Zepro ZN 2500-130 Installation Instruction Download

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

E-mail: [email protected]

zepro.com

76510TL

2022-06-09

Installation Instruction

Tail Lift

ZN 2500-130
ZN 2500-150

Summary of Contents for ZN 2500-130

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 76510TL 2022 06 09 Installation Instruction Tail Lift ZN 2500 130 ZN 2500 150...

Page 2: ......

Page 3: ...sions ZN 2500 130 12 3 6 Rear beam cut outs 14 3 7 Adjusting the chassis brackets 15 3 8 Temporary connection 16 3 9 Prepare the tail lift 19 4 Installation 21 4 1 Chassis bracket 21 4 2 Support frame...

Page 4: ...t 56 8 4 Z 2500 MA Autotilt IFM ZePRO1 57 8 5 ZN 2500 130 150 DA 58 9 Lubrication and fluid level check 59 9 1 Lubrication 59 9 2 Oil level check 59 10 Marking 60 10 1 Loading diagram 61 10 2 Identifi...

Page 5: ...g 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 information...

Page 6: ...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 only t...

Page 7: ...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 repeatedly...

Page 8: ...vehicle 2 3 Installation m WARNING Installation where the platform cannot reach ground level is prohibited m WARNING ZEPRO tail lifts are only approved for installation using ZEPRO assembly kits IMPOR...

Page 9: ...f inertia of 937cm4 around the x axis See Image 7 If in doubt contact ZEPRO for support 3 2 Statutory dimensions Distance between the beam and the ground when the vehicle is unloaded Max 450 mm for ve...

Page 10: ...f the wheel Max 100 mm See Image 9 The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm See Image 10 Each of the individual parts of the und...

Page 11: ...lift arms in their upper position to vehicle floor level dimension A 3 3 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 supp...

Page 12: ...12 Installed dimensions 3 4 Installed dimensions ZN 2500 150 C A D 715 216 726 680 202 767 630 186 818 580 173 861 530 162 899 480 153 931 430 145 959 360 136 992 3 5 Installed dimensions ZN 2500 130...

Page 13: ...ZN 2500 130 150 Before installation 13 www zepro com Image 13 Installed dimensions Image 14 Installed dimensions...

Page 14: ...ition 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 b...

Page 15: ...ether see illustration below 2 Fit the two parts of the brackets in the correct position with the eight bolts and nuts NOTE If the chassis width is 1300 mm or more fit the lower part to the inside B o...

Page 16: ...control card to simulate that the CS switch is turned on Remove the jumper immediately after completed operation m WARNING Take great care while running the lift functions and make sure nothing gets...

Page 17: ...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 2H1 E CD...

Page 18: ...nnecting 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 Out Do...

Page 19: ...mage 21 and pull out the hydraulic unit until the tank cap is accessible see Image 22 m CAUTION Make sure no cables are pinched or in any other way damaged when the control card relay card is folded o...

Page 20: ...ore installation www zepro com 54853 Image 22 Where necessary replace the transport plug with a regular tank cap Image 23 Hydraulic unit and relay card RELAY CARD TANK CAP MOTOR OIL TANK SOLENOID VALV...

Page 21: ...ce between the brackets according to the chassis width and centre the frame so that the distance from the end of the frame to the bracket is the same on the left and the right 3 Attach the clamp on th...

Page 22: ...mporarily connect the control card to enable the lift functions see section 3 8 Temporary connec tion on page 16 5 Raise the lift arms to their highest position 6 Attach the 1st booms to the lugs on t...

Page 23: ...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 us ing a torque wrench T...

Page 24: ...e 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 th...

Page 25: ...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 w...

Page 26: ...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 t...

Page 27: ...er the platform is fitted lubricate all bearings via normal grease nipples see section 16 Lubrication and fluid level check on page 3 Fit the platform to the arms using the supplied shafts and screws...

Page 28: ...ders 3 Loosen the three lock screws on the other tilt cyl inder See Image 43 Max 40 mm Min 38 mm Image 39 Check the position in rela tion to the rear beam of the vehicle Image 40 The platform underhan...

Page 29: ...tform See Image 44 7 Fit the other tilt cylinder to the platform mount ing Use the supplied shaft and support wheel NOTE Make sure the cylinders are installed with the grease nipples facing up 8 Tight...

