Zepro Z 45-90 User manual

ZEPRO
Tel.: [phone]
Email: [email protected] |zepro.com
54990TL
2022-07-04
Installation instructions
Tail Lift
Z/ZU 45/75-90/110
ZL/ZLU 45/75-90/110
ZN/ZNU 45/75-90/110

Z 45/75-90/110Contents
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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
2.4 Connection of third-party equipment is forbidden................................... 9
2.5 Installation .............................................................................................. 9
3 Before installation .......................................................................................... 10
3.1 Vehicle chassis requirements ............................................................... 10
3.2 Statutory dimensions ............................................................................ 10
3.3 Calculating the installed dimensions .................................................... 11
3.4 Rear beam cut-outs .............................................................................. 17
3.5 Temporary connection .......................................................................... 18
3.6 Connecting the control device to the ZePRO1 control card ................. 19
3.7 Connecting the control device to the TLC-B1 relay card...................... 20
4 Installation ...................................................................................................... 21
4.1 Hydraulic unit........................................................................................ 21
4.2 Support frame....................................................................................... 23
4.3 Lift platform........................................................................................... 25
4.4 Purging the cylinders ............................................................................ 25
4.5 Open platform alarm............................................................................. 26
4.6 Angle sensor for autotilt (option)........................................................... 26
4.7 Angle sensor for 2-hand operation ....................................................... 27
4.8 Angle sensor IFM for autotilt (TLC-B1 option only) .............................. 27
4.9 Underrun protection.............................................................................. 28
4.10 Arm stops ............................................................................................. 31
4.11 Sealing strip (horizontal), surface-mounted rubber strip....................... 32
4.12 Sealing strip (vertical) ........................................................................... 32
4.13 Sealing strip, integrated rubber strip..................................................... 33
4.14 Adjusting the tilt angle ......................................................................... 34
4.15 Transport lock....................................................................................... 35
4.16 Controllers ............................................................................................ 36
5 Cable routing ................................................................................................. 38
5.1 General................................................................................................. 38
5.2 Sizing electrical systems ...................................................................... 39
5.3 Main power cable, earth cable, main fuse and main switch ................. 41

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5.4 Open platform alarm............................................................................. 43
5.5 Control power cable.............................................................................. 44
5.6 Warning lighting/foot controller ............................................................. 44
6 Connection...................................................................................................... 45
6.1 Cable grommet ..................................................................................... 45
6.2 Connection .......................................................................................... 45
6.3 After connection.................................................................................... 45
6.4 Connecting the control device to the ZePRO1 control card ................. 46
6.5 Connecting the controller to the TLC-B1 relay card ............................. 47
6.6 Warning lighting and foot controls (TLC-B1) ........................................ 48
6.7 Warning lighting and foot controls (ZePRO1)....................................... 49
6.8 Cabin switch and open platform alarm (TLC-B1) ................................. 50
6.9 Cabin switch and open platform alarm (ZePRO).................................. 51
7 Electrical and hydraulic diagrams ................................................................ 52
7.1 Z 45/75 (TLC-B1).................................................................................. 52
7.2 Z 45/75 (ZePRO1) ................................................................................ 53
7.3 Z 45/75 with electric Autotilt (TLC-B1).................................................. 54
7.4 Z 45/75, with hydraulic autotilt (ZePRO1)............................................. 55
8 Lubrication and oil level check ..................................................................... 56
8.1 Lubrication ............................................................................................ 56
8.2 Oil level check ...................................................................................... 56
9 Marking............................................................................................................ 57
9.1 Loading diagram................................................................................... 58
9.2 Identicationplate................................................................................ 59
9.3 Work area ............................................................................................ 59
9.4 Warning tape ....................................................................................... 59
9.5 Controller sticker................................................................................... 60
9.6 Danger area ......................................................................................... 61
9.7 Warningags....................................................................................... 61
10 Testing and verification ................................................................................. 62
10.1 Static load test ...................................................................................... 62
10.2 Dynamic load test. ................................................................................ 63
10.3 Test of safety functions......................................................................... 64
11 Registration .................................................................................................... 65
12 Specifications ................................................................................................ 66
12.1 Weights ................................................................................................ 66
12.2 Tightening torque.................................................................................. 67

