Zepro ZHD 3000-150 Installation guide

Brand: Zepro

Model: ZHD 3000-150

Type: Installation guide

ZHD 3000-150

Sales

Mossvägen 8, 641 49 KATRINEHOLM, SWEDEN

Telephone: +46 150 - 489550

Telefax: +46 150 - 489551

E-mail: [email protected]

Internet: www.zepro.com

Factory

Allévägen 4, 840 73 BISPGÅRDEN, SWEDEN

Telephone: +46 696 - 17200

Telefax: +46 696 - 17242

E-mail: [email protected]

Internet: www.zepro.com

2020-05-14

72689TL

INSTALLATION INSTRUCTION

Z-LYFTEN PRODUKTION AB

Contents

1. CE marking................................................................................ 4

2. General ...................................................................................... 5

Technical description .........................................................................................................5

 Identicationslist/Weights ..............................................................................................6

Center of gravity .................................................................................................................7

 Maxpowerconsumption/Torquevalues ........................................................................8

Loading diagrams ..............................................................................................................9

3. Dimensions for installation .................................................... 10

4. Installation support frame .......................................................11

5. Electrical installtion................................................................. 12

Cable routing of earth and supply cable to the lift ........................................................13

Connection of non-original components on zepro tail lifts .........................................13

6. Electrical and hydraulic diagram ........................................... 14

7. Connection unit ....................................................................... 19

8. Installation, miscellaneous ..................................................... 26

9. Important information ............................................................. 31

10. Markings, positioning of decals on lift ................................ 32

11. Post installation maintenance .............................................. 34

12. Testing the lift ........................................................................ 35

13. Dismantling ............................................................................ 37

Since 1/1/1995 ZEPRO tail lifts sold to the European

market are stamped with a CE mark. This is the

manufacturer's guarantee that the product conforms

to the European Machinery Directive.

The application of the European Machinery Directive

is intended to harmonise product safety levels across

Europe.

There are some general principals that should be

made clear when performing the installation of

ZEPRO lifts.

Follow the installation instructions. If it is not

possible to follow the installation instructions or

if modications are required, the modications

must be approved by the manufacturer. This is a

consequence of the CE marking regulations as it

cannot be possible for a manufacturer to certify

conformity to the Machinery Directive if the product

is subsequently changed without his knowledge or

approval. In order for the product's CE marking to

remain applicable the forms supplied by ZEPRO

must be completed in case of modication.

Welding is not allowed unless specically

recommended by the manufacturer.

In order to increase security, additional decals, which

are diagrammatic and easily understood independent

of language will be sent with the lifts.

Ensure that these decals are axed so that the

information contained on them is available for all

users of the lift.

Position the control unit to ensure that the operator

has a good view of the load, the working area and

the loading area, whilst maintaining a safe

distance from the risk zone between the platform and

the body. Follow the operator’s instructions for use of

the control unit and its functions.

1. CE marking

The ZEPRO-lift is electro-hydraulically driven. An

electric motor which gets its power from the truck's

ordinary battery drives a hydraulic pump which

supplies oil via hoses and pipes to the working

hydraulic cylinders. The system is steered by

electrical valves.

The hydraulic power unit with all details is built into

the lift's support frame. The control system is built

into a seperate box. Both systems are easy to reach

for service and maintenance.

The platform is supported by the lift arm which is

very strong and rigid. The underrun protection bar is

directly attached to the support frame. The platform

has a non-slip surface.

The lift arm lifting work is done by lift cylinders

which have built in safety valves for protection

against hose breakage. The lift cylinder circuit is

equipped with 1 or 2 electric safety valves, which are

leakproof. These safety valves can also act as an

extra transport lock for the platform. The valves are

built into the cylinders.

The platform's tilt function is also provided by

cylinders with similar design to the lift cylinders. Tilt

cylinders can have one speed operation. The tilt

cylinder circuit is also equipped with 1 or 2 electric

safety valves. Lifting and tilting up and down speeds

are xed by the pump capacity. Lowering speed are

controlled by a special constant ow valve. These

valve give the same speed independent of the load.

