Zepro ZHD 2500-130, Installation Instructions Manual

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 55987TL 2021 05 04 Installation Instructions Tail Lift ZHD 2500 130 150...

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Page 3: ...ders 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 beam cut outs 15 6 Installation 16 6 1 Supp...

Page 4: ...HD 2500 Config 1 MA 44 10 2 ZHD 2500 Config 3 DA 46 11 Connection unit 48 11 1 Power save mode 48 11 2 Operating information 48 12 Marking 54 12 1 Loading diagram 55 12 2 Identification plate 56 12 3...

Page 5: ...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 of da...

Page 6: ...t meets relevant requirements according to EN 1756 1 2001 A1 2008 1 4 Hydraulic oil If the hydraulic oil needs to be replenished only the oil recommended by ZEPRO is permitted to be used Hydraulic sys...

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 actin...

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 im pair durability NOTE Image 1 Piston ro...

Page 9: ...owing 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...

Page 10: ...injury 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 platfor...

Page 11: ...ligning 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...

Page 12: ...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...

Page 13: ...2 685 570 187 728 520 172 773 470 160 812 420 150 844 370 142 871 330 136 890 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 96...

Page 14: ...ZHD 2500 130 150 14 Calculating the installed dimensions www zepro com 994 245 245 A max 1524 1010 min 750 max 930 1509 1966 2411 34 35 62 100 385 350 133 301 617 817 Image 9 ZHD 2500...

Page 15: ...position 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 mu...

Page 16: ...rame should be positioned as high as possible within the specified C dimension Adjust the frame to the ideal height under the chassis A workshop jack is useful The frame must be positioned parallel wi...

Page 17: ...he inside of the vehicle chassis Installation must be performed with at least 8 bolts in the outer holes The bolt that was installed initially in the slot shaped hole may not be included in this figur...

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: ...ms or walls If there are quick connectors make sure they are effectively protected from moisture and dirt Do not bend the cable to too small a radius as this can cause damage to the cable NOTE 2 Conne...

Page 20: ...tween the vehicle s rear edge and centre of the control devices must be 400 mm 100 mm The distance between the control devices must be at least 250 mm See illustration 23 All cable inlets must be poin...

Page 21: ...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 must be taken when routing all the c...

Page 22: ...age 23 2 3 Connect a cable from the battery s positive terminal see Image 23 3 4 Screw the cable connections and fuse into place with the knob Install the cables at 90 or 180 from each other Install t...

Page 23: ...around the x axis See illustration If in doubt contact ZEPRO for support 6 6 2 Statutory dimensions for underrun protection Distance between the beam and the ground when the vehicle is unloaded Max 45...

Page 24: ...outside of the wheel Max 100 mm See figure 28 The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm See figure 29 Each of the individual par...

Page 25: ...Statutory dimensions for underrun protection 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...

Page 26: ...ng on the right arm the sensor s cable input must be facing downwards NOTE Image 35 Fit end stops between the lift arms and the rear beam of the vehicle floor 6 10 Sealing strip horizontal The track i...

Page 27: ...er the platform is fitted lubricate all bearings via normal grease nipples see section 13 Lubrication and fluid level check on page 59 NOTE 3 Fit the platform to the arms using the supplied shafts and...

Page 28: ...3 Loosen the three lock screws on the cylinder fitted to the platform See Image 43 5 Test the lift by carefully raising it to the vehicle floor level and tilting it to the vertical position Check the...

Page 29: ...tilt cylinder aligns with the attachment on the platform See Image 45 The max length of both cylinders must be adjusted equally to avoid unwanted breakout forces mWARNING 7 Fit the other tilting cyli...

Page 30: ...oots 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 adjusting collar and the end of...

Page 31: ...e lift to the vehicle floor Image 49 2 Loosen the lock screw of the end stop 2 Screw the end stop all the way back towards the platform 3 Image 50 3 Tilt the platform down to max 10 degrees below the...

Page 32: ...platform fully against the vehicle body and then tilting all the way down 6 14 Transport lock Electric hose breakage valves serve as locks for the platform The lock opens automatically if the down fun...

