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Summary of Contents for Zepro ZN 2500-130
- Page 1 Installation Instruction Tail Lift ZN 2500-130 ZN 2500-150 ZEPRO Tel.: +46 (0)10-459 05 00 E-mail: zeprotech@hiab.com zepro.com 76510TL 2022-06-09...
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Page 3: Table Of Contents
Contents ZN 2500-130/150 Contents Important information ..................5 1.1 Attention! .....................5 1.2 Technical support ..................5 1.3 Identifikation ....................6 1.4 CE marking ....................6 1.5 Product approval ..................6 1.6 Hydraulic oil ....................6 1.7 Guarantee .....................6 1.8 Repainting .....................7 1.9 Battery maintenance ..................7 Safety rules ......................8 2.1 Moving parts - free movement ..............8... - Page 4 Contents ZN 2500-130/150 Connection ....................... 44 6.1 Cable grommet ...................44 6.2 Connection ....................45 Powering up the tail lift ..................53 Electrical and hydraulic drawings ..............54 8.1 ZN 2500-130/150 MA .................54 8.2 Z 2500 MA Autotilt IFM (TLC-B1) ..............55 8.3 ZN 2500-130/150 MA with electrical autotilt ..........56 8.4 Z 2500 MA Autotilt IFM (ZePRO1) ..............57 8.5 ZN 2500-130/150 DA ..................58 Lubrication and fluid level check ...............
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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: Identifikation
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 ZN 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
Before installation ZN 2500-130/150 Before installation Vehicle chassis requirements In order to comply with the applicable underrun R6(x2) protection standards, there are requirements for the vehicle chassis on which the rear tail lift is mounted. The moment of inertia in a cross-section on the current... - Page 10 Before installation ZN 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 ZN 2500-130/150 Calculating the installed dimensions For ease of installation it is best to calculate and specify the necessary dimensions in advance. Determine the C dimension first, then obtain the other dimensions from the relevant table. Try to place the lift as high as possible within the C dimension specified in the table. -
Page 12: Installed Dimensions Zn 2500 - 150
Before installation ZN 2500-130/150 Installed dimensions ZN 2500 - 150 Image 11. Installed dimensions Installed dimensions ZN 2500 - 130 Image 12. Installed dimensions www.zepro.com... - Page 13 Before installation ZN 2500-130/150 Image 13. Installed dimensions Image 14. Installed dimensions www.zepro.com...
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Page 14: Rear Beam Cut-Outs
Before installation ZN 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 15: Adjusting The Chassis Brackets
Before installation ZN 2500-130/150 Adjusting the chassis brackets The chassis brackets can be set to two different heights. This affects the distance between the lift frame and the chassis (202 mm/242 mm). Take this into account when calculating the C dimension. The brackets must also be fitted differently depending on the chassis width, see the description below. -
Page 16: Temporary Connection
Before installation ZN 2500-130/150 Temporary connection When the tail lift is installed, it is sometimes necessary to operate its functions in order to change the position of the cylinders and the lift arms. Temporarily connect the lift to enable the lift functions. - Page 17 Before installation ZN 2500-130/150 3.8.2 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.
- Page 18 Before installation ZN 2500-130/150 3.8.3 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.
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Page 19: Prepare The Tail Lift
Before installation ZN 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 18. 3. Fold out the control card / relay card (B) and loosen the cabling at the connector on the hydraulic unit; see Image 19 and Image 20. - Page 20 Before installation ZN 2500-130/150 54853 cap supplied. Image 22. Where necessary, replace the transport plug with a regular tank cap OIL TANK TANK CAP VALVE HOUSING SOLENOID MOTOR RELAY CARD Image 23. Hydraulic unit and relay card www.zepro.com...
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Page 21: Installation
Installation ZN 2500-130/150 Installation NOTE! Consult the trailer manufacturer’s body instructions and Zepro’s instruction booklet before installation. WARNING! Zepro tail lifts are only approved for installation with Zepro installation kits. Chassis bracket 1. Place the chassis brackets on the support frame. -
Page 22: Support Frame, Trailer
Installation ZN 2500-130/150 Support frame, trailer NOTE! In cases where assembly jigs cannot be used due to, for example, locking devices, go directly to step 3. 1. Measure and mark the midpoint of the rear beam of the trailer. See illustration. - Page 23 Installation ZN 2500-130/150 7. The support frame should be positioned as high as possible within the specified C dimension. Adjust the frame to the ideal height under the chassis. A car jack is useful. If necessary you can adjust the height of the bracket by installing its upper and lower parts in an alternative pattern of holes.
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Page 24: Support Frame, Truck
Installation ZN 2500-130/150 Support frame, truck 1. Measure and mark the midpoint of the rear beam of the vehicle. See Image 29. 2. Bolt or spot-weld the mounting jig (product no. 78183TL) to the rear beam, so that both mid-points are aligned. - Page 25 Installation ZN 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’...
- Page 26 Installation ZN 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 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 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 36. 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 ZN 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 29 Installation ZN 2500-130/150 4. Turn the adjusting collar so that the tilt cylinder aligns with the attachment on the platform. See Image 43. Image 42. Adjusting the fit with the vehicle body. 5. Loosen the three lock screws on the other tilt cylinder, see Image 43 6.
- Page 30 Installation ZN 2500-130/150 Max. 30 mm 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.. 11. Fit the cylinder boots. Image 46. Image 45. Adjusting the tilt angle...
- Page 31 Installation ZN 2500-130/150 4.4.2 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 pre- vious page). Image 47. The tilt angle must be ad- WARNING! justed to max.10°...
