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Summary of Contents for Zepro ZDK 250 135
- Page 1 Installation Instructions Tail Lift ZDK 250 135/155 ZEPRO Tel.: +46 (0)10-459 05 00 E-mail: zeprotech@hiab.com zepro.com 78353TL 2022-06-03...
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Page 3: Table Of Contents
Contents ZDK 250 135/155 Contents Important information ..................5 1.1 Attention! ....................5 1.2 Technical support ..................5 1.3 Identification ................... 6 1.4 CE marking ..................... 6 1.5 Product approval ................... 6 1.6 Hydraulic oil .................... 6 1.7 Guarantee ....................6 1.8 Repainting .................... - Page 4 Contents ZDK 250 135/155 Electrical and hydraulic diagrams ..............51 8.1 ZDK 250 MA (TLC-B1) ................. 51 8.2 ZDK 250 MA (ZePRO1) ................ 52 8.3 ZDK 250 MA with electric autotilt, Angle sensor IFM (TLC-B1) .... 53 8.4 ZDK 250 MA with electric autotilt, Inclinometer (ZePRO1) ....54 8.5 ZDK 250 MA with electric autotilt, Angle sensor IFM (ZePRO1) ..
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Page 5: Important Information
NOTE refers to additional information that may help the reader understand, or perform, a given operation. 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: Identification
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. no. 21963, 1 litre). -
Page 7: Repainting
Important information ZDK 250 135/155 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
Before installation ZDK 250 135/155 Before installation Vehicle chassis requirements In order to comply with the applicable underrun R6(x2) 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... - Page 10 Before installation ZDK 250 135/155 Horizontal distance from the outer edge of the member to the outside of the wheel: Max. 100 mm. See Image 9. 0-100 mm. Image 9. Statutory dimensions The lateral distance between the underrun protection and the moving parts of the tail lift must not exceed 25 mm.
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Page 11: Calculating The Installed Dimensions
Before installation ZDK 250 135/155 Calculating the installed dimensions For ease of installation it is best to calculate and specify the necessary dimensions in advance. Determine the C dimension first, then obtain the other dimensions from the relevant table. Try to place the lift as high as possible within the C dimension specified in the table. 3.3.1 C dimension The C dimension is the distance between the top of the support frame and the vehicle floor 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 floor level (dimension A). - Page 12 Before installation ZDK 250 135/155 Image 11. ZDK 250-135 715 680 680 725 630 781 580 828 530 869 480 904 430 934 Image 12. ZDK 250-155 www.zepro.com...
- Page 13 Before installation ZDK 250 135/155 1435 1014 min. 750 - max. 930 1515 1870 2424 Image 13. ZDK 250 617-817 Image 14. ZDK 250 www.zepro.com...
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Page 14: Rear Member Cut-Outs
Before installation ZDK 250 135/155 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 15: Prepare The Tail Lift
Before installation ZDK 250 135/155 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 16. 3. Fold out the control card / relay card (B) and loosen the cabling at the connector on the hydraulic unit; see Image 17 and Image 18. - Page 16 Before installation ZDK 250 135/155 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. Image 20. Where necessary, replace the transport plug with a regular tank cap OIL TANK TANK CAP VALVE HOUSING...
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Page 17: Temporary Connection
Before installation ZDK 250 135/155 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. - Page 18 Before installation ZDK 250 135/155 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, configuration and relevant market. WARNING! Make sure the control relay is disconnected from power before connecting. Connecting more than one controller to each connection is not permitted.
- Page 19 Before installation ZDK 250 135/155 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, configuration and relevant market. 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.
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Page 20: Installation
Also consult the vehicle manufacturer’s body instruc- tions and Zepro’s instruction booklet before installation. WARNING! Zepro tail lifts are only approved for installation with Zepro assembly kits. Image 23. Measure and mark the midpoint of the rear member of the vehicle. - Page 21 Installation ZDK 250 135/155 When installing on chassis with pre-drilled holes, go directly to point 16. with the frame, see Image 26. 9. When installing on a frame without pre-drilled holes, install first with a screw in the brackets’ slot-shaped holes. On the mark the middle of the brackets’ slot- shaped holes and then drill Ø14 mm.