Z 45/75-90/110Important 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. Phone: [phone], Email: [email protected].
Always be ready to state the production number of the tail lift to guarantee you receive the correct information.
Theproductionnumberisgivenontheidenticationplatelocatedonthetailliftframe.
Image 1. Identification plate

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Important information
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1.3 Identication
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.
E.g. Z 75 - 110 SA
_ _ _ _ _ _ - _ _ _ _ _
Identication list
Z = Standard model
ZL = Wide frame, wide lift arm
ZN = Wide frame, narrow lift arm
ZU = Standard model, 3 - part u protection
ZLU = Wide frame, wide lift arm, 3 - part u protection
ZNU = Wide frame, narrow lift arm, 3 - part u protection
Max. lifting capacity x 10 (kg)
Max. lifting height x 10 (mm)
Cylinder model, S = Single acting Single speed Tilt
Single acting Single speed Lift
SA = Single acting Single speed Adjustable Tilt
Single acting Single speed Lift

Z 45/75-90/110Important 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/cables and
impair durability.
Image 2. Piston rods, cyl-
inder covers and boots
Image 3. Hydraulic hoses Image 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
Image 5. Clearance to the closest
part of the cylinder must be at least 40 mm
Image 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at-
tachment 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 45/75-90/110Safety rules
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2.4 Connection of third-party equipment is forbidden
mWARNING!
You must not attach third-party equipment (electric or hydraulic) to Zepro tail lifts. Attaching third-party equipment may interfere
with the lift system and its safety functions. Risk of personal injury and material damage. If necessary to install other equipment,
checkthevehiclemanufacturer’sbodyinstructionsandusetheattachmentoptionsonthevehicle.
2.5 Installation
mWARNING!
The platform must not be installed so it cannot reach ground level .
mWARNING!
Zepro tail lifts are only approved for installation with Zepro assembly kits .
NOTE!
All specied tightening torques apply when using torque wrench or screw/nut runner with torque control. Torque
spread max ±5%.

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Before installation
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3 Before installation
3.1 Vehicle chassis requirements
To comply with applicable underrun protection stand-
ards, 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
frame beam in question must not be less than 306
cm4. For this reason, the frame beam cross-section
shall have a dimension of at least 140x70x3 mm,
corresponding to a minimum surface moment of
inertia of 306 cm4around the x-axis. See Image 7. If
in doubt, contact ZEPRO for support.
Image 7. Cross section of vehi-
cle chassis frame beam
X
140
70
3(x2)
Y
mWARNING!
The dimensions above are the minimum permitted
for the installation of underrun protection. The
strength requirements for mounting the tail lift
usually require larger dimensions .
3.2 Statutory dimensions
• Distance between the beam and the ground when the vehicle is unloaded: Max. 550 mm.
• Horizontal distance from the outermost part of the platform to the underrun protection: Max 328 mm. See Image 8.
NOTE!
The underrun protection must be located further back and lower.
Max 550 mm
Max 328 mm.
Image 8. Statutory dimensions

Z 45/75-90/110Before installation
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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 governs how far the lift needs to be installed under the vehicle body (D dimension) and the space there
willbebetweenthe1stboomsintheupperpositionandthevehicleoorlevel(Adimension).
3.3.2 D dimension
The D dimension is the room required by the lift, 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 lift arm 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 platform must always be able to reach ground level.
~70 mm
NOTE!
The chassis bracket is in 2 parts and must be screwed
together above the support frame. This aects the
dimension between the lift frame and vehicle chassis.
Take this into account when calculating the installed
dimension, C dimension.

