79072TL - EN - Technical Manual ZePRO1 211116

Technical Manual
ZePRO1 Control System
ZEPRO
Tel.: +46 (0)10-459 05 00
Email: zeprotech@hiab.com | zepro.com
79072TL
2021-11-16
Technical Manual
Contents
1 Technical description............................................................................................... 4
1.1 General.................................................................................................................. 4
1.2 Power save mode................................................................................................. 4
1.3 Operating information.......................................................................................... 4
1.4 Supply voltage.................................................................................................... 10
1.5 Minimum recommended battery capacity........................................................ 11
1.6 Minimum recommended conductor cross-sectional area
(copper cables, positive and negative cables)................................................. 11
1.7 Power consumption........................................................................................... 12
2 Functional description ........................................................................................... 13
2.1 Cylinder models.................................................................................................. 13
2.2 Models - Configurations..................................................................................... 13
2.3 Configuration 14 - MA........................................................................................ 14
2.4 Configuration 14 - MA Autotilt........................................................................... 18
2.5 Configuration 16 DA........................................................................................... 23
2.6 Configuration 1................................................................................................... 27
2.7 Configuration 9................................................................................................... 30
2.8 Configuration 1 ML............................................................................................. 37
3 Electrical and hydraulic diagrams........................................................................... 40
3.1 Z/ZL 1500-2000.................................................................................................. 40
3.2 Z 2500 ................................................................................................................ 45
3.3 Z 45/75................................................................................................................ 50
3.4 Z3N, Z3NU, Z3NW, Z3NWU................................................................................ 54
www.zepro.com 3
Technical description Technical Manual
1 Technical description
1.1 General
All lift functions are controlled via the control card. The card has a number of inputs and outputs for connect-
ing the tail lift solenoid (hydraulic pump), valves, sensors and control devices. The card also has LEDs and an
alphanumeric display that shows system status.
1.2 Power save mode

If the control card is not used for about 5 mins, it will go into power save mode. Press any control button for
approx. 0.5 seconds to "wake" the control card again.
1.3 Operating information

All the lift functions are controlled and monitored through the control card, which is equipped with an alpha-
numerical display with a flashing light and 2 red LEDs. These display current operating information. In the
event of any operational disturbances, fault codes will be displayed to facilitate troubleshooting.
The display indicates:
- Active control device
- Fault display
- Program configuration
- Current status of sensors
Flashing light indicates:
- Off: No supply voltage
- On: Supply voltage available but CS (cabin switch) is not active.
- Flashing: CS (cabin switch) is active, the system is awaiting input signal.
LED 1 indicates:
- Active input, button(s) on control device pressed.
LED 2 indicates:
- Active output (approved input signal from control device and sensors), the lift is operated.
LED 1
LED 2
Display
Flashing light
Image 1. The control card is equipped with an alphanumerical display with a flashing light and 2 red LEDs
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1.3.1 Information codes

Codes are shown on the display in this sequence. First a letter for identification of information,
followed by figures or segments for further information and then ending with a pause.When the CS
(cabin switch) is switched on, the current program configuration (P) is displayed first, followed by
configuration number. The number of volts detected is then displayed and, after this, the current
software version (J), followed by version number.
As long as no control devices are used, a rolling sequence is then displayed, with sensor indication (C), followed
by 0-6 segments showing which sensors have a signal.
When a control device is being used, its number (1-7) is displayed, followed by which button has been
pressed, segments B, C, E or X (X symbolises the 4th button on the respective control device (2h1 for fixed con-
trol device 1, 2h2 for fixed control device 2, lock knob for radio control device and coil control device).
The control devices are symbolised by the numbers 1-7.
1. Fixed control device 1, including two-hand button 2h1
3. Radio control device, External
4. Coil control device
5. Slider control device
6. Radio control device, internal module
7. CS (cabin switch)
Once a button has been released, the control system for the current control device is locked for a while to ensure
that no other person operates the lift from another control device. The current control device number (1-7) will
flash on the display while the control system is locked to it. This primarily applies to radio and coil control de-
vices, as other control devices have such a short locking period that there is hardly time to see the indication.
Coil control devices can be equipped with a locking function. Once the control device has been used, the con-
trol system is locked for the current control device until it is unlocked manually with the respective control
device’s deactivation button.
The radio control device is also equipped with a locking function. The control system can then be locked/
unlocked by pressing and holding button 5. The lock status is indicated by the lock function LED, which lights
up when the lock is activated. In the event of a fault in the remote control, it can be unlocked by turning the
control power (CS) Off/On.
If the remote control is in the locked position and the lift has been unlocked by switching the control power
(CS) Off/On, the lift will be locked again as soon as any button on the remote control is pressed.
NOTE!
The lift remains locked if it loses power and is then started again, the number 6 will flash on the control card dis-
play. It can be unlocked as described above.
www.zepro.com 5
Information codes
Code Code
Identification Code 1 Information Other
2 3
00-99 Configuration setting
P
(Application configu- - Dividers
ration)
12/24 Number of volts detected
J 01-99 _ 1-9 Firmware version number