- Page 22 Installation ZDK 250 135/155 When installing on chassis with pre-drilled holes 14. Remove the mounting jig. 15. Bolt the brackets securely on the outside of the vehicle chassis. Install in the slot-shaped holes with at least 6 screws. Use suitable bolts (dura- bility equivalent to M14 10.9 or higher) and install...
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Page 23: Platform
Ensure that the small holes on the inside of the bushings are filled with grease. NOTE! Lubricate the bushings See Image 30. Use Zepro lubricant or the equivalent. IMPORTANT Carefully lubricate the metal bushings on the upper bearing of the arms. Make sure the small holes Image 30. - Page 24 Installation ZDK 250 135/155 5. Test the lift by carefully raising it to the vehicle Max. 40 mm, Min. 38 mm floor level and tilting it to the vertical position. Check the position in relation to the rear beam and side posts of the vehicle. See Image 34.
- Page 25 Installation ZDK 250 135/155 4. Turn the adjusting collar so that the platform just meets the seal on the vehicle body. Image 36. Image 36. Adjusting the fit with the vehicle body 5. Loosen the three lock screws on the other tilt cylinder.
- Page 26 Installation ZDK 250 135/155 Max. 30 mm IMPORTANT After finishing the adjustment, make sure the distance between the adjusting collar and the end of the thread is no more than 30 mm. 11. Fit the cylinder boots. Image 40. Image 39. Adjusting the tilt angle...
- Page 27 Installation ZDK 250 135/155 4.2.2 Adjusting the downward tilt angle NOTE! The tilt angle must be set at 90° to the vehicle body before the downward tilt angle is adjusted (see previ- ous page). WARNING! Image 41. The tilt angle must be ad- To ensure that the lift is safe and CE compliant, the justed to max.10°...
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Page 28: Armstops
Installation ZDK 250 135/155 Armstops Fit end stops between the lift arms and the rear member of the vehicle floor. The left and right end stops must be reached at the same time, as high up the lift arm as possible. Installation must take place against the vehicle body. - Page 29 Installation ZDK 250 135/155 4.5.1 Underrun protection Test the position of the underrun protection without tightening the bolts to check that the statutory dimensions are obtained. Adjust if necessary then tighten the bolts with a torque wrench. 1. Fit the inner part of each bracket at one of four heights.
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Page 30: Purging The Cylinders
Installation ZDK 250 135/155 Purging the cylinders Purge the lift cylinders by lowering the platform all the way to the ground a few times. It may be necessary to raise the truck to allow the platform to be lowered completely. -
Page 31: Angle Sensor / Inclinometer
Installation ZDK 250 135/155 Angle sensor / Inclinometer 4.8.1 Tail lift without autotilt 1. Install the angle sensor on the platform using the nuts, bolts and washers supplied and attach the cable using cable time; see. Image 51. 2. Connection is described later in section Image 51. - Page 32 Installation ZDK 250 135/155 4.8.3 Tail lift with angle sensor IFM for autotilt 1. Install the angle sensor on the platform using the nuts, bolts and washers supplied and attach the cable using cable time; see Image 53 2. Route the cables and secure with cable ties.
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Page 33: Controllers
Installation ZDK 250 135/155 Controllers 1. Install the primary controller on the side of the vehicle normally facing away from the traffic. The distance between the vehicle’s rear edge and the centre of the controller must be 300-600 mm. Connection is performed later in section Image 55 if this is not already done from the factory. 2. Any additional controllers can be installed in an optional location. Connection is described later in section IMPORTANT! The controller’s cable intake must always face downwards. - Page 34 Installation ZDK 250 135/155 4.9.1 Controller CD 1 1. Fit the controllers in the desired locations. 300 - 600 mm. However, locate them such that the operator’s working position is as safe as possible, and with an adequate overview of the load, tail lift and their working area.
