Zepro ZT MK2 User manual

ZEPRO
Tel.: [phone]
E-mail: [email protected] |zepro.com
78617TL
Installation instructions
INFORMATION FOR SUPERSTRUCTURE BUILDERS AND INSTALLERS
Tail lift
ZT MK2
2021-06-29

ZT MK2Contents
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Contents
1 Important information ............................................................................. 5
1.1 Attention! ...........................................................................................5
1.2 Conguration .....................................................................................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
2 Safety rules .................................................................................................8
2.1 Movingparts-freemovement...........................................................8
2.2 Connectionofthird-partyequipmentisforbidden.............................. 8
2.3 Installation .........................................................................................8
3 Before installation .....................................................................................9
3.1 Underrunprotection...........................................................................9
3.2 Calculatinginstallationdimensions(standardlift) ........................... 11
3.3 Calculating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proles .............................................................19
4 Installation.................................................................................................20
4.1 Supportframe..................................................................................20
4.2 Settingtheworkposition .................................................................21
4.3 Workpositionlock(Option) .............................................................22
4.4 Liftplatform......................................................................................23
4.7 Platformstop ...................................................................................25
4.6 Armstops ........................................................................................25
4.5 Purgingthecylinders.......................................................................25
4.8 Transportstops................................................................................26
4.9 Anglesensorforautotilt...................................................................28
4.10 Controldevice .................................................................................29
5 Running / connecting cabling ................................................................31
5.1 Maximumpowerconsumption-Minimumrecommended
 conductorcross-sectionalarea .......................................................31
5.2 General............................................................................................32
5.3 Mainpowercable,groundcableandmainfuse..............................32
5.4 Controlpowercable ........................................................................33
5.5 Openplatformalarm........................................................................33

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Contents
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6 Connection of controller and warning lights .........................................34
6.1 Cablegrommet................................................................................34
6.2 Footcontroller/Warninglights........................................................35
6.3 Connection ......................................................................................36
7 Powering up the tail lift ............................................................................38
8 Electrical and hydraulic diagrams ..........................................................39
8.1 ZT MK2............................................................................................39
8.2 ZTMK2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 Identicationplate ..........................................................................44
10.3 Workarea.......................................................................................44
10.4 Warningtape ..................................................................................44
10.5 Controldevicesticker ......................................................................45
10.6 Dangerarea ...................................................................................47
10.7 Warningags..................................................................................47
11 Testing and verification............................................................................48
11.1 Staticloadtest.................................................................................48
11.2 Dynamicloadtest............................................................................49
11.3 Testofsafetyfunctions....................................................................49
12 Registration...............................................................................................50
13 Specifications ..........................................................................................50
13.1 Weights .......................................................................................... 50

ZT MK2Important information
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1 Important information
1.1 Attention!
The following warning signs appear in the installation instructions and are intended to draw your attention to
circumstances that can potentially cause problems, near misses, personal injury and/or damage to the product,
etc.
mWARNING!
WARNING indicates a potential hazard, which if ignored may lead to serious, life-threatening injury.
mCAUTION!
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 that may help the reader understand, or perform, a given operation.
1.2 Conguration
This tail lift is available in a many different congurations. It is available in two versions, Standard and Slimline.
Lift height, lift capacity, slider prole length and platform size may vary. However, the installation principles are
the same whatever the conguration.
• Standard or Slimline
• Lifting capacity: 1500, 2000 or 2500 Kg.
• Max lift height: -135 (1356 mm), -155 (1542 mm).
• Slide proles: 1590, 1700 and 1850 mm.
• Platform: 1565 x 2400, 1765 x 2400, or 1965 x 2400 mm.
1.3 Technical support
If technical support is needed, please contact ZEPRO. Tel: [phone], E-mail: [email protected].
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 identication plate located on the tail lift frame.
Picture 1. Identication plate

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Important information
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1.4 CE marking
ZEPRO tail lifts for sale on the European market are CE marked (Conformité Européenne). The manufacturer
guarantees that the product complies with the EU Machinery Directive.
Follow the installation instructions carefully. Modications not approved in writing by the manufacturer are
not 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 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 lled with highly rened
mineral oil (art. no. 21963, 1 litre).
Hydraulic systems with hydraulic oil tanks marked with a specication for the hydraulic oil are only permitted
to be lled with the oil specied on the label.
1.7 Guarantee
After installation, testing and verication, the tail lift’s delivery card must be registered for the guarantee to be valid.

