Zepro ZL 1500-155 Installation Instructions Manual

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

Z 2500-130/150Contents

3www.zepro.com

Contents

1 Introduction ...................................................................................................... 6

1.1 Important .....................................................................................................6

1.2 Pagenavigaon.............................................................................................6

1.3 CE marking .................................................................................................... 7

1.5 Idencaon ................................................................................................8

1.4 Hydraulicuid ...............................................................................................8

2 Safety rules ........................................................................................................ 9

2.1 Repainng ................................................. ....................................................9

2.2 Transport plug ............................................................................................10

2.3 Moving parts - free movement ................................................................... 10

2.4 Third-partyequipmentmustnotbeaached ............................................11

2.5 Installaon ..................................................................................................11

3 Installation workflow ....................................................................................... 12

3.1 Installing the support frame .......................................................................12

3.2 Electricalconnecons .................................................................................12

3.3 Installingtheplaorm ................................................................................12

3.4 Installingcylinders ......................................................................................12

3.5 Aachingdecals .......................................................................................... 12

4 Calculating the installed dimensions ................................................................. 13

4.1 C 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lighng/footcontroller ................................................................21

6.5 Mainpowercable .......................................................................................23

6.6 Installaonofmainfuseonvehicleswithoutconneconpoint .................24

6.7 Cable lead-through .....................................................................................25

6.8 Underrunprotecon ..................................................................................26

6.9 Armstops ....................................................................................................28

6.10 Angle sensor ...............................................................................................28

6.11 Sealing strip (horizontal) ................................................. ............................29

6.12 Sealingstrip(vercal) .................................................................................29

6.13 Plaorm ......................................................................................................30

6.14 Purgingthecylinders ..................................................................................36

6.15 Transportlock .............................................................................................36

7 Temporary operation of lift............................................................................... 37

7.1 Connecon .................................................................................................37

7.2 Operaon ...................................................................................................37

7.3 Disconnecon .............................................................................................37

8 Hydraulic unit and control card ......................................................................... 38

8.1 Accessingthehydraulicunitandcontrolcard ............................................39

8.2 Connecngcontroller .................................................................................40

Z 2500-130/150

4

Contents

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9 Electrical

and

hydraulic drawings ...................................................................... 41