The cylinder piston rods are treated with carbon

nitriding which gives them very long life.

The hydraulic system is protected with a pressure

regulator when lifting or tilting up.

Note! This regulator does not prevent overload at

rest position or lowering.

The electric power is taken from the truck's ordinary

starter motor. Control current is taken from the dash

board. When the control current's isolator (cabin)

switch is o, the lift is "locked".

To save current the control current should be

switched o when the lift is not used.

The lift can also be operated from other, optional

units.

To ensure safe operation even with very long control

cables, the hydraulic unit is equipped with relays.

The relays situated in the electrical connection box

placed in the support frame steer current directly

from the main cable to the valves and the main

switch for the motor.

The electric motor is equipped with a thermostat

which breaks the current if the motor becomes

overheated. The motor will stop until it is cool again.

The platform can be tilted to all positions from

vertical to 10° below the horizontal. It has a

mechanical or electric lock which must be activate

during transport.

Hydraulic oil

A tail lift should operate just as well in tropical as

in arctic climates. Heat does not adversely eect

the hydraulic oil, however, low temperatures are

more critical. ZEPRO therefore supply a hydraulic

oil that meets the demands across the temperature

range. ZEPRO oil (art.no 21963 for 1 litre) is made

of a highly rened mineral oil, the lubricant additive

is free from zinc and gives good protection against

component wear. The hydraulic oil’s low temperature

properties and high viscosity index allow hydraulic

system start in a very cold climate and give reliable

functioning with varying temperature conditions. With

ZEPRO oil the hydraulic system also receives a very

good protection against corrosion.

ZEPRO also has a biologically degradable oil (art.

no 22235 for 1 litre) available which is based on

a synthetic base oil. This also provides very good

properties at low and high temperatures. It is even

liquid down to -50° C. Resistance to oxidation is

extremely good which gives long lifetime with longer

intervals between oil changes. Good ltration and

air seperation together with low density make the

oil easy to pump. This minimises risk for cavitation

and development of scum. Contact us for more

information.

2. General

Technical description

NB. Neither ATF nor HF oil should be used in the

ZEPRO hydraulic circuit as they can damage the

rubber in the sealing kits and reduce their lifetime.

2. General

ZHD = Standard model

Max lift capacity x 1 (kg)

Max lifting height -150 = 1500 mm

Cylindermodel, MA = Doubleacting Adjustable Tilt

Single acting one speed Lift

E.g. ZHD 3000 - 150 MA

_ _ _ _ _ _ _ _ _ _ _ _

Identicationslist

Some components of the tail lift must be manipulated by other lifting equipment during handling and

therefore could represent hazards if their weights exceed the equipment's permitted load. The following are

the ranges of weights for various heavy components.

Weights

Lift components (part of cpl. lift chassis).

Support frame ZHD 3000 132 kg

Lift arm ZHD 3000-150 63 kg

3-part underrun bar cpl. ZHD 3000-150 45 kg

Bracket cpl. pair ZHD 3000 58 kg

Lift cylinder ZHD 3000-150 15,8 kg/pce.

Tilt cylinder ZHD 3000-150 30,6 kg/pce.

Cpl. Lift chassis (without platform)

ZHD 3000-150 470 kg

Steel platforms

Steel platform 2000x2580 mm 378 kg

Steel platform 2500x2560 mm 466 kg

TP2

TP1

C = 360 C = 530 C = 715

TP1(mm) 238 229 214

TP2(mm) 3000 kg 852 861 876

2. General

ZHD 3000-150, steel platform 2000x2580 mm

Centre of gravity

Max load

280 Nm

80 Nm

280 Nm

180 Nm

ZHD 3000 (200 bar)

24 volt

200 A

2,1 A

0,75 A

0,85 A

1,5 mm2

35 mm2

50 mm2

170 Ah

18 Volt

7100

2. General

Max Power Consumption

Pump - Motor Unit

Magnet (hydraulic unit)

Magnet (electric safety valve)

Solenoid

Cable area:

Control cable

Main cable <8 m

Main cable 8-15 m

Main cable >15 m

Power source:

Min. capacity

Min. voltage

Torquevalues

Loading Diagram

2. General

C A D

715 207 742

680 193 783

630 178 834

580 165 877

530 155 915

480 143 947

430 126 975

360 105 1008

max 1500

max 785

244

214

194

ZHD 3000-150

1524

min 750 - max 930

1524

1970

2418

1443

994

245 245

A max

1037

max 550

100 385

350

617-817

133-301

3. Dimensions for installation

35 mm

Min 280

Min 20

Min 250

Min 20

Min D

Pict. 2

Pict. 1

Installation jig,

Art. no. 72650TL for ZHD 3000

Pict. 3

4. Installation support frame

Preparation/supportframe

Attention!Alsorefertothetruckmanufacturer´sinstructionsforauxiliaryequipment

1. Measure out and mark the centre point of the

truck's rear frame. See picture 1.

2. Fasten the jig with bolts or spot weld it to the rear

frame so that the middle points line up. See picture

3. Make the notches as required in the rear beam in

accordance with the measures on previous pages.

4. Place the support frame of the lift under the frame

of the truck and t the lift arms to the installation jig.

Use the specied platform pivot bolt.

5. Position the support frame as required under the

truck's chassis frame (a wheeled jack is a good aid).

See picture 3.

The support frame ought to be positioned as high as

possible. Note the measures on previous pages.

The support frame must be parallel with the chassis

frame, but it must not be pressed against the frame.

There must be some mm between.

If it is dicult to get the support frame into its right posi-

tion, loosen a hydraulic hose from one lift cylinder to let oil

or air out.

The brackets should be positioned according to picture

4. Slide the brackets over the support frame so that

the opening points towards the front of the vehicle see

picture 4. If adjustment is necessary, drill 16,5 mm holes

in the truck frame in the middle of the oval holes of the

bracket. Then fasten the brackets securely to the frame

(torque=180 Nm) with the delivered M16x60 8.8 screws.

Washers should be placed under the nuts. Bag 382, 31B.

See picture 4.

NB!Weldingonthemountingbracketsisnotallowed.

Install the u-prole end plate with the u pointing to the

front of the vehicle using the washers and nuts provided,

one plate for each mounting bracket, two nuts and two

washers for each plate (torque=280 Nm). After testing

the position of the lift relative to the chassis, drill the

remaining holes in the frame on each side and fasten the

brackets, min. 8 pcs. M16x60 8.8 180 Nm (this does not

include screws in oval holes).

NB. Do not run the lift up against the armstops during

installation before all the bolts between the mounting

brackets and vehicle frame are tightened.

Note! Please note that the space for the bracket requires

additional 35 mm between the frame of the truck and the support

frame.See pict. 4

Do not load the lift before all bolts are tightened.

Loosen the installation jig.

Pict. 4

Min 8 pcs.

M16x60 8.8

180 Nm

New hole

Install control units at suitable places, but the

position of the control unit should ensure that the

operator has a good view of the load, the working

area and the loading area, whilst maintaining a safe

distance from the risk zone between the platform

and the body. Note that all cables must be

connected from below so that water can´t get into

the units but condensation can drain out.

All control units must be connected in parallel.

The control cable is connected to the circuit card in

the connection unit (see electric schema).

Install the control current cable from the

dashboard of the truck according to the customers

requirements. The control current swich should

be located so it is possible to be reached from the

ground 10 A (24 V) fuse between the current source

and the switch.

The control current cable is connected to a xed

control unit. You can fasten the cable together with

the main cable to the hydraulic unit.

Connect the main power cable to the + pole of the

battery. The cable should be protected with a plastic

sheath. It must not be fastened together with brake

pipes or other electric cables of the truck. When

passing through holes the cables must be protected

with rubber bushings.

A 250 A (24 V) fuse is to be installed on the

main power cable running from the battery

compartment**. This acts to protect the electrical

systems from overloading and the risk of re.