Page 33: ...d 12 24V to the lift See also section 16 2 Maximum power consumption Minimum recommended conductor cross sectional area on page 64 3 Insert a jumper between CSPWR and CS to simulate a cabin switch CS...

Page 34: ...d 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 package is built into the frame of the lift The control c...

Page 35: ...e Konstr Designer Kontr Checked by Godk Approved by Artikelnr Stock nr Ritningsnr Drawing nr Blad Sheet Format Size Revision F r denna ritning g ller IS0 toleranser SMS ritregler Toleranser Tolerance...

Page 36: ...al 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 ller IS...

Page 37: ...ion unless otherwise 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 Checke...

Page 38: ...Lyften Produktion AB Material Dimension Revision 1 1 A CARGOTEC BRAND ZEPRO Rev Tag Date Rev number Revised ECR Approved A 2012 11 12 6698 ME MB CL B 2013 03 04 6763 TH MB CL C 2013 04 10 6791 TH 52 C...

Page 39: ...PWR 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 Sensors Not in use 1 1 2 2 3...

Page 40: ...nection to circuit board 4 button operation Nr No F rg Color Farbe 1 Gul Gr n Yellow Green Gelb Gr n 2 Bl Blue Blau 3 Brun Brown Braun 4 Svart Black Schwarz 5 Gr n Green Gr n 6 Vit White Wei 7 R d Red...

Page 41: ...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 Ctrl 6 Ctrl 5 Indication Se appendix in installation manual Outputs 9 7 Jumper two hand control When conn...

Page 42: ...lue 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...

Page 43: ...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 Contr l...

Page 44: ...trl 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 Raise B U0 U2 Autotilt...

Page 45: ...larm 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 out at Pa...

Page 46: ...l 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 1 Ctrl 2 45...

Page 47: ...larm 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 out at Pa...

Page 48: ...se display current operating information In the event of any operational disturbances fault codes are displayed to facilitate troubleshooting The display indicates Active control device Fault display...

Page 49: ...ce 5 CTRL 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 fo...

Page 50: ...vices as other control devices have such a short lock ing 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...

Page 51: ...d control device 2 including two hand button 2h2 3 CTRL 3 Radio control device External 4 CTRL 4 Coil control device 5 CTRL 5 Slider lift control device 6 CTRL 6 Radio control device internal module 7...

Page 52: ...in question is running function verified 1 7 U0 U7 dis played only after the respective output function has been ac tive 8 Control power 9 Sensor power Output not connect ed cable breakdown 0 7 Which...

Page 53: ...rol device s 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 volta...

Page 54: ...age 56 Overview of labelling 12 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 subsequ...

Page 55: ...oading diagram Affix the load diagrams for the appropriate lift model close to the primary controller and in a suitable clearly visible position on the vehicle body Image 57 Load diagram for load capa...

Page 56: ...tion 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 57: ...r is discarded www hiab com 55053TL 2020 03 04 Image 62 Controller sticker for CD 10 www hiab com 77661TL 2020 03 04 12 5 Controller sticker Affix the controller sticker next to the relevant controlle...

Page 58: ...side of the vehicle body next to the hand control unit 12 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 59: ...t 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 si...

Page 60: ...ive 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 14 1 2 Drift P...

Page 61: ...d 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 w...

Page 62: ...atform 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 suitabl...

Page 63: ...chas sis Support frame ZHD 2500 116 kg Lift arm ZHD 2500 130 57 kg Lift arm ZHD 2500 150 63 5 kg 3 part underrun protection complete ZHD 2500 130 41 kg 3 part underrun protection complete ZHD 2500 15...

Page 64: ...are recommended to disconnect the lift 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...

Page 65: ...ZHD 2500 130 150 Specifications 65 www zepro com Image 71 Loading diagram 16 4 Loading diagram...

Page 66: ...ations www zepro com Image 72 Tightening torque 16 5 Tightening torque 280 Nm 280 Nm 80 Nm 280 Nm 120 Nm All specified torque values apply for use with a screw or impact wrench with torque control Tor...

Page 67: ...ZHD 2500 130 150 Specifications 67 www zepro com...

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...