Zepro Z 1500-135 User manual

ZEPRO
Tel.: [phone]
E-mail: [email protected] |zepro.com
75976TL
2021-03-10
Installation Instructions
Tail Lift
Z 1500/2000-135/155/175
ZL 1500/2000-135/155/175

Z 1500/2000-135/155/175Contents
3www.zepro.com
Contents
1 Introduction ...................................................................................................... 6
1.1 Important ................................................................................................ 6
1.1 CE marking............................................................................................. 7
1.2 Product approval ................................................................................... 7
1.3 Hydraulic oil ............................................................................................ 7
1.4 Guarantee............................................................................................... 7
1.2 Identication ........................................................................................... 8
2 Safety rules ....................................................................................................... 9
2.1 Repainting .............................................................................................. 9
2.2 Transport plug....................................................................................... 10
2.3 Moving parts - free movement.............................................................. 10
2.4 Third-party equipment must not be attached........................................ 11
2.5 Installation ............................................................................................ 11
3 Installation workflow...................................................................................... 12
3.1 Installing the support frame .................................................................. 12
3.2 Electrical connections........................................................................... 12
3.3 Installing the platform ........................................................................... 12
3.4 Installing cylinders ................................................................................ 12
3.5 Attaching decals ................................................................................... 12
4 Calculating the installed dimensions ........................................................... 13
4.1 C dimension ......................................................................................... 13
4.2 D dimension ......................................................................................... 13
4.3 A dimension .......................................................................................... 13
4.4 H dimension.......................................................................................... 13
5 Rear member cut-outs ................................................................................... 16
6 Installation ..................................................................................................... 17
6.1 Support frame....................................................................................... 17
6.2 Control power cable.............................................................................. 20
6.3 Control devices..................................................................................... 21
6.4 Warning lighting/foot controller ............................................................. 22
6.5 Main power cable ................................................................................. 24
6.6 Installation of main fuse on vehicles without connection point ............. 25
6.7 Cable grommet ..................................................................................... 26
6.8 Underrun protection.............................................................................. 27
6.9 Armstops .............................................................................................. 30
6.10 Angle sensor......................................................................................... 30
6.11 Sealing strip (horizontal)....................................................................... 31
6.12 Sealing strip (vertical) ........................................................................... 31
6.13 Platform ................................................................................................ 32
6.14 Purging the cylinders ............................................................................ 38
6.15 Transport lock ....................................................................................... 38
7 Temporary operation of lift............................................................................ 39
7.1 Connection ........................................................................................... 39
7.2 Operation.............................................................................................. 39
7.3 Disconnection ....................................................................................... 39

Z 1500/2000-135/155/175
4
Contents
www.zepro.com
8 Hydraulic unit and control card .................................................................... 40
8.1 Accessing the hydraulic unit and control card ...................................... 41
8.2 Connecting controller............................................................................ 42
9 Electrical and hydraulic diagrams ................................................................ 43
9.1 Z 1500/2000 MA with electrical autotilt................................................. 43
9.2 Z 1500/2000 MA ................................................................................... 44
9.3 Z 1500/2000 DA.................................................................................... 45
9.4 Connecting warning lighting and foot controls...................................... 46
9.5 Connecting cabin switch and open platform alarm............................... 48
9.6 Connecting control devices .................................................................. 49
10 Functional description Z1500/2000 MA Autotilt (standard) ........................ 50
10.1 Sensors/Inputs...................................................................................... 50
10.2 Functionalschematicdrawing,cong14.............................................. 51
10.3 Restriction in use of control device (Tilt up/down) ................................ 54
10.4 Quick opening - activation zone ........................................................... 54
10.5 Foot controls and warning lights........................................................... 55
11 Functional description Z1500/2000 MA ........................................................ 56
11.1 Sensor .................................................................................................. 56
11.2 FunctionalschematicdrawingMA,cong14 ....................................... 57
11.3 Restriction in use of control device....................................................... 59
11.4 Quick opening - activation zone ........................................................... 59
12 Functional description Z1500/2000 DA......................................................... 60
12.1 Sensor .................................................................................................. 60
12.2 Functional schematic drawing .............................................................. 61
12.3 Restriction in use of control device....................................................... 63
12.4 Quick opening - activation zone ........................................................... 63
13 Connection unit .............................................................................................. 64
13.1 Power save mode................................................................................. 64
13.2 Operating information ........................................................................... 64
14 Marking and decals ........................................................................................ 70
14.1 Summary .............................................................................................. 70
14.2 Load diagram........................................................................................ 71
14.3 Identicationplate................................................................................ 71
14.4 Work area ............................................................................................ 71
14.5 Driver’s instructions .............................................................................. 72
14.6 Danger area ......................................................................................... 72
14.7 Warning tape ....................................................................................... 72
14.8 Warningags....................................................................................... 73
14.9 CE marking........................................................................................... 73
15 Lubrication and fluid level check.................................................................. 74
15.1 Lubrication ............................................................................................ 74
15.2 Oil level check ...................................................................................... 74

