Zepro ZHD 2500-130 User manual

ZEPRO
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E-mail: [email protected] |zepro.com
55987TL
2021-05-04
Installation Instructions
Tail Lift
ZHD 2500-130/150

ZHD 2500-130/150Contents
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Contents
1 Introduction ..................................................................................................... 5
1.1 Important ................................................................................................ 5
1.2 CE marking............................................................................................. 6
1.3 Product approval ................................................................................... 6
1.4 Hydraulic oil ............................................................................................ 6
1.5 Guarantee............................................................................................... 6
1.6 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 beam cut-outs........................................................................................ 15
6 Installation ..................................................................................................... 16
6.1 Support frame....................................................................................... 16
6.2 Control power cable.............................................................................. 19
6.3 Control devices..................................................................................... 20
6.4 Main power cable ................................................................................. 21
6.5 Installation of main fuse on vehicles without connection point ............. 22
6.6 Underrun protection.............................................................................. 23
6.7 Underrun protection.............................................................................. 25
6.8 Armstops .............................................................................................. 26
6.9 Angle sensor for autotilt........................................................................ 26
6.10 Sealing strip (horizontal)....................................................................... 26
6.11 Sealing strip (vertical) ........................................................................... 26
6.12 Platform ................................................................................................ 27
6.13 Purging the cylinders ............................................................................ 32
6.14 Transport lock ....................................................................................... 32
7 Temporary operation of lift............................................................................ 33
7.1 Connection ........................................................................................... 33
7.2 Operation.............................................................................................. 33
7.3 Disconnection ....................................................................................... 33

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Contents
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8 Hydraulic unit and control card .................................................................... 34
9 Electrical and hydraulic diagrams ................................................................ 35
9.1 ZHD 2500 NN ....................................................................................... 35
9.2 ZHD 2500 DVx4 NN ............................................................................. 36
9.3 ZHD 2500 DVx4 CE ............................................................................. 37
9.4 ZHD 2500 Hydraulic autotilt NN ........................................................... 38
9.5 Connection of connection card to control card ..................................... 39
9.6 Connection to circuit board 4-button operation..................................... 40
9.7 Jumper two hand control ...................................................................... 41
9.8 Connecting cabin switch and open platform alarm............................... 42
9.9 Alarm for open platform (trailer)............................................................ 42
9.10 Connecting control device .................................................................... 43
10 Function diagrams ......................................................................................... 44
10.1 ZHD2500(Cong1)MA ...................................................................... 44
10.2 ZHD2500(Cong3)DA....................................................................... 46
11 Connection unit .............................................................................................. 48
11.1 Power save mode................................................................................. 48
11.2 Operating information ........................................................................... 48
12 Marking............................................................................................................ 54
12.1 Loading diagram................................................................................... 55
12.2 Identicationplate................................................................................ 56
12.3 Work area ............................................................................................ 56
12.4 Warning tape ....................................................................................... 56
12.5 Controller sticker................................................................................... 57
12.6 Danger area ......................................................................................... 58
12.7 Warningags....................................................................................... 58
13 Lubrication and fluid level check.................................................................. 59
13.1 Lubrication ............................................................................................ 59
13.2 Oil level check ...................................................................................... 59
14 Testing and verification ................................................................................. 60
14.1 Static load test ...................................................................................... 60
14.2 Dynamic load test. ................................................................................ 61
14.3 Test of safety functions......................................................................... 61
15 Disassembly ................................................................................................... 62
16 Specifications ................................................................................................ 63
16.1 Weights ................................................................................................ 63
16.2 Maximum power consumption - Minimum recommended
conductor cross sectional area............................................................. 64
16.3 Battery maintenance............................................................................. 64
16.4 Loading diagram................................................................................... 65
16.5 Tightening torque.................................................................................. 66

ZHD 2500-130/150Introduction
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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 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.
1.3 Product approval
Properly assembled, this product meets relevant requirements according to EN 1756-1:2001 + A1:2008.
1.4 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.
1.5 Guarantee
Afterinstallation,testingandverication,thetaillift’sdeliverycardmustberegisteredfortheguaranteetobevalid.

ZHD 2500-130/150Introduction
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1.6 Identication
E.g. ZHD 2500 - 130 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 paint-
ed. Painting could damage 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im-
pair 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

ZHD 2500-130/150Safety rules
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2.2 Transport plug
When the lift is installed, the transport 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 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).
*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 titled down more than
max.10°fromhorizontalwhenpeopleareonthe
platform.
mWARNING!
min. 40 mm
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. The platform must not be tilted
down more than 10° from the horizontal

ZHD 2500-130/150
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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at-
tachment 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!
Allspeciedtorquevaluesapplyforusewithascreworimpactwrenchwithtorquecontrol.Torquedistribu-
tion max ± 5%.
NOTE!

ZHD 2500-130/150Installationworkow
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3 Installation workow
3.1 Installing the support frame
• Calculating the installed dimensions
• Attaching the mounting jig to the rear beam
• Aligning the support frame
• Mounting chassis brackets
• Detaching the mounting jig
3.2 Electrical connections
• Installing the control devices
• Installing the control device cables
• Installing the main power cable
3.3 Installing the platform
• Installing the platform
• Installing seals and end stops
• Installing the armstops
3.4 Installing cylinders
• Adjusting tilt cylinder
• Test running
3.5 Attaching decals

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Calculating the installed dimensions
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4 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.
4.1 C dimension
TheCdimensionisthedistancebetweenthetopofthesupportframeandthevehicleoorlevel.Thisdimen-
sion 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).
4.2 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.
4.3 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
4.4 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.

