Related Manuals for Zepro ZS MK2
Summary of Contents for Zepro ZS MK2
- Page 1 Installation instructions Tail Lift ZS MK2 ZEPRO Tel.: +46 (0)10-459 05 00 E-mail: zeprotech@hiab.com zepro.com 78612TL 2021-06-16...
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Page 3: Table Of Contents
Contents ZS MK2 Contents Important information ................5 Attention! ...................5 1.2 Configuration ..................5 1.3 Technical support ................5 1.4 CE marking ..................6 1.5 Product approval ................6 1.6 Hydraulic oil ..................6 1.7 Guarantee ..................6 1.8 Repainting ..................7 Battery maintenance .................7 Safety rules ....................8 2.1 Moving parts - free movement ............8 2.2 Connection of third-party equipment is forbidden ......8... - Page 4 Connection of controller and warning lights .........35 7.1 Cable grommet ................35 7.2 Foot controller / Warning lights ............36 Connection ..................37 Powering up the tail lift ................39 Electrical and hydraulic diagrams ............40 ZS MK2 ...................40 9.2 ZS MK2 Autotilt ................41 10 Lubrication and oil level check ...............42 10.1 Lubrication points ................42 10.2 Oil level check .................42 11 Marking ......................43...
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Page 5: Important Information
Platform: 1565 x 2400, 1765 x 2400, or 1965 x 2400 mm. Technical support If technical support is needed, please contact ZEPRO. Tel: +46 (0)10-459 05 04, E-mail: zeprotech@hiab.com. 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 identification plate located on the tail lift frame. -
Page 6: Ce Marking
Properly assembled, this product meets relevant requirements according to EN 1756-1:2001 + A1:2008. 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 filled with highly refined mineral oil (art. -
Page 7: Repainting
Important information ZS MK2 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. Picture 2. Piston rods, cyl- Picture 3. Hydraulic hoses Picture 4. Cables inder covers and boots 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. -
Page 8: Safety Rules
Connection of third-party equipment is forbidden WARNING! 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. -
Page 9: Before Installation
Certain configurations can render correct installation difficult and modifications may be necessary. Configurations highlighted in grey in the table below may mean that some modification is necessary for the tail lift underrun protection to meet statutory requirements. If in doubt, contact ZEPRO for support. - Page 10 220x70x4 mm, which corresponds to a minimum moment of inertia of 937cm4 around the x-axis. See Picture 7. If in doubt, contact ZEPRO for support. Picture 7. Cross section of ve- hicle chassis’ frame beam...
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Page 11: Calculating The Installation Dimensions (Standard Lift)
This makes sure the platform can be folded out. The easiest way to calculated the installation dimensions is to use a CAD program. 2D drawings are available for downloading from www.c-office.com. For help with calculating installation dimensions, contact ZEPRO. Phone: +46 (0)10-459 05 04, Email: zeprotech@hiab.com. - Page 12 Safety rules ZS MK2 Picture 10. Installation dimensions Lifting height (H) 1356 Max. 389 Max 927 1542 Max. 486 Max 1024 1727 Max. 513 Max. 1120 1905 1396 700-900 1310 Picture 11. Installation dimensions www.zepro.com...
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Page 13: Calculating The Installation Dimensions (Slimeline)
Safety rules ZS MK2 Calculating the installation dimensions (Slimeline) For easier installation it is useful to calculate and specify the necessary dimensions in advance. Efforts should be made to install the lift as high as possible. The platform and lift arm assembly are optimized for minimum overall length (O). Try to fit the slider profile in such a position that when the platform is folded its rear edge aligns with the rear edge of the superstructure. - Page 14 Safety rules ZS MK2 Picture 13. Installation dimensions Lifting height 1356 Max 397 Max 841 1542 Max 494 Max 938 1727 Max 590 Max 1034 1905 1396 700-900 1310 Picture 14. Installation dimensions www.zepro.com...
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Page 15: Rear Member Cut-Outs
Rear member cut-outs ZS MK2 Rear member 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. -
Page 16: Prepare The Tail Lift
Rear member cut-outs ZS MK2 Prepare the tail lift 1. Position the support frame under the vehicle’s chassis. 2. Remove the protective cap, secured with two quick-release locks, see Picture 16. 3. Fold out the control card (B) and loosen the cabling at the connector on the hydraulic unit, see Picture 17 and Picture 18. 4. Release the hydraulic unit by unscrewing the wing nut and corresponding screw (C); see Picture 19 and pull out the hydraulic unit until the tank cap is accessible; see Picture 21. - Page 17 Rear member cut-outs ZS MK2 54853 5. Check whether the hydraulic tank is fitted with a transport plug seal. If so, replace it with the regu- lar tank cap supplied. Picture 20. Where necessary, replace the transport plug with a regular tank cap...
