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Zepro Z 1500 Technical Manual

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ZEPRO
Tel.: +46 (0)10-459 05 00
Email: zeprotech@hiab.com
79870TL
2023-08-31
Technical Manual
|
zepro.com
ZEPRO Z 1500/2000
ZEPRO ZDK 250

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Summary of Contents for Zepro Z 1500

  • Page 1 Technical Manual ZEPRO Z 1500/2000 ZEPRO ZDK 250 ZEPRO Tel.: +46 (0)10-459 05 00 Email: zeprotech@hiab.com zepro.com 79870TL 2023-08-31...

  • Page 3: Table Of Contents

    TLC B1 relay card ..................21 Functional descriptions and schematics ............. 27 Z 1500/2000 MA (ZDK 250) ..............27 Z 1500/2000 MA with digital auto tilt ............. 37 Z 1500/2000 MA with analog auto tilt ............. 49 Z 1500/2000 DA ..................60 Troubleshooting ..................

  • Page 4: Product Overview

    The type sign The Zepro Z 1500/2000 product family consists of the Z 1500 and Z 2000 tail lifts and their variants such as the Zepro ZDK 250. These products are available in a number of different variants with varying levels of func- tionality. The control systems, cylinder configurations, available control units and sensors can vary between...
  • Page 5 Product overview For the Zepro ZDK 250, the same nomenclature is used with the only difference being the capacity which is given with three digits only in order not to ocnfuse the light duty ZDK 250 with the heavy duty Z 2500 tail lifts.
  • Page 6 The Z 1500/2000 can be equipped with two types of electrical auto tilt systems, one based on a digital auto tilt sensor and one based on a analog sensor. It can also be without any auto tilt functionality.
  • Page 7 Control cards The control card converts the inputs from the user and the sensors into outputs to the motor solenoid and the valves which accomplish the desired motion. The Z 1500/2000 can be equipped with one of two models of control cards, depending on market and required functionality. The first control card is the ZePRO1 control card which is an advanced processor based circuit card.

  • Page 8: Accessing The Card And Hydraulic Unit

    With the cover removed, the hydraulic unit is accessed by swinging the card out of the way, disconnecting the quick connector for the cable harness, removing the securing nut for the hydraulic unit tray and sliding the tray out. www.zepro.com...

  • Page 9: Battery And Cable Requirements

    Some vehicle models have restrictions regarding the amount of current the lift can access from the existing battery. Some vehicle models do not fully charge the battery. It may therefore be necessary to switch to a battery and sometimes also to a charger with a larger capacity. www.zepro.com...