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Page 35: Cable Routing
Cable routing ZDK 250 135/155 Cable routing General IMPORTANT In order to ensure a high degree of reliability for many years to come, it is important that components such as batteries, chargers, main current and earth cables, fuses and main switches are dimensioned correctly and assembled with great accuracy. Insufficient battery power can permanently damage the electrical components in the tail lift (solenoid, electric motor, solenoid valves, relay board/ control board and more.) -
Page 36: Sizing Electrical Systems
Cable routing ZDK 250 135/155 Sizing electrical systems Ensure that the battery and charger capacity is sufficient for the product in question and that cable with suf- ficient cross-sectional area is used. Hydraulic unit 7050 12 volt 24 Volt Pump - Motor unit 245 A 145 A Minimum recommended conductor cross-sectional area NOTE! (copper cables, plus and minus cables) Make sure the lift has Control power cable 1.5 mm... -
Page 37: Main Power Cable, Earth Cable, Main Fuse And Main Switch
Cable routing ZDK 250 135/155 Main power cable, earth cable, main fuse and main switch Main switch should always be mounted when cab switches (CS) are not used, for example when installing on trailers. Main switches can also be installed in combination with cab switches (CS) if desired. - Page 38 Cable routing ZDK 250 135/155 5.3.1 Main power switch 1. Mount the main switch on a bracket next to controller CD 19 or in any well-protected place with universal bracket, see Image 63 and Image 64. IMPORTANT The main switch drainage should always be directed downwards.
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Page 39: Control Power Cable
Open platform alarm ZEPRO recommends the installation of an alarm for open platform. This can be in the form of warning light in the cab or when mounted on a trailer, a lamp mounted on the outside of the body, visible in the rear view mirror from the driver's cab. -
Page 40: Connection
Connection ZDK 250 135/155 Connection Cable grommet 6.1.1 Before connection 1. Disconnect the cable grommet’s protective cover, which is secured with three screws; see Image 69. 2. Loosen the five screws on the cable grommet, see Image 70. Cables can now be installed/removed/ adjusted in the grommet. The cable should be installed together with existing cabling using cable ties. En- sure the length of the cable is sufficient. The outer casing should be stripped back 350 mm. See Image 71. -
Page 41: Connection
Connection ZDK 250 135/155 Connection IMPORTANT! Make sure that the control board is disconnected from the power before connecting peripheral equipment. Risk of material damage. 1. Release and tilt out the relay board. 2. Run the cabling through the grommet. - Page 42 Connection ZDK 250 135/155 6.2.1 Controller (TLC-B1) Connection of warning lights and the most commonly occurring controller (CD (Control Device)) models are shown below. Possible controller models vary depending on lift model, configuration and relevant market. WARNING! Make sure that the control board is not powered up before connecting. Connecting more than one controller to each connection is not permitted.
- Page 43 Connection ZDK 250 135/155 6.2.2 Controller (ZePRO1) The most commonly occurring controller (CD Control Device) models are shown below. Possible controller models vary depending on lift model, configuration and relevant market. WARNING! Make sure that the control board is not powered up before connecting. Connecting more than one controller to each connection is not permitted.
- Page 44 Connection ZDK 250 135/155 6.2.3 Warning light and foot controller (TLC-B1) Signal is required on relay card input S3 for the warning light to work. Depending on the model, this can be done by connecting angle sensors between S3 and S3+ or with jumper Gnd.
- Page 45 Connection ZDK 250 135/155 6.2.4 Warning lights and foot controls (ZePRO1) www.zepro.com...
- Page 46 Connection ZDK 250 135/155 6.2.5 Cab switch and open platform alarm (TLC-B1) Applies when installing without main switch www.zepro.com...
- Page 47 Connection ZDK 250 135/155 6.2.6 Cab switch and open platform alarm (ZePRO1) Applies when installing without main switch www.zepro.com...
- Page 48 Connection ZDK 250 135/155 6.2.7 Open platform alarm Applies when installing with main switch www.zepro.com...