9.1 Z2500-130/150MAwithelectricalautolt ................................................41

9.2 Z2500-130/150MA ....................................................................................42

9.3 Z2500-130/150DA .....................................................................................43

9.4 Connecngwarninglighngandfootcontrols...........................................44

9.5 Liwithoutinclinometer ............................................................................45

9.6 Connecngcabinswitchandopenplaormalarm ....................................46

9.7 Connecngcontroldevice ..........................................................................47

10 Functional description Z 2500 MA Autotilt (standard) ....................................... 48

10.1 Sensors/Inputs ............................................................................................ 48

10.2 Funconalschemacdrawing ....................................................................49

10.3 Limitaonofcontrolleruse(Tiltup/downandopening/closing) ...............51

10.4 QuickOpeningZone ...................................................................................51

10.5 Footcontrolsandwarninglights ................................................................52

11 Functional description Z 2500 MA .................................................................... 53

11.1 Sensor ......................................................................................................... 53

11.2 FunconalschemacdrawingMA,cong14 .............................................54

11.3 Restriconinuseofcontroldevice ............................................................56

11.4 Quickopening-acvaonzone .................................................................56

12 Functional description Z 2500 DA ..................................................................... 57

12.1 Sensor ......................................................................................................... 57

12.2 Funconalschemacdrawing,cong16 ...................................................58

12.3 Restriconinuseofcontroldevice ............................................................60

12.4 Quickopening-acvaonzone .................................................................60

13 Connection unit ................................................................................................ 61

13.1 Power save mode .......................................................................................61

13.2 Operanginformaon ................................................................................61

14 Marking and decals .......................................................................................... 67

14.1 Summary ....................................................................................................67

14.2 Load diagram ..............................................................................................68

14.3 Idencaonplate.....................................................................................68

14.4 Work area ..................................................................................................68

14.5 Driver’sinstrucons .................................................................................... 69

14.6 Danger area ...............................................................................................69

14.7 Warning tape .............................................................................................69

14.9 CE marking .................................................................................................. 70

14.8 Warningags .............................................................................................70

15 Lubrication and fluid level check ....................................................................... 71

15.1 Lubricaon .................................................................................................. 71

15.2 Fluidlevelcheck .........................................................................................71

16 Testing and verification .................................................................................... 72

16.1 Stacloadtest ............................................................................................72

16.2 Dynamicloadtest. ......................................................................................73

16.3 Testofsafetyfuncons ............................................................................... 73

17 Disassembly ..................................................................................................... 74

Z 2500-130/150Contents

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18 Specifications .................................................................................................. 75

18.1 Weights ...................................................................................................... 75

18.2 Maximumpowerconsumpon-

Minimumrecommendedconductorcross

seconalarea ................................76

18.3 Baerymaintenance ..................................................................................76

18.4 Loading diagram .........................................................................................77

18.5 Tightening torque .......................................................................................78

Z 2500-130/150

6

Introducon

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1 Introducon

1.1 Important

The following “warning markings” appear in the installation instructions and are intended to draw your attention to

circumstances potentially causing unwanted situations, near misses, personal injury or damage to the product, etc.

Take care.

Risk of damage to the product.

NOTE.

Take extra care. Risk of personal injury or damage to the product and the surroundings.

m WARNING!

1.2 Page navigaon

Each page in the installation instructions has a page header and a page footer containing the following information:

• Chapter

• Product

• Page number

• Company name

Page header:

The page header, at the top of the page, shows which chapter the visited page belongs to, and what product

the installation instructions apply to.

Chapter Product

Introduction Z 2500-130/150

Page footer:

The page footer, at the bottom of the page, shows the current page number and the company name.

Page no. Company

6 www.zepro.com

Z 2500-130/150Introducon

7www.zepro.com

1.3 CE marking

Z-Lyften tail lifts on sale on the European market have been CE marked (CE stands for Conformité Européenne)

since 1/1/1995. The manufacturer guarantees that the product complies with the EU Machinery Directive.

The aim of the Machinery Directive is to increase the safety of products throughout Europe.

There are some basic general rules that must be followed before Z-Lyften products are installed.

Follow the installation instructions. If it is not possible to follow the installation instructions or if changes must

be made, the changes must be approved by 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 or approval. To retain a valid CE marking for the product, it is essential to contact Z-Lyften.

Welding is not necessary except where recommended by the manufacturer.

To improve safety we supply decals for the lift that are easy to understand regardless of the language. Make

sure these decals are attached so that the information they contain can be seen by the lift operator.

Position control devices so that the operator is in the safest possible location and has a clear view of the load,

the tail lift and the surrounding area. Follow the driver’s instruction manual when using the control device and

its functions.

Z 2500-130/150

8

Introducon

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1.5 Idencaon

Z = Standard model

Max. lifting capacity x 1 (kg)

Max lifting height -130 = 1300 mm

-150 = 1500 mm

Cylinder model, MA = Double acting Adjustable Tilt

Single acting Single speed Lift

DA = Double acting Adjustable Tilt

Double acting Single speed Lift

E.g. Z - 2500 - 130 MA

_ _ _ - _ _ _ _ - _ _ _ _ _

1.4 Hydraulic uid

A tail lift must work just as well in tropical heat as in the Arctic cold. The heat is no problem for the uid. Cold,

on the other hand, is a big challenge for hydraulic uid. That is why Z-Lyften chose a hydraulic fuel that can

cope with all these conditions. Our hydraulic uid (product no. 21963, 1 litre) is made of highly rened mineral

oil. The anti-wear additives are zinc-free and provide excellent wear protection.