  • Page 10: Control Cards

    Control cards Control cards ZePRO1 circuit card 2.1.1 Overview The ZePRO1 control card can be split into different functional sections as shown in the following figure. In- depth explanations of each section are contained in the following chapters. Fig 3. ZePRO1 control card www.zepro.com...
  • Page 11 On/Off switch inside lockable driver's cab. The Zepro solution consists of a cab switch, which when active, sends power to the CS pin in the cab switch section of the card. When the switch is in its "Off" position any inputs are disregarded and the tail lift is efec- tively locked.
  • Page 12 2 analog sensors, Ai1 and Ai2. The card can accomodate the sensors shown in the table. Different variants of the Z 1500/2000 use different types and number of sensors, see the functional descriptions and schematics chapter for more information.
  • Page 13 Secondary devices do not offer the possibility of two-handed operation and therefore unable to operate certain functions. The most common primary control devices for the Z 1500/2000 are shown below. Fig 4. CD 19...
  • Page 14 Control cards Fig 5. CD 1 Fig 6. CD 3 www.zepro.com...
  • Page 15 Ctrl 4 - Input for a secondary control device such as in-box mounted device with a spiral cable. • Ctrl 5 - Input used for the slide out / slide in functionality of sliders. Not used on the Z 1500/2000. •...
  • Page 16 Control cards Fig 9. CD 11 Fig 10. Receiver module is mounted directly on the control board. www.zepro.com...
  • Page 17 LED2 is lit to indicate an active output. Startup sequence Every time the card is switched on, either by turning the cabin switch off and then back on or by cutting the power to the lift and turning it back on, a startup sequence is displayed on the display. The software configu- ration is displayed first, followed by the detected voltage and the firmware version number. It is crucial that the software configuration is the correct one for the tail lift it is installed on, see the software configurations chapter for more information. www.zepro.com...
  • Page 18 The number will stop flashing when one of the current control device buttons is pressed. If the control card has been without voltage and receives the voltage again when the CS (cabin switch) is switched on, “7” will flash on the display and the control card is locked until the Off/On on the CS is operated. www.zepro.com...
  • Page 19 L indicates the measured voltage. For example, L9 means that the measured voltage is 9 Volts. The fault code resets automatically once the voltage becomes acceptable again. U - Output not connected Fault code U is displayed when the card powers an output with nothing connected to it. The number 0-7 fol- lowing the letter U identifies the output in question, U0 through U7. The fault code is reset automatically when/if the card can detect normal current draw through the output. www.zepro.com...
  • Page 20 The output section is used for power delivery to the solenoid and the valve coils. It consists of 10 pins in total out of which four are interconnected in two pairs for cases where two coils need the same signal. The U0 output is reserved for the motor solenoid. U1-U3 are usualy used for valves V1, V2 and V3. U4 and U5 are usually used for the safety valves on the tilt and lift cylinders and the remaining ouput pins are used for adidional valves. See the functional descriptions and schematics chapter for more information. www.zepro.com...

  • Page 21: Tlc B1 Relay Card

    Control cards TLC B1 relay card 2.2.1 Overview The TLC B1 control card can be split into different functional sections as shown in the following figure. In- depth explanations of each section are contained in the following chapters. Fig 11. TLC B1 control card www.zepro.com...
  • Page 22 On/Off switch inside lockable driver's cab. The Zepro solution consists of a cab switch, which when active, sends power to the CS pin in the cab switch section of the card. When the switch is in its "Off" position any inputs are disregarded and the tail lift is efec- tively locked.
  • Page 23 Fig 14. Supply socket for different sensors The TLC B1 card can accomodate the sensor types shown in the table below. Different variants of the Z 1500/2000 use different types and number of sensors depending on functionality. See the functional descriptions and schematics chapter for connection information.
  • Page 24 Secondary devices do not offer the possibility of two-handed operation and are therefore unable to operate certain functions. The most common primary control devices for the Z 1500/2000 are shown below. Fig 15. CD 19 Fig 16.
  • Page 25 Control cards The most common secondary control devices for the Z 1500/2000 are shown below. Fig 18. CD 9 Fig 19. CD 10 Fig 20. CD 11 www.zepro.com...
  • Page 26 To the left of the output block there is a LED strip with 10 LED’s used for active output indication. The bottom LED lights up when the control card is powered. It should stay lit constantly during normal operation. The top 9 LED’s are used to indicate active output with each output having its own dedicated LED. www.zepro.com...

