Related Manuals for Zepro ZT MK2
Summary of Contents for Zepro ZT MK2
- Page 1 Installation instructions INFORMATION FOR SUPERSTRUCTURE BUILDERS AND INSTALLERS Tail lift ZT MK2 ZEPRO Tel.: +46 (0)10-459 05 00 E-mail: zeprotech@hiab.com zepro.com 78617TL 2021-06-29...
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Page 3: Table Of Contents
Contents ZT 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 1.9 Battery maintenance .................7 Safety rules ....................8 2.1 Moving parts - free movement ............8 2.2... - Page 4 Connection of controller and warning lights .........34 6.1 Cable grommet ................34 6.2 Foot controller / Warning lights ............35 Connection ..................36 Powering up the tail lift ................38 Electrical and hydraulic diagrams ............39 ZT MK2 ....................39 8.2 ZT MK2 Autotilt ................40 Lubrication and oil level check ...............41 9.1 Lubrication points ................41 9.2 Oil level check .................41 10 Marking ......................42...
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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 ZT 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. -
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 1003 cm around the x-axis. See Picture 7. If in doubt, contact ZEPRO for support. Picture 7. Cross section of vehicle chassis frame beam (all dimensions expressed in millimetres)
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Page 11: Calculating Installation Dimensions (Standard Lift)
In this way, it is guaranteed that 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 ZT MK2 Picture 10. Installation dimensions Lifting height (H) 1356 Max. 389 Max 927 1542 Max. 486 Max 1024 1905 1200-1300 1272 Picture 11. Installation dimensions All dimensions specified in millimetres www.zepro.com...
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Page 13: Calculating The Installation Dimensions (Slimeline)
Safety rules ZT MK2 Calculating the installation dimensions (Slimeline) For ease of installation it is best to calculate and specify the necessary dimensions in advance. The platform and lift arm assembly are optimized for minimum overall length (O). Aim to install the slide profile in a position that allows the rear edge of the platform in the folded position to align with the rear edge of the vehicle body. - Page 14 Safety rules ZT MK2 Picture 13. Installation dimensions Lifting height (H) 1356 Max 397 Max 841 1542 Max 494 Max 938 All dimensions specified in millimetres. 1905 1200-1300 1272 Picture 14. Installation dimensions All dimensions specified in millimetres www.zepro.com...
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Page 15: Rear Beam Cut-Outs
Safety rules ZT MK2 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 uppermost position. The size of the cut outs depends on the calculated installed dimen- sion “A”, see illustration below. -
Page 16: Prepare The Tail Lift
Safety rules ZT 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. - Page 17 Safety rules ZT 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. Replace the transport plug with the standard tank cap...
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Page 18: Temporary Connection Of Lift
Safety rules ZT 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
Safety rules ZT 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 ZT 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: Setting The Work Position
Installation ZT MK2 Setting the work position If necessary, the working position of the tail lift can be adjusted forwards (max. 55 mm). The adjustment option can be extended by installing a longer adjustment screw (M12). However, the screw should be no longer than 150 mm. -
Page 22: Work Position Lock (Option)
Installation ZT 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 23: Lift Platform
Installation ZT MK2 Lift platform 1. Check that all included components are clean, clean where necessary. 2. Lubricate the 1st booms’ metal bushings. Make sure that the small holes on the inside of the bushing are filled with grease. Use LE lubricant 4622. - Page 24 Installation ZT MK2 WARNING! To ensure lift safety and CE compliance, adjust the downward tilt angle to no more than 10º. Max 10º 6. Run the lift up, so the platform reaches the vehi- cle floor. Loosen the cylinder boots.
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Page 25: Platform Stop
Installation ZT 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 26: Transport Stops
Installation ZT 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 27 Installation ZT MK2 4.8.1 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 28: Angle Sensor For Autotilt
Installation ZT 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 29: Control Device
Installation ZT MK2 4.10 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 5.3 or... - Page 30 Installation ZT MK2 4.10.1 Installation with bracket on tail lift There is a bracket for use when installing controller CD 4 on the tail lift. 1. Fit the enclosed bracket to the tail lift. 2. Install the controller on the bracket.
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Page 31: Running / Connecting Cabling
Running / connecting cabling ZT 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... -
Page 32: General
Running / connecting cabling ZT 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 33: Control Power Cable
Running / connecting cabling ZT 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 34: Connection Of Controller And Warning Lights
Connection of controller and warning lights ZT MK2 Connection of controller and warning lights Cable grommet 6.1.1 Before installing cabling To be able to install cables in the cable grommet, its protective cover must be removed and the five screws loosened. -
Page 35: Foot Controller / Warning Lights
Connection of controller and warning lights ZT 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 36: Connection
Connection of controller and warning lights ZT MK2 Connection The connection of warning lights and the most commonly occurring controller (CD (Control Device)) mod- els 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. Risk of physical damage. CD19 Black Warning lights White ( ), if available) Brown Yellow Down Blue Blue Tilt Green Grey Brown CD11 Yellow Down Blue Tilt Grey Not used... - Page 37 Connection of controller and warning lights ZT 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.
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Page 38: Powering Up The Tail Lift
Powering up the tail lift ZT 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 39: Electrical And Hydraulic Diagrams
Electrical and hydraulic diagrams ZT MK2 Electrical and hydraulic diagrams ZT MK2 www.zepro.com... -
Page 40: Zt Mk2 Autotilt
Powering up the tail lift ZT MK2 ZT MK2 Autotilt www.zepro.com... -
Page 41: 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 42: Marking
Marking ZT 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. 10.1 10.3 10.5 www.hiab.c 2020-03-04 10.4 55057TL 10.5 10.6 10.7 Picture 58. Overview of labelling www.zepro.com... -
Page 43: Max Permissible Load
Marking ZT MK2 10.1 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. Picture 60. Load diagram for load capacity 2500 kg, load centre distance 750 mm. -
Page 44: Identification Plate
Marking ZT MK2 10.2 Identification plate Affix the identification plate to the tail lift frame. Affix the corresponding sticker version of the identifica- tion plate on the back of the owner’s manual and preferably also by the cab door post to facilitate identification. -
Page 45: Control Device Sticker
Marking ZT MK2 10.5 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 46 Marking ZT MK2 10.5.1 Autotilt additional sticker There is an additional sticker affixed next to the control device sticker on tail lifts fitted with autotilt. The stickers are available in standard versions and in a latterally reversed version (option) for affixing on the opposite side of the vehicle. Affix additional autotilt stickers for CD3 and CD9 next to their respective controller stickers and align them and with the two middle symbols for the tilt down and tilt up functions. www.hiab.com 78888TL 2021-06-11 www.hiab.com 77663TL 2020-02-10 www.hiab.com 55057TL 2020-03-04 www.hiab.com 55053TL 2020-03-04 Additional autotilt sticker for CD 3 Additional autotilt sticker for CD 9 Control device Sticker Sticker (latter-...
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Page 47: Danger Area
Marking ZT MK2 10.6 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 69. Danger area 10.7 Warning flags Attach warning flags as close as possible to the top... -
Page 48: Testing And Verification
Testing and verification ZT 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. -
Page 49: Dynamic Load Test
Testing and verification ZT MK2 11.2 Dynamic load test. 11.2.1 Test with max. load Place a test load on the platform according to the table (for the respective tail lift model/lifting capacity). Check that the lift operates 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 ZT 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 equip- ment, intelligent services and digital solutions for on-road load handling. As an industry pioneer, our company commitment is to increase the efficiency of our customers' operations and to shape the...