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Summary of Contents for Zepro ZHD 2500-130
- Page 1 Installation Instructions Tail Lift ZHD 2500-130/150 ZEPRO Tel.: +46 (0)10-459 05 00 E-mail: zeprotech@hiab.com zepro.com 55987TL 2021-05-04...
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Page 3: Table Of Contents
Contents ZHD 2500-130/150 Contents Introduction ..................... 5 Important ....................5 CE marking ..................... 6 Product approval ................... 6 Hydraulic oil .................... 6 Guarantee ....................6 1.6 Identification ................... 7 Safety rules ....................... 8 Repainting ....................8 Transport plug..................9 Moving parts - free movement ..............9 Third-party equipment must not be attached ........ - Page 4 Contents ZHD 2500-130/150 Hydraulic unit and control card ..............34 Electrical and hydraulic diagrams ..............35 ZHD 2500 NN ..................35 ZHD 2500 DVx4 NN ................36 ZHD 2500 DVx4 CE ................37 ZHD 2500 Hydraulic autotilt NN ............38 Connection of connection card to control card ........
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Page 5: Introduction
Introduction ZHD 2500-130/150 Introduction Important The following “warning markings” appear in the 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. NOTE. Take care. Risk of damage to the product. -
Page 6: Ce Marking
Properly assembled, this product meets relevant requirements according to EN 1756-1:2001 + A1:2008. Hydraulic oil If the hydraulic oil needs to be replenished, only the oil recommended by ZEPRO is permitted to be used. Hydraulic systems with hydraulic oil tanks without labelling are only permitted to be filled with highly refined mineral oil (art. no. 21963, 1 litre). -
Page 7: Identification
Introduction ZHD 2500-130/150 Identification E.g. ZHD 2500 - 130 MA _ _ _ _ _ _ - _ _ _ _ _ Identification list ZHD = Standard model ZHDL = Wide frame, wide lift arm Max. lifting capacity x 1 (kg) -
Page 8: Safety Rules
Safety rules ZHD 2500-130/150 Safety rules Repainting NOTE. 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 significantly im- pair durability. -
Page 9: Transport Plug
Safety rules ZHD 2500-130/150 54853 Transport plug NOTE. 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. Image 4. Replace the transport plug... -
Page 10: Third-Party Equipment Must Not Be Attached
Third-party equipment must not be attached WARNING! 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-... -
Page 11: Installation Workflow
Installation workflow ZHD 2500-130/150 Installation workflow 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 Electrical connections •... -
Page 12: Calculating The Installed Dimensions
Calculating the installed dimensions ZHD 2500-130/150 Calculating the installed dimensions For easier installation it is useful to calculate and specify the necessary dimensions in advance. Determine the C dimension first, then obtain the other dimensions from the relevant table. You should try to place the lift as high as possible within the specified C dimension in the table. C dimension The C dimension is the distance between the top of the support frame and the vehicle floor 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 floor level (A dimension). - Page 13 Calculating the installed dimensions ZHD 2500-130/150 ZHD 2500-130 Image 7. ZHD 2500 ZHD 2500-150 1002 Image 8. ZHD 2500 www.zepro.com...
- Page 14 Calculating the installed dimensions ZHD 2500-130/150 1010 1524 min. 750 - max. 930 1509 1966 2411 A max 617-817 Image 9. ZHD 2500 www.zepro.com...
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Page 15: Rear Beam Cut-Outs
Rear beam cut-outs ZHD 2500-130/150 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 platform is in the upper position. The size of the cut outs depends on the calculated installed dimension “A”, see illustration below. -
Page 16: Installation
Image 11. Measure and mark the mid- point of the rear beam of the vehicle. WARNING! Zepro tail lifts are only approved for installation with Zepro installation kits. Support frame 1. Measure and mark the midpoint of the rear beam of the vehicle. - Page 17 Installation ZHD 2500-130/150 When installing on chassis with pre-drilled holes, go directly to point 16. 10. When installing on a frame without pre-drilled holes, install first 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 16.
