Zepro Z3N 75-100 User manual

ZEPRO
Tel.: [phone]
E-mail: [email protected] |zepro.com
74598TL
2022-11-30
Installation Instruction
Tail Lift
Z3N / Z3NU 75-100
Z3NN / Z3NNU 75-100
Z3NW / Z3NWU 75-100

Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100Content
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Content
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 Z3N(U) 75-100...................................................................................... 11
3.5 Z3NN(U) 75-100 ................................................................................... 12
3.6 Z3NW(U) 75-100 .................................................................................. 13
3.7 Temporary connection .......................................................................... 14
4 Installation ...................................................................................................... 17
4.1 Frame ................................................................................................... 17
4.2 Hydraulic unit with circuit card, detailed image .................................... 19
4.3 Installation lift platform and sealing strip............................................... 20
4.4 Underrun protection.............................................................................. 25
4.5 Controllers ............................................................................................ 26
5 Cable routing ................................................................................................. 28
5.1 General................................................................................................. 28
5.2 Sizing electrical systems ...................................................................... 29
5.3 Main power cable, earth cable, main fuse and main switch ................. 30
5.4 Control power cable.............................................................................. 32
5.5 Open platform alarm............................................................................. 32
5.6 Warning lighting and Foot controls ....................................................... 32
6 Connection...................................................................................................... 33
6.1 Cable grommet ..................................................................................... 33
6.2 Connection ........................................................................................... 34
7 Powering up the tail lift.................................................................................. 41

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8 Electrical and hydraulic drawings ................................................................ 42
8.1 Z3N(U), Z3NN(U), Z3NW(U) 75-100 (TLC-B1) .................................... 42
8.2 Z3N(U), Z3NN(U), Z3NW(U) 75-100 (ZePRO1)................................... 43
8.3 Z3N(U), Z3NN(U), Z3NW(U) 75-100 electrical autotilt (TLC-B1) ......... 44
8.4 Z3N(U), Z3NN(U), Z3NW(U) 75-100 electrical autotilt (ZePRO1)........ 45
9 Lubrication and fluid level check.................................................................. 46
9.1 Lubrication ............................................................................................ 46
9.2 Oil level check ...................................................................................... 46
10 Marking............................................................................................................ 47
10.1 Loading diagram................................................................................... 48
10.2 Identicationplate................................................................................ 49
10.3 Work area ............................................................................................ 49
10.4 Warning tape ....................................................................................... 49
10.5 Controller sticker................................................................................... 50
10.6 Danger area ......................................................................................... 51
10.7 Warningags....................................................................................... 51
11 Testing and verification ................................................................................. 52
11.1 Static load test ...................................................................................... 52
11.2 Dynamic load test ................................................................................. 53
11.3 Test of safety functions......................................................................... 54
12 Disassembly ................................................................................................... 55
13 Specifications ................................................................................................ 56
13.1 Weights ................................................................................................ 56
13.2 Center of gravity Z3N / Z3NU ............................................................... 57
13.3 Center of gravity Z3NW / Z3NWU ........................................................ 58
13.4 Center of gravity Z3NN(U) ..................................................... 59
13.5 Loading diagram................................................................................... 60
13.6 Tightening torque.................................................................................. 61

Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100Content
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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: [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.
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
The ZEPRO warranty applies only if assembly has been carried out according to ZEPRO's assembly instruc-
tions by a ZEPRO approved bodybuilder.
Afterinstallation,testingandverication,registerthetaillift’sdeliverycardtovalidatethewarranty.
E.g. Z3N - 75 - 110 SA
_ _ _ - _ _ _ - _ _ _ _ _
ZN = 3 cylinders, narrow lift arm
Z3NU = 3 cylinders, narrow lift arm
u-protection
Z3NN = 3 cylinders, narrow lift arm
narrow frame
Z3NNU = 3 cylinders, narrow lift arm
narrow frame, u-protection
ZNW = 3 cylinders, narrow lift arm
wide frame
Z3NWU = 3 cylinders, narrow lift arm
wide frame, u-protection
Max. lifting capacity x 10 (kg)
Max lifting height x 10 (mm)
Cylinder model, MA = Double acting adjustable tilt
Single operation Lift

Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100Important information
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1.8 Repainting
Image 2. Piston rods, cyl-
inder covers and boots
Image 3. Hydraulic hoses
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.
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.
Image 4. Cables

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Safety rules
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2 Safety rules
2.1 Moving parts -
free movement
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 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%.
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 clearance 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.

Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100Before installation
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Image 7. Cross section of vehicle chassis’ frame beam
X
95
50
3
Y
R4(x2)
3 Before installation
3.1 Vehicle chassis
requirements
In order to comply with the applicable underrun protec-
tion 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 is not permitted to be less than 78 cm4. For
this reason, the frame beam’s cross-section shall have
at least dimensions of 95x50x3 mm, corresponding to
a minimum surface moment of inertia of 78 cm4around
the x-axis. See Image 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. 550 mm.
• Horizontal distance from the outermost part of the platform to the underrun protection: Max. 355 mm.
See Image 8.
NOTE!
The underrun protection must be located further back and lower.
Image 8. Statutory dimensions
The above dimensions are the minimum per-
mitted for the installation of underrun protec-
tion. The strength requirements for mounting
the tail lift usually require larger dimensions.
mWARNING!
max 550 mm
max. 355 mm
max. 100 mm
max. 1900 mm

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Safety rules
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3.3 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.
3.3.1 C dimension
TheCdimensionisthedistancebetweenthetopofthesupportframeandthevehicleoorlevel.
This dimension 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).
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liftarmandthevehicleoorwiththeliftintheraisedposition.TheAdimensionisdependent
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dimen-
sion must not be greater that the maximum lifting height of the lift. The platform must always be
able to reach ground level.

