Zepro ZT MK2 Installation Instructions Manual Download

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Summary of Contents for ZT MK2

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 78617TL Installation instructions INFORMATION FOR SUPERSTRUCTURE BUILDERS AND INSTALLERS Tail lift ZT MK2 2021 06 29...

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Page 3: ...culating the installation dimensions Slimeline 13 3 4 Rear beam cut outs 15 3 5 Prepare the tail lift 16 3 6 Temporary connection of lift 18 3 7 Adjustment of slide profiles 19 4 Installation 20 4 1 S...

Page 4: ...Autotilt 40 9 Lubrication and oil level check 41 9 1 Lubrication points 41 9 2 Oil level check 41 10 Marking 42 10 1 Max permissible load 43 10 2 Identification plate 44 10 3 Work area 44 10 4 Warning...

Page 5: ...form a given operation 1 2 Configuration This tail lift is available in a many different configurations It is available in two versions Standard and Slimline Lift height lift capacity slider profile l...

Page 6: ...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 syst...

Page 7: ...n 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 depe...

Page 8: ...osest part of the cylinder must be at least 40 mm Picture 6 The platform must not be tilted down by more than 10 from the horizontal 2 2 Connection of third party equipment is forbidden m WARNING Conn...

Page 9: ...ns 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...

Page 10: ...beam all dimensions expressed in millimetres 3 1 2 Statutory dimensions Make sure the installation location allows the tail lift to meet the statutory dimensions for underrun protec tion when in tran...

Page 11: ...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 of...

Page 12: ...Lifting height H Cmax M N 135 1356 429 Max 389 Max 927 155 1542 518 Max 486 Max 1024 Picture 10 Installation dimensions P2 P1 H C Max N 538 M Picture 11 Installation dimensions 1905 810 1272 1200 1300...

Page 13: ...ws the rear edge of the platform in the folded position to align with the rear edge of the vehicle body This makes sure the platform can be folded out Arm Lifting height Slide profile length B Lift pl...

Page 14: ...ax M N 135 1356 515 Max 397 Max 841 155 1542 604 Max 494 Max 938 All dimensions specified in millimetres Picture 13 Installation dimensions Picture 14 Installation dimensions 1905 810 1272 1200 1300 P...

Page 15: ...ts depends on the calculated installed dimen sion 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...

Page 16: ...g the wing nut and corresponding screw C and pull out the hy draulic unit until the tank cap is accessible seePicture 19 m CAUTION Ensure that no cables are trapped or in any other way damaged when th...

Page 17: ...ansport plug with the standard tank cap Picture 21 Hydraulic unit and control card CONTROL CARD TANK CAP MOTOR OIL TANK SOLENOID VALVE HOUSING 5 Check whether the hydraulic tank is fitted with a trans...

Page 18: ...nnectors on the main power cables of the lift 3 When operating connect a cable between an available power supply connection and CS on the relay card to simulate switch CS in the On position Remove the...

Page 19: ...h of the chassis and centre the frame so the distance from the brackets to the centre of the frame is equally long on both the left and right hand sides Measure the distance between the brackets and t...

Page 20: ...he frame in position to attain the correct dimensions in the X axis If necessary the rearmost position of the frame can be adjusted forwards in the slide profile with the help of the integrated adjust...

Page 21: ...adjusting the working position forwards is limited by the length of the platform Make sure the platform can be unfolded into the intended working position after installation 1 Unscrew the rear end cap...

Page 22: ...t The space for adjusting the working position forwards is limited by the length of the platform Make sure the platform can be unfolded into the intended working position after installation 1 Unscrew...

Page 23: ...s Tighten the screws Tightening torque 80 Nm 4 Fit one of the tilting cylinders to the platform Use the enclosed shaft and screw Tighten the screw Tightening torque 80 Nm NOTE Make sure the cylinder i...

Page 24: ...with the lock screw A See Picture 32 Tightening torque 3 5 Nm 11 Loosen the lock screw A on the other tilt cylinder 12 Turn the adjusting collar so the tilt cylinder aligns with the attachment on the...

Page 25: ...the lift arms and the vehi cle floor rear beam The left and right end stops must be reached at the same time as high as possible on the left arm IMPORTANT Welding on the lift arm is not permitted Inst...