  • Page 27: Functional Descriptions And Schematics

    Description The Z 1500/2000 MA variant is a tail lift with double acting tilt cylinders, single acting lift cylinders and no auto tilt functionality. It is equipped with a quick opening valve that increases the opening speed of the platform.
  • Page 28 Functional descriptions and schematics Z 1500/2000 MA (ZDK 250) Function: quick open Description: Platform opening from fully closed against box body to horizontal. Control input: Down + Tilt + 2H. Available on primary control devices only. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Sensor input (no buttons pressed) Input status LED's (flashing) DOWN...
  • Page 29 Functional descriptions and schematics Z 1500/2000 MA (ZDK 250) Function: lower Description: Vertical platform lowering. Control input: Down. Available on all control devices. Sensor input: None required for function. High pressure Return flow Active Card indication TLC-B1 Output status LED's Output fuse Input status LED's DOWN TILT S5(+S1) Input fuse Must be active for the function to be executed.
  • Page 30 Functional descriptions and schematics Z 1500/2000 MA (ZDK 250) Function: tilt down Description: Tilting down within +45/-10 degrees from horizontal. Control input: Down + Tilt. Available on all control devices. Sensor input: Active angle sensor on platform. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Input status LED's DOWN TILT S5(+S1) Input fuse Must be active for the function to be executed.
  • Page 31 Functional descriptions and schematics Z 1500/2000 MA (ZDK 250) Function: tilt up Description: Tilting up within +45/-10 degrees from horizontal. Control input: Up + Tilt. Available on all control devices. Sensor input: Active angle sensor on platform. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Input status LED's DOWN TILT S5(+S1) Input fuse Must be active for the function to be executed.
  • Page 32 Functional descriptions and schematics Z 1500/2000 MA (ZDK 250) Function: raise Description: Vertical platform raising. Control input: Up. Available on all control devices. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Input status LED's DOWN TILT S5(+S1) Input fuse Must be active for the function to be executed.
  • Page 33 Functional descriptions and schematics Z 1500/2000 MA (ZDK 250) Function: close Description: Closing fully against the box body. Control input: Up + Tilt + 2H. Available on primary control devices only. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed) Down (E)
  • Page 34 Functional descriptions and schematics 3.1.2 Summary of active valves Z 1500/2000 MA Safety Safety Motor Valve Valve Valve Quick Open Valve lift, Valve lift, Soleonid Valve, V6 Open Quick Open Lower Tilt Down Tilt up Raise Close www.zepro.com...
  • Page 35 Functional descriptions and schematics 3.1.3 Z 1500/2000 MA (ZDK 250) schematic, ZePRO1 www.zepro.com...
  • Page 36 Functional descriptions and schematics 3.1.4 Schematic Z 1500/2000 MA (ZDK 250) TLC-B1 www.zepro.com...

  • Page 37: Z 1500/2000 Ma With Digital Auto Tilt

    Description The Z 1500/2000 MA with digital auto tilt is a variant with double acting tilt cylinders and single acting lift cylinders. It is equipped with a quick opening valve that increases the opening speed of the platform. It is also equipped with digital auto tilt functionality with adjustable auto tilt angle that is adjusted by physically changing the angle on the IFM sensor.
  • Page 38 Functional descriptions and schematics Z 1500/2000 MA with digital auto tilt Function: quick open Description: Platform opening from fully closed against box body to horizontal. Control input: Down + Tilt + 2H. Available on primary control devices only. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Sensor input (no buttons pressed) Input status LED's...
  • Page 39 Functional descriptions and schematics Z 1500/2000 MA with digital auto tilt Function: lower Description: Vertical platform lowering. Control input: Down. Available on all control devices. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Input status LED's DOWN TILT S5(+S1) Input fuse Must be active for the function to be executed.
  • Page 40 Functional descriptions and schematics Z 1500/2000 MA with digital auto tilt Function: auto tilt down Description: Automatic down tilting of the platform once ground level has been reached. Control input: Down. Available on all control devices. Sensor input: Active pressure sensor on lift cylinder. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Sensor input (no buttons pressed) Input status LED's...
  • Page 41 Functional descriptions and schematics Z 1500/2000 MA with digital auto tilt Function: manual tilt down Description: Tilting down within +45/-10 degrees from horizontal. Control input: Tilt + Down + 2H button on all control devices. Sensor input: Active angle sensor on platform. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Sensor input (no buttons pressed) Input status LED's...
  • Page 42 Functional descriptions and schematics Z 1500/2000 MA with digital auto tilt Function: auto tilt up Description: Automatic up tilting of the platform untill it is tilted back to horizontal. Control input: Up. Available on all control devices. Sensor input: Active IFM type angle sensor on platform. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Sensor input (no buttons pressed) Input status LED's...
  • Page 43 Functional descriptions and schematics Z 1500/2000 MA with digital auto tilt Function: manual tilt up Description: Tilting up within +45/-10 degrees from horizontal. Control input: Tilt + Up on any of the connected control devices. Sensor input: Active angle sensor on platform. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Sensor input (no buttons pressed) Input status LED's...
  • Page 44 Functional descriptions and schematics Z 1500/2000 MA with digital auto tilt Function: raise Description: Vertical platform raising. Control input: Up on any of the connected control devices. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Output status LED's Output fuse Input status LED's DOWN TILT S5(+S1) Input fuse Must be active for the function to be executed.
  • Page 45 Functional descriptions and schematics Z 1500/2000 MA with digital auto tilt Function: close Description: Closing fully against the box body. Control input: Tilt + Up + 2H button on primary control device(s). Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 TLC-B1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed)
  • Page 46 Functional descriptions and schematics 3.2.2 Summary of active valves Z 1500/2000 MA digital auto tilt Safety Safety Motor Valve Valve Valve Quick Open Valve lift, Valve lift, Soleonid Valve, V6 Open Quick Open Lower Auto tilt down Tilt Down Auto tilt...
  • Page 47 Functional descriptions and schematics 3.2.3 Schematic Z 1500/2000 MA with digital auto tilt, ZePRO1 www.zepro.com...
  • Page 48 Functional descriptions and schematics 3.2.4 Schematic Z 1500/2000 MA with digital auto tilt, TLC-B1 www.zepro.com...