Z 1500/2000-135/155/175Contents
5www.zepro.com
16 Testing and verification ................................................................................. 75
16.1 Static load test ...................................................................................... 75
16.2 Dynamic load test. ................................................................................ 76
16.3 Test of safety functions......................................................................... 76
17 Disassembly ................................................................................................... 77
18 Specifications ................................................................................................ 78
18.1 Weights ................................................................................................ 78
18.2 Maximum power consumption - Minimum recommended conductor
cross sectional area................................................................................................ 79
18.3 Battery maintenance............................................................................. 79
18.4 Loading diagram................................................................................... 80
18.5 Tightening torque.................................................................................. 81

Z 1500/2000-135/155/175
6
Introduction
www.zepro.com
1 Introduction
1.1 Important
The following “warning markings” appear in the installation instructions and are intended to draw your atten-
tion to circumstances potentially causing unwanted situations, near misses, personal injury or damage to the
product, etc.
Take care. Risk of damage to the product.
NOTE.
Take extra care. Risk of personal injury or damage to the product and the surroundings.
mWARNING!

Z 1500/2000-135/155/175Introduction
7www.zepro.com
1.1 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.
1.2 Product approval
Properly assembled, this product meets relevant requirements according to EN 1756-1:2001 + A1:2008.
1.3 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.
1.4 Guarantee
Afterinstallation,testingandverication,thetaillift’sdeliverycardmustberegisteredfortheguaranteetobe
valid.

Z 1500/2000-135/155/175
8
Introduction
www.zepro.com
1.2 Identication
E.g. Z 1500 - 135 MA
_ _ _ _ _ _ - _ _ _ _ _
Identication list
Z = Standard model
ZL = Wide frame, wide lift arm
Max. lifting capacity x 1 (kg)
Max. lifting height -135 = 1340 mm
-155 = 1530 mm
-175 = 1710 mm
Cylinder model, MA = Double acting Adjustable Tilt
Single acting Single speed Lift
DA = Double acting Adjustable Tilt
Double acting Single speed Lift

Z 1500/2000-135/155/175Safety rules
9www.zepro.com
2 Safety rules
2.1 Repainting
Piston rods and cylinder covers must
not be painted. Painting could dam-
age the cylinder gaskets.
Boots, hydraulic hoses and cables
must not be painted/coated as the
solvent in the paint could damage
thehoses/cablesandsignicantly
impair durability.
NOTE.
Image 1. Piston rods, cylinder covers
and boots must not be painted/coated
Image 2. Hydraulic hoses must
not be painted/coated
Image 3. Cables must not be painted/coated

Z 1500/2000-135/155/175
10
Safety rules
www.zepro.com
2.2 Transport plug
When the lift is installed, the trans-
port plug in the hydraulic unit must
be removed and replaced with the
normal tank cap supplied with the
hydraulic unit.
NOTE.
54
8
5
3
2.3 Moving parts - free move-
ment
Whenthenalinspection*takes
place, 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).
*Thenalinspectionmustbecarried
outwiththeplatformatandtilted
down 10°. The clearance from the
closest part of the cylinder must be
at least 40 mm.
mWARNING!
The platform must not be tilted down
more than max. 10° from horizontal
when people are on the platform.
mWARNING!
min. 40 mm
10º
10º
Image 4. Replace the transport plug with
the normal tank cap
Image 5. Clearance to the closest
part of the cylinder must be at least 40 mm
Image 6. The platform must not be tilted
down more than 10° from the horizontal

Z 1500/2000-135/155/175Safety rules
11www.zepro.com
2.4 Third-party equipment must not be attached
You must not attach third-party equipment (electric or hydraulic) to Zepro tail lifts. Attach-
ing third-party equipment may interfere with the lift system and the safety functions. Risk of
injury and damage. If it is necessary to install other equipment, check the vehicle manufac-
turer’s body instructions and use the attachment features on the vehicle.
mWARNING!
2.5 Installation
The platform must not be installed so it cannot reach ground level.
mWARNING!
Zepro tail lifts are only approved for installation with Zepro installation kits.
mWARNING!
Allspeciedtorquevaluesapplyforusewithascreworimpactwrenchwithtorquecontrol.
Torque distribution max ± 5%.
NOTE!

