Zepro ZAHD 150/200 Installation Instructions Manual Download

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

E-mail: [email protected]

zepro.com

74227TL

2022-07-04

Installation Instructions

Tail Lift

ZAHD 150/200-155/175

ZAEHD 150/200-155/175

Summary of Contents for ZAHD 150/200

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 74227TL 2022 07 04 Installation Instructions Tail Lift ZAHD 150 200 155 175 ZAEHD 150 200 155 175...

Page 2: ......

Page 3: ...rotection 10 3 3 Calculating the installed dimensions 12 3 4 Rear beam cut outs 16 3 5 Prepare the tail lift 16 3 6 Temporary connection 18 4 Installation 21 4 1 Support Frame 21 4 2 Platform 23 4 3 A...

Page 4: ...ZePRO1 53 8 5 ZAHD ZAEHD 150 200 MA Autotilt IFM ZePRO1 54 9 Lubrication and fluid level check 55 9 1 Lubrication 55 9 2 Oil level check 55 10 Marking 56 10 1 Loading diagram 57 10 2 Identification p...

Page 5: ...atening injury m CAUTION CAUTION indicates a potential hazard which if ignored may lead to minor injuries IMPORTANT IMPORTANT indicates a risk of equipment damage NOTE NOTE refers to additional inform...

Page 6: ...g is not permitted 1 5 Product approval Properly assembled this product meets relevant requirements according to EN 1756 1 2001 A1 2008 1 6 Hydraulic oil If the hydraulic oil needs to be replenished o...

Page 7: ...ge and how much power other components in the vehicle take from the battery After a period of storage the battery must always be charged fully before operating the lift When the lift is operated repea...

Page 8: ...L Scania VBG EDH 2 3 766 770 ZAEHD 75243TL 75242TL MAN VBG EDH 3 766 770 ZAHD 75424TL 75423TL MAN VBG EDH 3 766 770 ZAEHD 75243TL 75242TL Mercedes VBG EDH 2 3 848 850 ZAHD 75431TL 75430TL Mercedes VBG...

Page 9: ...the vehicle 2 3 Installation m WARNING During final inspection the space occupied by the moving cylinders must be cleared and made safe There is a risk of collision between the cylin der and the follo...

Page 10: ...axis See illustration If in doubt contact ZEPRO for support 3 2 Statutory dimensions for underrun protection Distance between the beam and the ground when the vehicle is unloaded Max 450 mm for vehicl...

Page 11: ...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 prote...

Page 12: ...e there will be between the lift arms in the upper position and the vehicle floor level A dimension 3 3 2 D dimension The D dimension is the space the lift needs measured from the rear edge of the bod...

Page 13: ...C A 40 D without support wheel Image 11 ZAHD 150 200 155 Image 12 ZAHD 150 200 175 C A D R58 3 750 229 651 Approved 700 206 714 650 189 767 600 176 812 550 165 851 500 155 885 450 147 913 404 142 936...

Page 14: ...1510 220 200 C A 40 D 875 855 max 1710 1690 220 200 C A 40 D without support wheel C A D R58 3 750 229 651 Approved 700 206 714 650 189 767 600 176 812 571 171 836 550 165 851 500 155 885 450 147 913...

Page 15: ...mage 16 ZAHD 150 200 327 61 209 180 201 180 695 895 45 1432 970 2400 L 409 61 100 180 310 180 695 895 45 1432 970 2400 L Image 17 ZAEHD 150 200 elevated 61 209 180 201 180 1432 970 2400 L 327 695 895...

Page 16: ...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 t...

Page 17: ...Image 20 Where necessary replace the transport plug with a regular tank cap Image 21 Hydraulic unit 3 Check whether the hydraulic tank is fitted with a sealed transport plug In this case replace it wi...

Page 18: ...ection and CS on the relay card to simulate switch CS being on Remove the cable immediately after completed operation Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Contr l Power Sensor Power Ground IN OUT...

Page 19: ...ng Connecting more than one controller to each connection is not permitted Risk of material damage WL1 U7 U6 U5 U5 U4 U4 U3 U2 U1 U0 U0 U1 U2 U3 WL2 PA S5 S1 S4 S3 S2 S1 S5 S4 S3 S2 PA CS CS Down 2H O...

Page 20: ...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 o Brun B Gul E Bl C Bl 2H CD1 CD2 B C 2H...

Page 21: ...ft arms to the highest position 5 Attach the lift arms to the eye of the jig Use the normal bolts of the steel platform 6 The support frame should be positioned as high as possible within the specifie...

Page 22: ...age 27 The chassis brackets slot shaped holes facilitate fine adjustment of the lift s position Perform fine adjustment if necessary before tightening the bolts 9 Tighten the bolts using a torque wren...

Page 23: ...Nm 4 Fit one of the tilt cylinders to the platform Use the supplied bolt and support wheel Tighten the bolt using a torque wrench Tightening torque 80 Nm NOTE Lubricate the bushings Image 29 Carefully...

Page 24: ...to the rear beam of the vehicle Image 33 The platform underhang A varies according to platform type and this should be taken into account when fitting the upper seal 5 Test the lift by carefully rais...

Page 25: ...platform see illustration 7 Fit the other tilting cylinder to the platform mount ing Use the supplied shaft and support wheel 8 Tighten the bolts using a torque wrench Tightening torque 80 Nm 9 Adjust...

Page 26: ...ing boots 11 Now alternate the final adjustment between the two cylinders so that the platform meets the vehicle body see Image 39 Lift model A 1500 2000 155 300 5 1500 2000 175 420 5 IMPORTANT After...

Page 27: ...izontal 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...

Page 28: ...ermitted to perform welding in the lift arm Installation must take place against the vehicle body 4 4 Sealing strip horizontal The track is fitted using the self tapping screws provided 1 Mark where t...