  • Page 49: Z 1500/2000 Ma With Analog Auto Tilt

    Description The Z 1500/2000 MA with analog auto tilt is a variant with double acting tilt cylinders and single acting lift cylinders. It is equipped with a quick opening valve that increases the opening speed of the platform. It is also equipped with analog auto tilt functionality with angle setting which allows the user to manually set the auto tilt angle that the platform returns to during the auto tilt motion.
  • Page 50 Functional descriptions and schematics Z 1500/2000 MA with analog auto tilt Function: quick open Description: Platform opening from fully closed against box body to horizontal. Control input: Down + Tilt + 2H. Available on primary control devices only. Sensor input: Inclinometer voltage ~ 2,0-3,2V High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed)
  • Page 51 Functional descriptions and schematics Z 1500/2000 MA with analog auto tilt Function: lower Description: Vertical platform lowering. Control input: Down. Available on all control devices. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed)
  • Page 52 Functional descriptions and schematics Z 1500/2000 MA with analog auto tilt Function: auto tilt down Description: Automatic down tilting of the platform once ground level has been reached. Control input: Down. Available on all control devices. Sensor input: Active pressure sensor on lift cylinder. Inclinometer voltage ~ 1,7-2,5V. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input...
  • Page 53 Functional descriptions and schematics Z 1500/2000 MA with analog auto tilt Function: manual tilt down Description: Tilting up within +45/-10 degrees from horizontal. Control input: Tilt + Up. Available on all control devices. Sensor input: Inclinometer voltage ~ 1,7-2,1V. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input...
  • Page 54 Functional descriptions and schematics Z 1500/2000 MA with analog auto tilt Function: auto tilt up Description: Automatic up tilting of the platform untill it is tilted back to the saved angle. Control input: Up. Available on all control devices. Sensor input: Inclinometer voltage ~ 1,7-2,0V. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input...
  • Page 55 Functional descriptions and schematics Z 1500/2000 MA with analog auto tilt Function: manual tilt up Description: Tilting up within +45/-10 degrees from horizontal. Control input: Tilt + Up. Available on all control devices. Sensor input: Inclinometer voltage ~ 1,7-2,1V. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input...
  • Page 56 Functional descriptions and schematics Z 1500/2000 MA with analog auto tilt Function: raise Description: Vertical platform raising. Control input: Up. Available on all control devices. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 Sensor input Sensor input (no buttons pressed) buttons pressed) (flashing) Up (B) Tilt (C) ontrol unit input...
  • Page 57 Functional descriptions and schematics Z 1500/2000 MA with analog auto tilt Function: close Description: Closing fully against the box body. Control input: Tilt + Up + 2H. Available on primary control devices only. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed)
  • Page 58 Functional descriptions and schematics 3.3.2 Summary of active valves Z 1500/2000 MA analog auto tilt Safety Safety Motor Valve Valve Valve Quick Open Valve lift, Valve lift, Soleonid Valve, V6 Open Quick Open Lower Auto tilt down Tilt Down Auto tilt...
  • Page 59 Functional descriptions and schematics 3.3.3 Schematic Z 1500/2000 MA with analog auto tilt www.zepro.com...

