Zepro Z 2500-130 User manual

ZEPRO
Tel.: [phone]
E-mail: [email protected] |zepro.com
75981TL
2022-05-06
Installation Instructions
Tail Lift
Z 2500-130/150

Z 2500-130/150Contents
3www.zepro.com
Contents
1 Important information ....................................................................................... 6
1.1 Aenon! .....................................................................................................6
1.2 Technicalsupport .........................................................................................6
1.7 Idencaon ................................................................................................7
1.3 CEmarking....................................................................................................7
1.4 Productapproval .........................................................................................7
1.5 Hydraulicoil..................................................................................................7
1.6 Guarantee.....................................................................................................7
1.8 Repainng.....................................................................................................8
1.9 Baerymaintenance ....................................................................................8
2 Safety rules ........................................................................................................ 9
2.1 Movingparts-freemovement.....................................................................9
2.2 Conneconofthird-partyequipmentisforbidden ......................................9
2.3 Installaon ....................................................................................................9
3 Before installation ............................................................................................ 10
3.1 Vehiclechassisrequirements.....................................................................10
3.2 Statutorydimensionsforunderrunprotecon ..........................................10
3.3 Calculangtheinstalleddimensions ..........................................................12
3.4 Rearbeamcut-outs ....................................................................................14
3.5 Preparethetailli......................................................................................15
3.6 Temporaryconnecon................................................................................17
4 Installation ...................................................................................................... 20
4.1 Supportframe ............................................................................................20
4.2 Plaorm ......................................................................................................23
4.7 Armstops ....................................................................................................28
4.5 Sealingstrip(horizontal).............................................................................28
4.6 Sealingstrip(vercal) .................................................................................28
4.3 Purgingthecylinders ..................................................................................30
4.4 Transportlock.............................................................................................30
4.8 Anglesensor/Inclinometer .......................................................................31
4.9 Controllers ..................................................................................................33
5 Cable routing ................................................................................................... 35
5.1 General .......................................................................................................35
5.2 Maximumpowerconsumpon-Minimumrecommendedconductor
 crossseconalarea ....................................................................................36
5.3 Mainpowercable,earthcable,mainfuseandmainswitch ......................37
5.4 Controlpowercable ...................................................................................39
5.5 Openplaormalarm ..................................................................................39
5.6 Footcontroller/Warninglights .................................................................39
6 Connection....................................................................................................... 40
6.1 Cablegrommet...........................................................................................40
6.2 Connecon .................................................................................................41
7 Powering up the tail lift.................................................................................... 49

Z 2500-130/150
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Contents
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8 Electrical and hydraulic diagrams...................................................................... 50
8.1 Z2500-130/150MA(ZePRO1).....................................................................50
8.2 Z2500MAAutolt(TLC-B1).......................................................................51
8.3 Z2500MAAutoltInclinometer(ZePRO1) ................................................52
8.4 Z2500MAAutoltIFM(ZePRO1) ..............................................................53
8.5 Z2500-130/150DA .....................................................................................54
9 Marking............................................................................................................ 55
9.1 Loadingdiagram .........................................................................................56
9.2 Idencaonplate.....................................................................................57
9.3 Workarea ..................................................................................................57
9.4 Warningtape .............................................................................................57
9.5 Controllerscker ........................................................................................58
9.6 Dangerarea ...............................................................................................59
9.7 Warningags .............................................................................................59
10 Lubrication and fluid level check....................................................................... 60
10.1 Lubricaon..................................................................................................60
10.2 Fluidlevelcheck .........................................................................................60
11 Testing and verification .................................................................................... 61
11.1 Stacloadtest ............................................................................................61
11.2 Dynamicloadtest.......................................................................................62
11.3 Testofsafetyfuncons...............................................................................62
12 Disassembly ..................................................................................................... 63
13 Specifications .................................................................................................. 64
13.1 Weights......................................................................................................64

Z 2500-130/150Importantinformaon
5www.zepro.com
1 Important information
1.1 Attention!
The following warning signs appear in the installation instructions and are intended to draw your attention to cir-
cumstances that can potentially cause problems, near misses, personal injury and/or damage to the product, etc.
mWARNING!
WARNING indicates a potential hazard, which if ignored may lead to serious, life-threatening injury.
mCAUTION!
CAUTION indicates a potential hazard, which if ignored, may lead to minor injuries.
IMPORTANT!
IMPORTANT indicates a risk of equipment damage.
NOTE!
NOTE refers to additional information that may help the reader understand, or perform, a given operation.
1.2 Technical support
If technical support is needed, please contact ZEPRO. Tel: [phone], E-mail: zepr[email protected].
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 identication plate located on the tail lift frame.
Image 1. Identification plate