Page 26: ...s must always be installed in pairs one on each slider profile 1 Run the lift to transport position 2 Choose an appropriate hole pattern for installing the transport stop 3 If necessary cut the bracke...

Page 27: ...nsport position 2 Unscrew the end caps from the slide profiles 3 On each slide profile unscrew the nut that tensions the chain and the two nuts that hold the bracket 4 Swap position of the left and ri...

Page 28: ...hen delivered 1 When installing the angle sensor on the platform use the rivets supplied 2 Secure the sensor cable with cable ties IMPORTANT Route the cable between the platform and the lift arm tube...

Page 29: ...cables to get 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 The cable must be prote...

Page 30: ...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 3 In some cases the connector cabling may already be connected at t...

Page 31: ...Motor unit 245 A 145 A Minimum recommended conductor cross sectional area copper cables plus and minus cables Control power cable 1 5 mm2 1 5 mm2 Main power cable L 8m 35 mm2 35 mm2 Main power cable...

Page 32: ...mmended that the CD 4 controller with main power switch be used The main power cable has to be run through a plastic collar and must not be fastened to the brake line or the vehicle s existing electri...

Page 33: ...mage WL1 U7 U6 U5 U5 U4 U4 U3 U2 U1 U0 U1 U2 U3 WL2 PA S5 S4 S3 S2 S1 S1 S5 S4 S3 S2 PA CS CS Down 2H Out Down Down C1 C1 Up Tilt In C2 Up Tilt C3 Up U0 Picture 44 Connecting control current on tail l...

Page 34: ...it should be done together with existing cabling using cable ties Ensure the length of the cable is sufficient for moving the control card The outer sheathing on cables that connect to the control car...

Page 35: ...able 2 Run the cable and install with cable ties according to Picture 50 3 Connect the control device cables to ctrl 3 on the control card See section 6 3 4 Connect the warning light cable to WL1 on t...

Page 36: ...of physical damage Picture 51 Connection of controller and warning lights 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 CS Down 2H Out Down Down C1 C1 Up Tilt In C2 Up T...

Page 37: ...onnect 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 Ensure...

Page 38: ...e the fuse 2 above see Picture 53 3 Connect the main power cable 3 to the connection point see Picture 53 4 Screw the cable connections and fuse into place using the knob 4 Install the cables at 90 or...

Page 39: ...by Approved by Stock nr Drawing nr Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic ZT Mk2...

Page 40: ...vision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic ZT Mk2 c010 E AT ZT Mk2 c010 E AT Z55508 78757TL 2021 0...

Page 41: ...nd left side 2 Lift arm lift cylinder and tilt cylinder frame bearings right and left side 3 Slider wheels right and left side 9 2 Oil level check Check the oil level in the tank top up if necessary I...

Page 42: ...03 04 Picture 58 Overview of labelling 10 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...

Page 43: ...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 60 Load diagram for load capacity 2500 kg load ce...

Page 44: ...owing infor mation Type of lift Max permitted load in kg Production number Year of manufacture Address and tel no of manufacturer Country of manufacture Type number for approved underrun protection RU...

Page 45: ...20 03 04 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 opp...

Page 46: ...with the two middle symbols for the tilt down and tilt up functions Additional autotilt sticker for CD 19 2021 06 01 78877TL www hiab com Additional autotilt sticker for CD 9 www hiab com 77663TL 2020...

Page 47: ...r area If one is fitted affix the sticker on the inside of the vehicle body next to the hand control unit 10 7 Warning flags Attach warning flags as close as possible to the top and edge of the platfo...

Page 48: ...tform according to the table for the respective tail lift model lifting capacity Remove the test load from the platform Repeat the measurement of A B C D and verify that there has been no deformation...

Page 49: ...unctions must be tested Check That the red light in the driver s cab turns off when the platform is in transport position and that it turns on when the platform is run out That the tail lift cannot be...

Page 50: ...of the lift s parts are heavy requiring the use of lifting equipment to get them in place Make sure the weight of the parts does not exceed the maximum permitted load of the lifting equipment Complet...

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Page 52: ...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...

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Zepro ZT MK2, Installation Instructions Manual

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