  • Page 60: Z 1500/2000 Da

    Description The Z 1500/2000 DA is a variant with double acting tilt cylinders and double acting lift cylinders. It is equipped with a quick opening valve that increases the opening speed of the platform. It has no auto tilt functionality.
  • Page 61 Functional descriptions and schematics Z 1500/2000 DA Function: quick open Description: Platform opening from fully closed against box body to horizontal. Control input: Down + Tilt + 2H. Available on primary control devices only. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed) Down (E) 2H/X (flashing) Must be active for the function to be executed.
  • Page 62 Functional descriptions and schematics Z 1500/2000 DA Function: lower Description: Vertical platform lowering. Control input: Down. Available on all control devices. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed) Down (E) 2H/X (flashing) Must be active for the function to be executed.
  • Page 63 Functional descriptions and schematics Z 1500/2000 DA Function: tilt down Description: Tilting down within +45/-10 degrees from horizontal. Control input: Down + Tilt. Available on all control devices. Sensor input: Active angle sensor on platform. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed) Down (E) 2H/X (flashing) Must be active for the function to be executed.
  • Page 64 Functional descriptions and schematics Z 1500/2000 DA Function: tilt up Description: Tilting up within +45/-10 degrees from horizontal. Control input: Up + Tilt. Available on all control devices. Sensor input: Active angle sensor on platform. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed) Down (E) 2H/X (flashing) Must be active for the function to be executed.
  • Page 65 Functional descriptions and schematics Z 1500/2000 DA Function: raise Description: Vertical platform raising. Control input: Up. Available on all control devices. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed) Down (E) 2H/X (flashing) Must be active for the function to be executed.
  • Page 66 Functional descriptions and schematics Z 1500/2000 DA Function: close Description: Closing fully against the box body. Control input: Up + Tilt + 2H. Available on primary control devices only. Sensor input: None required for function. High pressure Return flow Active Card indication ZePRO1 Sensor input (no buttons pressed) (flashing) Up (B) Tilt (C) Control unit input (buttons pressed) Down (E) 2H/X (flashing) Must be active for the function to be executed.
  • Page 67 Functional descriptions and schematics 3.4.2 Summary of active valves Z 1500/2000 DA Safety Safety Motor Valve Valve Valve Quick Open Valve lift, Valve lift, Soleonid Valve, V6 Open Quick Open Lower Tilt Down Tilt up Raise Close www.zepro.com...
  • Page 68 Functional descriptions and schematics 3.4.3 Schematic Z 1500/2000 DA www.zepro.com...

  • Page 69: Troubleshooting

    "ON" position. If the tail lift is completely dead, use a multimeter to troubleshoot the power supply starting at the tail lift and moving towards the battery. Possible causes include but are not limited to a dead battery, a tripped fuse or disconnected or damaged power and/or ground cables. www.zepro.com...
  • Page 71 BUILT TO PERFORM Zepro, Del and Waltco are Hiab trade marks for tail lifts. Hiab is a world-leading supplier of equipment, intelligent services and digital solutions for on-road load handling. As an industry pioneer, our company commitment is to increase the efficiency...

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Z 2000Zdk 250

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