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Before installation
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Image 9. Installation dimensions for lift models with lifting height 900/1100 mm
Lifting height 900 mm
C A D
450 170 384
400 154 444
350 143 490
300 134 526
250 127 554
Lifting height 1100 mm
C A D
550 186 432
500 168 498
450 155 549
400 145 590
350 137 624
310 131 652
250 124 675
171
C
75
D
max
min
A
max 450/550
H 900/1100 max
Installation dimensions Z/ZL/ZN 45/75 - 90/110

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Image 10. Installation dimensions for lift models with lifting height 900/1100 mm
Lifting height 900 mm
C A D R58:3
450 170 384
Approved
400 154 444
350 143 490
310 134 526
250 127 554 *Approved
* Approvedwheninstallinglongerunderrun
brackets (available as option).
Lifting height 1100 mm
C A D R58:3
550 186 432
Approved
500 168 498
450 155 549
400 145 590
350 137 624
310 131 652
250 124 675
171
C
75
D
max
min
A
max 450/550
H 900/1100 max
Installation dimensions ZU/ZLU/ZNU 45/75 - 90/110

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Before installation
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ZU-45-110, ZU-75-110, ZU-45-90, ZU-75-90
Z-45-90, Z-45-110, Z-75-90, Z-75-110
ZU-45-110, ZU-75-110
250
183
72
122
1410
min 550 - max 1110
1410
2100 (1900 min.)
700 500
min 550 - max 1110
459
1171
500
318/418
524
250
183
72
122
ZU-45-90, ZU-75-90
250
183
72
122
424/524*
* Longerunderrunbracketsthatgivethesize524
mm are available as an option. These are needed to
achieve approved dimensions according to R58:3, if
the C dimension is < 310 mm.

Z 45/75-90/110Before installation
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ZLU-45-90, ZLU-75-90, ZLU-45-110, ZLU-75-110
ZL-45-90, ZL-45-110, ZL-75-90, ZL-75-110
ZLU-45-90, ZLU-75-90 ZLU-45-110, ZLU-75-110
250
183
72
122
1720
min 750 - max 1410
1720
2100 (1900 min.)
1000 350
min 750 - max 1410
758
1474
350
318/418
250
183
72
122
424/524*
524
250
183
72
122
* Longerunderrunbracketsthatgivethesize524
mm are available as an option. These are needed to
achieve approved dimensions according to R58:3, if
the C dimension is < 310 mm.

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Before installation
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ZNU-45-90, ZNU-75-90, ZNU-45-110, ZNU-75-110
ZN-45-90, ZN-45-110, ZN-75-90, ZN-75-110
ZNU-45-90, ZNU-75-90 ZNU-45-110, ZNU-75-110
1280
1960 (1700 min.)
350 575
min 660 - max 1020
446
446
575
318/418
250
183
72
122
424/524*
524
250
183
72
122
250
183
72
122
1280
min 660 - max 1020
* Longer underrun brackets that give the size 524 mm are avail-
able as an option. These will be required to obtain approved
dimensions according to R58:3, if the C dimension is < 310 mm.

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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 dimension “A”, see
illustration below.
1. Measure out 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 centre point of the beam.
2. Cut out along the markings.
3. Remove any burrs and sharp edges.
Image 11. Z-45-110, Z-75-110, Z-45-90, Z-75-90
ZU-45-110, ZU-75-110, ZU-45-90, ZU-75-90
Image 12. ZL-45-90, ZL-75-90, ZL-45-110, ZL-75-110
ZLU-45-90, ZLU-75-90, ZLU-45-110, ZLU-75-110
Image 13. ZN-45-90, ZN-75-90, ZN-45-110, ZN-75-110
ZNU-45-90, ZNU-75-90, ZNU-45-110, ZNU-75-110
750
155
Amax
155
1060
155
Amax
155
380
155
Amax
155

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Before installation
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3.5 Temporary connection
When the tail lift is installed, it is sometimes necessary to operate its functions in order to change the position
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 3.5.2/3.5.3.
2. Connectthe+12/24Vbatterytothetaillift’smainpowercable.
3. Connectthenegativebatteryterminaltothetaillift’searthcable(GND).
4. Control card ZePRO1:
When operating, connect the cable (jumper) between the CSPWR and CS on the control card to simu-
late 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
Image 14. Temporary connection
3.5.1 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 .
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
IMPORTANT!
The battery charger must not be connected when operating the lift. Risk of material damage.

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3.5.2 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 connections
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

Z 45/75-90/110
20
Before installation
www.zepro.com
3.5.3 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
CD19
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+