Zepro ZHD 3000-150 Installation Instruction
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Zepro ZHD 3000-150 Installation Instruction

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Z-LYFTEN PRODUKTION AB
INSTALLATION INSTRUCTION
Sales
Mossvägen 8, 641 49 KATRINEHOLM, SWEDEN
Telephone:
+46 150 - 489550
Telefax:
+46 150 - 489551
E-mail:
zepro@zepro.com
Internet:
www.zepro.com
ZHD 3000-150
Factory
Allévägen 4, 840 73 BISPGÅRDEN, SWEDEN
Telephone:
+46 696 - 17200
Telefax:
+46 696 - 17242
E-mail:
info@zepro.com
Internet:
www.zepro.com
72689TL
2020-05-14

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  • Page 1 Z-LYFTEN PRODUKTION AB 72689TL INSTALLATION INSTRUCTION ZHD 3000-150 2020-05-14 Sales Factory Mossvägen 8, 641 49 KATRINEHOLM, SWEDEN Allévägen 4, 840 73 BISPGÅRDEN, SWEDEN Telephone: +46 150 - 489550 Telephone: +46 696 - 17200 Telefax: +46 150 - 489551 Telefax: +46 696 - 17242 E-mail: zepro@zepro.com...

  • Page 3: Table Of Contents

    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.

  • Page 4: Ce Marking

    1. CE marking Since 1/1/1995 ZEPRO tail lifts sold to the European Welding is not allowed unless specifically market are stamped with a CE mark. This is the recommended by the manufacturer. manufacturer's guarantee that the product conforms to the European Machinery Directive.

  • Page 5: General

    ZEPRO oil (art.no 21963 for 1 litre) is made The cylinder piston rods are treated with carbon of a highly refined mineral oil, the lubricant additive nitriding which gives them very long life.

  • Page 6: Identifications List / Weights

    ZHD 3000-150 470 kg 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 Steel platforms Lift cylinder ZHD 3000-150 15,8 kg/pce. Steel platform 2000x2580 mm...

  • Page 7: Center Of Gravity

    2. General Centre of gravity Max load ZHD 3000-150, steel platform 2000x2580 mm C = 360 C = 530 C = 715 (mm) (mm) 3000 kg...

  • Page 8: Max Power Consumption / Torque Values

    2. General Max Power Consumption ZHD 3000 (200 bar) 7100 24 volt Pump - Motor Unit 200 A Magnet (hydraulic unit) 2,1 A Magnet (electric safety valve) 0,75 A Solenoid 0,85 A Cable area: Control cable 1,5 mm Main cable <8 m 35 mm Main cable 8-15 m 35 mm...

  • Page 9: Loading Diagrams

    2. General Loading Diagram...

  • Page 10: Dimensions For Installation

    3. Dimensions for installation ZHD 3000-150 max 550 1008 1037 1443 1524 min 750 - max 930 1524 1970 2418 617-817 A max...

  • Page 11: Installation Support Frame

    4. Installation support frame Attention! Also refer to the truck manufacturer´s instructions for auxiliary equipment If it is difficult to get the support frame into its right posi- Preparation/support frame tion, loosen a hydraulic hose from one lift cylinder to let oil 1. Measure out and mark the centre point of the or air out.

  • Page 12: Electrical Installtion

    5. Electrical installation Install control units at suitable places, but the If you have a spiral cable unit, its cable colours are position of the control unit should ensure that the different (see electric diagram): operator has a good view of the load, the working area and the loading area, whilst maintaining a safe Check that the hydraulic unit is well earthed distance from the risk zone between the platform...

  • Page 13: Cable Routing Of Earth And Supply Cable To The Lift

    It has always been forbidden to connect foreign equipment (both electric and hydraulic) on all Zepro tail lifts. Using non-original components can affect 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.

  • Page 14: Electrical And Hydraulic Diagram

    6. Electric and hydraulic diagram ZHD 3000-150 MA...
  • Page 15 6. Electric and hydraulic diagram ZHD 3000-150 MA, with hydraulic Auto-tilt...
  • Page 16 6. Electric and hydraulic diagram Cabin switch, Alarm for open platform Sensor Power Cabin switch, Alarm for open platform when control unit has main switch Tiltcylinder Control Power Pump Unit...
  • Page 17 6. Electric and hydraulic diagram Alarm for open platform (trailer) 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.
  • Page 18 6. Electric and hydraulic diagram Without cabin switch 3-button control unit with main switch and selector switch 3-button control unit Nr. /No. Färg / Color/Farbe Gul / Grön, Yellow / Green, Gelb / Grün Blå / Blue / Blau Brun / Brown / Braun Svart / Black / Schwarz Grön / Green / Grün Vit / White / Weiß...

