Related Manuals for Zepro Z 2500-130
Summary of Contents for Zepro Z 2500-130
- Page 1 Installation Instructions Tail Lift Z 2500-130/150 ZEPRO Tel.: +46 (0)10-459 05 00 E-mail: zeprotech@hiab.com zepro.com 75981TL 2022-05-06...
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Page 3: Table Of Contents
Contents Z 2500-130/150 Contents Important information ..................6 1.1 Attention! .....................6 1.2 Technical support ..................6 1.7 Identification ....................7 1.3 CE marking ....................7 1.4 Product approval ..................7 1.5 Hydraulic oil ....................7 1.6 Guarantee .....................7 1.8 Repainting .....................8 1.9 Battery maintenance ..................8 Safety rules ......................9 2.1 Moving parts - free movement ..............9... - Page 4 Contents Z 2500-130/150 Electrical and hydraulic diagrams ..............50 8.1 Z2500-130/150 MA (ZePRO1) ..............50 8.2 Z 2500 MA Autotilt (TLC-B1) ...............51 8.3 Z2500 MA Autotilt Inclinometer (ZePRO1) ..........52 8.4 Z 2500 MA Autotilt IFM (ZePRO1) ..............53 8.5 Z2500-130/150 DA ..................54 Marking......................55 9.1 Loading diagram ..................56 9.2 Identification plate ..................57 9.3 Work area ....................57 9.4 Warning tape .....................57 9.5 Controller sticker ..................58 9.6...
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Page 5: Important Information
NOTE refers to additional information that may help the reader understand, or perform, a given operation. Technical support If technical support is needed, please contact ZEPRO. Tel: +46 (0)10-459 05 04, E-mail: zeprotech@hiab.com. Always be ready to state the tail lift’s production number to guarantee you receive the correct information. The production number is given on the identification plate located on the tail lift frame. -
Page 6: Identification
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. -
Page 7: Repainting
Important information Z 2500-130/150 Repainting IMPORTANT Piston rods and cylinder covers must not be painted. Among other things, this can damage the cylinder gaskets. Boots, hydraulic hoses and cables may not be coated/painted as the solvent in the paint can damage the hoses and cables and impair durability. -
Page 8: Safety Rules
Connection of third-party equipment is forbidden WARNING! Connecting third-party equipment (electric or hydraulic) to Zepro tail lifts is forbidden. Connecting third- party equipment could interfere with the lift’s system and its 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 attachment features on the vehicle. -
Page 9: Before Installation
220x70x4 mm, corresponding to a surface moment of Image 7. The cross-secton of the frame beam inertia of 937cm4 around the x-axis. See illustration. If in doubt, contact ZEPRO for support. WARNING! The above dimensions are the minimum permit- ted for the installation of underrun protection. - Page 10 Before installation Z 2500-130/150 Horizontal distance from the outer edge of the beam to the outside of the wheel: Max. 100 mm. See Image 9. 0-100 mm. Image 9. Statutory dimensions The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm.
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Page 11: Calculating The Installed Dimensions
Before installation Z 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. - Page 12 Before installation Z 2500-130/150 Image 11. Z 2500-130 1002 Image 12. Z 2500-150 1010 1524 min. 750 - max. 930 1509 617-817 1966 2411 Image 13. Z 2500-130/-150 www.zepro.com...
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Page 13: Rear Beam Cut-Outs
Before installation Z 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 plat- form is in the upper position. The size of the cut outs depends on the calculated installed dimension “A”, see illustration below. -
Page 14: Prepare The Tail Lift
Before installation Z 2500-130/150 Prepare the tail lift 1. Position the support frame under the vehicle’s chassis. 2. Remove the protective cover mounted using to quick release locks; see Image 15. 3. Fold out the control card / relay card (B) and loosen the cabling at the connector on the hydraulic unit; see Image 16 and Image 17. - Page 15 Before installation Z 2500-130/150 54853 5. Check whether the hydraulic tank is fitted with a transport plug seal. If so, replace it with the regular tank cap supplied. Image 19. Where necessary, replace the transport plug with a regular tank cap...
