Zepro Z 2500-130 DA Installation Instructions Manual Download

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ZEPRO
Tel.: +46 (0)10-459 05 00

E-mail: [email protected]

zepro.com

75981TL

2020-01-24

Installation Instructions

Tail Lift

Z 2500-130/150

Summary of Contents for Z 2500-130 DA

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 light...

Page 4: ...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...

Page 5: ...nts 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 T...

Page 6: ...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 C...

Page 7: ...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 o...

Page 8: ...erties 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 als...

Page 9: ...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 rod...

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...

Page 11: ...njury 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...

Page 12: ...igning 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 c...

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 b...

Page 14: ...28 520 172 773 470 160 812 420 150 844 370 142 871 330 136 890 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...

Page 15: ...ion 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...

Page 16: ...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 th...

Page 17: ...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...

Page 18: ...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 th...

Page 19: ...tected 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 t...

Page 20: ...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 mus...

Page 21: ...n 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 Wa...

Page 22: ...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...

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 mu...

Page 24: ...ge 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 th...

Page 25: ...ble 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...

Page 26: ...atutory 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 re...

Page 27: ...ax 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 lat...

Page 28: ...hed 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 again...

Page 29: ...pping screws 2 Drill holes 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 scr...

Page 30: ...he 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 scr...

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...

Page 32: ...ylinderaligns 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...

Page 33: ...ts 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...

Page 34: ...d 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...

Page 35: ...e 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 d...

Page 36: ...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 actu...

Page 37: ...onnect 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 li...

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...

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...

Page 40: ...ee 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 th...

Page 41: ...ance 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...

Page 42: ...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...

Page 43: ...ce 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...

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 r Z Lyftens egendom och skyddad enligt internationellt g llande lag f r copyright och f r ej utan Z...

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 Fotman verdon Va...

Page 46: ...inish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Larm f r ppen brygga Detection open Platform Z54870 77752TL 2018 11 21 MB OE MB MK A2 1 1 Z Lyften Produktion AB C...

Page 47: ...k 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 A...

Page 48: ...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 t...

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 10 10 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 U...

Page 50: ...trl 4 p Ctrl 5 p Ctrl 6 10 0 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...

Page 51: ...lt 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 for...

Page 52: ...ctivate the warning lights and foot controls 45 10 6 Inclinometer voltage The voltage on the inclinometer output varies with inclinometer angle Below are some examples of different angles and approxim...

Page 53: ...o 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...

Page 54: ...om 89 down to approx 45 Quick opening is activated p Ctrl 1 p Ctrl 2 p Ctrl 3 p Ctrl 4 p Ctrl 5 p Ctrl 6 89 15 45 0 10 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...

Page 55: ...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 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 ilti...

Page 56: ...s 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 90 45 If the control buttons are kept pressed the qui...

Page 57: ...o 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...

Page 58: ...6 89 15 45 0 10 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 89 15 45 0...

Page 59: ...rl 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 u...

Page 60: ...s 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 90 45 If the control buttons are kept pressed the qui...

Page 61: ...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 flas...

Page 62: ...e 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 devic...

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 lockin...

Page 64: ...nal 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...

Page 65: ...vice 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...

Page 66: ...e 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 flas...

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: ...ched 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 I...

Page 69: ...a 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...

Page 70: ...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...

Page 71: ...ing 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 cyl...

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 Pl...

Page 73: ...ted 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...

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...

Page 75: ...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 25...

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 char...

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

Page 78: ...ations 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...

Page 79: ......

Page 80: ...ifts 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 o...

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