Zepro T60 User manual

Försäljning/Sales/Verkauf
Mossvägen 8, 641 49 KATRINEHOLM,SWEDEN
Telephone: +46 150 - 489550
Telefax: +46 150 - 489551
E-mail: [email protected]
Fabrik/Factory/Fabrik
Allévägen 4, 840 73 BISPGÅRDEN, SWEDEN
Telephone: +46 696 - 17200
Telefax: +46 696 - 17244
E-mail: [email protected]
Internet: www.zepro.com
2016-10-06
Z-LYFTEN PRODUKTION AB
Radio control unit
with angle sensor
INSTALLATION INSTRUCTION
55614TL

3
1. Important...................................................................................... 4
2. General information .................................................................... 4
3. Installation Zepro T60 receiver................................................... 4
4. Installation of angle sensor........................................................ 5
5. Electric- and hydraulic diagram ............................................... 6
6. Zepro T60 - 4 channel radio........................................................ 10
6. Zepro T60 - 8 channel radio........................................................ 11
7. Circuit card, 4 channel radio ...................................................... 12
7. Circuit card 8 channel radio ...................................................... 13
8. Programming: New transmitter to T60 receiver ..................... 14
9. Troubleshooting .......................................................................... 16
Content

4
1. Important
In order to use your system at optimum way, it´s important that you take some time to read the manual be-
fore you install your equipment.
Equipment that is correct installed gives both longer life and better reach.
At delivery the box contains following:
1 pce. Transmitter inc. battery (premounted)
1 pce. Receiver incl. cable set
1 pce. Angle sensor
1 pce. Guarantee form
1 pce. Installation manual
If something would be missing in the box, please contact your dealer as soon as possible.
2. General information
Zepro T60 works at frequency 433,92MHz.
Zepro T60 consists of 2 parts: transmitter and receiver including cables. The receiver is equipped with brack-
ets which simplies the installation of the equipment. The capsule of the receiver doesn’t require opening in
order to install the equipment.
The transmitter and the receiver are encoded from a factory. Encoded means that each transmitter and re-
ceiver in a pair from factory has received a code that´s specic for just this pair. There are 24 millions differ-
ent program variations (codes). No adjustments isn´t necessary on your new equipment. Encoding prevents
that some unauthorized by mistake can maneuver you’re tail lift
In order to maximum function on your radio control equipment, the following must be considered at installa-
tion:
* The cables must be turned downwards at installation.
* The receiver must be installed on trucks framework, NOT in a box. See a picture below.
At installation the voltage must be disconnected.
Note!
The old Zepro T60 6-channel occurs in 2 versions, a DA and a DC version. If your receiver is a new 8-chan-
nel, it´s a DF. One way to check which version that is available, is to remove the cap on the receiver and
read on sticker. See page 9.
3. Installation of Zepro T60 receiver

5
45°
45°
45º
4. Installation of angle sensor
NOTE! Angle sensor is not needed on slider lifts.
NOTE! Supplied angle sensor is not needed on Z3N lifts. Existing angle sensor on Z3N for fast opening may
also be used for the radio control.
Important:
The angle sensor constitutes a safety function for the radio control units. This should under no circumstance be
modify or disconnected. This is to prevent that the tail lift is being used intentionally or unintentionally when the
user don’t have control over the working area. Bypass of this function ceases the CE marking from Zepro.
See different options of mounting below.
ZHD 1500/2000
Drill a 7,4 mm hole and fasten the bracket for angle
sensor. NOTE! Make sure to position the sensor
correctly with its cable facing in the correct direction
and in 45° angle towards the platform to get proper
function.
ZHD 2500
Fasten angle sensor on the existing welding screw
with a nut as shown in the picture below.
NOTE! Make sure to position the sensor correctly
with its cable facing in the correct direction and in 45°
angle towards the platform to get proper function.
Other models
Fasten angle sensor according to the picture below. NOTE! Make sure to position the sensor correctly with its
cable facing in the correct direction and in 45° angle towards the platform to get proper function.