ZHD 2500-130/150Calculating the installed dimensions
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ZHD 2500-130
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
ZHD 2500-150
max 1500
785
220
214
194
C
A
40 D
Image 7. ZHD 2500
Image 8. ZHD 2500

ZHD 2500-130/150
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Calculating the installed dimensions
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994
245 245
Amax
1524
1010
min. 750 - max. 930
1509
1966
2411
34
35
62
100 385
350
133-301
617-817
Image 9. ZHD 2500

ZHD 2500-130/150Rear beam cut-outs
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5 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.
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 10. ZHD 2500
994
245 245
Amax

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Installation
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6 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!
6.1 Support frame
1. Measure and mark the midpoint of the rear beam
of the vehicle. See illustration.
2. Bolt or spot-weld the mounting jig to the rear beam,
so that both mid-points are aligned. See Image 12.
Art. no. 51724 for ZHD 2500
3. Position the support frame under the vehicle chassis.
4. Temporarily connect the control card to enable the
lift functions, see section "7 Temporary operation
of lift" on page 33.
5. Raise the lift arms to their highest position.
6. Attach the lift arms to the eye of the jig. Use the
steelplatform’snormalbolts.
7. 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 workshop 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
operating the lift.
8. 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.
9. 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 14.
Image 11. Measure and mark the mid-
point of the rear beam of the vehicle.
Image 12. Bolt or spot-weld the
mounting jig to the rear beam Art.
no. 51724 for ZHD 2500
Image 13. Mounting jig,
Image 14. Install the U-profile with as-
sociated washers and nuts

ZHD 2500-130/150Installation
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10. 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 16.
11. Bolt the brackets securely on the outside of the vehicle
chassis. U se M14x45 bolts and install the associated
washer and nut on the inside of the vehicle chassis.
Install the bolts but do not tighten.
12. Checkandperformneadjustmentregardingtheposition
of the lift. Then tighten the bolts with a torque wrench.
Tightening torque: 120 Nm.
13. Using a torque wrench, tighten the nuts holding the
U-proles.Tightening torque: 280 Nm.
14. D rill 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 chassis.
Installation must be performed with at least 8
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.
15. Remove the mounting jig.
Image 15. The chassis bracket requires
at least 35 mm clearance between ve-
hicle chassis and support frame
Image 16. Install the chassis bracket
with at least 8 M14x45 10.9 bolts
When installing on chassis with pre-drilled holes,
go directly to point 16.
35 mm
35 mm
Min. 260
Min. 20
Min. 202.5
Min. 20
Min. D
D
Min. 8 pcs.
M14x45 10.9
120 Nm
New hole

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Installation
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16. Bolt the brackets securely on the outside of the
vehicle chassis. Install in the slot-shaped holes
with at least 8 screws. Use suitable bolts (durability
equivalent to M14 10.9 or higher) and install the
associated washer and nut on the inside of the
vehicle chassis. Install the bolts but do not tighten.
See Image 17.
17. Check and perform ne adjustment regarding the
position of the lift. Then tighten the bolts with a
torque wrench. Tightening torque: Standard for
selected screw.
18. Using a torque wrench, tighten the nuts holding the
U-proles.Tightening torque: 280 Nm.
19. D rill holes in the vehicle chassis for mounting bolts
in each bracket’s two upper round holes. Use
suitable bolts (durability equivalent to M14 10.9 or
higher) and install the associated washer and nut
on the inside of the vehicle chassis. See Image 17.
Tighten the bolts with a torque wrench. Tightening
torque: Standard for selected screw.
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.
20. Remove the mounting jig.
When installing on chassis with pre-drilled
holes
Image 17. Installing the chassis bracket on
vehicle chassis with pre-drilled holes

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6.2 Control power cable
Seealsothetrailermanufacturer’selectricalinstructions.
NOTE.
1. Routethecontrolpowercablefromthedriver’scabtothelift.
The cable must be protected with rubber grommets when it passes through beams or walls. If there
arequickconnectors,makesuretheyaree󰀨ectivelyprotectedfrommoistureanddirt.Donotbendthe
cable to too small a radius as this can cause damage to the cable.
NOTE.
2. Connect the control power cable to the cabin switch (CS) on the vehicle instrument panel. Connect to the
on-boardelectricalsystemviaa10A(24V),15A(12V)fuseaccordingthecustomer’swishes.Seethe
connection diagram "9.8 Connecting cabin switch and open platform alarm" on page 42.

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Installation
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6.3 Control devices
If the vehicle is equipped with two-handed grip, the
operator must use both hands to operate the plat-
form. It also protects the operator from pinching and
crushing injuries.
1. Fit the control devices in the desired locations.
They must be positioned 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.
2. The distance between the vehicle's rear edge and
centre of the control devices must be 400 mm ±
100 mm. The distance between the control devices
must be at least 250 mm. See illustration 23.
All cable inlets must be pointing downwards.
NOTE.
3. The control device’s cable is connected to the
control card.
Image 18. Installing control
device with two-handed grip.
Min. 250 mm.
A control device must always be installed on the side
that is turned away from moving tra󰀩c. If a control
device is needed on the other side, a further control
device must be installed. Installation in any other way
increases the risk of personal injury.
mWARNING!
Image 19. Installing control device
400mm ± 100mm