- Page 18 Installation ZHD 2500-130/150 When installing on chassis with pre-drilled holes 16. Bolt the brackets securely on the outside of the vehicle chassis. Install in the slot-shaped holes with at least 8 screws. 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.
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Page 19: Control Power Cable
Installation ZHD 2500-130/150 Control power cable NOTE. See also the trailer manufacturer’s electrical instructions. 1. Route the control power cable from the driver’s cab to the lift. NOTE. The cable must be protected with rubber grommets when it passes through beams 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. -
Page 20: Control Devices
Installation ZHD 2500-130/150 Control devices If the vehicle is equipped with two-handed grip, the 400mm ± 100mm operator must use both hands to operate the plat- form. It also protects the operator from pinching and crushing injuries. 1. Fit the control devices in the desired locations. -
Page 21: Main Power Cable
Installation ZHD 2500-130/150 Main power cable 6.4.1 Cable routing 1. Route the main power cable from the lift to the battery. Route the cable through a plastic casing and ensure it is not clamped to the brake line or the vehicle's existing electrical system. -
Page 22: Installation Of Main Fuse On Vehicles Without Connection Point
Installation ZHD 2500-130/150 Installation of main fuse on vehicles without connection point On vehicles without connection point, the following fuse box with fuse, 150A (24V) or 250A (12V) must be installed. The fuse box must be positioned well-protected as close to the battery as possible. -
Page 23: Underrun Protection
220x70x4 mm, corresponding to a surface moment of inertia of 555 cm4 around the x-axis. See Image 27. The cross-secton of the frame beam illustration. If in doubt, contact ZEPRO for support. WARNING! The above dimensions are the minimum permit- ted for the installation of underrun protection. - Page 24 Installation ZHD 2500-130/150 • Horizontal distance from the outer edge of the beam to the outside of the wheel: Max. 100 mm. See figure 28. 0-100 mm. Min. area: 350 cm Image 29. Statutory dimensions • The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm. See figure 29.
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Page 25: Underrun Protection
Installation ZHD 2500-130/150 Underrun protection 6.7.1 Installation Test the position of the underrun protection without tightening the bolts to check that the statutory dimen- sions are obtained. Adjust if necessary then tighten the bolts with a torque wrench. Image 31. The inner part of the brack- ets can be fitted at one of four heights 1. -
Page 26: Armstops
Installation ZHD 2500-130/150 Armstops Fit end stops between the lift arms and the rear beam of the vehicle floor. The left and right end stops must be reached at the same time, as high up the lift arm as possible. Installation must take place against the vehicle body. Image 35. Fit end stops between the lift arms... -
Page 27: Platform
2. Lubricate the metal bushings on the upper bearing of the arms. Ensure that the small holes on the inside of the bushings are filled with grease. See Image 38. Use Zepro lubricant or the equivalent. NOTE! Lubricate the bushings NOTE. Carefully lubricate the metal bushings on the upper bearing of the arms. - Page 28 Installation ZHD 2500-130/150 5. Test the lift by carefully raising it to the vehicle floor Max. 40 mm, Min. 38 mm level and tilting it to the vertical position. Check the position in relation to the rear beam and side posts of the vehicle. See Image 41. Image 41. Check the position in rela-...
- Page 29 Installation ZHD 2500-130/150 4. Turn the adjusting collar so that the platform just meets the seal on the vehicle body. Image 44. Image 44. Adjusting the fit with the vehicle body 5. Loosen the three lock screws on the other tilt cylinder.
- Page 30 Installation ZHD 2500-130/150 Max. 30 mm 10. Tighten the lock screws of the adjusting collar using a torque wrench. Tightening torque: 3-5 WARNING! After finishing the adjustment, make sure the distance between the adjusting collar and the end of the thread is no more than 30 mm.