6
1
1
2
2
3
3
4
4
5
5
6
6
A
B
C
D
Denna ritning är Z-Lyftens egendom och skyddad enligt internationellt gällande lag för copyright
och får ej utan Z-Lyftens skriftliga medgivande kopieras, delges eller obehörigen användas.
This drawing is property of Z-Lyften Produktion AB and is loaned subject to return upon demand. It is not
to be reproduced or used directly or indirectly in any way detrimental to the interest of Z-Lyften Produktion AB.
Drawing interpretation unless otherwise
specified.
All measures intends finished 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
Drawn
A CARGOTEC BRAND
Used on:
ZEPRO
El & hydraulschema E&H Schematic
Lyftar med 2H vinkelgivare Lifts with 2H anglesensor
Z53534
75530TL
2016-07-04 MB MB PS PS
A2
- --
1:1
Z-Lyften Produktion AB
- -
Ctrl 4
Spiral
Ctrl 3
Radio
Ctrl 2
Ctrl 1
Control Power
Sensor Power
Ground
IN OUT
Ai 1 Ai 2
Di 1 Di 2 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/Spk-
LLED/Spk+
I-
I+
CR
CT
Ctrl 5
Indication
Se appendix in
installation manual
Outputs
Sensors
Not in use
2-3 Knappsdon
---
2-3 Button Control
10
2
8 3
2
8 3
2
8 3
4 4 4
6 6
3
Ctrl 1Ctrl 2
2-3 Knappsdon
---
2-3 Button Control
Slädmanöverdons
anslutning*
---
Sledcontroller
connection*
Ctrl 4
Spiralmanöverdon
---
Spiral cable controller
Anslutningstabell / Connectiontable
Config Input Exempel på lyftmodeller (inte alla) /
Examples of liftmodels (not all)
1 Di2 ZHD,Z45,Z75,ZAHD,ZKZ,ZS,ZD,ZT
2-Se anteckningar / See notes*** 3 - Se anteckningar / See notes*** 6 Di3 SZHS 8 Di6 Z100 9 Di3 Z3N
12 -Se anteckningar / See notes***
13 Di3 ZHDN
- Ingen vinkelgivare / No anglesensor
Se anslutningstabell nedan var
vinkelgivare ska monteras /
See connectiontable below
where to connect anglesensor
Jord anslutning finns ej på alla manöverdon / Earth connection is not present on all controls
4
Manöverdon
låsindikering**
---
Controller lock
indication**
Information
*
Beror på typ av lyft / Depends on the type of lift.
**
Anslutning av LED jord för manöverdon på CTRL1, 2
med låsindikering (ej spiral) / Connection for LED earth used for controls connected to CTRL1,2 with LED indicating lock (not spiral)
***
Vissa ZHD varianter främst som byggs med ett annat
arbetssätt på hydraulik / Certain ZHD variants that are
built on a different type of hydraulic design
2
Ctrl 3
Radiomanöverdon
---
Radiocontrol
3
4
2
8 3
9
46
5. Electric- and hydraulic diagram
Connection without connection card (ZePro1 controlercard, rmware 8.0 or later.

7
Drawing interpretation unless otherwise
specified.
All measures intends finished 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
Drawn
A CARGOTEC BRAND
Used on:
ZEPRO
El & hydraulschema E&H schematic
Styrkort med kopplingskort Control card w. conn.-card
Z53275
75279TL
2016-04-29 ME ME MB PS
A3
- --
1:1
Z-Lyften Produktion AB
- -
Ctrl 4
Spiral
Ctrl 3
Radio
Ctrl 2
Ctrl 1
Control Power
Sensor Power
Ground
IN OUT
Ai 1 Ai 2
Di 1 Di 2 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
Spk-
Spk+
I-
I+
CR
CT
Ctrl 5
Indication
Se appendix in
installation manual
Outputs
Sensors
Not in use
1
1
2
2
3
3
4
4
5
5
6
6
A
B
C
D
Denna ritning är Z-Lyftens egendom och skyddad enligt internationellt gällande lag för copyright
och får ej utan Z-Lyftens skriftliga medgivande kopieras, delges eller obehörigen användas.
This drawing is property of Z-Lyften Produktion AB and is loaned subject to return upon demand. It is not
to be reproduced or used directly or indirectly in any way detrimental to the interest of Z-Lyften Produktion AB.
Man.don 5 Släde /
Controller 5 Sled
2
8 3
46
För anslutning av manöverdon mot
kopplingskort, se ritning Z47616 /
For connection of control devices to the
connection card, see drawing Z47616
5. Electric- and hydraulic diagram
Connection of connection card to ZePro1 controlercard
Connection card is required when connecting Radio on ZePro1 controler card with rmware 7.0 or earlier.