The special temperature properties of the hydraulic uid and the high viscosity index mean that the hydraulic

system can be started in cold weather and runs reliably in uctuating operating temperatures. Our hydraulic

uid also provides excellent corrosion protection for the hydraulic system.

We also offer a biodegradable hydraulic fluid (environmental fluid) as an option (product no. 22235,

1 litre) made of a synthetic base oil called polyalphaolefin, which is biodegradable. This base oil

has outstanding properties at low and high temperatures. The fluid stays liquid down to tempera-

tures as low as -50°C. Oxidation stability is very good, resulting in a long service life with longer re-

placement intervals. The fluid is easy to pump thanks to good filtering and air separation properties

and low density. This minimises the risk of cavitation and foaming. Contact us for more information.

So-called ATF uid or HF uid cannot be used with Z-Lyften. These uids aect the rubber in the gaskets

and seals and shorten service life.

NOTE.

Z 2500-130/150Safety rules

9www.zepro.com

2 Safety rules

2.1 Repainng

Piston rods and cylinder covers must not be paint-

ed. Painting could damage 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 signicantly im-

pair durability.

NOTE.

Image 1. Piston rods, cylinder covers and

boots must not be painted/coated

Image 2. Hydraulic hoses must

not be painted/coated

Image 3. Cables must not be painted/coated

Z 2500-130/150

10

Safety rules

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2.2 Transport plug

When the lift is installed, the transport plug in the

hydraulic unit must be removed and replaced with

the normal tank cap supplied with the hydraulic

unit.

NOTE.

54

8

5

3

2.3 Moving parts - free movement

When the nal inspection* takes place, the space

occupied by the moving cylinders must be cleared

and made safe. There is a risk of collision between

the cylinder 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 nal inspection must be carried out with the

platform at and tilted down 10°. The clearance

from the closest part of the cylinder must be at

least 40 mm.

m WARNING!

The platform must not be tilted down more than

10° from the horizontal.

m WARNING!

min. 40 mm

10º

Image 4. Replace the transport plug with

the normal tank cap

Image 5. Clearance to the closest part of

the cylinder must be at least 40 mm

Image 6. The platform must not be tilted

down more than 10° from the horizontal

Z 2500-130/150Safety rules

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2.4 Third-party equipment must not be aached

You must not attach third-party equipment (electric or hydraulic) to Zepro tail lifts. Attaching third-party

equipment may interfere with the lift system and the safety functions. Risk of 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.

m WARNING!

2.5 Installaon

The platform must not be installed so it cannot reach ground level.

m WARNING!

Zepro tail lifts are only approved for installation with Zepro installation kits.

m WARNING!

All specied torque values apply for use with a screw or impact wrench with torque control.

Torque distribution max ± 5%.

NOTE!

Z 2500-130/150

12

Installaonworkow

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3 Installaon workow

3.1 Installing the support frame

• Calculating the installed dimensions

• Attaching the mounting jig to the rear beam

• Aligning the support frame

• Mounting chassis brackets

• Detaching the mounting jig

3.2 Electrical connecons

• Installing the control devices

• Installing the control device cables

• Installing the main power cable

3.3 Installing the plaorm

• Installing the platform

• Installing seals and end stops

• Installing the armstops

3.4 Installing cylinders

• Adjusting tilt cylinder

• Test running

3.5 Aaching decals

Z 2500-130/150Calculangtheinstalleddimensions

13www.zepro.com

4 Calculang the installed dimensions

For easier installation it is useful to calculate and specify the necessary dimensions in advance. Determine the

C dimension rst, then obtain the other dimensions from the relevant table. You should try to place the lift as

high as possible within the specied C dimension in the table.

4.1 C dimension

The C dimension is the distance between the top of the support frame and the vehicle oor level. This dimen-

sion governs how far the lift needs to be installed under the vehicle body (D dimension) and the space there

will be between the lift arms in the upper position and the vehicle oor level (A dimension).

