min voltage during operation Umin at lift 9 V 18 V L L Umin Imin Imin Umin 14 3 Maximum power consumption Mi...

Page 57: ...ZHDN 2500 150 Specifications 57 www zepro com Image 64 Loading diagram 14 4 Loading diagram ...

Page 58: ...ZHDN 2500 150 Specifications 58 www zepro com Image 65 Tightening torque 14 5 Tightening torque 180 Nm 180 Nm 80 Nm 80 Nm 80 Nm 260 Nm ...

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