Software version
Fixed light (1-6) displays active control
1-6 (Fixed light) 1-6 device during operation.
In
Active control de- B C
vice while operating Segment B, C, E or X lights up depending
Seg-
on which button is pressed X
ments E
B, C, E
or X. Out
Control device to which the control
1-7 (Flashing) system is locked.
The control device
This primarily applies to radio and coil
to which the control
control devices, as other control devices
system is locked for
have such a short locking period that
a while after com-
there is no time to see the indication.
pleted operation.
The number will stop flashing when
one of the current control device buttons is
1-7 pressed.
If the control card has been without volt-
age 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.
1-6 = Ctrl 1-6
7 = CS
C 1-9.0 segments indicate sensors.
Sensor indication Di2
On - signal in.
Di1 Di3
Segment Off - no signal in. 0V.
(See electrical and hydraulics diagrams Di6 Di4
for information about the location of the
sensors). Di5
6 www.zepro.com
Example of sequence with information codes:
Configuration 1 Voltage detected 12V Firmware 9.0
Example of sequence with sensor indication:

Sensor indication: C, Detected sensor: Di1
Example of sequence with control device indication:

Control device: 2, Detected button: B
1.3.2 Fault codes

If a fault arises, the fault code will be shown in the display in the form of a letter for identifying the fault, followed
by numbers and/or number segments for further information, followed by sensor indication (C) according to the
previous page.
The numbers (1-9) in fault codes E and F show which control device/output the fault code refers to.
3. Radio control device, External
4. Coil control device
5. Slider control device
6. Radio control device, internal module
7. CS (cabin switch)
8. Control Power
9. Sensor Power
If the system discovers several faults, only the fault code for the fault with the highest priority will be shown auto-
matically. The display is prioritised in the order in the table below, L/H, E, F and A.
When CS is turned off, the system scrolls through a list of the last five errors detected before the display
turns off after approx. 5 minutes, the control card then goes into sleep mode.
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Fault codes
Identification Code 1 Code 2 Code 3 Information Other
L 07-35 Voltage measured
Low battery voltage
H 07-35 Voltage measured
High battery voltage
E Fixed control device 1 (incl. two-
Control device 1 hand button 2h1 if they are moni-
locked tored)
Fixed control device 2 (incl. two-
2 hand button 2h2 if they are moni-
tored)
3 Radio control device, external
4 Coil control device
5 Slider control device
Radio control device, internal
6
module
7 CS (cabin switch)
In
Segments B, C, E or X are illumi- B C
nated depending on which button
Segment
signal has locked the control
device.
E X
Out
F 1-7 U 0 - U 7 , d i s -
Output short-circuit- played only af-
ed/high current The output that has short-circuit- ter the respec-
ed/has high current. Fault code is tive output/
0-9 reset automatically if the function function has
in question is running (function been active.
verified).
8 Control power
9 Sensor power
Output not connect- The output that is not connected/
Displayed only after
ed/cable break has cable break. Fault code is
the respective out-
0-7 reset automatically if the function
put U0-U7 has been
in question is running (function
active.
verified).
A Contact support
Internal fault 0- if the lift does not
function.
All fault codes can be reset manually by switching the CS (cabin switch) On/Off. Fault codes F0-F7 and U0-
U7 are reset automatically if the function in question is running (function verified). Fault codes L and H are
reset automatically if the battery voltage becomes correct. Fault code E is reset automatically if the control
system does not received a signal from the relevant control device for 6 minutes.
Example of sequence of fault codes:

Output no. 3 short-circuited.
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1.3.3 Fault codes control card
F9
F7
F6
F5
F4
F3
F2
F1
F0
+
Sensor Power
Contr l Power
U7
U4
U4
U3
U2
U1
U0
U6
U5
U5
F8 Outputs
Ground
B
E
E1 Ctrl 1 IN OUT
C
Lysdiod 1
2H1
Lysdiod 2
B PA-
E Display PA+
E2 Ctrl 2 Blinkpunkt
C CSPWR
2H2 Ctrl 6 E6 CS E7
B Di 6
E3 E Ctrl 3 Di 5 Sensor indication
C Radio Di 4
Lock Di2
Sensors
Di 3
B Ctrl 5
Di 2 Di1 Di3
LLED
Di 1
GND
E4
Out
E Ctrl 4
Di6 Di4
In
Ai 2
C Spiral
Ai 1
Lock Di5
E5 Lysdiod blinkar när

styrkortet är igång
(CS ska vara hög för detta)
www.zepro.com 9
1.3.4 Control device

If a control device button is held down for too long, the control device is blocked and cannot be used for
a number of minutes. Fault code E flashes on the display. The fault is also indicated on a non-active coil
control device with a lock button, if this is connected to Ctrl 4. The LED on the coil control device then flashes
the same number of times as the number on the control device in question, see the list in section "1.3.2 Fault
codes" on page 7.
Example: Control device 2 is blocked, the LED on the coil control device then flashes twice, goes out for a mo-
ment, flashes twice again, etc.
Coil control device LED

Fixed light The coil control device is active
Extinguished (weak glim- The coil control device is not active
mer)
Flashing One of the other control devices is blocked
1.4 Supply voltage

The illustrations below show the desired supply voltage for 12V and 24V systems. Specified voltage refers to
voltage when the lift is operated. See also sections "1.6 Minimum recommended conductor cross-sectional
area
(copper cables, positive and negative cables)" on page 11. and "1.7 Power consumption" on page 12.
The lift is not working.