8
1
1
2
2
3
3
4
4
5
5
6
6
A
B
C
D
Denna ritning är Z-Lyftens egendom och skyddad enligt internationellt gällande lag för copyright
och får ej utan Z-Lyftens skriftliga medgivande kopieras, delges eller obehörigen användas.
This drawing is property of Z-Lyften Produktion AB and is loaned subject to return upon demand. It is not
to be reproduced or used directly or indirectly in any way detrimental to the interest of Z-Lyften Produktion AB.
Material
Dimension
Revision
1/1
A CARGOTEC BRAND
ZEPRO
Rev.Tag Date Rev. number Revised ECR Approved
A 2009-03-24 6056 MW MB CL B 2011-02-18 6373 MB MB CL
C 2011-08-18 6469 MB MB CL D 2011-08-31 6482 MB MB CL
E 2013-01-11 6719 TH TH CL
F 2013-03-01 6761 TH TH CL
G 2014-04-02 6947 TH 177 CL
H 2015-08-24 7152 ME - MJ
5. Electric- and hydraulic diagram
Connection on a lift with connection card (Order. no. 55027TL), all controls

9
OBS! Bygel på kretskort ska tas bort
innan vinkelgivare monteras
NOTE! The circuit card jumper must be
removed before angle sensor is installed
Connection on a lift with connection card (Order. no. 55027TL), radio only
5. Electric- and hydraulic diagram

10
6. Zepro T60 - 4 channel radio
Colour of cable and function.
1. White: Earth (marked with a - minus sign)
2. Black: 12 V DC or 24 V AC/DC (or black marked with a + plus sign)
3. Brown: UP function
4. Blue: TILT function
5. Yellow/Green: DOWN function
6. Grey Lock/Unlock function
The lock/ unlock function
Press button 4 to lock. Press button 2 to unlock.
Note! When the transmitter is locked, button 1 and 3 cannot be activated.
When the transmitter is locked, button 2 unlocks the transmitter. When the
transmitter is unlocked, button 2 activates the tilt function.
Applies only control system with software version 9.0 or later:
Locking is maintained if the lift loses power and then is started up again, the
number 7 is ashing on the control board display. Unlocking is done by turning
operating power Off/On using the cabin switch (CS).

11
6. Zepro T60 - 8 channel radio
Colour of cable and function
1. White: Earth (marked with - minus)
2. Black: 12 V DC or 24 V AC/DC (marked with a plus sign)
3. Brown: UP function
4. Blue: TILT function
5. Yellow/Green: DOWN function
6. Grey: LOCK / UNLOCK-function
7. Brown: SLIDE OUT function
8. Blue: SLIDE IN function
The lock/ unlock function
Press button 7 to lock. Press button 8 to unlock.
Note! When the transmitter is locked, button 1 to 6 cannot be activated.
Applies only control system with software version 9.0 or later:
Locking is maintained if the lift loses power and then is started up again,
the number 7 is ashing on the control board display. Unlocking is done
by turning operating power Off/On using the cabin switch (CS).