Page 29: ...n according to Image 45 at the far end of the lower row of holes and next to the far end in the upper one Assemble without tightening the bolts NOTE The underrun protection may be placed further back...

Page 30: ...d and attach the cable using cable time see Image 48 2 Connection is described later in section 6 Image 48 Installing the angle sensor x4 x4 4 7 2 Tail lift with inclinometer for autotilt 1 Install th...

Page 31: ...e with cable ties Connection is described later in section 6 Image 50 Installing an angle sensor for auto tilt Bracket on the platform Autotilt angle setting By default the autotilt angle is set to 0...

Page 32: ...always be fitted on the side that is facing away from moving traffic Fitting in any other way involves increased risk of injury 300 600 mm IMPORTANT The controller s cable intake must always face dow...

Page 33: ...lift and their working area 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 Image...

Page 34: ...ound cable area may result in overheating poor performance of the electrical system and shortened life expectancy of the main electrical components Earthing must not be made to anything other than the...

Page 35: ...rk when the lift is operated repeatedly without the vehicle being started and used the battery charger must be used between operations to main tain the battery s charge level NOTE The battery charger...

Page 36: ...The result must not be greater than 4 second 4 If necessary adjust the tilt speed using the knob on the hydraulic unit The knob is fastened with a check nut Then repeat steps 1 4 until the desired ti...

Page 37: ...hout connecting Connection is described later in section 6 3 On tail lifts with cable mounted quick connector for its earth connection connect the earth cable to the quick connector 4 Route the tail l...

Page 38: ...itch and controller cables on the underside of the arm and fasten with cable ties 5 Pull the main power cable from the main switch to the fuse box battery plus pole Prepare the cable with a cable term...

Page 39: ...roller warning lighting cable 2 Route the cable and install with cable ties according to Image 64 and Image 65 The quick connector must be positioned in such a way that it does not conflict with the u...

Page 40: ...t cover secured with four screws see Image 67 2 Loosen the unused cable grommets Cables can now be installed removed adjusted in the grommets 6 1 2 After connection 1 Tighten the cable grommets when a...

Page 41: ...eral equipment Risk of material damage 1 Route the cabling through the grommets 2 Connect the relevant controller See Section 6 2 1 6 2 2 3 Where applicable connect the warning lights See Section 6 2...

Page 42: ...2 U3 WL2 PA S5 S1 S4 S3 S2 S1 S5 S4 S3 S2 PA CS CS Down 2H Out Down Down C1 C1 Up Tilt In C2 Up Tilt C3 Up Ctrl 3 Ctrl 2 Ctrl 1 CD4 Up Tilt 2H Down CD9 Up Tilt Down CD10 Up Down CD14 Up S Down Up Tilt...

Page 43: ...In GND LLED Ctrl 5 Outputs Sensors o CD11 CD1 CD2 B C 2H1 E CD15 B C 2H E Black Black 2H Black Black Black White White White CD14 B S E CD12 Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Contr l Power Sens...

Page 44: ...s 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 Weldin...

Page 45: ...r Z Lyftens egendom och skyddad enligt internationellt g llande lag f r copyright och f r ej utan Z Lyftens skriftliga medgivande kopieras delges eller obeh rigen anv ndas This drawing is property of...

Page 46: ...d 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 Larm f r ppen bry...

Page 47: ...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 Larm f r ppen brygga Detection open Platform Z54...

Page 48: ...ZAHD ZAEHD 150 200 155 175 48 Connection www zepro com 6 2 7 Open platform alarm Applies when installing with main switch 4 11...

Page 49: ...power cable 3 to the fuse box positive terminal see Image 68 Image 69 6 Screw tight the cable connections and fuse with the knob 4 Install the cables at 90 or 180 from each other Install the fuse at r...

Page 50: ...ale 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...

Page 51: ...ZAHD ZAEHD 150 200 155 175 Electrical and hydraulic diagrams 51 www zepro com 8 2 ZAHD ZAEHD 150 200 MA ZePRO1...

Page 52: ...proved 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 ZA ZAE c000...

Page 53: ...ZAHD ZAEHD 150 200 155 175 Electrical and hydraulic diagrams 53 www zepro com 8 4 ZAHD ZAEHD 150 200 MA Autotilt Inclinometer ZePRO1...

Page 54: ...awing 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 ZA ZAE 1500 2000 EATilt ZA ZAE 15...

Page 55: ...de at 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 upp...

Page 56: ...Image 74 Overview of labelling 10 Marking Below an overview of the location of the different markings is shown Image of marking and further information can be found under the each subchapter for subse...

Page 57: ...ams for the appropriate lift model close to the primary controller and in a suitable clearly visible position on the vehicle body Image 75 Load diagram for load capacity 1500 kg centre of gravity dist...

Page 58: ...ormation Type of lift Max permitted load in kg Production number Year of manufacture Address and tel no of manufacturer Country of manufacture Type number for approved underrun protection RUPD Type nu...

Page 59: ...iab com 55053TL 2020 03 04 Image 81 Controller sticker for CD 10 www hiab com 77661TL 2020 03 04 10 5 Controller sticker Affix the controller sticker next to the relevant controller The stickers are a...

Page 60: ...he inside of the vehicle body next to the hand control unit 10 7 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...

Page 61: ...ective 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 11 1 2 Drif...

Page 62: ...st 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 63: ...0 175 377 kg Alu platform 1705x2540 mm 161 kg ZAHD 200 155 369 kg Alu platform 2005x2540 mm 180 kg ZAHD 200 175 378 kg Alu platform 2205x2540 mm 194 kg Steel platforms Steel platform 2000x2540 mm 335...

Page 64: ...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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