Zepro ZDK 250 135, Installation Instructions Manual

Page 1: ...ZEPRO Tel 46 0 10 459 05 00 E mail zeprotech hiab com zepro com 78353TL 2022 06 03 Installation Instructions Tail Lift ZDK 250 135 155...

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Page 3: ...utory dimensions 9 3 3 Calculating the installed dimensions 11 3 4 Rear member cut outs 14 3 5 Prepare the tail lift 15 3 6 Temporary connection 17 4 Installation 20 4 1 Platform 23 4 2 Armstops 28 4...

Page 4: ...autotilt Angle sensor IFM ZePRO1 55 8 6 ZDK 250 DA ZePRO1 56 9 Lubrication and oil level check 57 9 1 Lubrication 57 9 2 Oil level check 57 10 Marking 58 10 1 Loading diagram 59 10 2 Identification pl...

Page 5: ...g injury m CAUTION 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...

Page 6: ...ot 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...

Page 7: ...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 opera...

Page 8: ...vehicle 2 3 Installation m WARNING Installation where the platform cannot reach ground level is prohibited m WARNING ZEPRO tail lifts are only approved for installation using ZEPRO assembly kits IMPOR...

Page 9: ...f 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 ve...

Page 10: ...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 protec tion mu...

Page 11: ...lift arms in their upper position to vehicle floor 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 supp...

Page 12: ...250 135 Image 12 ZDK 250 155 C D A 610 620 197 570 669 182 520 721 163 470 764 144 420 800 126 360 835 104 815 max 1530 220 C A 40 D C D A 715 680 229 680 725 212 630 781 194 580 828 179 530 869 164...

Page 13: ...ZDK 250 135 155 Before installation 13 www zepro com Image 13 ZDK 250 1014 min 750 max 930 1435 2424 1515 1870 D 28 336 35 62 305 133 301 617 817 Image 14 ZDK 250...

Page 14: ...er 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...

Page 15: ...unscrewing the wing nut and corresponding screw C see Image 19 and pull out the hydraulic unit until the tank cap is accessible see Image 21 m CAUTION Make sure no cables are pinched or in any other...

Page 16: ...ssary replace the transport plug with a regular tank cap Image 21 Hydraulic unit and relay card RELAY CARD TANK CAP MOTOR OIL TANK SOLENOID VALVE HOUSING 5 Check whether the hydraulic tank is fitted w...

Page 17: ...control card to simulate that the CS switch is turned on Remove the jumper immediately after completed operation m WARNING Take great care while running the lift functions and make sure nothing gets...

Page 18: ...nnecting 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 Do...

Page 19: ...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 Bl C Bl 2H CD1 CD2 B C 2H1 E CD...

Page 20: ...in the specified C dimension Adjust the frame to the ideal height under the chassis A workshop jack is useful The frame must be positioned parallel with the floor of the vehicle body and must not be i...

Page 21: ...he U profiles Tightening torque 280 Nm 13 Drill holes in the vehicle chassis for mounting bolts 14 mm Drill in the outer holes of each bracket Use M14x45 bolts and install the associated washer and nu...

Page 22: ...m 18 Drill holes in the vehicle chassis for mounting bolts in each bracket s two upper round holes Use suitable bolts durability equivalent to M14 10 9 or higher and install the associated washer and...

Page 23: ...talling the platform grease all bearings including the two regular grease nipples see section 9 Lubrication and oil level check on page 56 3 Fit the platform to the arms using the supplied shafts and...

Page 24: ...rs 3 Loosen the three lock screws on the cylinder fit ted to the platform Image 35 Image 33 The platform underhang A varies according to platform type and this should be taken into account when fittin...

Page 25: ...orm See Image 37 7 Fit the other tilting cylinder to the platform mount ing Use the supplied shaft and support wheel IMPORTANT Make sure the cylinder is installed with the grease nipples facing up 8 T...

Page 26: ...djusting the tilt angle Image 40 Installing boots 11 Fit the cylinder boots Image 40 Lift model A ZDK 250 135 180 5 ZDK 250 155 300 5 IMPORTANT After finishing the adjustment make sure the distance be...

Page 27: ...t the platform down to max 10 degrees below the horizontal Image 41 4 Adjust the end stop all the way to the top of the cylinder 4 Image 42 5 Tighten the lock screw in the end stop 5 See il lustration...

Page 28: ...m Installation must take place against the vehicle body 4 4 Sealing strip horizontal The track is fitted using the self tapping screws provided 1 Mark where to drill holes for the self tapping screws...

Page 29: ...ensions on page 9 Use the corresponding bolts M12x80 Assemble without tightening the bolts See Image 47 3 Check that the installation meets the statutory requirements 4 Tighten all the bolts using a t...

Page 30: ...reater than 4 second 4 If necessary adjust the tilt speed using the knob on the hydraulic unit The knob is fastened with a check nut Then repeat steps 1 4 until the desired tilt speed is attained Fast...

Page 31: ...attach the cable using cable time see Image 51 2 Connection is described later in section 6 Image 51 Installing the angle sensor x4 x4 4 8 2 Tail lift with inclinometer for autotilt 1 Install the inc...

Page 32: ...cable ties Connection is described later in section 6 Image 53 Installing an angle sensor for auto tilt Bracket on the platform Autotilt angle setting By default the autotilt angle is set to 0 If nece...

