Zepro Z 1500-135 User manual

ZEPRO
Tel.: [phone]
Email: [email protected] |zepro.com
75976TL
Installation instructions
Tail Lift
Z 1500/2000-135/155/175
ZL 1500/2000-135/155/175
2021-12-08

Contents
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Contents
1 Important information ...............................................................................5
1.1 Attention! ...........................................................................................5
1.2 Technical support ..............................................................................5
1.3 Identication ......................................................................................6
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 Vehicle chassis requirements............................................................9
3.2 Statutory dimensions.........................................................................9
3.3 Calculating the installed dimensions ...............................................10
3.4 Rear beam cut-outs.........................................................................13
3.5 Prepare the tail lift ...........................................................................14
3.6 Temporary connection .....................................................................16
3.7 Connecting the control device to the ZePRO1 control card ............17
3.8 Connecting the control device to the TLC-B1 relay card.................18
4 Installation ................................................................................................19
4.1 Frame ..............................................................................................19
4.2 Platform ...........................................................................................22
4.3 Purging the cylinders.......................................................................27
4.4 Open platform alarm........................................................................27
4.5 Angle sensor / Inclinometer.............................................................28
4.6 Control device .................................................................................30
5 Cable routing ............................................................................................31
5.1 Maximum power consumption - Minimum recommended
cable cross-sectional area...............................................................31
5.2 General............................................................................................32
5.3 Main power cable, ground cable and main fuse..............................33
5.4 Control power cable ........................................................................34
5.5 Warning lighting/foot controller ........................................................35
6 Connection................................................................................................37
6.1 Cable grommet................................................................................37
6.2 Connection .....................................................................................38
6.3 Connecting the control device to the ZePRO1 control card ............39
6.4 Connecting the control device to the TLC-B1 relay card.................40
6.5 Connecting the control device to the TLC-B1 relay card with ADC .41

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7 Electrical and hydraulic diagrams ..........................................................42
7.1 Warning light (ZePRO1) ..................................................................42
7.2 Warning light (TLC-B1)....................................................................43
7.3 Z 1500/2000 MA (ZePRO1).............................................................44
7.4 Z 1500/2000 MA (TLC-B1) ..............................................................45
7.5 1500/2000 MA with electric autotilt (ZePRO1) ................................46
7.6 1500/2000 MA with electric autotilt (TLC-B1) ..................................47
7.7 1500/2000 MA with electric autotilt (TLC-B1+ ADC)........................48
7.8 Z 1500/2000 DA (ZePRO1) .............................................................49
7.9 Cab switch and open platform alarm (ZePRO1) .............................50
7.10 Cab switch and open platform alarm (TLC-B1) ...............................51
8 Powering up the tail lift ............................................................................52
9 Lubrication and oil level check ...............................................................53
9.1 Lubrication.......................................................................................53
9.2 Oil level check .................................................................................53
10 Marking......................................................................................................54
10.1 Loading diagram..............................................................................55
10.2 Identicationplate ..........................................................................56
10.3 Work area .......................................................................................56
10.4 Warning tape ..................................................................................56
10.5 Controller sticker .............................................................................57
10.6 Danger area ...................................................................................58
10.7 Warningags..................................................................................58
11 Testing and verification............................................................................59
11.1 Static load test.................................................................................59
11.2 Dynamic load test............................................................................60
11.3 Test of safety functions....................................................................60
12 Registration...............................................................................................61
13 Specifications ..........................................................................................61
13.1 Weights ..........................................................................................61

Z/ZL 1500/2000-135/155/175Important 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 cir-
cumstances 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 Technical support
If technical support is needed, please contact ZEPRO. Tel: [phone], E-mail: z[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.
Figure 1. Identication plate

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Important information
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1.3 Identication
T.ex Z 1500 - 135 MA
_ _ _ _ _ _ - _ _ _ _ _
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
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, register the tail lift’s delivery card to validate the warranty.

Z/ZL 1500/2000-135/155/175Important 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.
Figure 2. Piston rods, cyl-
inder covers and boots
Figure 3. Hydraulic hoses Figure 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.

Z/ZL 1500/2000-135/155/175
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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
Figure 5. Clearance to the closest part of
the cylinder must be at least 40 mm
Figure 6. The platform may not be tilted
down more than 10º 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%.

Z/ZL 1500/2000-135/155/175Before installation
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Max. 450 mm.
(Air suspension)
Max. 500 mm.
(Conventional suspension)
Max 300 mm.
8º
Figure 7. Cross section of vehicle chassis frame beam
70
70
220
4
R6(x2)
X
Y
3 Before installation
3.1 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 on the current
frame beam (excluding any support frame) shall not be
less than 937 cm4. Thus the frame beam cross-section
must measure at least 220x70x4 mm, which corre-
sponds to a minimum moment of inertia of 937cm4
around the x-axis. See Figure 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 vehicles with air suspension.
• Max. 500 mm for vehicles with conventional suspension.
If the exit angle with the above setting is less than 8º, the distance between beam and ground in an unladen
vehicle may be increased until the angle is 8º, but to max 550 mm.
Horizontal distance from the outermost part of the platform to the underrun protection: Max 300 mm.
See Figure 8.
NOTE!!
The underrun protection must be located further back and lower.
Figure 8. Statutory dimensions
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.
mWARNING!

