Zepro ZAHD 150/200 User manual

ZEPRO
Tel.: [phone]
E-mail: [email protected] |zepro.com
74227TL
2022-07-04
Installation Instructions
Tail Lift
ZAHD 150/200-155/175
ZAEHD 150/200-155/175

ZAHD, ZAEHD 150/200-155/175Contents
3www.zepro.com
Contents
1 Important information ....................................................................................... 5
1.1 Aenon! .....................................................................................................5
1.2 Technicalsupport .........................................................................................5
1.3 Idenkaon ................................................................................................6
1.4 CEmarking....................................................................................................6
1.5 Productapproval .........................................................................................6
1.6 Hydraulicoil..................................................................................................6
1.7 Guarantee.....................................................................................................6
1.8 Repainng.....................................................................................................7
1.9 Baerymaintenance ....................................................................................7
1.10 Conguraon................................................................................................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 ....................................................................................16
3.5 Preparethetailli......................................................................................16
3.6 Temporaryconnecon................................................................................18
4 Installation ...................................................................................................... 21
4.1 SupportFrame...........................................................................................21
4.2 Plaorm......................................................................................................23
4.3 Armstops ....................................................................................................28
4.4 Sealingstrip(horizontal).............................................................................28
4.5 Sealingstrip(vercal) .................................................................................28
4.6 Underrunprotecon ..................................................................................29
4.7 Anglesensor/Inclinometer .......................................................................30
4.8 Controllers ..................................................................................................32
5 Cable routing ................................................................................................... 34
5.1 General .......................................................................................................34
5.3 Maximumpowerconsumpon ..................................................................35
5.2 Baerymaintenance ..................................................................................35
5.4 Purgingthecylinders ..................................................................................36
5.5 Plaormltspeed ......................................................................................36
5.6 Mainpowercable,earthcable,mainfuseandmainswitch ......................37
5.7 Controlpowercable ...................................................................................39
5.8 Openplaormalarm ..................................................................................39
5.9 Footcontroller/Warninglights .................................................................39
6 Connection....................................................................................................... 40
6.1 Conneconunit ..........................................................................................40
6.2 Connecon .................................................................................................41

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Contents
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7 Powering up the tail lift .................................................................................... 49
8 Electrical and hydraulic diagrams...................................................................... 50
8.1 ZAHD/ZAEHD150/200MA(TLCB1) .........................................................50
8.2 ZAHD/ZAEHD150/200MA(ZePRO1) .......................................................51
8.3 ZAHD/ZAEHD150/200MAAutolt(TLC-B1)............................................52
8.4 ZAHD/ZAEHD150/200MA,Autolt(Inclinometer)(ZePRO1)..................53
8.5 ZAHD/ZAEHD150/200MA,Autolt(IFM)(ZePRO1)................................54
9 Lubrication and fluid level check....................................................................... 55
9.1 Lubricaon..................................................................................................55
9.2 Oillevelcheck.............................................................................................55
10 Marking............................................................................................................ 56
10.1 Loadingdiagram .........................................................................................57
10.2 Idencaonplate.....................................................................................58
10.3 Workarea ..................................................................................................58
10.4 Warningtape .............................................................................................58
10.5 Controllerscker ........................................................................................59
10.6 Dangerarea ...............................................................................................60
10.7 Warningags .............................................................................................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 Registration...................................................................................................... 63
13 Specifications .................................................................................................. 63
13.1 Weights......................................................................................................63

ZAHD, ZAEHD 150/200-155/175Important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: [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

ZAHD, ZAEHD 150/200-155/175
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Importantinformaon
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ZAHD = Standard model
Max liftcapacity x 10 (kg)
Max lifting height -155 = 1530 mm
-175 = 1710 mm
Cylindermodel, MA = Doubleacting Adjustable Tilt
Single acting one speed Lift
T.ex ZAHD - 150 - 155 MA
_ _ _ _ - _ _ _ - _ _ _ _ _
Identications list
1.3 Identikation
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 instruc-
tions by a ZEPRO approved bodybuilder.
After installation, testing and verication, register the tail lift’s delivery card to validate the warranty.

ZAHD, ZAEHD 150/200-155/175Importantinformaon
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1.8 Repainting
Image 2. Piston rods, cyl-
inder covers and boots
Image 3. Hydraulic hoses
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.
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 4. Cables

ZAHD, ZAEHD 150/200-155/175
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Importantinformaon
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1.10 Conguration
Thetablebelowshowswhichchassisbracketsmatcheachvehiclemodel.
Truck make Draw-
bar
End panel Chassis
width
Chassis
brackets
Com-
plete
weight
Art. no.
(left, right)
DAF VBG EDH-2/3 790 ZAHD 14.9 kg 75443TL, 75442TL
DAF VBG EDH-2/3 790 ZAEHD 14.9 kg 75390TL, 75389TL
Iveco VBG EDH-3 758 ZAHD 75437TL, 75436TL
Iveco VBG EDH-3 758 ZAEHD 75397TL, 75396TL
Scania VBG EDH-2/3 766-770 ZAHD 75424TL, 75423TL
Scania VBG EDH-2/3 766-770 ZAEHD 75243TL, 75242TL
MAN VBG EDH-3 766-770 ZAHD 75424TL*, 75423TL*
MAN VBG EDH-3 766-770 ZAEHD 75243TL*, 75242TL*
Mercedes VBG EDH-2/3 848-850 ZAHD 75431TL, 75430TL
Mercedes VBG EDH-2/3 848-850 ZAEHD 75378TL, 75377TL
Volvo Volvo Volvo 850 ZA/HD elevated 25.4 kg 53887TL, 53886TL
Volvo Volvo Volvo 850 ZAE/HD 38.2 kg 57014TL, 57013TL
Volvo VBG EDH-2/3 848-850 ZAHD 75414TL, 75413TL
Volvo VBG EDH-2/3 848-850 ZAEHD 75365TL*, 75364TL*
*Duringinstallaon,ashimplateinaccordancewiththefollowingtableisalsorequired.
Truck make Drawbar End panel Chassis
width
Shim plate Complete weight Art. no.
MAN VBG EDH-3 766-770 ZAHD, ZAEHD 75383TL
Volvo 848 ZAEHD 77806TL