If you have a spiral cable unit, its cable colours are

dierent (see electric diagram):

Check that the hydraulic unit is well earthed

according to truck manufacturer´s instructions

(earthing is made through leading in plate, se

picture).

If you must lead a spiral cable up through the oor

you must protect it with a sheath up from the oor.

If you need to use power from the circuit card +ve

connection point a fuse must be installed, eg.

overload alarm 7.5 Ampere.

Test run all functions from all control units.

Alarm for open platform

The alarm consists of a warning lamp (which should

be placed clearly visible in the driver cabin), which

illuminates when the ignition key is turned on,

and the lift platform is not pressed up against the

underside of the chassis

The device consists of:

*Pressure guard placed on the tilt cylinder circuit.

*Cable to the dash board

*Fuse

*Warning lamp 24 Volt

Alarm for open platform (trailer)

The alarm consists of a warning lamp (which should

be placed on the body of trailer, clearly visible so

that the driver can see it in the rear mirror), which

illuminates if the lift platform is not pressed up

against the underside of the chassis

The device consists of:

*Pressure guard placed on the tilt cylinder circuit.

*Cable to the warning lamp

*Fuse

*Warning lamp 24 Volt

5. Electrical installation

Positioning of control unit

NB. The quick connectors must be well protected

and should be positioned inside the vehicle chassis.

**Note! The fuse should be placed on a well

protected place and as near as possible to the

battery.

5. Elmontage

Routing of earth and supply cable to the lift.

Due to the risk of cables being pinched and / or

damaged which can lead to short circuits and cable

re, the earth and supply cable should be mounted

outside the clamping bracket (see photos above).

They must also be suciently far away from edges

so there is no risk for abrasion.

Also make sure that the routing of cables is done

with similar care to avoid damage from contact with

edges of the frame and other parts of the vehicle.

This will increase the life of the cables and reduce

the risk of unnecessary downtime.

Connection of non-original components on zepro

tail lifts

It has always been forbidden to connect foreign

equipment (both electric and hydraulic) on all

Zepro tail lifts. Using non-original components can

aect tail lift safety. If it's really important for you to

make such installations please check with the vehicle

manufacturers installation instructions and use the

trucks capabilities.

ZHD 3000-150 MA

Denna ritning är Z-Lyftens egendom och skyddad enligt internationellt gällande lag för copyright

och får ej utan Z-Lyftens skriftliga medgivande kopieras, delges eller obehörigen användas.

This drawing is property of Z-Lyften Produktion AB and is loaned subject to return upon demand. It is not

to be reproduced or used directly or indirectly in any way detrimental to the interest of Z-Lyften Produktion AB.

Där annat ej anges / Drawing

interpretation unless otherwise specified.

All measures intends finished product

Alla mått avser färdig produkt.

Benämning/Title

Material

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

För denna ritning gäller

IS0 toleranser SMS ritregler

Toleranser/

Tolerance:

Ytjämnhet/

Surface finish:

Svets/Welding:

1 /1

Ritad/Drawn

A HIAB brand - part of Cargotec Corporation

Samm./Used on:

Rev./

Rev.Tag Datum/

Date Ändring/

Rev. number

Införd av/

Revised by Kontrol./

Checked

Godk./

Approved

A 2011-04-16 6417 MB MB CL

B 2012-11-12 6698 ME MB CL

C 2013-03-14 6774 TH FN CL

D 2014-04-04 6954 TH

176

E 2014-06-25 7025 TH 207 TH

F 2016-02-22 7227 MB - PS

G 2018-12-19 7608 OE - MK

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

2H1

2H2

Lock

Ctrl 6

Out

GND/Spk-

LLED/Spk+

Ctrl 5

Indication

Se appendix in

installation manual

Outputs

Sensors

GND

6. Electric and hydraulic diagram

Denna ritning är Z-Lyftens egendom och skyddad enligt internationellt gällande lag för copyright

och får ej utan Z-Lyftens skriftliga medgivande kopieras, delges eller obehörigen användas.