Page 33: ...ways be fitted on the side that is facing away from moving traffic Fitting in any other way involves increased risk of injury 300 600 mm IMPORTANT The controller s cable intake must always face downwa...

Page 34: ...and their working area 2 The distance between the vehicle s rear edge and the centre of the controllers must be 300 600 mm The distance between the controllers must be at least 260 mm See Image 57 3...

Page 35: ...an be used The earthing point must be so well protected that increased voltage drop due to oxidation over time can be eliminated Risk of material damage Warranty rights do not apply to material damage...

Page 36: ...35 mm2 Main power cable L 8 15m 50 mm2 35 mm2 Main power cable L 15m 50 mm2 Battery Min capacity Imin available for lift 180 Ah 170 Ah Min voltage during operation Umin at lift 9 Volt 18 Volt NOTE Mak...

Page 37: ...he earth cable to the quick connector 4 Route connect the tail lift earth cable to the negative terminal of the battery or to a well protected earth ing point When installing without main switch 5 On...

Page 38: ...nd controller cables on the underside of the arm and fasten with cable ties 5 Pull the main power cable from the main switch to the fuse box battery plus pole Prepare the cable with a cable terminal a...

Page 39: ...r warning lighting cable 2 Route the cable and install with cable ties according to Image 66 and Image 67 The quick connector must be positioned in such a way that it does not conflict with the underr...

Page 40: ...g 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 6 1 2 After connection 1 Tighten the five screws once all cables a...

Page 41: ...rse of the control board relay board and secure it with cable ties See Image 72 7 Tilt in and secure the relay board 8 Replace the cable grommet see Section 6 1 2 Image 72 Installing cabling with cabl...

Page 42: ...L2 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 3 Ctrl 2 Ctrl 1 CD4 Up Tilt 2H Down CD9 Up Tilt Down CD10 Up Down CD14 Up S Down Up Tilt Down...

Page 43: ...LLED Ctrl 5 Outputs Sensors o CD11 CD1 CD2 B C 2H1 E CD15 B C 2H E Black Black 2H Black Black Black White White White CD14 B S E CD12 Ctrl 4 Spiral Ctrl 3 Radio Ctrl 2 Ctrl 1 Contr l Power Sensor Powe...

Page 44: ...ished product Title Material Dimension Date Weigh kg Scale Designer Checked by Approved by Stock nr Drawing nr Sheet Size Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1...

Page 45: ...Lyftens egendom och skyddad enligt internationellt g llande lag f r copyright och f r ej utan Z Lyftens skriftliga medgivande kopieras delges eller obeh rigen anv ndas This drawing is property of Z Ly...

Page 46: ...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 Larm f r ppen brygga D...

Page 47: ...Revision IS0 tolerances and drawing rules Tolerance Surface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Larm f r ppen brygga Detection open Platform Z54870 7...

Page 48: ...ZDK 250 135 155 48 Connection www zepro com 6 2 7 Open platform alarm Applies when installing with main switch 4 11...

Page 49: ...cable 3 to the fuse box positive terminal see Image 73 Image 74 6 Screw tight the cable connections and fuse with the knob 4 Install the cables at 90 or 180 from each other Install the fuse at right a...

Page 50: ...oved 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 Z1500 2000 c00...

Page 51: ...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 Z1500 2000 C14 Z1500 2000 C14 Z53807 75864TL 20...

Page 52: ...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 Z1500 2000 c000 E AT Z1500 2000 c000 E AT Z5548...

Page 53: ...t 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 Z1500 2000 EATilt g 3 C14 Z1500 2000 EATilt g...

Page 54: ...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 Z1500 2000...

Page 55: ...urface finish Welding 1 1 Drawn A CARGOTEC BRAND Used on ZEPRO El hydraulschema E H Schematic Z1500 2000 Dvx4 C16 Z1500 2000 Dvx4 C16 Z53857 75938TL 2016 10 31 MB MB PS PS C A2 1 1 Z Lyften Produktion...

Page 56: ...der at lower bearing 5 Left tilting cylinder at lower bearing 6 Lift arm left side at lower bearing 7 Left tilting cylinder at upper bearing 8 Right tilting cylinder at upper bearing 9 Lift arm right...

Page 57: ...9 Overview of labelling 10 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 sub...

Page 58: ...Grey 4C Grafik text PMS Black C Streckad linje visar kant mellan dekaler 4 dekaler p samma bakpapper Max 2500 Kg mm 78876TL 750 1000 1500 500 Max 750 mm Max 900 mm Max 1250 mm Max 1500 mm 2500 Kg 200...

Page 59: ...ax permitted load in kg Production number Year of manufacture Address and tel no of manufacturer Country of manufacture Type number for approved underrun protection RUPD Type number for electromagneti...

Page 60: ...2020 03 04 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 si...

Page 61: ...e vehicle body next to the hand control unit 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...

Page 62: ...Repeat the measurement of A B C D and verify that there has been no deformation of the lift or its at tachment point 11 1 2 Operation Place a test load on the platform as shown in the table The tail l...

Page 63: ...d Check That the red lamp in the vehicle s driver s cab goes out when the platform is fully closed against the body and conversely that it comes on when the platform opens That the tail lift cannot be...

Page 64: ...d load of the lifting equipment The following is a list of selected components with their weight Complete lift chassis without platform Lift components included in complete lift chassis ZDK 250 135 33...

Page 65: ...ZDK 250 135 155 Registration 65 www zepro com...

Page 66: ...ifts 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 o...