12
7. Circuit card - 4 channel radio.
Circuit card: explanation
1. Yellow LED indicates correct voltage.
2. Green LED indicates receiving of radio signal.
3. Red LED off = no transmitter programmed.
Red LED blinks = transmitter programmed.
Red LED shines = receiver in program mode.
4. Not in use.
5. Not in use
6. Indicates that UP function is activated (shine when button is pushed)
7. Indicates that TILT function is activated (shine when button is pushed)
8. Indicates that DOWN function is activated (shine when button is pushed)
9. In use at programming new transmitter
10. Indicates that LOCK function is activated

13
Tele Radio
R60 XX
V x.x
14
7. Circuit card - 8 channel radio.
Circuit card: explanation
1. Yellow LED indicates correct voltage.
2. Green LED indicates receiving of radio signal.
3. Red LED off = no transmitter programmed.
Red LED blinks = transmitter programmed.
Red LED shines = receiver in program mode.
4. Not in use.
5. Not in use
6. Indicates that UP function is activated (shine when button is pushed)
7. Indicates that TILT function is activated (shine when button is pushed)
8. Indicates that DOWN function is activated (shine when button is pushed)
9. Indicates that SLIDE IN function is activated (shine when button is pushed)
10. Indicates that SLIDE OUT function is activated (shine when button is pushed)
11. Indicates that LOCK/UNLOCK function is activated (shine when button is pushed)
12. In use at programming new transmitter
13. In use at programming new transmitter (only for DA recievers)
14. Sticker stating version of reciever(R60 DA, DC or DF).

14
1. Open lid at receiver.
2. Push button on receiver circuit card for programming new transmitter (see page 8 and
9), whereupon red LED (3) shines with a permanent light. Keep button down at least 6 sec.
until red LED stops shining.
3. All old memorized transmitters are now erased from the memory in the receiver.
8. Programming: New transmitter to T60 receiver.
Erase old transmitters
4. Push button on receiver circuit card for programming new transmitter (see page 8 and
9), whereupon red LED (3) shines with a permanent light.
5. Release the button.
6. When button is released, the red LED (3) shines with a permanent light.
7. When the red LED (3) shines permanent, push an optional button on the new transmit-
ter until red LED (3) blinks. This must be started within 6 sec.
8. The transmitter is now programmed at the receiver, perform a test by push one or some
buttons.
If you contrary to expectations not get your system to function. Please contact your
dealer.
Note! All steps below must be carried out
Applies all 3 / 4 - channel radio and DC / DF varieties of T60 receiver
Program new transmitters

15
8. Programming: New transmitter to T60 receiver.
Applies DA variety of 6 - channel radio.
Erase old transmitters
1. Open lid at receiver.
2. Push-button (12 & 13) at the same time,
red LED shines with a permanent light. Keep
button down until red LED stops shining.
The erase is completed.
Program new transmitters
3. Push button (12) red LED is lit. Release
the button, red LED shines with a permanent
light.
4. Push button(13) 3 times in a row, this must
be started before red LED (3) stops shining
(5 sec.) Red LED (3) blinks.
5. Push button (1) at your new transmitter,
red LED (3) blinks 3 times.
The receiver is now programmed!
6. Perform a test by push one or some but-
tons.
If you contrary to expectations not get
your system to function. Please contact
your dealer.
1
2
3
4
5

16
Malfunction Possible cause Correction
The receiver does not func-
tion at transmitting.
The receiver isn’t properly
installed. The receiver has
got wrong operating voltage.
Check installation of the
receiver.
The green LED no:2 on the
receiver shines at transmit-
ting, but the relay doesn’t
functioning.
The code in the transmit-
ter isn’t the same as in the
receiver.
Contact your dealer.
The green LED no:2 on
the receiver shines despite
there’s no transmitting.
There is an another radio
control unit in the area at the
same frequency in use
Test the system at a another
place. If the problem re-
mains, contact your dealer.
The green LED no:2 on the
receiver doesn’t shine at
transmitting.
The battery in the receiver is
nished. The transmitter is
broken.
Change the battery or con-
tact your dealer.
The range is to short. The battery is poor. The
system isn’t installed prop-
erly according to installation
instructions.
Check out that the system is
installed properly according
to installation instruction.
It seems that the transmit-
ter is functioning normally.
The relay inside the receiver
clicks, but the tail lift re-
mains still.
+ and - is mixed up at instal-
lation.
Shift + and -
9. Troubleshooting.