ZAHD, ZAEHD 150/200-155/175Safetyrules
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2 Safety rules
2.1 Moving parts - free movement
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!
During nal inspection*, the space occupied by
the moving cylinders must be cleared and made
safe. There is a risk of collision between the cylin-
der and the following items: subframe, truck chas-
sis, 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.
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%.

ZAHD, ZAEHD 150/200-155/175
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Beforeinstallaon
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Max 450 mm.
(Air suspension)
Max 500 mm.
(Spring suspension)
Max 294 mm.
8º
Image 7. The cross-secton of the frame beam
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 cur-
rent frame beam (excluding any support frame) shall
not be less than 1929 cm⁴. The cross-section of the
frame beam shall therefore have at least dimensions of
255x70x6 mm, corresponding to a surface moment of
inertia of 1929 cm⁴ 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
vehicle 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. 294 mm. See
illustration below.
NOTE!
The underrun protection may be placed further back and lower.
Image 8. Statutory dimensions
70
70
255
6
R8(x2)
X
Y
mWARNING!
The above dimensions are the minimum permit-
ted for the installation of underrun protection. The
strength requirements for mounting the tail lift usu-
ally require larger dimensions.

ZAHD, ZAEHD 150/200-155/175Beforeinstallaon
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Max 100 mm.
• Horizontal distance from the outer edge of the beam to
the outside of the wheel: Max 100 mm See illustration.
• The lateral distance between the underrun
protection and the moving parts of the tail lift
must not exceed 25 mm. See illustration.
• Each of the individual parts of the underrun
protection must have a surface area of at least
350 cm2. See illustration.
Image 9. Statutory dimensions
Image 10. Statutory dimensions
Max 25 mmMax 25 mm
Min. Area: 350 cm2

ZAHD, ZAEHD 150/200-155/175
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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 di-
mension) 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 deter-
mined, 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.

ZAHD, ZAEHD 150/200-155/175Beforeinstallaon
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780 (*760)
max 1530 (*1510)
220 (*200)
C
A
40
D
* without support wheel
875 (*855)
max 1710 (*1690)
220 (*200)
C
A
40
D
* without support wheel
Image 11. ZAHD 150/200-155
Image 12. ZAHD 150/200-175
C A D R58:3
750 229 651
Approved
700 206 714
650 189 767
600 176 812
550 165 851
500 155 885
450 147 913
404 142 936
395 140 940
C A D R58:3
835 230 736
Approved
800 215 780
750 198 835
700 185 883
650 174 925
637 172 936
600 165 961
550 156 993
500 149 1021
435 141 1052

ZAHD, ZAEHD 150/200-155/175
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Image 13. ZAEHD 150/200-155
Image 14. ZAEHD 150/200-175
* without support wheel
780 (*760)
max 1530 (*1510)
220 (*200)
C
A
40
D
875 (*855)
max 1710 (*1690)
220 (*200)
C
A
40
D
* without support wheel
C A D R58:3
750 229 651
Approved
700 206 714
650 189 767
600 176 812
571 171 836
550 165 851
500 155 885
450 147 913
395 140 940
C A D R58:3
835 230 736
Approved
800 215 780
750 198 835
700 185 883
650 174 925
637 172 936
600 165 961
550 156 993
500 149 1021
435 141 1052

ZAHD, ZAEHD 150/200-155/175Beforeinstallaon
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Image 15. ZAHD 150/200
Image 16. ZAHD 150/200
327
61
209
180
201
180
695-895
45
1432
970
2400
L
409
61
100
180
310
180
695-895
45
1432
970
2400
L
Image 17. ZAEHD 150/200 elevated
61
209
180
201
180
1432
970
2400
L
327
695-895
Chassis width L
L - 20
790
870
Chassis
width L
L - 16
786
866
Chassis width L
L - 20
790
870

ZAHD, ZAEHD 150/200-155/175
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Beforeinstallaon
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994245 245
Amax
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 burr or sharp edges.
Image 18. Rear beam cut outs
3.5 Prepare the tail lift
1. Position the support frame under the vehicle chassis.
2. Remove the connection unit cover, secured with four screws, see Image 19.
Relay card/control
card
Image 19. Connection unit

ZAHD, ZAEHD 150/200-155/175Beforeinstallaon
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54
8
5
3
Image 20. Where necessary, replace the
transport plug with a regular tank cap
Image 21. Hydraulic unit
3. Check whether the hydraulic tank is tted with a
sealed transport plug. In this case, replace it with the
regular tank cap supplied.
OIL TANK
TANK CAP
VALVE HOUSING
MOTOR

ZAHD, ZAEHD 150/200-155/175
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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 position
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 simu-
late 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.
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 22. 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 .
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
mWARNING!
Take great care while running the lift functions and make sure nothing gets pinched: risk of personal
injury and material damage.
IMPORTANT!
The battery charger must not be connected when operating the lift. Risk of material damage.

ZAHD, ZAEHD 150/200-155/175Before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
When connecting Warning Lights: Loop between S3 - S3+

ZAHD, ZAEHD 150/200-155/175
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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 connections
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