4.2 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

support frame (in the direction of the vehicle). Once the C dimension is determined, the D dimension can be

obtained from the table.

4.3 A dimension

The A dimension is the space provided for the rear beam, i.e. the space there will be between the lift arms and

the vehicle oor with the lift in the raised position. The A dimension depends on the C dimension.

4.4 H dimension

The H dimension is the height from the ground (unloaded) to the vehicle oor level. The H dimension must not

be greater that the maximum lifting height of the lift. The platform must always be able to reach ground level.

Z 2500-130/150

14

Calculangtheinstalleddimensions

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Image 7. Z 2500-130

Image 8. Z 2500-150

C A D

610 202 685

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

430 143 969

360 134 1002

max 1500

785

220

214

194

C

A

40 D

Image 9. ZAEHD 150/200

1524

1010

min. 750 - max. 930

1509

1966

2411

34

35

62

100 385

350

133-301

617-817

Z 2500-130/150Rearbeamcut-outs

15www.zepro.com

5 Rear beam cut-outs

It is often necessary to create cut outs in the rear beam to provide space for the platform arms when the plat-

form is in the upper 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 must be

centred on the rear beam, i.e. both cut outs must be an equal distance from the mid-point of the beam.

2. Cut along the markings.

3. Grind away any burrs or sharp edges.

Image 10. Rear beam cut-outs

994

245 245

A max

Z 2500-130/150

16

Installaon

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6 Installaon

Also consult the vehicle manufacturer’s body in-

structions and Zepro’s instruction booklet before

installation.

NOTE.

Zepro tail lifts are only approved for installation

with Zepro installation kits.

m WARNING!

6.1 Support frame

1. Measure and mark the midpoint of the rear beam of the

vehicle. See Image 11.

2. Bolt or spot-weld the mounting jig

to the rear beam,

so that both

mid-points are aligned. See Image 12

.

3. Position the support frame under the vehicle chassis.

4. Temporarily connect the control card to enable the

lift functions, see section "7 Temporary operation

of lift" on page 37.

5. Raise the lift arms to the highest position.

6. Attach the lift arms 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 specied 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 oor of the vehicle body and must

not be in contact with the vehicle chassis; there

must be a few millimetres of play. If necessary

adjust the angle of the arms by carefully operat-

ing the lift.

8. Install the brackets on the support frame so that its

opening is facing towards the front of the vehicle,

and adjust the position of the frame so they are in

contact with the vehicle chassis.

Image 11. Measure and mark the midpoint of

the rear beam of the vehicle.

Image 12. Bolt or spot-weld the

mounting jig to the rear beam

Art. nr. 57370TL for Z 2500

Image 13. Mounting jig,

Image 14. Install the U-profile with as-

sociated washers and nuts

Z 2500-130/150Installaon

17www.zepro.com

9. Install the U-prole with associated washers and nuts,

but do not tighten these. Screw on the nuts alternately

until the U-prole is aligned in contact with the frame,

see Image 14.

10. When installing on a frame without pre-drilled holes,

install rst

with

a screw in the brackets’ slot-shaped

holes. On the vehicle chassis, mark the middle of the

brackets’ slot-shaped holes and then drill Ø14 mm

holes in the frame, see Image 31.

11. Bolt the brackets securely on the outside of the vehicle

chassis. U

se M14x45

bolts and install the associated

washer and nut on the inside of the vehicle chassis.

Install the bolts but do not tighten.

12. Check and perform ne adjustment regarding the posi-

tion of the lift. Then tighten the bolts with a torque wrench.

Tightening torque: 120 Nm.

13. Using a torque wrench, tighten the bolts holding the

U-proles. Tightening torque: 280 Nm.