This drawing is property of Z-Lyften Produktion AB and is loaned subject to return upon demand. It is not

to be reproduced or used directly or indirectly in any way detrimental to the interest of Z-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 CL

D 2014-04-04 6954 TH

176

E 2014-06-25 7025 TH 207 TH

F 2016-02-22 7227 MB - PS

G 2017-08-08 7435 ME 735 PS

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

2H1

2H2

Lock

Ctrl 6

Out

GND/Spk-

LLED/Spk+

Ctrl 5

Indication

Se appendix in

installation manual

Outputs

Sensors

GND

H 2018-12-18 7608 OE - MK

GND

ZHD 3000-150 MA, with hydraulic Auto-tilt

6. Electric and hydraulic diagram

Cabin switch, Alarm for open platform

6. Electric and hydraulic diagram

Pa-

Sensor Power

Di4

Cabin switch, Alarm for open platform

when control unit has main switch

Control Power

Ps1

Tiltcylinder

Pump Unit

Pa-

Control Power

Tiltcylinder

Pump Unit

Gnd

ZEPRO recommends that a strobe lamp/light placed on the trailer body exterior represents the alarm indica-

tion, clearly visible so that the driver can see it in the mirror

The light must be of amber color.

Connect the lamp/indicator according to the electric diagram.

3A fuse connected between the circuit card and the pressure switch.

Alarm for open platform (trailer)

6. Electric and hydraulic diagram

Gnd

Sensor Power

Gnd

Sensor Power

3-button control unit with main switch and selector switch

Withoutcabinswitch

6. Electric and hydraulic diagram

3-button remote control unit with spiral cable

3-button control unit

Nr./No. Färg/Color/Farbe

1. Gul / Grön, Yellow / Green, Gelb / Grün

2. Blå / Blue / Blau

3. Brun / Brown / Braun

4. Svart / Black / Schwarz

5. Grön / Green / Grün

6. Vit / White / Weiß

7. Röd / Red / Rot

8. Gul / Yellow / Gelb

9. Grå / Grey / Grau

10. Orange / Orange / Orange

7. Connection unit

Operating information

All the lift's functions are controlled and monitored through the connection unit and its circuit board. The

circuit board is equipped with an alphanumerical display with a ashing light and 2 red LEDS. These display

current operating information. In the event of any operational disturbances, fault codes are displayed to

facilitate troubleshooting.

The display indicates:

- Function display

- Fault display

- Program conguration.

Theashinglightindicates:

- Supply voltage

- O: 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 1

Ai 2

Di 1

Di 2

Di 3

Di 4

Di 5

Di 6

PA-

PA+

CSPWR

2H1

2H2

Lock

Ctrl 6

Out

GND

LLED

Ctrl 5

Outputs

Sensors

Display

Flashing light

LED 2

LED 1

Information codes

Codes are shown on the display in a sequence. First a letter for identication of information, followed by

gures or segments for further information and then ending with a pause:

When the CS (cabin switch) is switched on, the current program conguration (P) is displayed rst, followed

by conguration number.

The number of volts detected is then displayed and, after this, the current software

version (J), followed by version number.

As long as no control device is used, a scrolling sequence is then displayed, with sensor indication (C), followed

by 0-6 segments showing which sensors have a signal.

When a control device is used, the control device being used (1-7) is displayed, followed by which button has

been pressed,

segments B, C, E or X (X symbolises the 4th button on the respective control device (2h1 for xed

control device 1,

2h2 for xed control device 2, lock knob for radio control device and coil control device).

The control devices are symbolised by the gures 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 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 device, its number (1-7) will ash on the display. This primarily applies to radio and coil

control devices as control devices have such a short locking period that there is hardly time to see the indication.

Coil and radio control devices can be equipped with a locking function. Once the control device has been used,

the control system is locked for the current control device until it is unlocked manually from the respective control

device's deactivation button. With some congurations, however, the coil control device can, for safety reasons,

always tilt the platform down in the event of the operator getting shut inside.

7. Connection unit

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Zepro ZHD 3000-150 Installation guide

Brand: Zepro

Model: ZHD 3000-150

Type: Installation guide

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Zepro ZHD 3000-150 Installation guide

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