ZT MK2Important information
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1.8 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-
inder covers and boots
Picture 3. Hydraulic hoses Picture 4. Cables
1.9 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. The length of
time the vehicle can be stored without the battery charge level becoming too low depends on the condition of
the battery, the charge level prior 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 operated repeatedly without starting or using the vehicle during lift installation or carrying out
service and repairs, use the battery charger between operations to maintain battery charge .
IMPORTANT!
The battery charger must be disconnected when operating the lift. Risk of material damage.

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Safety rules
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2 Safety rules
2.1 Moving parts - free movement
mWARNING!
During nal inspection*, the space occupied by the
moving cylinders must be cleared and made safe.
There is a risk of collision between the cylinder and
the following items: subframe, truck chassis, beam
for rear light (number plate) and the chassis bracket
of the lift (with a short overhang).
**Final inspection to be carried out with the platform
at the vehicle oor and tilted down 10°. The clear-
ance from the closest part of the cylinder must be
at least 40 mm.
mWARNING!
The platform may not be tilted down more than
10º from the horizontal.
min. 40 mm
10º
10º
Picture 5. Clearance to the closest 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
mWARNING!
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.
2.3 Installation
mWARNING!
Installation where the platform cannot reach ground level is prohibited.
mWARNING!
ZEPRO tail lifts are only approved for installation using ZEPRO assembly kits.
IMPORTANT!
All specied tightening torques apply when using torque wrench or screw/nut runner with torque control.
Torque spread max ±5%.

ZT MK2Before installation
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3 Before installation
3.1 Underrun protection
Because the tail lift transport stop forms a vital part of the underrun protection, correct installation is
very important. Certain congurations can render correct installation dicult and modications may be
necessary. Congurations highlighted in grey in the table below may mean that some modication is
necessary for the tail lift underrun protection to meet statutory requirements. If in doubt, contact ZEPRO
for support.
Model Arm Platform
(length)
Length of slide proles
1590 1700 1850
Standard
135
1565
1765 OK
1965 OK OK
155
1565 OK
1765 OK OK
1965 OK OK OK
Slimline
135
1565 OK
1765 OK OK
1965 OK OK
155
1565 OK OK
1765 OK OK OK
1965 OK OK OK
All dimensions specified in millimetres

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Safety rules
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8°
Max. 450 mm.
(Air suspen-
sion)
Max. 500 mm.
(Conventional
suspension)
Max 300 mm.
3.1.1 Vehicle chassis requirements
In order to comply with the applicable underrun
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 of the
frame beam concerned (excluding any support
frame) must not be less than 1003 cm4. Accordingly,
the frame beam’s cross-section must at a minimum
have dimensions as illustrated, corresponding to a
minimum surface moment of inertia of 1003 cm4
around the x-axis. See Picture 7.
If in doubt, contact ZEPRO for support.
110
140
10 10
5
90°
90°
Picture 7. Cross section of vehicle chassis frame
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 transport mode
Distance between the platform and the ground when the vehicle is unladen:
Max 450 mm for vehicles with air suspension.
Max 500 mm for vehicles with conventional suspension.
If the departure angle with the above setting is less than 8°, the distance between the platform and the
ground on an unladen vehicle must be increased until the angle reaches 8°, but by not more than 550 mm.
Horizontal distance from the outermost part of the vehicle to the platform: Max 300 mm.
See Picture 8.
mWARNING!
The above dimensions are the minimum permit-
ted for the installation of underrun protection. The
strength requirements for mounting the tail lift
usually require larger dimensions.
Picture 8. Statutory dimensions for underrun protection

ZT MK2Safety rules
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3.2 Calculating installation dimensions (standard lift)
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. (ZS)
The platform and 1st boom combinations are optimized for minimum total length (O). Aim to install the slide
prole 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. 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-oce.com. For help with calculating installation dimensions, contact ZEPRO.
Phone: [phone], Email: zepr[email protected].
Arm Lifting
height
Slide profile
(length)
B Lift platform
(length)
O
1565 1669
135 1356 1590 989* 1765 1769
1965 1869
1565 1789
155 1542 1700 1109* 1765 1889
1965 1989
*Appliesto50mmbavetta.Witha70mmbavetta,dimension(B)isreducedby20mm.
Length of slide profile
100
115
B
Total overhang (O)
495
Picture 9. Installation dimensions
46 36
All dimensions specified in millimetres