14. D

rill holes in the vehicle chassis for mounting

bolts, Ø14 mm. Drill in the 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 bolt that was

installed initially in the slot-shaped hole may not

be included in this gure. If necessary, this bolt can

now be moved to one of the outer holes, see illustra-

tion. Then tighten the bolts with a torque wrench.

Tightening torque: 120 Nm.

Welding is not permitted on the chassis brackets.

Do not move the lift all the way to the armstops or

with the platform tted before all the bolts are fully

tightened against the chassis.

Do not place the lift under load until:

· the correct number of bolts have been installed

and torque-tightened.

· the vehicle body is installed to reinforce the truck

chassis.

NOTE.

15. Remove the mounting jig.

Min. 260

Min. 20

Min. 180

35 mm

Min. 20

Min. D

D

Min. 6 pcs.

M14x45 10.9

120 Nm

New hole

Image 15. The chassis bracket requires

at least 35 mm clearance between ve-

hicle chassis and support frame

Image 16. Install the chassis bracket

with at least six M14x45 10.9 bolts

When installing on chassis with pre-drilled holes, go

directly to point 16.

Z 2500-130/150

18

Installaon

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16. Bolt the brackets securely on the outside of the

vehicle chassis. Install in the slot-shaped holes

with at least 6 screws. Use suitable bolts (durabil-

ity equivalent to M14 10.9 or higher) and install

the

associated

washer and nut on the inside of the

vehicle chassis. Install the bolts but do not tighten.

See Image 17.

17. Check and perform ne adjustment regarding the

position of the lift.

Then tighten the bolts with a

torque wrench.

Tightening torque: Standard for

selected screw.

18. Using a torque wrench, tighten the bolts holding the

U-proles. Tightening torque: 280 Nm.

19. D

rill holes in the 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 the vehicle chassis. See Image 17.

Tighten the bolts with a torque wrench. Tightening

torque: Standard for selected screw.

Welding is not permitted on the chassis brackets.

Do not move the lift all the way to the armstops or

with the platform tted before all the bolts are fully

tightened against the chassis.

Do not place the lift under load until:

· the correct number of bolts have been installed

and torque-tightened.

· the vehicle body is installed to reinforce the

truck chassis.

NOTE.

20. Remove the mounting jig.

When installing on chassis with pre-drilled holes

Image 17. Installing the chassis bracket on ve-

hicle chassis with pre-drilled holes

Z 2500-130/150Installaon

19www.zepro.com

6.2 Control power cable

See also the vehicle manufacturer’s electrical

instructions.

NOTE.

1. If the control power cable is not pre-routed, e.g.

VDHH, route the control power cable from the

driver’s cabin to the lift.

The cable must be protected with rubber grommets

when it passes through beams or walls. If there are

quick connectors, make sure they are eectively

protected from moisture and dirt.

NOTE.

2. Connect the control power cable to the cabin switch

(CS) on the vehicle instrument panel. Connect to

the on-board electrical system via a 10 A (24 V),

15 A (12 V) fuse according the customer’s wishes.

See the connection diagram "9.5 Lift without incli-

nometer" on page 45.

Image 18. Quick connectors must be well protected

Z 2500-130/150

20

Installaon

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6.3 Control devices

If the vehicle is equipped with two-handed grip this

means that the operator must use both hands to be

able to operate the loading platform, while this protects

the operator from pinch point injuries.

1. Fit the control devices in the desired locations.

They must be positioned so that the operator is in

the safest possible location and has a clear view

of the load, the tail lift and the surrounding 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 illustration 23

.

All cable inlets must be pointing downwards.

NOTE.

3. The control device’s cable is connected to the

control card.

Image 19. Installing control de-

vice with two-handed grip.

A controller must always be tted on the side that

is facing away from trac in motion. If there is a

need for a controller on the opposite side, a fur-

ther controller must therefore be tted. Fitting on

the other side involves increased risk of injury.

m WARNING!

Image 20. Installing control device

Min. 260 mm.

300 - 600 mm.

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