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Page 18: Temporary Connection Of Lift
Rear member cut-outs ZS MK2 Temporary connection of lift When the lift is installed, it is sometimes necessary to operate the lift functions in order to change the posi- tions of the cylinders and the 1st booms. Temporarily connect the lift to enable the lift functions. -
Page 19: Adjustment Of Slide Profiles
Rear member cut-outs ZS MK2 Adjustment of slide profiles The position of the slide profiles on the support frame has to be adjusted to the vehicle’s frame width. 1. Loosen the nuts holding the clamps on the back of the frame brackets. -
Page 20: Installation
Installation ZS MK2 Installation Support frame 1. Carefully drive the slide function so the support frame is positioned as far back as possible. 2. Carefully raise the 1st booms to their highest position. 3. Raise the support frame to the trailer frame. A workshop jack is helpful. Measure the distance between the 1st boom and the platform, see Picture 24. - Page 21 When installing on Mercedes-Benz chassis with a pre-drilled frame, drill out the holes to Ø16.5 mm. Suitable M16 nuts and bolts (Part no: P403TL) can be ordered separately, please contact ZEPRO for more information. IMPORTANT! Welding is not permitted on the chassis brackets.
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Page 22: Setting The Work Position
Installation ZS MK2 Setting the work position If necessary, the working position of the tail lift can be adjusted forwards (max. 55 mm). The adjustment op- tion can be extended by installing a longer adjustment screw (M12). However, the screw should be no longer than 150 mm. -
Page 23: Work Position Lock (Option)
Installation ZS MK2 Work position lock (Option) If the stop position for the slider profile’s rear end does not correspond to the lift’s working position after maximum adjustment of the adjusters screw, a working position lock (part no 56280) may be installed to correct the distance between the platform and the superstructure. -
Page 24: Platform
Installation ZS MK2 Platform 1. Check that all included components are clean, clean where necessary. 2. Lubricate the lift arms’ metal bushings before installation. Make sure that the small holes on the inside of the bushing are filled with grease. - Page 25 Installation ZS MK2 7. Run the lift up until the platform reaches the vehicle floor. Loosen the cylinder boots. 8. Undo lock screw (A) on the tilt cylinder installed Max 10º on the platform. Screw the stop all the way back (B) toward the platform.
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Page 26: Platform Stop
Installation ZS MK2 Platform stop The platform is fitted with two platform stops installed beneath the bavetta (rear edge of platform). If neces- sary, the platform stops can be moved sideways if they are e.g. in the way of the superstructure shute bolt. -
Page 27: Transport Stops
Installation ZS MK2 Transport stops Transport stops must be installed to secure the platform during transport. IMPORTANT! Transport stops must always be installed in pairs, one on each slider profile. 1. Run the lift to transport position. Choose an appropriate hole pattern for installing the transport stop. - Page 28 Installation ZS MK2 5.8.1 Alternative installation Transport stops can be installed on the inside or outside of the slider profile. This is done by swapping posi- tion on the right and left sides respectively. 1. Run the lift to transport position.
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Page 29: Angle Sensor For Autotilt
Installation ZS MK2 Angle sensor for autotilt Install the angle sensor on the platform if the tail lift is fitted with autotilt. The angle sensor is connected but not secured to the tail lift when delivered. 1. When installing the angle sensor on the platform, use the rivets supplied. -
Page 30: Control Device
Installation ZS MK2 5.10 Control device 1. Install the primary controller on the side of the vehicle normally facing away from the traffic. The dis- tance between the vehicle’s rear edge and the centre of the controller must be 300-600 mm. Connection is performed later in sections 6.3 or... - Page 31 Installation ZS MK2 5.10.1 Installation with bracket on tail lift (accessory) For controller CD 4, there is a bracket that is used for installation on the tail lift. 1. Install the bracket on the tail lift. 2. Installing the controller on the bracket.