Z 2500-130/150
6
Importantinformaon
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Z = Standard model
Max. lifting capacity x 1 (kg)
Max lifting height -130 = 1300 mm
-150 = 1500 mm
Cylinder model, MA = Double acting Adjustable Tilt
Single acting Single speed Lift
DA = Double acting Adjustable Tilt
Double acting Single speed Lift
E.g. Z - 2500 - 130 MA
_ _ _ - _ _ _ _ - _ _ _ _ _
1.3 Identication
1.4 CE marking
ZEPRO tail lifts for sale on the European market are CE marked (Conformité Européenne). The manufacturer
guarantees that the product complies with the EU Machinery Directive.
Follow the installation instructions carefully. Modications not approved in writing by the manufacturer are not
permitted. Welding is not permitted.
1.5 Product approval
Properly assembled, this product meets relevant requirements according to EN 1756-1:2001 + A1:2008.
1.6 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 lled with highly rened
mineral oil (art. no. 21963, 1 litre).
Hydraulic systems with hydraulic oil tanks marked with a specication for the hydraulic oil are only permitted
to be lled with the oil specied on the label.
1.7 Guarantee
The ZEPRO warranty applies only if assembly has been carried out according to ZEPRO's assembly instructions
by a ZEPRO approved bodybuilder.
After installation, testing and verication, register the tail lift’s delivery card to validate the warranty.

Z 2500-130/150Importantinformaon
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1.8 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.
Image 2. Piston rods, cyl-
inder covers and boots
Image 3. Hydraulic hoses Image 4. Cables
1.9 Battery maintenance
When storing for longer than 1 week, it is recommended to disconnect the lift from the battery via the main
switch or by releasing the lift’s main fuse, in order to reduce the risk of the battery discharging. The length of
time the vehicle can be stored without the battery charge level becoming too low depends on the condition of
the battery, the charge level prior to storage and how much power other components in the vehicle take from
the battery. After a period of storage, the battery must always be charged fully before operating the lift.
When the lift is operated repeatedly without starting or using the vehicle during lift installation or carrying out
service and repairs, use the battery charger between operations to maintain battery charge .
IMPORTANT!
The battery charger must be disconnected when operating the lift. Risk of material damage.

Z 2500-130/150
8
Safetyrules
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2 Safety rules
2.1 Moving parts - free movement
mWARNING!
During nal inspection*, the space occupied by the
moving cylinders must be cleared and made safe.
There is a risk of collision between 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).
**Final inspection to be carried out with the platform
at the vehicle oor and tilted down 10°. The clear-
ance from the closest part of the cylinder must be
at least 40 mm.
mWARNING!
The platform may not be tilted down more than
10º from the horizontal.
min. 40 mm
10º
10º
Image 5. Clearance to the closest part of
the cylinder must be at least 40 mm
Image 6. The platform may not be tilted
down more than 10º from the horizontal
2.2 Connection of third-party equipment is forbidden
mWARNING!
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.
2.3 Installation
mWARNING!
Installation where the platform cannot reach ground level is prohibited.
mWARNING!
ZEPRO tail lifts are only approved for installation using ZEPRO assembly kits.
IMPORTANT!
All specied tightening torques apply when using torque wrench or screw/nut runner with torque control.
Torque spread max ±5%.

Z 2500-130/150Beforeinstallaon
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Max 450 mm.
(Air suspension)
Max 500 mm.
(Spring suspension)
Max 300 mm.
8º
Image 7. The cross-secton of the frame beam
70
70
220
4
R6(x2)
X
Y
3 Before installation
3.1 Vehicle chassis requirements
In order to comply with the applicable underrun protec-
tion 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
frame beam (excluding any support frame) shall not
be less than 937 cm4. The cross-section of the frame
beam shall therefore have at least dimensions of
220x70x4 mm, corresponding to a surface moment of
inertia of 937cm4 around the x-axis. See illustration. If
in doubt, contact ZEPRO for support.
3.2 Statutory dimensions for underrun protection
Distance between the beam and the ground when the vehicle is unloaded:
Max. 450 mm for vehicles with air suspension.
Max. 500 mm for vehicles with conventional suspension.
If the exit angle with the above setting is less than 8º, the distance between beam and ground in an unladen ve-
hicle may be increased until the angle is 8º, but to Max. 550 mm.
Horizontal distance from the outermost part of the platform to the underrun protection: Max. 300 mm. See illustra-
tion below.
The underrun protection may be placed further back and lower.
NOTE!
Image 8. Statutory dimensions
The above dimensions are the minimum permit-
ted for the installation of underrun protection.
The strength requirements for mounting the tail
lift usually require larger dimensions.
mWARNING!