- Page 31 Installation ZHD 2500-130/150 6.12.2 Adjusting the downward tilt angle NOTE. The tilt angle must be set at 90° to the vehicle body before the downward tilt angle is adjusted (see previous page). Image 49. The tilt angle must be ad- justed to max.10° down WARNING! To ensure that the lift is safe and CE compliant, the downward tilt angle must be adjusted to max. 10° if...
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Page 32: Purging The Cylinders
Installation ZHD 2500-130/150 6.13 Purging the cylinders Fully lower the platform a few times. You may have to lift the truck to fully lower the platform. For tilting cylinder model The tilt cylinders can be purged by raising the platform fully against the vehicle body and then tilting all the way down. -
Page 33: Temporary Operation Of Lift
Temporary operation of lift ZHD 2500-130/150 Temporary operation of lift When the lift is installed, it is sometimes necessary to operate the lift functions in order to change the posi- tion of the cylinders and the lift arms. To do this, the lift control card can be connected temporarily to run the functions. To access the lift’s control card, see section "8 Hydraulic unit and control card" on page 34. -
Page 34: Hydraulic Unit And Control Card
Hydraulic unit and control card ZHD 2500-130/150 Hydraulic unit and control card The hydraulic package is built into the frame of the lift. The control card is housed in a separate enclosure. VALVE BODY TANK CAP OIL TANK SOLENOID MOTOR CONTROL CARD www.zepro.com... -
Page 35: Electrical And Hydraulic Diagrams
Electrical and hydraulic diagrams ZHD 2500-130/150 Electrical and hydraulic diagrams ZHD 2500 NN www.zepro.com... -
Page 36: Zhd 2500 Dvx4 Nn
Electrical and hydraulic diagrams ZHD 2500-130/150 ZHD 2500 DVx4 NN www.zepro.com... -
Page 37: Zhd 2500 Dvx4 Ce
Electrical and hydraulic diagrams ZHD 2500-130/150 ZHD 2500 DVx4 CE www.zepro.com... -
Page 38: Zhd 2500 Hydraulic Autotilt Nn
Electrical and hydraulic diagrams ZHD 2500-130/150 ZHD 2500 Hydraulic autotilt NN www.zepro.com... -
Page 39: Connection Of Connection Card To Control Card
Electrical and hydraulic diagrams ZHD 2500-130/150 Connection of connection card to control card www.zepro.com... -
Page 40: Connection To Circuit Board 4-Button Operation
Electrical and hydraulic diagrams ZHD 2500-130/150 Connection to circuit board 4-button operation Control Power Nr. /No. Färg / Color/Farbe Gul / Grön, Yellow / Green, Gelb / Grün Blå / Blue / Blau Brun / Brown / Braun Svart / Black / Schwarz Grön / Green / Grün... -
Page 41: Jumper Two Hand Control
Electrical and hydraulic diagrams ZHD 2500-130/150 Jumper two hand control When connecting the connection card, jumper shall be made according to figure below. Only for markets without requirement of two hand control. Sensor Power Outputs Ctrl 1 IN OUT Indication Se appendix in installation manual Ctrl 2 CSPWR Ctrl 6 Di 6... -
Page 42: Connecting Cabin Switch And Open Platform Alarm
Electrical and hydraulic diagrams ZHD 2500-130/150 Connecting cabin switch and open platform alarm Tiltcylinder Sensor Power Not in use Outputs NC 60bar Pump unit Ctrl 1 IN OUT Indication Se appendix in installation manual Ctrl 2 CSPWR 12-24v Ctrl 6... -
Page 43: Connecting Control Device
Electrical and hydraulic diagrams ZHD 2500-130/150 9.10 Connecting control device The most commonly occurring control device (CD) models are shown below. Possible control device models vary depending on lift model, configuration and relevant market. NOTE. Only 1 control device/connection may be connected. White (-) must be con- Black (+) -
Page 44: Function Diagrams
Function diagrams ZHD 2500-130/150 Function diagrams 10.1 ZHD 2500 (Config 1) MA Function Input sig- Input Output Comment Control Illustration nal high signal signal devices low (0v) 90º 45º Open from vehicle Ctrl 1 C+E+2H U0+U1+U3+U5 body down to Ctrl 2 0º... - Page 45 Function diagrams ZHD 2500-130/150 0º -10º 10.1.1 Restriction in use of control device (Config 1) Tilt up/down 90º 90º B+C+2H Control device 1,2 (Ctrl 1 & 2) 45º Coil (Ctrl 4) Radio (Ctrl 3 & 6) Control device 1,2 (Ctrl 1 & 2) 0º...