The lift is working but is issuing a warning. This voltage range is only recommended for
emergency operation.
The lift is working, but the voltage range outside the ‘heart-marked’ area is only rec-
ommended for operation for short periods.
The lift is working within the voltage range for optimum function and service life.
8-15V
12V 0V 10-14V 36V
0-7V 16-36V
18-30V
24V 0V 20-28V 36V
0-16V 32-36V
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1.5 Minimum recommended battery capacity
Minimum recommended battery capacity
Lifting capacity < 1000 kg. 140 Ah

Lifting capacity > 1500 kg. 180 Ah
NB!
Make sure the lift has access to the minimum recommended current capacity (Imin). Some vehicle models have
restrictions regarding the amount of power the lift can access from the existing battery.
1.6 Minimum recommended conductor cross-sectional area

(copper cables, positive and negative cables)
Minimum recommended conductor cross-sectional area

Control cable 1.5 mm2
Lifting capac- Main power cable L < 8m 25 mm2
ity < 1000 kg Main power cable L > 8 m 35 mm2
Main power cable L < 8m 35 mm2
Lifting capac- Main power cable, L = 8 - 50 mm2 (12 volts) / 35 mm2 (24
ity >1500 kg 15m volts)
Main power cable L > 15m 50 mm2 (Only 24 volts)
Imin Umin
-+
Imin
Umin
-+
Image 2. Minimum recommended battery capacity - Minimum recommended conductor cross-sectional area
www.zepro.com 11
1.7 Power consumption
Power consumption
12 volt 24 volt
shut-off valve
shut-off valve
Pump - Motor
Pump - Motor
Magnet (elec.
Magnet (elec.
(hyd. unit)
(hyd. unit)
Solenoid
Solenoid
Magnet
Magnet
unit
unit
Z/ZL 1500
Z/ZL 2000
ZDK 250
SZL 1500 245 A 4.2 A 1.5 A 1.8 A 145 A 2.1 A 0.75 A 1.2 A
SZL 2000
SZN 1500
SZN 2000
Z/ZL 2500 200 A 2.1 A 0.75 A 0.85 A
ZS/ZSS/ZD 150
245 A 4.2 A 1.5 A 1.5 A 125 A 2.1 A 0.75 A 0.85 A
ZT/ZTS 150/200
ZS/ZSS/ZD 200/250 250 A 4.2 A 1.5 A 1.5 A 150 A 2.1 A 0.75 A 0.85 A
ZSSUHD 2000 245 A 4.2 A 1.5 A 1.8 A 145 A 2.1 A 0.75 A 0.9 A
Z100 200 A 1.5 A 1.5 A 1.8 A 90 A 0.75 A 0.75 A 0.9 A
ZHD 1500/2000 245 A 4.2 A 1.5 A 1.8 A 135 A 2.1 A 0.75 A 0.9 A
Z 45 95 A 1.4 A 1.5 A 1.8 A 60 A 0.7 A 0.75 A 0.9 A
Z 75 115 A 1.4 A 1.5 A 1.8 A 75 A 0.7 A 0.75 A 0.9 A
Z3N 75 115 A 1.4 A 1.5 A 1.8 A
12 www.zepro.com
Functional description Technical Manual
2 Functional description
2.1 Cylinder models
L = Double-acting tilt with limited stroke - Single-acting lift
DL = Double-acting tilt with limited stroke - Double-acting lift
MA = Double-acting adjustable tilt - Single-acting single-speed lift
DA = Double-acting adjustable tilt - Double-acting single-speed lift
S = Double-acting single-speed tilt - Single-acting single-speed lift
SA = Single-acting single-speed adjustable tilt - Single-acting single-speed lift
2.2 Models - Configurations
Model Configuration Page
Z/ZL 1500/2000/2500, ZDK 250, Z/ZN 2500 - MA 14 14

Z/ZL 1500/2000/2500 - MA,autotilt (standard) 14 18
Z/ZL 1500/2000/2500 - DA 16 23
Z 45/75 - S, SA 1 27
Z3N(U)/Z3NN(U)/Z3NW(U) - MA 9 30
www.zepro.com 13
2.3 Configuration 14 - MA
"2.3.1 Sensors/Inputs"
"2.3.2 Functional diagram"
"2.3.3 Restriction in use of control device"
"2.3.4 Quick opening - activation zone"
2.3.1 Sensors/Inputs
Designation Position Function Description

(standard)
Ai 1 Not used in this configuration
B Control device Up button
E Control device Down button
C Control device Tilt button Used in combination with B and E for tilt-up and tilt-down
2H Control devices Two-hand but- Activated in connection with opening and closing of vehicle body. Used for
ton quick opening.
Di1 Not used in this configuration
Di3 Angle sensor Non-actuated Di3 disables Tilt up with the secondary control device so
that the operator must use the two-hand button - 2H along with the primary
control device in order to continue to maintain the tilt up function.
Di4 Tilt cylinder Open platform Pressure sensor for falling pressure connected to +side of tilt cylinder. In the
alarm actuated state, returns the connection signal (+) to Di4, resulting in output
signal (-) at Pa-. Also phase (+) signal out on Pa+. 60 Bar (NC).

