Zepro ZHD 1500-135 User manual

ZHD 1500/2000-135/155/175
ZHDL 1500/2000-135/155/175
Sales
Mossvägen 8, 641 49 KATRINEHOLM, SWEDEN
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.zepro.com
Factory
Allévägen 4, 844 41 BISPGÅRDEN, SWEDEN
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.zepro.com
01/05/2019
59581TL
INSTALLATION INSTRUCTIONS
Z-LYFTEN PRODUKTION AB

ZHD 1500/2000-135/155/175Contents
3www.zepro.com
Contents
1 Introduction ..................................................................................................... 5
1.1 Important ................................................................................................ 5
1.2 CE marking............................................................................................. 6
1.3 Hydraulicuid ......................................................................................... 6
1.4 Identication ........................................................................................... 7
2 Safety rules ....................................................................................................... 8
2.1 Repainting .............................................................................................. 8
2.2 Transport plug......................................................................................... 9
2.3 Moving parts - free movement................................................................ 9
2.4 Third-party equipment must not be attached........................................ 10
2.5 Installation ............................................................................................ 10
3 Installation workflow...................................................................................... 11
3.1 Installing the support frame .................................................................. 11
3.2 Electrical connections........................................................................... 11
3.3 Installing the platform ........................................................................... 11
3.4 Installing cylinders ................................................................................ 11
3.5 Attaching decals ................................................................................... 11
4 Calculating the installed dimensions ........................................................... 12
4.1 C dimension ......................................................................................... 12
4.2 D dimension ......................................................................................... 12
4.3 A dimension.......................................................................................... 12
4.4 H dimension.......................................................................................... 12
5 Rear member cut-outs ................................................................................... 15
6 Installation ..................................................................................................... 16
6.1 Support frame....................................................................................... 16
6.2 Control devices..................................................................................... 19
6.3 Control power cable.............................................................................. 19
6.4 M ain power cable.................................................................................. 20
6.5 Underrun protection.............................................................................. 22
6.6 Armstops .............................................................................................. 24
6.7 Angle sensor for autotilt........................................................................ 24
6.8 Sealing strip (horizontal)....................................................................... 24
6.9 Sealing strip (vertical)........................................................................... 24
6.10 Platform ................................................................................................ 25
6.11 Purging the cylinders............................................................................ 30
6.12 Transport lock....................................................................................... 30
7 Temporary operation of lift............................................................................ 31
7.1 Connection ........................................................................................... 31
7.2 Operation.............................................................................................. 31
7.3 Disconnection....................................................................................... 31
8 Hydraulic unit and control card .................................................................... 32

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Contents
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9 Electrical and hydraulic drawings................................................................. 33
9.1 ZHD 1500/2000 NN.............................................................................. 33
9.2 ZHD 1500/2000 CE .............................................................................. 34
9.3 ZHD 1500/2000 DVx4 NN .................................................................... 35
9.4 ZHD 1500/2000 DVx4 CE .................................................................... 36
9.5 ZHD 1500/2000 Hydraulic autotilt NN .................................................. 37
9.6 ZHD 1500/2000 Hydraulic autotilt CE................................................... 38
9.7 Connecting cabin switch and open platform alarm............................... 39
9.8 Alarm for open platform (trailer)............................................................ 39
9.9 Connecting control devices .................................................................. 40
10 Functional schematic drawings.................................................................... 41
10.1 ZHD1500-2000(Cong1)MA............................................................. 41
10.2 ZHD1500-2000(Cong3)DA
........................................................................................................... 43
11 Connection unit .............................................................................................. 45
11.1 Power save mode................................................................................. 45
11.2 Operating information........................................................................... 45
12 Marking and decals ........................................................................................ 51
12.1 Summary .............................................................................................. 51
12.2 Load diagram........................................................................................ 52
12.3 Identicationplate................................................................................ 52
12.4 Work area ............................................................................................ 52
12.5 Driver’s instructions .............................................................................. 53
12.6 Danger area ......................................................................................... 53
12.7 Warning tape ....................................................................................... 53
12.8 Warningags....................................................................................... 54
12.9 CE marking........................................................................................... 54
13 Lubrication and fluid level check.................................................................. 55
13.1 Lubrication............................................................................................ 55
13.2 Oil level check ...................................................................................... 55
14 Testing and verification ................................................................................. 56
14.1 Static load test...................................................................................... 56
14.2 Dynamic load test................................................................................. 57
14.3 Test of safety functions......................................................................... 57
15 Dismantling..................................................................................................... 58
16 Specifications ................................................................................................ 59
16.1 Weights ................................................................................................ 59
16.2 Maximum power consumption - Minimum recommended conductor cross sectional
area.................................................................................................... 60
16.3 Battery maintenance............................................................................. 60
16.4 Loading diagram................................................................................... 61
16.5 Tightening torque.................................................................................. 62