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Page 46: Zhd 2500 (Config 3) Da
Function diagrams ZHD 2500-130/150 10.2 ZHD 2500 (Config 3) DA Function Input sig- Input Output Comment Control de- Illustration nal high signal signal vices low (0v) 90º 45º Ctrl 1 Open Ctrl 2 U0+U1+U3+U5 (Tilt down) Ctrl 3 0º Ctrl 4 -10º... - Page 47 Function diagrams ZHD 2500-130/150 0º -10º 10.2.1 Restriction in use of control device (Config 3) Tilt up/down 90º 90º B+C+2H Control device 1,2 (Ctrl 1 & 2) 45º Coil (Ctrl 4) Radio (Ctrl 3 & 6) Control device 1,2 (Ctrl 1 & 2) 0º...
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Page 48: Connection Unit
Connection unit ZHD 2500-130/150 Connection unit 11.1 Power save mode If the control card is not used for a certain amount of time, it goes into power save mode. For 5 or 20 minutes depending on which mode the control card is in and whether CS is on or off. Press any control button for approx. 0.5 seconds to “wake up” the control card again. - Page 49 Connection unit ZHD 2500-130/150 11.2.1 Information codes Codes are shown on the display in a sequence. First a letter for identification of information, fol- lowed 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. 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.
- Page 50 Connection unit ZHD 2500-130/150 Information codes Code Code Identification Code 1 Information Other 00–99 Cancelled configuration Dividers (Program-configu- ration) 12/24 Number of volts detected 01–99 Version number Software version Fixed light (1-6) displays active control 1-6 (Fixed light) device during operation.
- Page 51 Connection unit ZHD 2500-130/150 11.2.2 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 indica- tion (C) in accordance with the previous page.
- Page 52 Connection unit ZHD 2500-130/150 Fault codes Code Identification Code 1 Code 2 Information Other 07-35 Voltage measured Low battery voltage 07-35 Voltage measured High battery voltage Fixed control device 1 (incl. two- hand button 2h1 if they are moni- Control device...
- Page 53 Connection unit ZHD 2500-130/150 11.2.3 Control devices If a control device button is held down for too long, the control device is blocked and cannot be used for a number of minutes. Fault code E flashes on the display. The fault is also indicated on a The LED on the coil non-active coil control device with a lock button, if this is connected to Ctrl 4.