Z 1500/2000-135/155/175
12
Installationworkow
www.zepro.com
3 Installation workow
3.1 Installing the support frame
• Calculating the installed dimensions
• Attaching the mounting jig to the rear beam
• Aligning the support frame
• Mounting chassis brackets
• Detaching the mounting jig
3.2 Electrical connections
• Installing the control devices
• Installing the control device cables
• Installing the main power cable
3.3 Installing the platform
• Installing the platform
• Installing seals and end stops
• Installing the armstops
3.4 Installing cylinders
• Adjusting tilt cylinder
• Test running
3.5 Attaching decals

Z 1500/2000-135/155/175Calculating the installed dimensions
13www.zepro.com
4 Calculating the installed dimensions
For easier installation it is useful to calculate and specify the necessary dimensions in advance. Determine
theCdimensionrst,thenobtaintheotherdimensionsfromtherelevanttable.Youshouldtrytoplacethe
liftashighaspossiblewithinthespeciedCdimensioninthetable.
4.1 C dimension
TheCdimensionisthedistancebetweenthetopofthesupportframeandthevehicleoorlevel.Thisdimen-
sion governs how far the lift needs to be installed under the vehicle body (D dimension) and the space there will
bebetweentheliftarmsintheupperpositionandthevehicleoorlevel(Adimension).
4.2 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
support frame (in the direction of the vehicle). Once the C dimension is determined, the D dimension can be
obtained from the table.
4.3 A dimension
The A dimension is the space provided for the rear member, i.e. the space there will be between the lift arm
andthevehicleoorwiththeliftintheraisedposition.TheAdimensionisdependentontheCdimension
4.4 H dimension
TheHdimensionistheheightfromtheground(unloaded)tothevehicleoorlevel.TheHdimensionmust
not be greater that the maximum lifting height of the lift. The platform must always be able to reach ground
level.

Z 1500/2000-135/155/175
14
Installationworkow
www.zepro.com
Image 7. Z 1500/2000-135
Image 8. Z 1500/2000-155
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
480 904 145
430 934 129
910
max. 1710
220
C
A
40 D
Image 9. Z 1500/2000-175
C D A
800 767 228
765 811 213
715 866 197
665 913 184
615 955 167
565 991 149
515 1023 134
465 1051 120
210
180
210
180
730
max. 1340
220
C
A
40 D
210
180

Z 1500/2000-135/155/175Installationworkow
15www.zepro.com
Image 10. Z 1500/2000
Image 11. ZL 1500/2000
1014
min. 750 - max. 930
1435
2424
1515
1870
1246
min. 982 - max. 1162
1669
2481
1749
2102
D28
336
35
62
305
133-301
617-817
Image 12. Z/ZL 1500/2000

Z 1500/2000-135/155/175
16
Rear member cut-outs
www.zepro.com
5 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.
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.
Image 13. Z 1500/2000
Image 14. ZL 1500/2000
994
245 245
Amax
1226
245 245
Amax

Z 1500/2000-135/155/175Installation
17www.zepro.com
6 Installation
Zepro tail lifts are only approved for installation
with Zepro installation kits.
mWARNING!
6.1 Support frame
1. Measure and mark the midpoint of the rear
member of the vehicle. See "Image 15. Measure
and mark the midpoint of
the rear member of the vehicle." on page 17.
2. Bolt or spot-weld the mounting jig to the rear
member, so that both mid-points are aligned. See
"Image 16. Bolt or spot-weld the
mounting jig to the rear member
Art. no. 51724 for Z 1500/2000
Art. no. 52312 for ZL 1500/2000" on page 17.
Art. no. 51724 for Z 1500/2000
Art. no. 52312 for ZL 1500/2000.
3. Position the support frame under the vehicle chassis.
4. Temporarily connect the control card to enable
the lift functions, see section "7 Temporary op-
eration of lift" on page 39.
5. Raise the lift arms to their highest position.
6. Attach the lift arms to the eye of the jig. Use the
steel platform’s normal bolts.
7. The support frame should be positioned as high
aspossiblewithinthespecied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oorofthe
vehicle body and must not be in contact with the
vehicle chassis; there must be a few millimetres
of play. If necessary, adjust the angle of the
arms by carefully operating the lift.
8. Install the brackets on the support frame so that
its opening is facing towards the front of the
vehicle, and adjust the position of the frame so
they are in contact with the vehicle chassis.
Also consult the vehicle manufacturer’s body in-
structions and Zepro’s instruction booklet before
installation.
NOTE.
Image 15. Measure and mark the midpoint of
the rear member of the vehicle.
Image 16. Bolt or spot-weld the
mounting jig to the rear member
Art. no. 51724 for Z 1500/2000
Art. no. 52312 for ZL 1500/2000
Image 17. Mounting jig,
Image 18. Install the U-profile with as-
sociated washers and nuts