Z 2500-130/150
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Beforeinstallaon
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0-100 mm.
Horizontal distance from the outer edge of the beam to the
outside of the wheel: Max. 100 mm. See Image 9.
The lateral distance between the underrun protection
and the moving parts of the tail lift must not exceed
25 mm. See Image 10.
Each of the individual parts of the underrun
protection must have a surface area of at least 350
cm2. See Image 10.
Image 9. Statutory dimensions
Image 10. Statutory dimensions
Max 25 mmMax 25 mm
Min. Area: 350 cm2

Z 2500-130/150Beforeinstallaon
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3.3 Calculating the installed dimensions
For easier installation it is useful to calculate and specify the necessary dimensions in advance. Determine the
C dimension rst, then obtain the other dimensions from the relevant table. You should try to place the lift as
high as possible within the specied C dimension in the table.
3.3.1 C dimension
The C dimension is the distance between the top of the support frame and the vehicle oor level. This dimension
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 oor level (A dimension).
3.3.2 D dimension
The D dimension is the space the lift needs, measured from the rear edge of the body to the front edge of the
support frame (in the direction of the vehicle). Once the C dimension is determined, the D dimension can be
obtained from the table.
3.3.3 A dimension
The A dimension is the space provided for the rear beam, i.e. the space there will be between the lift arms and
the vehicle oor with the lift in the raised position. The A dimension depends on the C dimension.
3.3.4 H dimension
The H dimension is the height from the ground (unloaded) to the vehicle oor level. The H dimension must not
be greater that the maximum lifting height of the lift. The platform must always be able to reach ground level.

Z 2500-130/150
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Image 11. Z2500-130
Image 12. Z2500-150
C A D
610 202 685
570 187 728
520 172 773
470 160 812
420 150 844
370 142 871
330 136 890
max 1300
690
220
214
194
C
A
40 D
C A D
715 211 736
680 197 777
630 182 828
580 170 871
530 159 909
480 151 941
430 143 969
360 134 1002
max 1500
785
220
214
194
C
A
40 D
Image 13. Z2500-130/-150
1524
1010
min. 750 - max. 930
1509
1966
2411
34
35
62
100 385
350
133-301
617-817

Z 2500-130/150Beforeinstallaon
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3.4 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.
1. Measure and mark the location and depth of the cut outs on the rear beam. The two cut outs must be
centred on the rear beam, i.e. both cut outs must be an equal distance from the mid-point of the beam.
2. Cut along the markings.
3. Grind away any burrs or sharp edges.
Image 14. Rear beam cut-outs
994
245 245
Amax

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Beforeinstallaon
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3.5 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.
4. Release the hydraulic unit by unscrewing the wing nut and corresponding screw (C); see Image 18 and
pull out the hydraulic unit until the tank cap is accessible; see Image 20.
mCAUTION!
Make sure no cables are pinched or in any other way damaged when the control card / relay card is
folded out or removed. Do not pull out the hydraulic unit more than necessary; make sure it is not
pulled completely out of the frame, as this can entail a risk of injury and damage to the equipment.
Image 15. Remove the protective cap
C
AB
Image 16. Release mechanism
Image 17. Connection socket Image 18. Releasing the hydraulic unit

Z 2500-130/150Beforeinstallaon
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54
8
5
3
Image 19. Where necessary, replace the
transport plug with a regular tank cap
Image 20. Hydraulic unit and relay card
RELAY CARD
TANK CAP
MOTOR
OIL TANK
SOLENOID
VALVE HOUSING
5. Check whether the hydraulic tank is tted with
a transport plug seal. If so, replace it with the
regular tank cap supplied.