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Page 49: Powering Up The Tail Lift
Powering up the tail lift ZDK 250 135/155 Powering up the tail lift 1. If applicable, ensure that the main switch is in the "Off" position. 2. If applicable, ensure that the cab switch (CS) is in the "Off" position. 3. When using a fuse box, connect the cable (1) to the battery’s positive terminal and to the fuse box and place the fuse (2) above, see Image 73. -
Page 50: Electrical And Hydraulic Diagrams
Electrical and hydraulic diagrams ZDK 250 135/155 Electrical and hydraulic diagrams ZDK 250 MA (TLC-B1) www.zepro.com... -
Page 51: Zdk 250 Ma (Zepro1)
Electrical and hydraulic diagrams ZDK 250 135/155 ZDK 250 MA (ZePRO1) Config 14, Firmware 9.7 or later www.zepro.com... -
Page 52: Zdk 250 Ma With Electric Autotilt, Angle Sensor Ifm (Tlc-B1)
Electrical and hydraulic diagrams ZDK 250 135/155 ZDK 250 MA with electric autotilt, Angle sensor IFM (TLC-B1) www.zepro.com... -
Page 53: Zdk 250 Ma With Electric Autotilt, Inclinometer (Zepro1)
Electrical and hydraulic diagrams ZDK 250 135/155 ZDK 250 MA with electric autotilt, Inclinometer (ZePRO1) Config 14, Firmware 9.8 or later www.zepro.com... -
Page 54: Zdk 250 Ma With Electric Autotilt, Angle Sensor Ifm (Zepro1)
Electrical and hydraulic diagrams ZDK 250 135/155 ZDK 250 MA with electric autotilt, Angle sensor IFM (ZePRO1) www.zepro.com... -
Page 55: Zdk 250 Da (Zepro1)
Electrical and hydraulic diagrams ZDK 250 135/155 ZDK 250 DA (ZePRO1) Config 16, Firmware 9.7 or later www.zepro.com... -
Page 56: Lubrication And Oil Level Check
Lubrication and oil level check ZDK 250 135/155 Lubrication and oil level check The following lubrication points must be greased on installation. They must then be lubricated at least 4 times a year. Lubrication NOTE! Use LE lubricant 4622 or the equivalent. -
Page 57: Marking
Marking ZDK 250 135/155 Marking Below, an overview of the location of the different markings is shown. Images of markings and additional information can be found under the relevant subchapter for subsequent pages. 10.1 10.4 10.3 10.5 10.5 10.6 10.7 Image 79. Overview of labelling www.zepro.com... -
Page 58: Loading Diagram
Marking ZDK 250 135/155 10.1 Loading diagram Affix the load diagrams for the appropriate lift model close to the primary controller and in a suitable clearly visible position on the vehicle body. Max. 2500 Kg Dekalark med 4 dekaler på samma bakpapper. Mått: BxH 90x65 mm. Färger: 1000 1500 Bakgrund PMS Cool Grey 4C Gra k & text PMS Black C 2500 Kg Max. -
Page 59: Identification Plate
Marking ZDK 250 135/155 10.2 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 infor- mation: • Type of lift • Max. permitted load in kg Image 81. Identification plate • Production number • Year of manufacture • Address and tel. no. of manufacturer •... -
Page 60: Controller Sticker
Marking ZDK 250 135/155 10.5 Controller sticker Affix the controller sticker next to the relevant controller. The stickers are available in standard versions and in reversed version 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. Image 84. Standard mounting Image 85. Reversed mounting Control device Sticker CD 1, 2, 9 55053TL* CD 4 55055TL CD 10 77661TL The sticker section for 2-hand operation is delivered on the same backing paper and has to be affixed if the application has 2-hand operation. -
Page 61: Danger Area
Marking ZDK 250 135/155 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 65977TL 2020-05-14 Image 89. Danger area 10.7 Warning flags Install warning flags as close to the top and as close to the edge of the platform as possible, but without the risk of the flags coming loose when the platform is placed on the ground. Swage the tracks together to secure the warning flags. -
Page 62: Testing And Verification
Testing and verification ZDK 250 135/155 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. 11.1 Static load test 11.1.1 Deformation • Position the tail lift half way to vehicle floor level and with the platform horizontal. Measure dimensions A-B-C-D for comparison as illustrated.Image 91 •... -
Page 63: Dynamic Load Test
Testing and verification ZDK 250 135/155 11.2 Dynamic load test. 11.2.1 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 operates correctly in the normal range of movement, i.e. up, down, tilting at ground level and tilting at vehicle floor level. -
Page 64: Registration
Registration ZDK 250 135/155 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. Specifications 13.1 Weights Many of the lift components are heavy, requiring the use of lifting equipment. Make sure the weight of the components does not exceed the maximum permitted load of the lifting equipment. - Page 65 Registration ZDK 250 135/155 www.zepro.com...
- Page 66 BUILT TO PERFORM Zepro, Del and Waltco are Hiab brands 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 of...