Cs Cabin Activation No signal in at Cs results in blocked control device terminals. Signal to Cs
usually comes from the cabin switch. In individual cases when the cabin
switch is not used, the (+) signal comes in to Cs jumpered from (CS PWR) on
nearby terminal.
ton quick opening.
"2.2 Models - Configurations" on page 13
14 www.zepro.com
2.3.2 Functional diagram
Input signal
Output Control de-
Function High Low (0v) signal Comment vices Image
p U0
p Di1 p U1 p Ctrl 1 89º
p Di2 p U2 Open from 89º down to p Ctrl 2 45º

C approx. 45º.
1 E
p Di3* p U3 p Ctrl 3
15º
2H p Di4 p U4 Quick opening is p Ctrl 4 0º
p Di5 p U5 activated. p Ctrl 5 -10º
p Di6 p U6** p Ctrl 6

p U7
Opening
p U0
2
C p Di3 p U3 Opens the body from p Ctrl 3
15º
E p Di4 p U4 inside. p Ctrl 4 0º
p Di5 p U5 p Ctrl 5 -10º
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Lower E
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
* Only required at start of motion; after change of sensor, it is ignored until a re-run takes place.
** 0.2 second delay of output signal.

"2.3 Configuration 14 - MA" on page 14
www.zepro.com 15
Input signal
Output Control de-
p U0
p Di1 p U1 p Ctrl 1
C
Tilt down E
p Di3 p U3 p Ctrl 3
Di3* p Di4 p U4 p Ctrl 4
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
Raise B
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
B
Tilt up C
p Di3 p U3 Tilting up to approxi- p Ctrl 3
p Di4 p U4 mately 45º p Ctrl 4 0º
Di3 -10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
B
Closing C
p Di3 p U3 Close against vehicle p Ctrl 3
p Di4 p U4 body p Ctrl 4 0º
2H
-10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
Sensor name with /-symbol in front = 0, i.e., no signal.

** Autotilt, lower: Tilt up only until Di2 switches to not actuated, then lower. Di2 is ignored until a re-run takes place.

16 www.zepro.com
2.3.3 Restriction in use of control device
Ctrl 1 & 2 Ctrl 3 & 6 Ctrl 4
Image 3. The use of control devices connected to Ctrl 1 and Ctrl 2 is not limited by the angle of the platform.
The use of control devices connected to Ctrl 3 & 6 is limited by the angle of the platform.
The use of control device connected to Ctrl 4 is limited by the angle of the platform when tilting up.
2.3.4 Quick opening - activation zone
90º
45º
-10º
Image 4. Quick opening can be activated when the platform angle is 90º-45º.
Provided that the control unit buttons are pressed and held, the quick opening will be active down to -10º.

www.zepro.com 17
2.4 Configuration 14 - MA Autotilt

"2.4.4 Quick opening zone"
"2.4.5 Foot controls and warning lights"
"2.4.6 Inclinometer - voltage"

(standard)
Ai 1 Platform Inclinometer Measures the angle of the bridge to Earth's gravity
ton quick opening. (Does not apply to CE market.)
Di1 Lift arm Angle sensor For Autotilt, safety function
signal (-) at Pa-. Also phase (+) signal out on Pa+. 60 Bar (NC).
Di5 Lift cylinder Pressure sensor For autotilt. 5 Bar (NC).

switch is not used, the (+) signal comes in to Cs jumpered from (CS PWR) on
nearby terminal.

"2.4 Configuration 14 - MA Autotilt" on page 18
18 www.zepro.com
es
er
l
a
vic
ign
et
de
en
om
ts
Input signal
mm
ol
tpu
lin
ntr
Inc
Co
High Low (0v)
Ou
Co
Function Image
p U0
p Di2 p U2 p Ctrl 2
C
1 E
p Di3*** 0° p U3 Quick opening p Ctrl 3
10º
p Di4 p U4 is activated. p Ctrl 4
2H
p Di5 p U5 p Ctrl 5
Ai1
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2*** p U2 p Ctrl 2
2
C p Di3*** 0°
p U3 Quick opening p Ctrl 3
Tilt down E is activated.
p Di5 p U5 p Ctrl 5
-10º
Ai1 p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
3
C p Di3*** p U3 p Ctrl 3
0°
E p Di4 p U4 p Ctrl 4 15º
p Di5 p U5 p Ctrl 5
-10º
p Di6 p U6 p Ctrl 6
Ai1 p U7
Does not affect
p U0
function
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
1 E
p Di3
0°
p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
Ai1 p U7
Lower
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
E
2 Di1
p Di3**
0°
p U3
Autotilt down.
p Ctrl 3
-10º
p Di6 p U6 p Ctrl 6
Ai1
p U7
*** Unconnected

www.zepro.com 19
es
er
vic
a
ign
et
de
en
om
Input signal
ts
ol
mm
tpu
lin
ntr
Inc
Co
High Low (0v)
Ou
Co
Function Image
p U0
p Di1 p U1 p Ctrl 1
1 B
p Di3 0° p U3
Autotilt up
p Ctrl 3
p Di4 p U4 p Ctrl 4
-10º
p Di6 p U6 p Ctrl 6
Ai1 p U7
Raise
Does not affect
p U0
function
p Di1 p U1 p Ctrl 1
2 B
p Di3 0° p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
Ai1 p U7
p U0
p Di1 p U1 p Ctrl 1
45º
p Di2 p U2 p Ctrl 2
Tilt up
B p Di3*** 0° p U3 p Ctrl 3
C p Di4 p U4 p Ctrl 4 -10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
Ai1 p U7
Does not affect
function
p U0
p U1 p Ctrl 1
p U2 p Ctrl 2
B
Closing C 0° p U3 p Ctrl 3
2H p U4 p Ctrl 4
p U5 p Ctrl 5
p U6 p Ctrl 6
Ai1
p U7
*** Unconnected