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3.6 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.
1. Connect a suitable control device to Ctrl 1/C1, see 3.6.2/3.6.3.
2. Connect the +12/24V battery to the tail lift’s main power cable.
3. Connect the negative battery terminal to the tail lift’s earth cable (GND).
4. Control card ZePRO1:
When operating, connect the cable (jumper) between the CSPWR and CS on the control card to simulate
that the CS switch is turned on. Remove the jumper immediately after completed operation.
Relay card TLC-B1:
When operating, connect a cable (jumper) between an available power supply connection (+) and CS on
the relay card to simulate switch CS being on. Remove the cable immediately after completed operation.
mWARNING!
Take great care while running the lift functions and make sure nothing gets pinched: risk of personal
injury and material damage.
Ctrl 4
Spiral
Ctrl 3
Radio
Ctrl 2
Ctrl 1
Contrl Power
Sensor Power
Ground
IN OUT
Ai 1
Ai 2
Di 1
Di 2
Di 3
Di 4
Di 5
Di 6
PA-
PA+
CSPWR
CS
+
B
E
C
2H1
B
E
C
2H2
B
E
C
Lock
B
E
C
Lock
U7
U6
U5
U4
U3
U5
U4
U2
U1
U0
Ctrl 6
Out
In
GND
LLED
Ctrl 5
Outputs
Sensors
Image 21. Temporary connection
3.6.1 Battery maintenance
When installing the lift, when the lift is operated repeatedly, the battery charger must be used between opera-
tions to maintain the battery charge level .
The battery charger must not be connected when operating the lift. Risk of material damage .
IMPORTANT!
WL1 U7 U6 U5 U5 U4 U4 U3 U2 U1 U0
++
WL2
PA+
S5
S1+
S4
S3
S2
S1
S5+
S4+
S3+
S2+
PA-
CS+
Down
2H
Out
Down
Down
C1+
C1+
Up
Tilt
In
C2+
Up
Tilt
C3+
Up
CS
+
U1
U2
U3
U0 +
ZePRO1 TLC-B1
Jumper
Jumper
Ctrl 1
C1

Z 2500-130/150Beforeinstallaon
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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, conguration and relevant market.
mWARNING!
Make sure the control relay is disconnected from power before connecting. Connecting more than one
controller to each connection is not permitted. Risk of material damage.
WL1 U7 U6 U5 U5 U4 U4 U3 U2 U1 U0
++
U0 +
+
U1
U2
U3
WL2
PA+
S5
S1+
S4
S3
S2
S1
S5+
S4+
S3+
S2+
PA-
CS
CS+
Down
2H
Out
Down
Down
C1+
C1+
Up
Tilt
In
C2+
Up
Tilt
C3+
Up
Ctrl 1
CD4
Up
Tilt
2H
Down
Up
Tilt
Down
2H
CD1
CD19
Up
Down
Tilt up
Tilt down
2H
2H
Tilt down
Up
Down
Tilt up
Black C1+
White ( )*
Brown Up
Yellow Down
Blue Tilt
Black C1+
White ( )
Brown Up
Yellow Down
Blue Tilt
Black C1+
White ( )
Brown Up
Yellow Down
Blue Tilt
Pink 2H
*appliestocontrollerswithheangonly
Black C1+
Blue 2H

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Beforeinstallaon
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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, conguration and relevant market.
mWARNING!
Make sure that the control card is disconnected from the power before connecting. Connecting more
than one controller to each connection is not permitted. Risk of material damage.
Ctrl 4
Spiral
Ctrl 3
Radio
Ctrl 2
Ctrl 1
Contrl Power
Sensor Power
Ground
IN OUT
Ai 2
Ai 1
Di 1
Di 2
Di 3
Di 4
Di 5
Di 6
PA-
PA+
CSPWR
CS
+
B
E
C
2H1
B
E
C
2H2
B
E
C
Lock
B
E
C
Lock
U7
U6
U5
U4
U3
U5
U4
U2
U1
U0
Ctrl 6
Out
In
GND
LLED
Ctrl 5
Outputs
Sensors
o
Brun B
Gul E
Blå C
* Blå 2H
CD1, CD2
B
C
2H1
E
CD15
B
C
2H
E
Black (+)
Black (+)
2H Black (+)
Black (+)
White (-)*
White (-)*
Ctrl 4
Spiral
Ctrl 3
Radio
Ctrl 2
Ctrl 1
Contrl Power
Sensor Power
Ground
IN OUT
Ai 2
Ai 1
Di 1
Di 2
Di 3
Di 4
Di 5
Di 6
PA-
PA+
CSPWR
CS
+
B
E
C
2H1
B
E
C
2H2
B
E
C
Lock
B
E
C
Lock
U7
U6
U5
U4
U3
U5
U4
U2
U1
U0
Ctrl 6
Out
In
GND
LLED
Ctrl 5
Outputs
Sensors
o
White (-) must be con-
nected to the connec-
tions marked “Ground”.
Brown B
Yellow E
Blue C
Green 2H
Brown B
Yellow E
Blue C
Blue 2H
Brown B
Yellow E
Blue C
Pink 2H
White (-)
Black (+)
*appliestocontrollerswithheangonly
Up
Down
Tilt up
Tilt down
2H
2H
Tilt down
Up
Down
Tilt up