Z/ZL 1500/2000-135/155/175
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Safety rules
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3.3 Calculating the installed dimensions
For ease of installation it is best to calculate and specify the necessary dimensions in advance. Determine
the C dimension rst, then obtain the other dimensions from the relevant table. Try to place the lift as high
as possible within the C dimension specied in the table.
3.3.1 C dimension
The C dimension is the distance between the top of the support frame and the vehicle oor level. This dimen-
sion determines the space the lift needs beneath the body (dimension D) and the distance from the lift arms in
their upper position to vehicle oor 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
support frame (in the direction of the vehicle). Once the C dimension is determined, the D dimension can be
obtained from the table.
3.3.3 A dimension
The A dimension is the space provided for the rear member, i.e. the space there will be between the 1st
boom and the vehicle oor with the lift in the raised position. The A dimension depends on the C dimension
3.3.4 H dimension
The H dimension is the height from the ground (unloaded) to the vehicle oor level. The H dimension must
not be greater than the maximum lifting height of the lift. The lift platform must always be able to reach
ground level.

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Figure 9. Z 1500/2000-135
Figure 10. 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
Figure 11. 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

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Safety rules
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Figure 12. Z 1500/2000
Figure 13. 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
Figure 14. Z/ZL 1500/2000

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3.4 Rear beam cut-outs
It is often necessary to make cut-outs in the rear beam to make room for the platform arms when the platform
is in the top position. Cut-out size is determined by the calculated integration dimension ‘A’; see gure below.
1. Measure and mark the location and depth of the cut-outs on the rear beam. Centre the two rear beam cut-
outs, i.e. the cut-outs must be equidistant from the beam’s centre point .
2. Cut along the markings.
3. Grind away any burrs or sharp edges.
Figure 15. Z 1500/2000
Figure 16. ZL 1500/2000
994
245 245
Amax
1226
245 245
Amax

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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 cover mounted using to quick release locks; see Figure 17.
3. Fold out the control card / relay card (B) and loosen the cabling at the connector on the hydraulic unit; see
Figure 18 and Figure 19.
4. Release the hydraulic unit by unscrewing the wing nut and corresponding screw (C); see Figure 20 and
pull out the hydraulic unit until the tank cap is accessible; see Figure 22.
mCAUTION!
Make sure no cables are pinched or in any other way damaged when the control card / relay 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.
Figure 17. Remove the protective cap
C
AB
Figure 18. Release mechanism
Figure 19. Connection socket Figure 20. Releasing the hydraulic unit

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54
8
5
3
Figure 21. Where necessary, replace the
transport plug with a regular tank cap
Figure 22. Hydraulic unit and relay card
RELAY 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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3.6 Temporary connection
When the tail lift is installed, it is sometimes necessary to operate its functions in order to change the posi-
tion of the cylinders and the lift arms. Temporarily connect the lift to enable the lift functions.
1. Connect a suitable control device to Ctrl 1/C1, see page 17/page 18.
2. Connect earth connection (GND) and +12/24V to the quick connectors on the main power cables of the lift.
3. Control card ZePRO1:
When operating, connect the cable (jumper) between the CSPWR and CS on the control card to simulate
that the CS switch is turned on. Remove the jumper immediately after completed operation.
Relay card TLC-B1:
When operating, connect a cable (jumper) between an available power supply connection (+) and CS on
the relay card to simulate switch CS being on. Remove the cable immediately after completed operation.
mWARNING!
Take great care while running the lift functions and make sure nothing gets pinched: risk of personal
injury and material damage.
Ctrl 4
Spiral
Ctrl 3
Radio
Ctrl 2
Ctrl 1
Contrl 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
LLED
Ctrl 5
Outputs
Sensors
Figure 23. Temporary connection
3.6.1 Battery maintenance
When installing the lift, when the lift is operated repeatedly, the battery charger must be used between opera-
tions to maintain the battery charge level .
The battery charger must not be connected when operating the lift. Risk of material damage .
IMPORTANT!
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 +
ZePRO1 TLC-B1
Jumper
Jumper
Ctrl 1
C1

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3.7 Connecting the control device to the ZePRO1 control card
The most commonly occurring controller (CD Control Device) models are shown below. Possible controller
models vary depending on lift model, conguration and relevant market.
mWARNING!
Make sure that the control card is disconnected from the power before connecting. Connecting more
than one controller to each connection is not permitted. Risk of material damage.
Ctrl 4
Spiral
Ctrl 3
Radio
Ctrl 2
Ctrl 1
Contrl Power
Sensor Power
Ground
IN OUT
Ai 2
Ai 1
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
LLED
Ctrl 5
Outputs
Sensors
o
Brun B
Gul E
Blå C
* Blå 2H
CD1, CD2
B
C
2H1
E
CD15
B
C
2H
E
Black (+)
Black (+)
2H Black (+)
Black (+)
White (-)*
White (-)*
Ctrl 4
Spiral
Ctrl 3
Radio
Ctrl 2
Ctrl 1
Contrl Power
Sensor Power
Ground
IN OUT
Ai 2
Ai 1
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
LLED
Ctrl 5
Outputs
Sensors
o
White (-) must be con-
nected to the connec-
tions marked “Ground”.
Brown B
Yellow E
Blue C
Green 2H
Brown B
Yellow E
Blue C
Blue 2H
Brown B
Yellow E
Blue C
Pink 2H
White (-)
Black (+)
* applies to controllers with heating only
Up
Down
Tilt up
Tilt down
2H
2H
Tilt down
Up
Down
Tilt up