Z3N/Z3NU/Z3NN/Z3NNU/Z3NW/Z3NWU 75-100Safety rules
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Image 9. Installation dimensions for Z3N(U) 75-100
C A D R58:3
425 133 557
Approved
400 127 580
375 120 601
362 116 611
350 113 620
3.4 Z3N(U) 75-100
C
75
D
max
min
A
1000 max
Max 575
166
44
380155
Amax
155
549
232
719
992
1900

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Safety rules
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Image 10. Installation dimensions for Z3NN(U) 75-100
C A D R58:3
463 133 607
Approved
438 127 630
413 120 651
400 116 661
388 113 670
3.5 Z3NN(U) 75-100
C
75 D
max
min
A
1000 max
Max 537
166
6
380155
Amax
155
549
313
719
840
1900

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Image 11. Installation dimensions for Z3NW(U) 75-100
380
155
Amax
155
549
232
719
1080
1900
3.6 Z3NW(U) 75-100
C
75 D
max
min
A
1000 max
Max 545
166
14
C A D R58:3
455 133 607
Approved
430 127 630
405 120 651
392 116 661
380 113 670

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Safety rules
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3.7 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 section 3.7.2/3.7.3.
2. Connect the tail lift’s main power cable to battery +12/24V.
3. Connect the negative battery terminal to the tail lift’s earth cable (GND).
4. Relay card TLC-B1: When operating, connect a cable (jumper) between an available power supply con-
nection (+) and CS on the relay card to simulate switch CS being on. Remove the cable immediately after
completed operation.
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.
mWARNING!
Take great care while running the lift functions and make sure nothing gets pinched: risk of personal injury and material
damage.
Image 12. Temporary connection
3.7.1 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 .
TLC-B1
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 +
Jumper
C1
IMPORTANT!
The battery charger must not be connected when operating the lift. Risk of 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
ZePRO1
Jumper
Ctrl 1

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3.7.2 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

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Safety rules
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3.7.3 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

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4 Installation
4.1 Frame
1. Mount the lift to the chassibracket. The number of
screws and theír placement depends on the type
of bracket used, see installation instruction for the
mounting kit in question.
2. Measure and mark the midpoint of the vehicle's
rear beam.
3. Check the A measure, if cut outs need to be
done in the rear beam, see marking Image 13.
4. Do the necessary cut outs from the rear beam
according to the illustrations with the installation
dimensions for the respective lift model. See
section 3.3
5. Attach the mounting jig, part no 74632TL för
Z3N 75, to the rear beam so that the respective
midpoint corresponds. Use clamps, screws or
spot weld.
6. Place the lifting frame under the vehicle's frame
and mount the lift arms at the eye of the jig. Use
ordinary bolts for the lifting platform.
Theliftingframemustbeparallelwiththeoorof
the vehicle body.
7. Tightly screw the lifting frame into the frame
attachments. If lift needs to be adjusted longitu-
dinally in the slot.Use 4 M14x45 10.9 (120 Nm)
per side.
NOTE!
Use washers on both sides of the fastening!.
Image 13. Measure and mark the mid-
point of the rear beam of the vehicle
Image 14. Attach the mounting jig,
part no 74632TL för Z3N 75
Image 15. Adjust the frame to the ideal height
under the frame. A car jack is a good tool.

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Installation
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4.1.1 Attaching hydraulic unit,
Z3N(U), Z3NW(U)
Mount the unit on the lifting frame according to the
illustration. Use supplied M10x25 (50Nm).
4.1.2 Hydraulic unit and hydraulic hoses
The hydraulic unit is supplied with pre-connected
hydraulic hoses and electric cables.
4.1.3 Hydraulic hoses
A = Oil return Tilt circuit.
B = ressure to lift and tilt circuit.
Image 16. Mount the unit on the lifting frame
Image 17. Hydraulic unit
Image 18. A = Oil return Tilt circuit.
B = ressure to lift and tilt circuit.
AB

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4.2 Hydraulic unit with circuit card, detailed image
Image 19. Hydraulic unit
FILLER CAP VALVE
U1 CIRCUIT CARD
CHASSIS
WITH TANK
SOLENOID
(S) MOTOR

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Installation
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4.3 Installation lift platform and
sealing strip
4.3.1 Lift platform
1. Check that all included components are clean,
clean where necessary.
2. Lubricate the metal bushings on the upper be-
aring of the arms. Make sure the small holes on
theinsideofthebushingsarelledwithgrease.
Use Zepro lubricant or equivalent.
NOTE!
Carefully lubricate the metal bushings on the
upper bearing of the arms. Make sure the small
holes are lled with grease. After installation of
the platform, the same bearings are also lubrica-
ted through the regular lubrication nipples, see
section "9Lubricationanduidlevelcheck"on
page 46
3. Fit the platform to the arms and fasten the tilt
cylinders to the platform. Use the supplied shafts
and locking nuts. Tightening torque: 25 Nm.
NOTE!
The tilt cylinders should be adjusted before xing
to the platform.
Image 20. Fit the platform with the
shafts and locking nuts provided.