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Safety rules
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Arm 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
CMax
N
538
M
Picture 11. Installation dimensions
1905
810
1272
1200-1300
All dimensions specified in millimetres

ZT MK2Safety rules
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3.3 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
prole 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. This makes sure the platform can be folded out.
Arm Lifting
height
Slide profile
(length)
B Lift platform
(length)
O
1565 1734
135 1356 1590 1054* 1765 1834
1965 1934
1565 1856
155 1542 1700 1176* 1765 1956
1965 2056
*Appliesto50mmbavetta.Witha70mmbavetta,dimension(B)isreducedby20mm.
Length of slide profile
100
115
B
Total overhang (O)
495
Picture 12. Installation dimensions
All dimensions specified in millimetres

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Safety rules
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Arm Lifting height (H) Cmax 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
P2 P1
H
CMax
N
444
M
All dimensions specified in millimetres

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3.4 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.
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, i.e. both cut outs must be an equal distance from the mid-point of the beam.
2. Cut along the markings.
3. Grind away any burrs or sharp edges.
Picture 15. Rear beam cut-outs
245 245
Amax
650
All dimensions specified in millimetres

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Safety rules
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3.5 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) and pull out the hy-
draulic unit until the tank cap is accessible; see Picture 19 .
mCAUTION!
Ensure that no cables are trapped or in any other way damaged when the control card is folded out
or removed.
Do not pull out the hydraulic unit more than necessary; make sure it is not pulled completely out of
the frame, as this can entail a risk of injury and damage to the equipment.
Picture 16. Remove the protective cap
C
AB
Picture 17. Release latch control card
Picture 18. Connection socket Picture 19. Releasing the hydraulic unit

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54
8
5
3
Picture 20. Replace the transport 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 tted with a
transport plug seal. If so, replace it with the regu-
lar tank cap supplied.

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Safety rules
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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+
Down
2H
Out
Down
Down
C1+
C1+
Up
Tilt
In
C2+
Up
Tilt
C3+
Up
CS
+
U1
U2
U3
U0 +
Picture 22. Temporary connection of controller
Jumper
3.6 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.
1. Connect the controller to the relay card.
2. Connect earth connection (GND) and +12/24V to the quick connectors 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 jumper immediately after completed operation.
mWARNING!
Take great care when running the lift functions and make sure nothing gets trapped: risk of injury and
material damage.
3.6.1 Battery maintenance
When the lift is operated repeatedly during installation, use the battery charger between operations to main-
tain battery charge .
The battery charger must not be connected when operating the lift. Risk of material damage .
IMPORTANT!
Jumper (Factory installed)
Black C1+
White ( ), if available)
Brown Up
Yellow Down
Blue Tilt
Green In
Grey Out
Up
Tilt
Down
Slider out
Slider in
Main power switch

ZT MK2Safety rules
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3.7 Adjustment of slide proles
The position of the slide proles 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.
2. Adjust the distance of the slide proles from each other to the width 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 the 1st boom’s attachment.
3. Tighten the nuts alternately until the clamp bears fully on the frame.
4. Tighten the nuts. Tightening torque: 260 Nm.
IMPORTANT!
The frame brackets must be mounted completely parallel with each other and perpendicular to the
support frame.
X mm. X +1.0 mm.
Picture 23. Adjusting the chassis bracket

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Installation
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Picture 24. Installation of support frame in the working position
4 Installation
4.1 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.
• Position in Y-axis: Adjust the angle of the arms by carefully running the lift up/down to attain the correct
dimensions in the Y-axis when all the attachment points of the tail lift bear on the trailer frame.
• Position in X-axis: Install the slide proles against the 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 prole
with the help of the integrated adjustment for working position, see section 4.2.
4. Fit the support frame to the trailer frame using the clamping brackets. Tighten the screws (12x).
Tightening torque: 180 Nm.
IMPORTANT!
Welding is not permitted on the chassis brackets.
Do not run the lift all the way to the arm stops or with the platform tted before all the bolts are fully
tightened against the chassis.
Do not load the lift until all bolts are tightened.
Do not load the lift before the bodywork is installed.
X=94mm(with50mmbavetta)
 114mm(with70mmbavetta)
Y= 38 mm
mWARNING!
The friction plates are
an important part of
the underrun protec-
tion and must therefore
always be installed be-
tween the brackets and
the vehicle's chassis
beams.