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Page 54: Marking
Marking ZHD 2500-130/150 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 subsequent pages. 12.1 12.4 12.3 12.5 12.5 12.6 12.7 Image 56. Overview of labelling www.zepro.com... -
Page 55: Loading Diagram
Marking ZHD 2500-130/150 12.1 Loading 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 capacity 2500 kg, centre of gravity distance 1000 mm. www.zepro.com... -
Page 56: Identification Plate
Marking ZHD 2500-130/150 12.2 Identification plate The identification plate is fixed on to the tail lift’s frame. Affix the corresponding sticker version of the identifica- tion plate, preferably by the cab door post to facilitate identification. The identification plate contains the following informa- tion: • Type of lift • Max. permitted load in kg Image 58. Identification plate • Production number • Year of manufacture •... -
Page 57: Controller Sticker
Marking ZHD 2500-130/150 12.5 Controller sticker Affix the controller sticker next to the relevant controller. The stickers are available in standard versions and in reversed version (Option) for affixing on the opposite side of the vehicle. Make sure the stickers are affixed so the image of the vehicle/tail lift on the sticker is in the same direction as the vehicle on which it is affixed. Image 63. Standard mounting Image 64. Reversed mounting Controller Sticker (Stand- Sticker ard) (Reversed) CD 1,2,9 55053TL* 55054TL* CD 4 55055TL 55056TL CD 10 77661TL 77662TL * The sticker section for 2-hand operation is delivered on the same backing paper and has to be affixed if the application has 2-hand operation. -
Page 58: Danger Area
Marking ZHD 2500-130/150 12.6 Danger area If one is fitted, affix the sticker on the inside of the vehicle body next to the hand control unit. www.hiab.com 65977TL 2020-05-14 Image 66. Danger area 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 the platform is lowered to the ground. -
Page 59: Lubrication And Fluid Level Check
Lubrication and fluid level check ZHD 2500-130/150 Lubrication and fluid level check The following lubrication points must be greased on installation. They must then be lubricated at least 4 times a year. 13.1 Lubrication NOTE. Use LE lubricant 4622 or the equivalent. 1. Right tilt cylinder, at lower bearing. -
Page 60: Testing And Verification
Testing and verification ZHD 2500-130/150 Testing and verification Testing and verification of the tail lift takes place in accordance with the installation/delivery inspection. Verify that the tail lift is suitable for the vehicle in question and for the intended use. 14.1 Static load test 14.1.1 Deformation Position the tail lift half way up to the vehicle floor level and with the platform in the horizontal position. Meas- ure dimensions A-B-C-D for comparison as illustrated. Place a test load on the platform according to the table for the respective tail lift model and lifting capacity. -
Page 61: Dynamic Load Test
Testing and verification ZHD 2500-130/150 14.2 Dynamic load test. 14.2.1 Test with max. load Place a test load on the platform according to the table for the respective tail lift model and lifting capacity. Check that the lift operates correctly in the normal range of movement allowed, i.e. up, down, tilting at ground level and tilting at the vehicle floor level. -
Page 62: Disassembly
Disassembly ZHD 2500-130/150 Disassembly If the tail lift has to be removed from the vehicle, for example to transfer it to another vehicle, for storage or for modification, please follow these instructions. 1. Support the platform with a crane or similar equipment that can safely carry the platform's weight (see weight info.). -
Page 63: Specifications
Lift components (included in complete lift chas- ZHD 2500-130 404 kg sis). ZHD 2500-150 423 kg 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 Steel platforms ZHD 2500-130 41 kg... -
Page 64: Maximum Power Consumption - Minimum Recommended Conductor Cross Sectional Area
Specifications ZHD 2500-130/150 16.2 Maximum power consumption - Minimum recommended conductor cross sectional area ZHD 2500 (200 bar) Hydraulic unit 7050 12 volt 24 volt Pump - Motor unit 245 A 135 A Magnet (hydraulic unit) 4.2 A 2.1 A Magnet (electric safety valve) 1.5 A... -
Page 65: Loading Diagram
Specifications ZHD 2500-130/150 16.4 Loading diagram Image 71. Loading diagram www.zepro.com... -
Page 66: Tightening Torque
Specifications ZHD 2500-130/150 16.5 Tightening torque NOTE! All specified torque values apply for use with a screw or impact wrench with torque control. Torque distribu- tion max ± 5%. 280 Nm 280 Nm 120 Nm 280 Nm 80 Nm Image 72. Tightening torque www.zepro.com... - Page 67 Specifications ZHD 2500-130/150 www.zepro.com...
- Page 68 BUILT TO PERFORM Zepro, Del and Waltco are Hiab brands for tail lifts. 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...