20 www.zepro.com

(Tilt up/down and opening/closing)
Ctrl 1 & 2 Ctrl 3, 4 & 6
Image 5. The use of control devices connected to Ctrl 1 & 2 is not limited by the angle of the platform.
The use of control devices connected to Ctrl 3, 4 & 6 is limited by the angle of the platform.
2.4.4 Quick opening zone
90º
10º
Image 6. Quick opening can be activated when the platform angle is approx. 90º-10º

www.zepro.com 21
2.4.5 Foot controls and warning lights
45º
Image 7. When the angle is 45º or less, signal is given on U7 for activating warning lighting and foot controls
2.4.6 Inclinometer - voltage

The voltage of the inclinometer output varies with the inclinometer angle. Below are some examples of differ-
ent angles and approximate voltage.
~3,2V
~2,5V 90º
45º
~1,8V 0º
Image 8. Approximate voltage at various angles

22 www.zepro.com
2.5 Configuration 16 DA
"2.5.1 Sensors/inputs"
"2.5.4 Quick opening - activation zone"
2.5.1 Sensors/inputs

(standard)
2H Control devices Two-hand but- Activated in connection with opening and closing of vehicle
ton body. Used for quick opening.
Di3 Angle sensor Non-actuated Di3 disables Tilt up with the secondary control
device so that the operator must use the two-hand button -
2H along with the primary control device in order to continue
to maintain the tilt up function.
Di4 Tilt cylinder Open platform Pressure sensor for falling pressure connected to +side of tilt
alarm cylinder. In the actuated state, returns the connection signal
(+) to Di4, resulting in output signal (-) at Pa-. Also phase (+)
signal out on Pa+. 60 Bar (NC).

Cs Cabin Activation No signal in at Cs results in blocked control device terminals.
Signal to Cs usually comes from the cabin switch. In individual
cases when the cabin switch is not used, the (+) signal comes
in to Cs jumpered from (CS PWR) on nearby terminal.
2H Control devices Two-hand but- Activated in connection with opening and closing of vehicle
ton body. Used for quick opening.
www.zepro.com 23
Input signal
Output Control de-
p U0
p Di2 p U2 Open from 89º down to p Ctrl 2 45º

C approx. 45º.
1 E
15º
2H p Di4 p U4 Quick opening is p Ctrl 4 0º
p Di5 p U5 activated. p Ctrl 5 -10º

p U7
Opening
p U0
p Ctrl 1 89º
p Di1 p U1
p Ctrl 1
p Di2 p U2 45º
p Ctrl 2
2
C p Di3 p U3 Opens from inside the
E body. p Ctrl 3 15º
p Di4 p U4 0º
p Ctrl 4
p Di5 p U5 -10º
p Ctrl 5
p Di6 p U6**
p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
1 E
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
Lower
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Manual down, replaces
2
E p Di3 p U3
lower 1 and 2 at jump-
p Ctrl 3
Di6 p Di4 p U4 p Ctrl 4
ered Di6.
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7

"2.5 Configuration 16 DA" on page 23
24 www.zepro.com
Input signal
Output Control de-
p U0
p Di1 p U1 p Ctrl 1
C
Tilt down E
p Di3 p U3 p Ctrl 3
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
1 B
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
Raise
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Manual up, replaces
2
B p Di3 p U3
raise 1 and 2 at jump-
p Ctrl 3
ered Di6.
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
B
Tilt up C
p Di4 p U4 mately 45º. p Ctrl 4 0º
Di3 -10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Ctrl 1
p Di1 p U1 90º
p Ctrl 1
p Di2 p U2 45º
B p Ctrl 2
Closing C
p Di3 p U3 Close against vehicle
body. p Ctrl 3
2H p Di4 p U4 0º
p Ctrl 4 -10º
p Di5 p U5
p Ctrl 5
p Di6 p U6
p Ctrl 6
p U7

www.zepro.com 25
Ctrl 1 & 2 Ctrl 3 & 6 Ctrl 4
Image 9. The use of control devices connected to Ctrl 1 and Ctrl 2 is not limited by the angle of the platform.
The use of control device connected to Ctrl 4 is limited by the angle of the platform when tilting up.
2.5.4 Quick opening - activation zone
90º
45º
-10º
Image 10. Quick opening can be activated when the platform angle is 90º-45º.
Provided that the control unit buttons are pressed and held, the quick opening will be active down to -10º.

26 www.zepro.com
2.6 Configuration 1

(standard)
Di1 Not used on this lift model and must not be connected.
Di2 Platform Angle sensor Non-actuated Di2 disables Tilt up with the secondary control device so that the
operator has to use the two-hand button (2H) along with the primary control
device in order to continue to maintain the tilt up function.
Di3 Lift arm Angle sensor For Autotilt, safety function.
signal (-) at Pa-. Also phase (+) signal out on Pa+.
Cs Cabin Activation No signal in at Cs results in blocked control device terminals.
Signal to Cs usually comes from the cabin switch.
2H Control devices Two-hand Activated in connection with opening and closing of vehicle body. Used for
button quick opening.

