Zepro ZHDN 2500-150 Service manual

ZHDN 2500-150
Sales
Mossvägen 8, 641 49 KATRINEHOLM, SWEDEN
Telephone: 0150 - 489550
Fax: 0150 - 489551
E-mail: [email protected]
Internet: www.z-lyften.se
Factory
Allévägen 4, 840 73 BISPGÅRDEN, SWEDEN
Telephone: 0696 - 17200
Fax: 0696 - 17242
E-mail: [email protected]
Internet: www.z-lyften.se
2016-07-07
75354TL
INSTALLATION INSTRUCTIONS
Z-LYFTEN PRODUKTION AB

ZHDN 2500-150Contents
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Contents
1 Introduction ...................................................................................................... 5
1.1 General .........................................................................................................5
1.2 Important .....................................................................................................5
1.3 CE marking....................................................................................................6
1.4 Hydraulicuid...............................................................................................6
1.5 Idencaon ................................................................................................7
2 Safety rules ........................................................................................................ 8
2.1 Repainng.....................................................................................................8
2.2 Transport plug ..............................................................................................9
2.3 Moving parts - free movement.....................................................................9
2.4 Third-partyequipmentmustnotbeaached............................................10
2.5 Installaon..................................................................................................10
3 Installation workflow ....................................................................................... 11
3.1 Installing the support frame .......................................................................11
3.2 Electricalconnecons.................................................................................11
3.3 Installingtheplaorm ................................................................................11
3.4 Installing cylinders ......................................................................................11
3.5 Aachingdecals..........................................................................................11
4 Calculating the installed dimensions................................................................. 12
4.1 C dimension ...............................................................................................12
4.2 A dimension................................................................................................12
4.3 H dimension................................................................................................12
5 Adjusting the chassis brackets .......................................................................... 14
5.1 Adjustment.................................................................................................14
6 Installation ....................................................................................................... 15
6.1 Chassis brackets.........................................................................................15
6.2 Rear beam cut outs ....................................................................................15
6.3 Support frame ............................................................................................16
6.4 Control power cable ...................................................................................18
6.5 Control devices ...........................................................................................18
6.6 M ain power cable.......................................................................................19
6.7 O penplaormalarm ..................................................................................20
6.8 Third-partyequipmentmustnotbeaached............................................20
6.9 Underrunprotecon ..................................................................................21
6.10 Armstops ....................................................................................................23
6.11 Hydraulicautolt........................................................................................23
6.12 Sealing strip (horizontal).............................................................................23
6.13 Sealingstrip(vercal) .................................................................................23
6.14 Plaorm......................................................................................................24
6.15 Purging the cylinders ..................................................................................29
6.16 Transport lock.............................................................................................29

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7 Temporary operation of lift............................................................................... 30
7.1 Connecon .................................................................................................30
7.2 Operaon ...................................................................................................30
7.3 Disconnecon.............................................................................................30
8 Electrical and hydraulic drawings ...................................................................... 31
8.1 ZHDN 2500-150 ..........................................................................................31
8.2 ZHD 2500-150, angle sensors .....................................................................32
8.3 Connecngcontroldevice .........................................................................33
8.4 Connecngcontroldevice .........................................................................34
8.5 Connecngcabinswitchandopenplaormalarm....................................35
9 Connection unit ............................................................................................... 36
9.1 Operanginformaon................................................................................36
9.2 Autolt........................................................................................................41
9.3 Funconalschemacdrawing....................................................................42
9.4 Restriconofuseofcontroldevice ............................................................43
9.5 Sensor ....................................................................................................44
9.6 Hydraulic unit .............................................................................................45
10 Marking and decals .......................................................................................... 46
10.1 Summary ....................................................................................................46
10.2 Load diagram..............................................................................................47
10.3 Idencaonplate.....................................................................................47
10.4 Work area ..................................................................................................47
10.5 Driver'sinstrucons....................................................................................48
10.6 Danger area ...............................................................................................48
10.7 Warning tape .............................................................................................48
10.8 CE marking..................................................................................................49
10.9 Warningags.............................................................................................49
11 Lubrication and fluid level check....................................................................... 50
11.1 Lubricaon..................................................................................................50
11.2 Fluid level check .........................................................................................50
12 Testing and verification .................................................................................... 51
12.1 Stacloadtest ............................................................................................51
12.2 Dynamic load test.......................................................................................52
12.3 Testofsafetyfuncons...............................................................................52
13 Disassembly ..................................................................................................... 53
14 Specifications .................................................................................................. 54
14.1 Weights ......................................................................................................54
14.2 Centre of gravity .........................................................................................55
14.3 Maximumpowerconsumpon-Minimumrecommendedconductorcrossseconal
area ............................................................................................................56
14.4 Loading diagram .........................................................................................57
14.5 Tightening torque .......................................................................................58