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Page 16: Temporary Connection
Before installation Z 2500-130/150 Temporary connection When the tail lift is installed, it is sometimes necessary to operate its functions in order to change the posi- tion of the cylinders and the lift arms. Temporarily connect the lift to enable the lift functions. - Page 17 Before installation Z 2500-130/150 3.6.2 Connecting the control device to the TLC-B1 relay card The connection of warning lights and the most commonly occurring controller (CD (Control Device)) models is shown below. Possible controller models vary depending on lift model, configuration and relevant market.
- Page 18 Before installation Z 2500-130/150 3.6.3 Connecting the control device to the ZePRO1 control card The most commonly occurring controller (CD Control Device) models are shown below. Possible controller models vary depending on lift model, configuration and relevant market. WARNING! Make sure that the control card is disconnected from the power before connecting. Connecting more than one controller to each connection is not permitted.
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Page 19: Installation
Zepro’s instruction booklet before installation. WARNING! Image 22. Measure and mark the midpoint of Zepro tail lifts are only approved for installation the rear beam of the vehicle. with Zepro installation kits. Support frame 1. Measure and mark the midpoint of the rear beam of the vehicle. - Page 20 Installation Z 2500-130/150 When installing on chassis with pre-drilled holes, go directly to point 16. 9. 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’...
- Page 21 Installation Z 2500-130/150 When installing on chassis with pre-drilled holes 15. 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.
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Page 22: 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 illustration. Use Zepro lubricant or the equivalent. NOTE! Lubricate the bushings NOTE. - Page 23 Installation Z 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.
- Page 24 Installation Z 2500-130/150 4. Turn the adjuster sleeve until the platform fits perfectly against the seal on the body. Image 35. Image 35. Adjusting the fit to the vehicle body 5. Undo the three locking screws on the other tilt cylinder.
- Page 25 Installation Z 2500-130/150 Max. 30 mm IMPORTANT After finishing the adjustment, make sure the distance between the adjusting collar and the end of the thread is no more than 30 mm. 11. Fit the tilt cylinder boots. Image 39. Image 38. Adjusting the tilt angle...
- Page 26 Installation Z 2500-130/150 4.2.2 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 40. The tilt angle must be ad- justed to max.10°...
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Page 27: Armstops
Installation Z 2500-130/150 Armstops Fit end stops between the lift arms and the rear member 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. - Page 28 Installation Z 2500-130/150 4.5.1 Underrun protection 1. Test the position of the underrun protection with- out tightening the bolts to check that the statutory dimensions are obtained. Adjust if necessary then tighten the bolts with a torque wrench. 2. Fit the inner part of each bracket at one of four heights.
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Page 29: Purging The Cylinders
Installation Z 2500-130/150 Purging the cylinders Fully lower the platform a few times. You may have to lift the truck to fully lower the platform. The tilt cylinders can be purged by raising the platform fully against the vehicle body and then tilting all the way down. -
Page 30: Angle Sensor / Inclinometer
Installation Z 2500-130/150 Angle sensor / Inclinometer 4.7.1 Tail lift without autotilt 1. Install the angle sensor on the platform using the nuts, bolts and washers supplied and attach the cable using cable time; see. Image 49. 2. Connection is described later in section Image 49. - Page 31 Installation Z 2500-130/150 4.7.3 Tail lift with angle sensor IFM for autotilt 1. Install the angle sensor on the platform using the nuts, bolts and washers supplied and attach the cable using cable time; see Image 51 2. Route the cables and secure with cable ties.