ZHD 1500/2000-135/155/175Introduction
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1 Introduction
1.1 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.
Take care. Risk of damage to the product.
NOTE.
Take extra care. Risk of personal injury or damage to the product and the surroundings.
mWARNING!

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Introduction
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1.2 CE marking
Zepro’s tail lifts on sale on the European market have been CE marked (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 during installation. Follow the instal-
lation 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 Zepro.
Welding is not necessary except where expressly requested by the manufacturer.
To improve safety, we supply decals for the lift that are easy to understand regardless of the lan-
guage. 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.
1.3 Hydraulic uid
Our 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Zeprohas
chosenhydraulicuidsthatcancopewithalltheseconditions.
1.3.1 Highly rened mineral oil (part no. 21963, 1 litre)
Contains zinc-free anti-wear additives and provides 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. Also gives optimum corrosion protection for the hydraulic system.
1.3.2 Biodegradable hydraulic uid (part no. 22235, 1 litre)
Weofferabiodegradablehydraulicuid(environmentaluid)asanoptionmadeofasynthetic
baseoilcalledpolyalphaolen,whichisbiodegradable.Thisbaseoilhasoutstandingproper-
tiesatlowandhightemperatures.Theuidstaysliquiddowntotemperaturesaslowas-50°C.
Oxidation stability is very good, resulting in a long service life with longer replacement intervals.
Theuidiseasytopumpthankstogoodltering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maynotbeused.Theseuidsaffecttherubberinthegaskets
and seals and shorten service life.
NOTE.

ZHD 1500/2000-135/155/175Introduction
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1.4 Identication
E.g. ZHD 1500 - 135 MA
_ _ _ _ _ _ - _ _ _ _ _
Identication list
ZHD = Standard model
ZHDL = Wide frame, wide lift arm
Max. lifting capacity x 1 (kg)
Max. lifting height -135 = 1340 mm
-155 = 1530 mm
-175 = 1710 mm
Cylinder model, MA = Double acting Adjustable Tilt
Single acting lift
DA = Double acting Adjustable Tilt
Double acting lift

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Safety rules
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2 Safety rules
2.1 Repainting
Piston rods and cylinder covers must
not be painted. Painting could dam-
age 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
impair durability.
NOTE.
Fig. 1. Piston rods, cylinder covers and
boots must not be painted/coated
Fig. 2. Hydraulic hoses must not be painted/coated
Fig. 3. Cables must not be painted/coated

ZHD 1500/2000-135/155/175Safety rules
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2.2 Transport plug
When the lift is installed, the trans-
port plug in the hydraulic unit must
be removed and replaced with the
normal tank cap supplied with the
hydraulic unit.
NOTE.
54
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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 be-
tween the cylinder and the following
items: subframe, truck chassis, mem-
ber for rear lights (number plate) and
the lift’s chassis bracket (with a short
overhang).
*Thenalinspectionmustbecarried
outwiththeplatformatthevehicleoor
and tilted down 10°. The clearance
from the closest part of the cylinder
must be at least 40 mm.
mWARNING!
The platform must not be tilted down
morethanmax.10°fromhorizontal
when people are on the platform.
mWARNING!
min. 40 mm.
10°
10°
Fig. 4. Replace the transport plug with
the normal tank cap
Fig. 5. Clearance to the closest
part of the cylinder must be at least 40 mm
Fig. 6. The platform must not be tilted down
more than 10° from the horizontal

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Safety rules
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2.4 Third-party equipment must not be attached
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 attachment features on the vehicle.
mWARNING!
2.5 Installation
The platform must not be installed so it cannot reach ground level.
mWARNING!
Zepro tail lifts are only approved for installation with Zepro installation kits.
mWARNING!