ZHDN 2500-150
Introducon
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1 Introducon
1.1 General
Z-Lyften is electro-hydraulically driven. An electric motor which gets its power from the truck's
ordinary battery drives a hydraulic pump which supplies uid via hoses to the working hydraulic
cylinders. The hdraulic system is controlled by electric valves which are controlled from push but-
tons on the control devices. The number of available control devices depends on the conguration.
The hydraulic package containing the entire drive system is built into the frame of the lift. The control
system is housed in a separate box. Both systems are easy to access for inspection and service.
The platform is supported by the lift arm which is very strong and rigid. The underrun protection is
bolted directly to the support frame. The platform has a non-slip surface.
The arms are driven by the lift cylinders with integrated hose breakage valves to protect against
possible leakage. The lift cylinders can also be equipped with one or two electric hose breakage
valves. These hose breakage valves can also act as an extra transport lock for the platform.
The tilt function of the platform is also driven by hydraulic cylinders with the same design as the
lift cylinders. The tilt cylinders, too, can be equipped with one or two hose breakage valves. The
speed of lifting and up/down tilting is determined by the oil pump. The lowering speed is controlled
by a so-called constant ow control valve that provides the same speed independent of the load.
The piston rods of the hydraulic valves are treated by a method that provides a very long lifespan.
An integrated bypass valve protects the hydraulic system from overload when lifting and tilting up.
Note that the bypass valve does not prevent overload at rest position or during down movements.
The electricity supply is from the normal vehicle battery. The control power is taken from the central
electrical unit near the driver’s seat. When the control power is off, the lift is locked.
To save battery power, always switch off the control power when the lift is not in use.
The electric motor has a thermostatic switch that isolates the control circuit of the motor contac-
tors if the motor overheats. The control circuit of the motor contactors is connected again once
the motor has cooled down.
The platform can be set to any position from vertical to a 10° decline.
1.2 Important
The following “warning markings” appear in the installation instructions and are intended to draw
your attention to circumstances potentially causing unwanted situations, near misses, personal
injury 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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ZHDN 2500-150
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Introducon
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1.3 CE marking
Z-Lyften tail lifts on sale on the European market have been CE marked (CE stands for 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 before Z-Lyften products are installed.
Follow the installation 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 Direc-
tive 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 Z-Lyften.
Welding is not necessary except where recommended 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.
1.4 Hydraulic uid
A 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 Z-Lyften
chose a hydraulic fuel that can cope with all these conditions. Our hydraulic uid (product no.
21963, 1 litre) is made of highly rened mineral oil. The anti-wear additives are zinc-free and
provide 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. Our hydraulic uid also provides excellent corrosion protection for the hydraulic
system.
We also offer a biodegradable hydraulic uid (environmental uid) as an option (product no.
22235, 1 litre) made of a synthetic base oil called polyalphaolen, which is biodegradable. This
base oil has outstanding properties at low and high temperatures. The uid stays liquid down
to temperatures as low as -50 º 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 cannot be used with Z-Lyften. These uids affect the rubber in
the gaskets and seals and shorten service life.
NOTE.

ZHDN 2500-150
Introducon
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E.g. ZHDN 2500 - 135 MA
1.5 Idencaon
ZHD = Standard model
ZHDN = Narrow frame
Max lifting capacity x 1 (kg)
Max lifting height -135 = 1340 mm
Cylinder model, MA = Double acting Adjustable Tilt
Single acting Single speed Lift
DA = Double acting Adjustable Tilt
Double acting Single speed Lift

ZHDN 2500-150
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Safety rules
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2 Safety rules
2.1 Repainng
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.
Image 1. Piston rods, cylinder covers and
boots must not be painted/coated
Image 2. Hydraulic hoses must
not be painted/coated
Image 3. Cables must not be painted/coated

ZHDN 2500-150
Safety 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
8
5
3
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, beam
for rear light (number plate) and the
chassis bracket of the lift (with a short
overhang).
*The nal inspection must be carried
out with the platform at 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 10º from the horizontal.
mWARNING!
min 40mm
10º
10º
Image 4. Replace the transport plug
with the normal tank cap
Image 5. Clearance to the closest part of
the cylinder must be at least 40 mm
Image 6. Platform must not be tilted down
more than 10º from the horizontal

ZHDN 2500-150
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Safety rules
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2.4 Third-party equipment must not be aached
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!
Image 7. You must not attach third-party equipment to Zepro tail lifts
2.5 Installaon
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!