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Page 32: Armstops
Installation ZN 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 33: Underrun Protection
Installation ZN 2500-130/150 Underrun protection 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. 1. Fit the inner part of each bracket at one of four heights. -
Page 34: Purging The Cylinders
Installation ZN 2500-130/150 Purging the cylinders Purge the lift cylinders by lowering the platform all the way to the ground a few times. It may be necessary to raise the truck to allow the platform to be lowered completely. Purge the tilt cylinders by tilting the platform all the way up to the vehicle body and then all the way down. -
Page 35: Angle Sensor / Inclinometer
Installation ZN 2500-130/150 4.11 Angle sensor / Inclinometer 4.11.1 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 57. 2. Connection is described later in section Image 57. - Page 36 Installation ZN 2500-130/150 4.11.3 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 59 2. Route the cables and secure with cable ties.
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Page 37: Controllers
Installation ZN 2500-130/150 4.12 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 performed later in section 6 if this is not already done from the factory. - Page 38 Installation ZN 2500-130/150 4.12.1 Controller CD 1 1. Fit the controllers in the desired locations. 300 - 600 mm. However, locate them such that the operator’s working position is as safe as possible, and with an adequate overview of the load, tail lift and their working area.
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Page 39: Cable Routing
Cable routing ZN 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. Insufficient battery power can permanently damage the electrical components in the tail lift (solenoid, electric motor, solenoid valves, relay board/ control board and more.) -
Page 40: Maximum Power Consumption - Minimum Recommended Conductor Cross Sectional Area
Cable routing ZN 2500-130/150 Maximum power consumption - Minimum recommended conductor cross sectional area ZN 2500 (200 bar) OBSERVERA! Hydraulic unit 7100 12 volt 24 volt Ensure that the lift has access to the minimum recommended Pump - Motor unit 145 A power capacity (I ). -
Page 41: Main Power Cable, Earth Cable, Main Fuse And Main Switch
Cable routing ZN 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. - Page 42 Cable routing ZN 2500-130/150 5.4.1 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 69 and Image 70. IMPORTANT The main switch drainage should always be directed downwards.
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Page 43: 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 44: Connection
Connection ZN 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 75. 2. Loosen the five screws on the cable grommet, see Image 76. Cables can now be installed/removed/adjusted in the grommet. -
Page 45: Connection
Connection ZN 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 46 Connection ZN 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 controller to each connection is not permitted.
- Page 47 Connection ZN 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 controller to each connection is not permitted.
- Page 48 Connection ZN 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 49 Connection ZN 2500-130/150 6.2.4 Warning lights and foot controls (ZePRO1) www.zepro.com...
- Page 50 Connection ZN 2500-130/150 6.2.5 Connecting cabin switch and open platform alarm (TLC-B1) www.zepro.com...
- Page 51 Connection ZN 2500-130/150 6.2.6 Connecting cabin switch and open platform alarm (ZePRO1) www.zepro.com...
- Page 52 Connection ZN 2500-130/150 6.2.7 Open platform alarm Applies when installing with main switch www.zepro.com...
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Page 53: Powering Up The Tail Lift
Powering up the tail lift ZN 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 79. -
Page 54: Electrical And Hydraulic Drawings
Electrical and hydraulic drawings ZN 2500-130/150 Electrical and hydraulic drawings ZN 2500-130/150 MA Config 14, Firmvare 9.7 or later www.zepro.com... -
Page 55: Z 2500 Ma Autotilt Ifm (Tlc-B1)
Electrical and hydraulic drawings ZN 2500-130/150 Z 2500 MA Autotilt IFM (TLC-B1) www.zepro.com... -
Page 56: Zn 2500-130/150 Ma With Electrical Autotilt
Electrical and hydraulic drawings ZN 2500-130/150 ZN 2500-130/150 MA with electrical autotilt Config 14, Firmvare 9.8 or later www.zepro.com... -
Page 57: Z 2500 Ma Autotilt Ifm (Zepro1)
Electrical and hydraulic drawings ZN 2500-130/150 Z 2500 MA Autotilt IFM (ZePRO1) www.zepro.com... -
Page 58: Zn 2500-130/150 Da
Electrical and hydraulic drawings ZN 2500-130/150 ZN 2500-130/150 DA Config 16, Firmvare 9.7 or later www.zepro.com... -
Page 59: Lubrication And Fluid Level Check
Lubrication and fluid level check ZN 2500-130/150 Lubrication and fluid level check The following lubrication points must be greased on installation. They must then be lubricated at least once a year. Lubrication NOTE! Use LE lubricant 4622 or the equivalent. 1. Right tilt cylinder, at lower bearing. -
Page 60: Marking
Marking ZN 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. 10.1 10.4 10.3 10.7 10.5 10.6 10.7 Image 85. Overview of labelling... -
Page 61: Loading Diagram
Max. 2500 Kg Marking ZN 2500-130/150 1000 1500 10.1 Loading diagram 2500 Kg Max. 1000 mm Affix the load diagrams for the appropriate lift model close to the primary controller and in a suitable clearly 2000 Kg Max. 1250 mm visible position on the vehicle body. -
Page 62: Identification Plate
Marking ZN 2500-130/150 10.2 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: •... -
Page 63: Controller Sticker
Marking ZN 2500-130/150 10.5 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. -
Page 64: Danger Area
Marking ZN 2500-130/150 10.6 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 95. Danger area 10.7 Warning flags Attach warning flags as close as possible to the top... -
Page 65: Testing And Verification
Testing and verification ZN 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 66: Dynamic Load Test
Testing and verification ZN 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 67: Specifications
Specifications ZN 2500-130/150 Specifications 12.1 Weights Many of the lift components are heavy, requiring the use of lifting equipment. Make sure the weight of the components does not exceed the maximum permitted load of the lifting equipment. The following is a list of selected components with their weight. - 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...