  • Page 19: Connection Unit

    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 flashing light and 2 red LEDS. These display current operating information.
  • Page 20 7. Connection unit Information codes Codes are shown on the display in a sequence. First a letter for identification of information, followed by figures or segments for further information and then ending with a pause: When the CS (cabin switch) is switched on, the current program configuration (P) is displayed first, followed by configuration number.
  • Page 21 7. Connection unit Information codes Code Code Identification Code 1 Information Other 00–99 Cancelled configuration (Program Dividers configuration) 12/24 Number of volts detected Version number 01–99 Software version Fixed light (1-7) displays active control 1.-7 (Fixed light) device during operation. Active control device while operating Segments B, C, E or X are illuminated de-...
  • Page 22 7. Connection unit Fault codes If a fault arises, the fault code is shown in the display in the form of a letter for identifying the fault, followed by numbers and/or number segments for further information, followed by sensor indication (C) in accord- ance with the previous page.
  • Page 23 7. Connection unit All fault codes can be reset manually by switching On/Off the CS (cabin switch) Fault codes F0-F7 and U0-U7 are reset automatically if the function in question is running (function verified). Fault codes L and H are reset automatically if the battery voltage becomes correct.
  • Page 24 7. Connection unit Function schema (also refer to corresponding. el & hyd. diag.) ZHD 3000-150 MA ZHD 3000-150 MA, with hydraulic Auto-tilt (config 1, art. no. 34301TL) Function Signal in Signal Out Notes Lift U0+U2 Lower U1+U2+U4 Lower E+Di3 U1+U2+U4+U5 Tilt up U0+U3 Tilt down...
  • Page 25 7. Connection unit, hydraulic unit VENTILHUS VALVE BODY VENTIL GEHAUSE TANKLOCK FILLER CAP TANKDECKEL TANKLÅDA CHASSIS WITH TANK ÖLTANK SOLENOID SWITCH MAGNETSCHELTER MOTOR KRETSKORT CIRCUIT CARD GETRUCTE SCHALTUNG KOPPLINGSENHET CONNECTION UNIT KOPPLUNGS EINHEIT...

  • Page 26: Installation, Miscellaneous

    8. Installation, continued Installation of adjustable 3 parts bumper bar Install the bumper bar temporarily. Check that it is positioned within applicable dimensions. Max 550 mm between bar and ground when vehicle is unloaded. Maximum 375 mm horizontally from the outermost part of the lift platform to the bumper bar.
  • Page 27 8. Installation, continued Installation of platform Install platform onto the lift arms and tilt cylinders to the platform. Use axles and support wheels provided. Axles is locked with eye bolt incl. screw M12x25 (80Nm), bag 380 and 381. NOTE! O-rings must be installed at the same time as axles.
  • Page 28 Pict. 14 Transport lock For CE marked lifts with 1000kg max lifting capacity and over ZEPRO provides platforms without transport lock. For other lifts transport lock are installed on the platforms right side. Electric safety valves can serve as transport locks for platforms.
  • Page 29 8. Installation, continued NB. Do not adjust the tilt cylinders before they are Pict. 17 installed onto the platform. Tilt cylinders are pre- adjusted at the factory. 1. Loosen rubber bellows. 2. Assemble only one tilt cylinder in the platform. 3.
  • Page 30 8. Installation, continued Adjustment of tilt down angle. NOTE! To have the taillift to comply with CE requirements and be safe, it is required that tilt down angle is adjusted to a maximum of 10º. NOTE! It is necessary to first adjustment the 90º tilt angle up against the body before adjusting tilt down angle.

  • Page 31: Important Information

    9. Important information Repainting NB. If the cylinders are to be repainted, ensure that the Replace the transport plug cylinder push rod and cover are not painted (this can During installation the oil tank transport plug should be damage the seals/gaskets). This also applies to rubber removed and replaced 54853 54853...

  • Page 32: Markings, Positioning Of Decals On Lift

    10. Markings, decals (see pictures on next page) An operating instructions decal should be placed next to the main control unit. A danger zone decal, warning of the danger area between the platform and the vehicle bed is to be The loading diagram plates should be placed near affixed on the inside of the vehicle body near to the the control unit and in a clearly visible position on...
  • Page 33 10. Markings, decals...

  • Page 34: Post Installation Maintenance

    11. Maintenance Grease all bearings and platform locks with LE lubricant 4622 or equivalent. Grease at least 4 times / year Right liftcylinder, lower bearing. Left liftcylinder, lower bearing. Right liftcylinder, upper bearing. Left liftcylinder, upper bearing. The hydraulic unit tank is filled with a mineral based hydraulic oil (art.no 21963 for 1 litre.) or a biodegradable synthetic oil (art.no 22235 for 1 litre).

  • Page 35: Testing The Lift

    12. Load testing the tail lift Static loading (Test load 1,25 x tail lift loading Testing and verification of the tail lift. capacity). For tail lifts with load centre of 1000 Carried out in accordance with the installation instruction and delivery check list. Capacity Load 2000 kg Load 2500 kg...
  • Page 36 12. Load testing the tail lift Dynamic load testing Test of safety functions Test with nominal load The tail lifts safety functions must be tested Place a test load on the platform according to the Check: table for the respective tail lift model and lifting capacity.

  • Page 37: Dismantling

    13. Dismantling 1. In the event of dismantling the tail lift from the 10. Check that the battery is disconnected. Unscrew vehicle, in the case of transferring it to another the cable from the battery to the tail lift and all the vehicle, for storage or for modification please follow cables and wires between the hydraulic unit and the these instructions.

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Zhd 3000-150 ma

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