Page 30: ...ing the tilt angle Image 46 Installing boots 11 Fit the cylinder boots Image 46 10 mm A Lift model A 2500 130 142 5 2500 150 252 5 m WARNING After finishing the adjustment make sure the distance betwe...

Page 31: ...he platform 3 Image 48 3 Tilt the platform down to max 10 below the hori zontal Image 47 4 Adjust the end stop all the way to the top of the cylinder 4 Image 48 5 Tighten the lock screw in the end sto...

Page 32: ...Installation must take place against the vehicle body Image 51 Installing a sealing strip 4 6 Sealing strip horizontal The track is fitted using the self tapping screws pro vided 1 Mark where to dril...

Page 33: ...3 2 Statutory dimensions on page 9 Use the correct bolts M12x100 As semble without tightening the bolts see Image 52 2 Fit the outer part of each bracket at one of five positions Select a position th...

Page 34: ...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 tilt speed is attained Fas...

Page 35: ...attach the cable using cable time see Image 57 2 Connection is described later in section 6 Image 57 Installing the angle sensor x4 x4 4 11 2 Tail lift with inclinometer for autotilt 1 Install the in...

Page 36: ...h cable ties Connection is described later in section 6 Image 59 Installing an angle sensor for auto tilt Bracket on the platform Autotilt angle setting By default the autotilt angle is set to 0 If ne...

Page 37: ...s 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 downwards...

Page 38: ...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 63 3...

Page 39: ...must be made primarily to the negative terminal of the battery Alternatively another well protected earthing point which will not increase the voltage drop can be used The earthing point must be so we...

Page 40: ...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...

Page 41: ...the earth cable to the quick connector 4 Route connect the tail lift earth cable to the negative terminal of the battery or to a well protected earthing point When installing without main switch 5 On...

Page 42: ...nd 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 terminal a...

Page 43: ...r warning lighting cable 2 Route the cable and install with cable ties according to Image 72 and Image 73 The quick connector must be positioned in such a way that it does not conflict with the underr...

Page 44: ...g cabling using cable ties Ensure the length of the cable is sufficient The outer casing should be stripped back 350 mm See Image 77 6 1 2 After connection 1 Tighten the five screws once all cables ar...

Page 45: ...rse of the control board relay board and secure it with cable ties See Image 78 7 Tilt in and secure the relay board 8 Replace the cable grommet see Section 6 1 2 Image 78 Installing cabling with cabl...

Page 46: ...L2 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 Down...

Page 47: ...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 Sensor Pow...

Page 48: ...ished 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...

Page 49: ...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 Z Ly...

Page 50: ...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 brygga Detection open Pl...

Page 51: ...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 Ctrl 4 Spiral Ctr...

Page 52: ...ZN 2500 130 150 52 Connection www zepro com 6 2 7 Open platform alarm Applies when installing with main switch 4 11...

Page 53: ...cable 3 to the fuse box positive terminal see Image 79 Image 80 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 right a...

Page 54: ...ing 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 Z2500 C14 Z2500 C14 Z53838 75914TL...

Page 55: ...IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Z2500 c000 E AT Z2500 c000 E AT Z55623 79066TL 2021 11 10 MB M...

Page 56: ...ze Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Z2500 EATilt C14 Z2500 EATiltC14 Z54831 77651TL 20...

Page 57: ...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 Z2500 EATilt C14 Z2500 EATiltC...

Page 58: ...e Revision IS0 tolerances and drawing rules Tolerance Surface 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 7593...

Page 59: ...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 be...

Page 60: ...ge 85 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 subseque...

Page 61: ...n the vehicle body Image 86 Load diagram for load capacity 2500 kg centre of gravity distance 1000 mm Max 2500 Kg mm 22542TL 1000 1500 500 Max 1000 mm Max 1250 mm Max 1600 mm 2500 Kg 2000 Kg 1500 Kg M...

Page 62: ...ion 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 number...

Page 63: ...3 04 www hiab com 77661TL 2020 03 04 10 5 Controller sticker Affix the controller sticker next to the relevant controller The stickers are available in standard versions and in reversed version Option...

Page 64: ...side 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 when...

Page 65: ...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 ther...

Page 66: ...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 tai...

Page 67: ...ght Complete lift chassis without platform Lift components included in complete lift chassis ZN 2500 150 341 kg Support frame ZN 2500 89 kg Lift arm Z 2500 150 53 kg Steel platforms 3 part underrun pr...

Page 68: ...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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