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Page 32: Controllers
Installation Z 2500-130/150 Controllers 1. Install the primary controller on the side of the vehicle normally facing away from the traffic. The distance between the vehicle’s rear edge and the centre of the controller must be 300-600 mm. Connection is per- formed later in section 6 if this is not already done from the factory. - Page 33 Installation Z 2500-130/150 4.8.1 Controller CD 1 1. Fit the controllers in the desired locations. However, 300 - 600 mm. locate them such that the operator’s working posi- tion is as safe as possible, and with an adequate overview of the load, tail lift and their working area.
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Page 34: Cable Routing
Cable routing Z 2500-130/150 Cable routing General IMPORTANT In order to ensure a high degree of reliability for many years to come, it is important that components such as batteries, chargers, main current and earth cables, fuses and main switches are dimensioned correctly and assembled with great accuracy. -
Page 35: Maximum Power Consumption - Minimum Recommended Conductor Cross Sectional Area
Cable routing Z 2500-130/150 Maximum power consumption - Minimum recommended conductor cross sectional area Z 2500 ( 200 bar) Hydraulic unit 7100 24 volt Pump - Motor unit 200 A Magnet (hydraulic unit) 2.10 A Magnet (electric safety valve) 0.75 A Solenoid 0.85 A... -
Page 36: Main Power Cable, Earth Cable, Main Fuse And Main Switch
Cable routing Z 2500-130/150 Main power cable, earth cable, main fuse and main switch Main switch should always be mounted when cab switches (CS) are not used, for example when installing on trailers. Main switches can also be installed in combination with cab switches (CS) if desired. 1. If the positive battery terminal is suitable for the main fuse of the lift, it can be used for mounting the fuse. Otherwise, secure the fuse box in a suitable, well-protected place as close to the battery as possible. - Page 37 Cable routing Z 2500-130/150 5.3.1 Main power switch 1. Mount the main switch on a bracket next to controller CD 19 or in any well-protected place with universal bracket, see Image 61 and Image 62. IMPORTANT The main switch drainage should always be directed downwards.
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Page 38: Control Power Cable
Open platform alarm ZEPRO recommends the installation of an alarm for open platform. This can be in the form of warning light in the cab or when mounted on a trailer, a lamp mounted on the outside of the body, visible in the rear view mirror from the driver's cab. -
Page 39: Connection
Connection Z 2500-130/150 Connection Cable grommet 6.1.1 Before connection 1. Disconnect the cable grommet’s protective cover, which is secured with three screws; see Image 67. 2. Loosen the five screws on the cable grommet, see Image 68. Cables can now be installed/removed/adjusted in the grommet. -
Page 40: Connection
Connection Z 2500-130/150 Connection IMPORTANT! Make sure that the control board is disconnected from the power before connecting peripheral equipment. Risk of material damage. 1. Release and tilt out the relay board. 2. Run the cabling through the grommet. 3. Connect the relevant controller. See Section 6.2.1 - 6.2.2. - Page 41 Connection Z 2500-130/150 6.2.1 Controller (TLC-B1) Connection of warning lights and the most commonly occurring controller (CD (Control Device)) models are shown below. Possible controller models vary depending on lift model, configuration and relevant market. WARNING! Make sure that the control board is not powered up before connecting. Connecting more than one con- troller to each connection is not permitted.
- Page 42 Connection Z 2500-130/150 6.2.2 Controller (ZePRO1) The most commonly occurring controller (CD Control Device) models are shown below. Possible controller models vary depending on lift model, configuration and relevant market. WARNING! Make sure that the control board is not powered up before connecting. Connecting more than one con- troller to each connection is not permitted.
- Page 43 Connection Z 2500-130/150 6.2.3 Warning light and foot controller (TLC-B1) Signal is required on relay card input S3 for the warning light to work. Depending on the model, this can be done by connecting angle sensors between S3 and S3+ or with jumper Gnd.
- Page 44 Connection Z 2500-130/150 6.2.4 Warning lights and foot controls (ZePRO1) www.zepro.com...
