Zepro ZN 2500-130 User manual

ZEPRO
Tel.: [phone]
E-mail: [email protected] |zepro.com
76510TL
2022-06-09
Installation Instruction
Tail Lift
ZN 2500-130
ZN 2500-150

ZN 2500-130/150Contents
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
2 Safety rules ........................................................................................................ 8
2.1 Movingparts-freemovement.....................................................................8
2.2 Conneconofthird-partyequipmentisforbidden ......................................8
2.3 Installaon ....................................................................................................8
3 Before installation .............................................................................................. 9
3.1 Vehiclechassisrequirements .......................................................................9
3.2 Statutorydimensions ...................................................................................9
3.3 Calculangtheinstalleddimensions ..........................................................11
3.4 InstalleddimensionsZN2500-150............................................................12
3.5 InstalleddimensionsZN2500-130............................................................12
3.6 Rearbeamcut-outs ....................................................................................14
3.7 Adjusngthechassisbrackets....................................................................15
3.8 Temporaryconnecon................................................................................16
3.9 Preparethetailli......................................................................................19
4 Installation ....................................................................................................... 21
4.1 Chassisbracket ..........................................................................................21
4.2 Supportframe,trailer.................................................................................22
4.3 Supportframe,truck ..................................................................................24
4.4 Plaorm ......................................................................................................27
4.5 Armstops ....................................................................................................32
4.6 Sealingstrip(horizontal).............................................................................32
4.7 Sealingstrip(vercal) .................................................................................32
4.8 Underrunprotecon ..................................................................................33
4.9 Purgingthecylinders ..................................................................................34
4.10 Plaormltspeed ......................................................................................34
4.11 Anglesensor/Inclinometer .......................................................................35
4.12 Controllers ..................................................................................................37
5 Cable routing ................................................................................................... 39
5.1 General .......................................................................................................39
5.2 Maximumpowerconsumpon-Minimumrecommendedconductor
 crossseconalarea ....................................................................................40
5.3 Baerymaintenance ..................................................................................40
5.4 Mainpowercable,earthcable,mainfuseandmainswitch ......................41
5.5 Controlpowercable ...................................................................................43
5.6 Openplaormalarm ..................................................................................43
5.7 Footcontroller/Warninglights .................................................................43

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Contents
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6 Connection....................................................................................................... 44
6.1 Cablegrommet...........................................................................................44
6.2 Connecon .................................................................................................45
7 Powering up the tail lift.................................................................................... 53
8 Electrical and hydraulic drawings...................................................................... 54
8.1 ZN2500-130/150MA .................................................................................54
8.2 Z2500MAAutoltIFM(TLC-B1)................................................................55
8.3 ZN2500-130/150MAwithelectricalautolt.............................................56
8.4 Z2500MAAutoltIFM(ZePRO1) ..............................................................57
8.5 ZN2500-130/150DA ..................................................................................58
9 Lubrication and fluid level check....................................................................... 59
9.1 Lubricaon..................................................................................................59
9.2 Oillevelcheck.............................................................................................59
10 Marking............................................................................................................ 60
10.1 Loadingdiagram .........................................................................................61
10.2 Idencaonplate.....................................................................................62
10.3 Workarea ..................................................................................................62
10.4 Warningtape .............................................................................................62
10.5 Controllerscker ........................................................................................63
10.6 Dangerarea ...............................................................................................64
10.7 Warningags .............................................................................................64
11 Testing and verification .................................................................................... 65
11.1 Stacloadtest ............................................................................................65
11.2 Dynamicloadtest.......................................................................................66
11.3 Testofsafetyfuncons...............................................................................66
12 Specifications .................................................................................................. 67
12.1 Weights......................................................................................................67

ZN 2500-130/150Importantinformaon
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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. Identication plate

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Importantinformaon
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1.3 Identikation
E.g. ZN 2500 - 130 MA
Z = Standard model
ZN = Narrow frame
Max. lifting capacity x 1 (kg)
Max lifting height -130 = 1340 mm
Cylinder model, MA = Double acting adjustable tilt
Single acting lift
DA = Double acting adjustable tilt
Double acting lift
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.

ZN 2500-130/150Important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

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Safety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!
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%.
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 clearance 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.