Z 1500/2000-135/155/175
18
Installation
www.zepro.com
9. InstalltheU-prolewithassociatedwashersand
nuts, but do not tighten these. Screw the bolts al-
ternatelyuntiltheU-proleisalignedincontactwith
the frame, see "Image18.InstalltheU-prolewith
associated washers and nuts" on page 17.
10. When installing on a frame without pre-drilled holes ,
installrst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. holes in the
frame; see "Image 20. Install the chassis bracket
with at least six M14x45 10.9 bolts" on page 18
11. Bolt the brackets securely on the outside of the
vehicle chassis. U se M14x45 bolts and install the as-
sociated washer and nut on the inside of the vehicle
chassis. Install the bolts but do not tighten.
12. Checkandperformneadjustmentregardingthe
position of the lift. Then tighten the bolts with a
torque wrench.
Tightening torque: 120 Nm.
13. Using a torque wrench, tighten the bolts holding the
U-proles.Tightening torque: 280 Nm.
14. D rill holes in the vehicle chassis for mounting bolts,
Ø14 mm. Drill in the outer holes of each bracket.
Use M14x45 bolts and install the associated
washer and nut on the inside of the vehicle chas-
sis. Installation must be performed with at least 6
bolts in the outer holes. The bolt that was installed
initially in the slot-shaped hole may not be included
inthisgure.Ifnecessary,thisboltcannowbe
moved to one of the outer holes, see illustration.
Then tighten the bolts with a torque wrench.
Tightening torque: 120 Nm.
15. Remove the mounting jig.
Min. 260
Min. 20
Min. 180
35 mm
Min. 20
Min. D
D
Min. 6 pcs.
M14x45 10.9
120 Nm
New hole
Image 19. The chassis bracket re-
quires at least 35 mm clearance between
vehicle chassis and support frame
Image 20. Install the chassis bracket
with at least six M14x45 10.9 bolts
When installing on chassis with pre-drilled holes, go
directly to point 16.

Z 1500/2000-135/155/175Installation
19www.zepro.com
16. 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
the associated washer and nut on the inside of
the vehicle chassis. Install the bolts but do not
tighten.
See Image 21.
17. Checkandperformneadjustmentregardingthe
position of the lift. Then tighten the bolts with a
torque wrench. Tightening torque: Standard for
selected screw.
18. Using a torque wrench, tighten the bolts holding
theU-proles.Tightening torque: 280 Nm.
19. D rill 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 nut on the inside of the vehicle chassis.
See Image 21. Tighten the bolts with a torque
wrench. Tightening torque: Standard for se-
lected screw.
20. Remove the mounting jig.
Welding is not permitted on the chassis brackets.
Do not move the lift all the way to the armstops
orwiththeplatformttedbeforealltheboltsare
fully tightened against the chassis.
Do not place the lift under load until:
· the correct number of bolts have been in-
stalled and torque-tightened.
· the vehicle body is installed to reinforce the
truck chassis.
NOTE.
When installing on chassis with pre-drilled holes
Image 21. Installing the chassis bracket on
vehicle chassis with pre-drilled holes

Z 1500/2000-135/155/175
20
Installation
www.zepro.com
6.2 Control power cable
See also the relevant vehicle manufacturer’s
electrical instructions.
NOTE.
1. If the control power cable is not pre-routed, e.g.
VDHH, route the control power cable from the
driver’s cab to the lift.
The cable must be protected with rubber
grommets when it passes through mem-
bers or walls. If there are quick connectors,
makesuretheyaree󰀨ectivelyprotected
from moisture and dirt.
NOTE.
2. Connect the control power cable to the cabin
switch (CS) on the vehicle instrument panel.
Connect to the on-board electrical system via
a 10 A (24 V), 15 A (12 V) fuse according the
customer’s wishes. See the connection diagram
"9.5 Connecting cabin switch and open platform
alarm" on page 48.
Image 22. Quick connectors must be well protected