(Tilt up/down and opening/closing)
Ctrl 1, 2 & 4 Ctrl 3, 4 & 6
Image 11. The use of control devices connected to Ctrl 1 & 2 is not limited by the angle of the platform.
Control devices connected to Ctrl 3, 4 & 6 are limited by the angle of the platform.
www.zepro.com 27
Input signal
Output Control de-
p U0
C p Di2 p U2 p Ctrl 2 45º

Open from vehicle
1
E p Di3 p U3 body down to about
p Ctrl 3
2H p Di4 p U4 p Ctrl 4 0º
45°
Di6 -10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
Opening
p U0
D
2 E
p Di3 p U3 p Ctrl 3
Di6 p Di4 p U4 p Ctrl 4 0º
-10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
1 E
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
Lower
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
2
E p Di3 p U3 Autotilt down
p Ctrl 3
0º
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
C
45º
Tilt down
E p Di3 p U3 p Ctrl 3
Di6 0º
p Di6 p U6 p Ctrl 6
p U7

"2.6 Configuration 1" on page 27
28 www.zepro.com
Input signal
Output Control de-
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
B
p Di3 p U3
Autotilt up
p Ctrl 3
p Di4 p U4 p Ctrl 4
0º
p Di6 p U6 p Ctrl 6
p U7
Raise
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
B
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
B
Tilt up 1 C
Di2 -10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
B
Closing C
2H
-10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7

www.zepro.com 29
2.7 Configuration 9
"2.7.3 Functional diagram - Ctrl 1, 2 & 3"
"2.7.4 Functional diagram - Ctrl 4"
"2.7.5 Functional diagram - with auto-levelling"
"2.7.6 Functional diagram - without autotilt"

(standard)
Di1 Control card Jumper Jumpered = Auto-levelling On
Di2 Platform Angle sensor For autotilt
Di3 Platform Angle sensor Non-actuated Di3 disables Tilt up with the secondary control device so that
the operator must use the two-hand button - 2H1 together with the primary
control device in order to continue to maintain the tilt up function.
Actuated Di3 enables activation with both the primary and secondary control
device.
When the two-hand button is actuated along with operation of the primary
control device, the signal from Di3 will be ignored.
Tilt down using the primary device and active 2H button (C+E+2H) gives quick
opening via U6.
However, when Di2 and autotilt are actuated, quick opening will be blocked.
Secondary device does not have quick opening.
Di5 Lift cylinder Pressure sensor For autotilt.
Di6 Control card Jumper For manual operation with no autotilt.

switch is not used, the (+) signal comes in to Cs jumpered from (+) on nearby
terminal.
ton quick opening.
Ctrl 1, 2 & 4 Ctrl 3 & 6
Image 12. The use of control devices connected to Ctrl 1, 2 & 4 is not limited by the angle of the platform.
30 www.zepro.com
2.7.3 Functional diagram - Ctrl 1, 2 & 3

Di1 and Di6 NOT jumpered (without auto-levelling, with autotilt)
Input signal
Output Control de-
p U0
C
Opening E
p Di3 p U3 Quick opening
p Ctrl 3
2H p Di4 p U4 p Ctrl 4 0º
-10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Lower 1 E
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7 Without auto-levelling
p U0 Di1 NOT jumpered)
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Lower
(autotilt 2
down)
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
C
p Di3 p U3 p Ctrl 3
1 E p Ctrl 4
Di3* p Di4 p U4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
C 45º
Tilt down 2 E
p Di3 p U3 p Ctrl 3
2H1 p Di4 p U4 p Ctrl 4
0º
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
C p Di2 p U2 p Ctrl 2
3
Di3*
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
www.zepro.com 31
Input signal
Output Control de-
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Raise
(Autotilt 1
B p Di3 p U3 p Ctrl 3
up)
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Raise 2 B
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
B
Tilt up C
Di3 -10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
B
Closing C
2H1
-10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7

32 www.zepro.com
2.7.4 Functional diagram - Ctrl 4

Di1 and Di6 NOT jumpered (without auto-levelling, with autotilt)
Input signal
Output Control de-
p U0
Opening
C p Di3 p U3 Opening from vehicle p Ctrl 3
E p Di4 p U4 body p Ctrl 4 0º
-10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Lower 1 E
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7 Without auto-levelling
p U0 (Di1 NOT jumpered)
p Di1 p U1 pCtrl 1
p Di2 p U2 p Ctrl 2
Lower
(Autotilt 2
down)
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
45º
Tilt down
C p Di3 p U3 p Ctrl 3
0º
p Di6 p U6 p Ctrl 6
p U7

www.zepro.com 33
Input signal
Output Control de-
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Raise
(Autotilt 1
up)
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Raise 2 B
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
Tilt up
B p Di3 p U3 Tilting up to approxi- p Ctrl 3
C p Di4 p U4 mately 45º p Ctrl 4 0º
-10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
Tilt up
C p Di4 p U4 p Ctrl 4 0º
-10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7

34 www.zepro.com
2.7.5 Functional diagram - with auto-levelling

Di1 jumpered
Input signal
Output Control de-
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Lower E
(Auto-tilt 1 Di1
p Di3 p U3 p Ctrl 3
up) Di2* p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
E
Lower 2 Di1
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Lower E
(Autotilt 3 Di1
p Di3 p U3 p Ctrl 3
down) Di5* p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7

www.zepro.com 35
2.7.6 Functional diagram - without autotilt

Di1 jumpered
Input signal
Output Control de-
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Lower E p Di3 p U3 p Ctrl 3
(Manual) Di6 p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Raise B p Di3 p U3 p Ctrl 3
(Manual) Di6 p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7