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Max. 450 mm.
(Air suspension)
Max. 500 mm.
(Conventional suspension)
Max 300 mm.
8º
Image 7. Cross section of vehi-
cle chassis 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
protection 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. Thus the frame beam cross-section
must measure at least 220x70x4 mm, which cor-
responds to a minimum moment of inertia of 937cm4
around the x-axis. See Image 7. If in doubt, contact
ZEPRO for support.
3.2 Statutory dimensions
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 300 mm.
See Image 8.
NOTE!!
The underrun protection must be located further back and lower.
Image 8. Statutory dimensions
mWARNING!
The above dimensions are the minimum permitted for the
installation of underrun protection. The strength requirements
for mounting the tail lift usually require larger dimensions.

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Image 9. Statutory dimensions
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.
Max 25 mmMax 25 mm
Image 10. Statutory dimensions
0-100 mm.
Min. area: 350 cm2

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3.3 Calculating the installed dimensions
For ease of installation it is best to calculate and specify the necessary dimensions in advance. Determine
the C dimension rst, then obtain the other dimensions from the relevant table. Try to place the lift as high as
possible within the C dimension specied 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 dimen-
sion determines the space the lift needs beneath the body (dimension D) and the distance from the lift arms in
their upper position to vehicle oor level (dimension A).
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 member, i.e. the space there will be between the 1st
boom 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 than the maximum lifting height of the lift. The lift platform must always be able to reach
ground level.

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Image 11. Installed dimensions
Image 12. Installed dimensions
3.4 Installed dimensions ZN 2500 - 150
C A D
715 216 726
680 202 767
630 186 818
580 173 861
530 162 899
480 153 931
430 145 959
360 136 992
3.5 Installed dimensions ZN 2500 - 130
C A D
610 203 680
570 187 723
520 172 768
470 160 807
420 150 839
370 141 867
330 135 885

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Image 13. Installed dimensions
Image 14. Installed dimensions

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3.6 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 15. Rear beam cut-outs
700245 245
Amax

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3.7 Adjusting the chassis brackets
The chassis brackets can be set to two di󰀨erent heights. This a󰀨ects the distance between the lift frame and
the chassis (202 mm/242 mm). Take this into account when calculating the C dimension. The brackets must
also be tted di󰀨erently depending on the chassis width, see the description below.
3.7.1 Adjustment
1. Undo the 8 bolts and nuts holding the two parts of the bracket together, see illustration below.
2. Fit the two parts of the brackets in the correct position with the eight bolts and nuts.
NOTE!
If the chassis width is 1300 mm or more, t the lower part to the inside (B) of the upper part, see illustration
below. If the chassis is narrower than 1300 mm, t the lower part to the outside (A) of the upper part, see
illustration below.
3. Tighten the bolts using a torque wrench. Tightening torque: 180 Nm.
202 mm.
242 mm.
Position 1 Position 2
Image 16. Adjusting the chassis brackets
Chassis width
A B B A
mWARNING!
The parts must always be installed with eight screws – two in the front row of holes and three each in the middle and rear rows
of holes.

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3.8 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 section 3.8.2/3.8.3.
2. Connect the tail lift’s main power cable to battery +12/24V.
3. Connect the negative battery terminal to the tail lift’s earth cable (GND).
4. Relay card TLC-B1: When operating, connect a cable (jumper) between an available power supply con-
nection (+) and CS on the relay card to simulate switch CS being on. Remove the cable immediately after
completed operation.
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.
mWARNING!
Take great care while running the lift functions and make sure nothing gets pinched: risk of personal
injury and material damage.
Image 17. Temporary connection
3.8.1 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!
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
ZePRO1
Jumper
Ctrl 1
TLC-B1
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 +
Jumper
C1

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3.8.2 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

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3.8.3 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+

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3.9 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 18.
3. Fold out the control card / relay card (B) and loosen the cabling at the connector on the hydraulic unit; see
Image 19 and Image 20.
4. Release the hydraulic unit by unscrewing the wing nut and corresponding screw (C); see Image 21 and
pull out the hydraulic unit until the tank cap is accessible; see Image 22.
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.
5. Check whether the hydraulic tank is tted with a transport plug seal. If so, replace it with the regular tank
Image 18. Remove the protective cap
C
AB
Image 19. Release mechanism
Image 20. Connection socket Image 21. Releasing the hydraulic unit

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54
8
5
3
Image 22. Where necessary, replace the
transport plug with a regular tank cap
Image 23. Hydraulic unit and relay card
RELAY CARD
TANK CAP
MOTOR
OIL TANK
SOLENOID
VALVE HOUSING
cap supplied.