- Page 45 Connection Z 2500-130/150 6.2.5 Cab switch and open platform alarm (TLC-B1) Applies when installing without main switch www.zepro.com...
- Page 46 Connection Z 2500-130/150 6.2.6 Cab switch and open platform alarm (ZePRO1) Applies when installing without main switch www.zepro.com...
- Page 47 Connection Z 2500-130/150 6.2.7 Open platform alarm Applies when installing with main switch www.zepro.com...
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Page 48: Powering Up The Tail Lift
Powering up the tail lift Z 2500-130/150 Powering up the tail lift 1. If applicable, ensure that the main switch is in the "Off" position. 2. If applicable, ensure that the cab switch (CS) is in the "Off" position. 3. When using a fuse box, connect the cable (1) to the battery’s positive terminal and to the fuse box and place the fuse (2) above, see Image 71. -
Page 49: Electrical And Hydraulic Diagrams
Electrical and hydraulic diagrams Z 2500-130/150 Electrical and hydraulic diagrams Z2500-130/150 MA (ZePRO1) Config 14, Firmvare 9.7 or later www.zepro.com... -
Page 50: Z 2500 Ma Autotilt (Tlc-B1)
Electrical and hydraulic diagrams Z 2500-130/150 Z 2500 MA Autotilt (TLC-B1) www.zepro.com... -
Page 51: Z2500 Ma Autotilt Inclinometer (Zepro1)
Electrical and hydraulic diagrams Z 2500-130/150 Z2500 MA Autotilt Inclinometer (ZePRO1) Config 14, Firmvare 9.8 or later www.zepro.com... -
Page 52: Z 2500 Ma Autotilt Ifm (Zepro1)
Electrical and hydraulic diagrams Z 2500-130/150 Z 2500 MA Autotilt IFM (ZePRO1) www.zepro.com... -
Page 53: Z2500-130/150 Da
Electrical and hydraulic diagrams Z 2500-130/150 Z2500-130/150 DA Config 16, Firmvare 9.7 or later www.zepro.com... -
Page 54: Marking
Marking Z 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. Image 76. Overview of labelling www.zepro.com... -
Page 55: Loading Diagram
Marking Z 2500-130/150 1000 1500 2500 Kg Max. 1000 mm Loading diagram 2000 Kg Max. 1250 mm Affix the load diagrams for the appropriate lift model close to the primary controller and in a suitable clearly 1500 Kg Max. 1600 mm visible position on the vehicle body. -
Page 56: Identification Plate
Marking Z 2500-130/150 Identification plate The identification plate is fixed on to the tail lift’s frame. Affix the corresponding sticker version of the identification plate, preferably by the cab door post to facilitate identification. The identification plate contains the following infor- mation: •... -
Page 57: Controller Sticker
Marking Z 2500-130/150 Controller sticker Affix the controller sticker next to the relevant controller. The stickers are available in standard versions and in reversed version 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. -
Page 58: Danger Area
Marking Z 2500-130/150 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 86. Danger area Warning flags Install warning flags as close to the top and as close... -
Page 59: Lubrication And Fluid Level Check
Lubrication and fluid level check Z 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. 10.1 Lubrication NOTE. Use LE lubricant 4622 or the equivalent. Right tilt cylinder, at lower bearing. -
Page 60: Testing And Verification
Testing and verification Z 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. 11.1 Static load test 11.1.1... -
Page 61: Dynamic Load Test
Testing and verification Z 2500-130/150 11.2 Dynamic load test. 11.2.1 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
Support frame Z 2500 116 kg Lift arm Z 2500-130 57 kg Lift arm Z 2500-150 63.5 kg 3-part underrun protection complete Z 2500-130 41 kg 3-part underrun protection complete Z 2500-150 46 kg Chassis bracket complete par Z 43 kg Lift cylinder Z 2500-130 12.5 kg each... -
Page 63: Specifications
Specifications Z 2500-130/150 www.zepro.com... - Page 64 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...