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Page 32: Running / Connecting Cabling
Running / connecting cabling ZS MK2 Running / connecting cabling Maximum power consumption - Minimum recommended conductor cross-sectional area Ensure that cable with sufficient wire area is used. Hydraulic unit 7050 12 volt 24 Volt Pump - Motor unit 245 A 145 A Minimum recommended conductor cross-sectional area... -
Page 33: General
Running / connecting cabling ZS MK2 General IMPORTANT Pay attention and be careful during all cable routing in order to obtain longer life for the cables and to reduce the risk of unnecessary downtime. The cable must not be fastened to brake lines or the vehicle’s normal electrical system. -
Page 34: Control Power Cable
Running / connecting cabling ZS MK2 Control power cable When installing tail lifts on the trailer, it is recommended a main power switch be installed on the main power cable. This means that the control power cable from the driver's cab is not needed. -
Page 35: Connection Of Controller And Warning Lights
Connection of controller and warning lights ZS MK2 Connection of controller and warning lights Cable grommet 7.1.1 Before installing cabling To be able to install cables in the cable grommet, its protective cover must be removed and the five screws loos- ened. 1. Disconnect the cable grommet’s protective cover, which is secured with three screws, see Picture 46. -
Page 36: Foot Controller / Warning Lights
Connection of controller and warning lights ZS MK2 Foot controller / Warning lights If the tail lift is equipped with warning lights and/or foot controller, their cabling must be routed and connect- ed according to the following description. 1. Connect the supplied cable to the connector on the foot controller/warning lights cable. -
Page 37: Connection
Connection of controller and warning lights ZS MK2 Connection The connection of warning lights and the most commonly occurring controller (CD (Control Device)) models is shown below. Possible control device models vary depending on lift model, configuration and the market concerned. WARNING! Make sure that the control card is disconnected from the power before connecting. Connecting more than one controller to each connection is not permitted. - Page 38 Connection of controller and warning lights ZS MK2 1. Release and fold out the control card. 2. Run the cabling through the grommet. 3. Connect the appropriate controllers and, where applicable, the warning lights. 4. Run the cabling on the reverse of the control card and secure with cable ties. 5. Fold in and secure the control card. IMPORTANT! Ensure that no cables are trapped or in any other way damaged when the control card is folded out/in.
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Page 39: Powering Up The Tail Lift
Powering up the tail lift ZS MK2 Powering up the tail lift 1. Make sure that the main power switch is in the "OFF" position. 2. Connect the cable (1) between the battery’s positive terminal and the connection point and place the fuse (2) above, see Picture 53. -
Page 40: Electrical And Hydraulic Diagrams
Electrical and hydraulic diagrams ZS MK2 Electrical and hydraulic diagrams ZS MK2 www.zepro.com... -
Page 41: Zs Mk2 Autotilt
Electrical and hydraulic diagrams ZS MK2 ZS MK2 Autotilt www.zepro.com... -
Page 42: Lubrication And Oil Level Check
Check the oil level in the tank, top up if necessary. 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 filled with highly refined mineral oil (art. -
Page 43: Marking
Marking ZS MK2 Marking Below, an overview of the location of the different markings is shown. Image of marking and further informa- tion can be found under the each subchapter for subsequent pages. 11.1 11.3 11.5 11.4 www.hiab.c 55057TL 2020-03-04 11.5... -
Page 44: Max Permissible Load
Marking ZS MK2 11.1 Max permissible load Affix a ‘Max permissible load’ sticker for the model concerned next to all control device stickers. Picture 59. Max permissible load for load capacity 1500 kg, load centre distance 750 mm. Picture 61. Load diagram for load capacity 2000 kg, load centre distance 750 mm. -
Page 45: Identification Plate
Marking ZS MK2 11.2 Identification plate The identification plate is fixed on to the tail lift’s frame. Affix the corresponding sticker version of the identification plate, preferably by the cab door post to facilitate identification. The identification plate contains the following information: •... -
Page 46: Control Device Sticker
Marking ZS MK2 11.5 Control device sticker Affix the controller sticker next to the relevant controller. The stickers are available in standard versions and in reversed version (Option) for affixing on the opposite side of the vehicle. Make sure the stickers are affixed so the image of the vehicle/tail lift on the sticker is in the same direction as the vehicle on which it is affixed. -
Page 47: Danger Area
Marking ZS MK2 11.6 Danger area If one is fitted, affix the sticker on the inside of the vehicle body next to the hand control unit. www.hiab.com 55061TL 2020-05-14 Picture 70. Danger area 11.7 Warning flags Install warning flags as close to the top and as close... -
Page 48: Testing And Verification
Testing and verification ZS MK2 Testing and verification Testing and verification of the tail lift takes place in accordance with the installation/delivery inspection. Verify that the tail lift is suitable for the vehicle in question and for the intended use. 12.1 Static load test 12.1.1 Deformation... -
Page 49: Dynamic Load Test
Testing and verification ZS MK2 12.2 Dynamic load test. 12.2.1 Test with max. load Place a test load on the platform, as shown in table (for each lift model/lift capacity). Check that the lift oper- ates correctly in the normal range of movement, i.e. up, down, tilting at ground level and tilting at vehicle floor level. -
Page 50: Registration
Registration ZS MK2 Registration For the tail lift’s guarantee to be valid, the delivery card must be registered in C-care (www.c-office.com). The bodybuilder is responsible for registration in C-care and must certify in the intended location in tail lift's manual that registration has been done. - Page 52 BUILT TO PERFORM Zepro, Del and Waltco are Hiab trade marks for tail lifts. Hiab is a world-leading supplier of equipment, intelligent services and digital solutions for on-road load handling. As an industry pioneer, our company commitment is to increase the efficiency...