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4 Installation
Also consult the vehicle manufacturer’s body in-
structions and Zepro’s instruction booklet before
installation.
NOTE.
Zepro tail lifts are only approved for installation
with Zepro installation kits.
mWARNING!
4.1 Support frame
1. Measure and mark the midpoint of the rear beam
of the vehicle. See Image 22.
2. Bolt or spot-weld the mounting jig to the rear beam,
so that both mid-points are aligned. See Image 23 .
3. Position the support frame under the vehicle
chassis.
4. Raise the lift arms to the highest position.
5. Attach the lift arms to the eye of the jig. Use the
steel platform’s normal bolts.
6. The support frame should be positioned as high as
possible within the specied C dimension. Adjust
the frame to the ideal height under the chassis. A
car jack is useful. The frame must be positioned
parallel with the oor of the vehicle body and must
not be in contact with the vehicle chassis; there
must be a few millimetres of play. If necessary
adjust the angle of the arms by carefully operat-
ing the lift.
7. Install the brackets on the support frame so that its
opening is facing towards the front of the vehicle,
and adjust the position of the frame so they are in
contact with the vehicle chassis.
8. Install the U-prole with associated washers and
nuts, but do not tighten these. Screw on the nuts
alternately until the U-prole is aligned in contact
with the frame, see Image 25.
Image 22. Measure and mark the midpoint of
the rear beam of the vehicle.
Image 23. Bolt or spot-weld the
mounting jig to the rear beam
Art. nr. 57370TL for Z 2500
Image 24. Mounting jig,
Image 25. Install the U-profile with as-
sociated washers and nuts

Z 2500-130/150
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Installaon
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9. When installing on a frame without pre-drilled
holes, install rst 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 27.
10. Bolt the brackets securely on the outside of the ve-
hicle chassis. Use M14x45 bolts and install the as-
sociated washer and nut on the inside of the vehicle
chassis. Install the bolts but do not tighten.
11. Check and perform ne adjustment regarding the
position of the lift. Then tighten the bolts with a
torque wrench.
Tightening torque: 120 Nm.
12. Using a torque wrench, tighten the bolts holding the
U-proles. Tightening torque: 280 Nm.
13. Drill holes in the vehicle chassis for mounting bolts,
Ø14 mm. Drill in the outer holes of each bracket.
Use M14x45 bolts and install the associated
washer and nut on the inside of the vehicle chas-
sis. Installation must be performed with at least 6
bolts in the outer holes. The bolt that was installed
initially in the slot-shaped hole may not be included
in this gure. If necessary, this bolt can now be
moved to one of the outer holes, see illustration.
Then tighten the bolts with a torque wrench.
Tightening torque: 120 Nm.
Welding is not permitted on the chassis brackets.
Do not move the lift all the way to the armstops or
with the platform tted before all the bolts are fully
tightened against the chassis.
Do not place the lift under load until:
· the correct number of bolts have been installed
and torque-tightened.
· the vehicle body is installed to reinforce the truck
chassis.
NOTE.
14. Remove the mounting jig.
Min. 260
Min. 20
Min. 180
35 mm
Min. 20
Min. D
D
Min. 6 pcs.
M14x45 10.9
120 Nm
New hole
Image 26. The chassis bracket requires
at least 35 mm clearance between ve-
hicle chassis and support frame
Image 27. Install the chassis bracket
with at least six M14x45 10.9 bolts
When installing on chassis with pre-drilled holes, go
directly to point 16.