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3.8 Connecting the control device to the TLC-B1 relay card
The connection of warning lights and the most commonly occurring controller (CD (Control Device)) models
is shown below. Possible controller models vary depending on lift model, conguration and relevant market.
mWARNING!
Make sure the control relay is disconnected from power before connecting. Connecting 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
Down
Down
C1+
C1+
Up
Tilt
In
C2+
Up
Tilt
C3+
Up
Ctrl 1
CD4
Up
Tilt
2H
Down
Up
Tilt
Down
2H
CD1
CD15
Up
Down
Tilt up
Tilt down
2H
2H
Tilt down
Up
Down
Tilt up
Black C1+
White ( )*
Brown Up
Yellow Down
Blue Tilt
Black C1+
White ( )
Brown Up
Yellow Down
Blue Tilt
Black C1+
White ( )
Brown Up
Yellow Down
Blue Tilt
Pink 2H
* applies to controllers with heating only
Black C1+
Blue 2H
When connecting Warning Lights: Loop between S3 - S3+

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4 Installation
Zepro tail lifts are only approved for installation
with Zepro assembly kits.
mWARNING!
4.1 Frame
1. Measure and mark the midpoint of the vehicle's
rear beam. See "Figure 74. Standard mounting"
on page 57.
2. Fasten or spot-weld the assembly jig to the rear
beam so that each centre point aligns. See "Fig-
ure 8. Statutory dimensions" on page 9. Art.
no. 51724TL for Z 1500/2000
Art. no. 52312 for ZL 1500/2000.
3. Position the support frame under the vehicle frame.
4. Raise the lift arms to their highest position.
5. Attach the lift arms to the lugs on the jig. Use the
steel platform’s regular pivots.
6. 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 helpful. The frame
must be positioned parallel with the oor of the
vehicle body and must not be in contact with the
vehicle frame; there must be a few millimetres of
play. If necessary, adjust the angle of the arms
by carefully operating the lift.
7. 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 frame.
8. Install the U-prole with associated washers and
nuts, but do not tighten them. Screw the nuts on
alternately until the U-prole is at against the
Figure 24. Measure and mark the mid-
point of the rear beam of the vehicle
Figure 25. Fasten or spot-weld the assembly jig to the
rear beam
Art. no. 51724TL for Z 1500/2000
Art. no. 52312TL for ZL 1500/2000
Figure 26. Mounting jig,
Figure 27. Install the U-prole with as-
sociated washers and nuts
NOTE!
Also refer to the relevant vehicle manufacturer’s vehi-
cle body instructions and Zepro’s instruction manual
before installation.

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Installation
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Min. 260
Min. 20
Min. 180
35 mm
Min. 20
Min. D
D
Min. 6 pcs.
M14x45 10.9
120 Nm
New hole
Figure 28. The frame mount requires at
least 35 mm of space between the ve-
hicle chassis and the support frame
Figure 29. Install the chassis bracket
with at least six M14x45 10.9 bolts
When installing on chassis with pre-drilled holes, pro-
ceed straight to Item 15.
body, see Figure 28
9. When mounting on frame without pre-drilled
holes, rst install using a screw in the grooved
bracket holes. Mark the centre of the vehicle
frame in the grooved bracket holes, then drill Ø14
mm holes In the frame; see "6 Connection" on
page 37
10. Bolt the mountings securely on the exterior of
the vehicle frame. Use M14x45 bolts and install
the associated washer and nut on the inside of
the vehicle frame. Install the bolts but do not
tighten.
11. Check and ne trim the lift’s position. Then
tighten the bolts with a torque wrench.
Tightening torque: 120 Nm.
12. Using a torque wrench, tighten the nuts holding
the U-proles. Tightening torque: 280 Nm.
13. Drill holes in the vehicle frame for Ø14 mm at-
tachment bolts. Drill in the outer holes of each
mounting. Use M14x45 bolts and install the
associated washer and nut on the inside of the
vehicle frame. Installation must be performed
with at least 6 bolts in the outer holes. Do not
include the rst screw installed in the grooved
hole. If necessary, it may now be moved to one
of the outer holes; see gure. Then tighten the
bolts with a torque wrench.
Tightening torque: 120 Nm.
14. Remove the mounting jig.
When installing on chassis with pre-drilled holes
15. Bolt the mountings securely on the exterior
of the vehicle frame. Install in the slot-shaped