36 www.zepro.com
2.8 Configuration 1 ML
"2.8.1 Sensor/Inputs (Config 1)"
2.8.1 Sensor/Inputs (Config 1)

(standard)
Di2 Platform Angle sensor Non-actuated Di2 disables Tilt up with the secondary control device so that the
operator has to use the two-hand button (2H) along with the primary control
device in order to continue to maintain the tilt up function.
Di3 Lift arm Angle sensor For Autotilt, safety function.
switch is not used, the (+) signal comes in to Cs jumpered from (+) on nearby
terminal.
2H Control devices Two-hand Activated in connection with opening and closing of vehicle body. Used for
button quick opening.
Tilt up/down
Image 13. All existing control devices can be used throughout the work area
www.zepro.com 37
Input signal
Output Control de-
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
1 E
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
Lower
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
2
E p Di3 p U3 Autotilt down.
p Ctrl 3
0º
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
C 45º
Tilt down 2 E
p Di3 p U3 p Ctrl 3
0º
p Di6 p U6 p Ctrl 6
p U7
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
B
p Di3 p U3 Autotilt up.
p Ctrl 3
p Di4 p U4 p Ctrl 4
0º
p Di6 p U6 p Ctrl 6
p U7
Raise
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
B
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
p U0
B
Tilt up C
p Di4 p U4 mately 45º. p Ctrl 4 0º
Di2 -10º
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
38 www.zepro.com
Input signal
Output Control de-
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
Out
p Di3 p U3 p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
Platform folds out

Slider out
manually
Platform folds in
manually
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
1 In
p Di3 p U3 Normal
p Ctrl 3
p Di4 p U4 p Ctrl 4
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7
Slider in
p U0
p Di1 p U1 p Ctrl 1
p Di2 p U2 p Ctrl 2
C
2 In
p Di3 p U3 Safe
p Ctrl 3
p Di5 p U5 p Ctrl 5
p Di6 p U6 p Ctrl 6
p U7

"2.8 Configuration 1 ML" on page 37
www.zepro.com 39
6 5 4 3 2 1
3
Rev.Tag Date Rev. number Revised ECR Approved
40
GND Indikerar jordanslutningar, koppla dessa till någon av
styrkortets jordpunkter / Indicates ground connection, A 2018-05-11 7505 OE - MK
3.1
connect these to ground connection on controlcard. 3 + Deg B 2018-08-15 7560 OE - MK
4 Sig C 2018-10-25 7599 OE - MK
3.1.1
2 Gnd
2 GND
C
GND
GND
Electrical and hydraulic diagrams
Z/ZL 1500-2000
Z/ZL 1500-2000 MA
This drawing is property of Z-Lyften Produktion AB and is loaned subject to return upon demand. It is not
to be reproduced or used directly or indirectly in any way detrimental to the interest of Z-Lyften Produktion AB.
GND
7 2 8 2 8 5 3 4 3
+ 4
Sensor Power
6 GND
U7
U6
U5
U5
U4
U4
U3
U2
U1
U0
Outputs Not in use 6 GND
6 GND
Control Power
6 GND
2 GND
Ground
GND
B
E A
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in
E installation manual PA+
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5
C Radio Di 4 11
Lock Di 3 4
Di 2
Sensors
B Ctrl 5
Di 1
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2
C Spiral
Ai 1
Lock
och får ej utan Z-Lyftens skriftliga medgivande kopieras, delges eller obehörigen användas.
Denna ritning är Z-Lyftens egendom och skyddad enligt internationellt gällande lag för copyright
Title Used on: Drawing interpretation unless otherwise All measures intends finished product
specified. IS0 tolerances and drawing rules
El & hydraulschema Z1500/2000 C14 Welding:
t E&H Schematic Z1500/2000 C14 Surface finish:

Material Sheet
Tolerance:
1 /1
Dimension Weigh(kg) Stock nr. Size
75864TL A1
Date Designer Drawn Checked by Approved by Scale Drawing nr. Revision
2016-10-07 MB MB PS PS 1:1
ZEPRO
A CARGOTEC BRAND
Z-Lyften Produktion AB Z53807 C
6 5 4 3 2 1
Technical Manual
www.zepro.com
6 5 4 3 2 1
Indikerar jordanslutningar, koppla dessa till någon av Rev.Tag Date Rev. number Revised ECR Approved
GND
styrkortets jordpunkter / Indicates ground connection, A 2019-12-12 7800 ME 3098 MK
connect these to ground connection on controlcard.
3.1.2
D
4 + Deg
5 Sig
6 Gnd
www.zepro.com
Inclinometer
GND
C
GND
GND
GND
7 2 8 2 8 5 3 4 4 3
4 + 4
Sensor Power
6 GND
U7
U6
U5
U5
U4
U4
U3
U2
U1
U0
6 GND
Control Power
6 GND
6 GND
GND Ground
2 GND
B
E A
Ctrl 1
C IN OUT
Z/ZL 1500-2000 MA with electric autotilt
2H1
B Indication PA-
Se appendix in
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5 12
C Radio Di 4 11
Lock Di 3
Di 2
Sensors
Ctrl 5 3 + Deg
B
Di 1 4 4 Sig
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2 GND 2 Gnd
C Spiral
Ai 1 5
Lock
El & hydraulschema Z1500/2000 EATilt g.3 C14 Welding:
t E&H Schematic Z1500/2000 EATilt g.3 C14 Surface finish:

Material Sheet
Tolerance:
1 /1
77539TL A2
2018-08-08 MB OE MB MK 1:1
ZEPRO
A CARGOTEC BRAND
Z-Lyften Produktion AB Z54746 A
6 5 4 3 2 1
41
Technical Manual
6 5 4 3 2 1
42
4 Sig C 2018-10-25 7599 OE - MK
3.1.3
2 Gnd
2 GND
C
GND
GND
Z/ZL 1500-2000 DA
GND
7 2 8 2 8 5 3 4 3
+ 4
Sensor Power
6 GND
U7
U6
U5
U5
U4
U4
U3
U2
U1
U0
GND
6 GND
Control Power
6 GND
2 GND
Ground
B
E A
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5
C Radio Di 4 11
Lock Di 3 4
Di 2
Sensors
B Ctrl 5
Di 1
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2
C Spiral
Ai 1
Lock
El & hydraulschema Z1500/2000 Dvx4 C16 Welding:
t E&H Schematic Z1500/2000 Dvx4 C16 Surface finish:

Material Sheet
Tolerance:
1 /1
75938TL A2
2016-10-31 MB MB PS PS 1:1
ZEPRO
A CARGOTEC BRAND
6 5 4 3 2 1
Technical Manual
www.zepro.com
6 5 4 3 2 1
Rev./ Datum/ Ändring/ Införd av/ Kontrol./ Godk./
Rev.Tag Date Rev. number Revised by Checked Approved
A 2019-06-19 7702 OE - MK 3.1.4
B 2020-11-20 7908 DN - MK
C 2021-10-22 8045 DN - MK
www.zepro.com
Sensor Power
U7
U4
U4
U2
U0
U6
U5
U5
U3
U1
Outputs
Control Power
Ground
Warning lighting and foot controls
B
E
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in B
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5
C Radio Di 4
Lock Di 3
Di 2
Sensors
B Ctrl 5
Di 1
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2
C Spiral
Ai 1
Lock
Benämning/Title Samm./Used on: Där annat ej anges / Drawing All measures intends finished product
interpretation unless otherwise specified. Alla mått avser färdig produkt.
Svets/Welding: För denna ritning gäller
IS0 toleranser SMS ritregler
Ytjämnhet/
Surface finish:
Material Blad/Sheet A
Toleranser/
Tolerance: 1 /1
Dimension Vikt/Weigh(kg) Artikelnr./Stock nr. Format/Size
Datum / Date Konstr./Designer Ritad/Drawn Kontr./Checked by Godk./Approved by Skala/Scale Ritningsnr./Drawing nr. Revision
A HIAB brand - part of Cargotec Corporation
6 5 4 3 2 1
43
Technical Manual
6 5 4 3 2 1
44
3.1.5
D
C
Connection for Truck Connection for Trailer
4 4
4 4
+
11 +
11
B
Sensor Power Sensor Power
U7
U5
U5
U4
U4
U3
U2
U1
U0
U4
U0
U6
U7
U6
U5
U5
U4
U3
U2
U1
Outputs Not in use Outputs Not in use 11
Control Power
Control Power
Ground
Ground
B B
E E
Ctrl 1 Ctrl 1
C IN OUT C IN OUT
2H1 2H1
B Indication B Indication PA-
Se appendix in
PA- 10 Se appendix in
E installation manual PA+ E installation manual PA+
Ctrl 2 Ctrl 2
C CSPWR C CSPWR
Cabin switch and open platform alarm
2H2 Ctrl 6 CS 4 2H2 Ctrl 6 CS

B Di 6 B Di 6
E Ctrl 3
A
E Ctrl 3 Di 5 Di 5
C Radio Di 4 11 C Radio Di 4
Lock Di 3 Lock Di 3
Di 2 Di 2
Sensors
Sensors
Ctrl 5 B Ctrl 5
B
Di 1 Di 1
E Ctrl 4 E Ctrl 4
Out
GND/Spk-
LLED/Spk+
Out
GND/Spk-
LLED/Spk+
In
In
Ai 2 Ai 2
C Spiral C Spiral
Ai 1 Ai 1
Lock Lock
El & hydraulschema Larm för öppen brygga Welding:
E&H Schematic Detection open Platform Surface finish:

Material Sheet
Tolerance:
1 /1
77752TL A2
2018-11-21 MB OE MB MK 1:1
ZEPRO
A CARGOTEC BRAND
Z-Lyften Produktion AB Z54870
6 5 4 3 2 1
Technical Manual
www.zepro.com
6 5 4 3 2 1
GND Indikerar jordanslutningar, koppla dessa till någon av Rev.Tag Date Rev. number Revised ECR Approved

connect these to ground connection on controlcard. 3 +
4 Sig
Deg B
C
2018-08-15
2018-10-23
7560
7599
OE
OE
-
-
MK
MK
3.2
3.2.1
2 Gnd
2 GND
www.zepro.com
Z 2500
Z 2500 MA
C
GND
GND
GND
GND
GND
7 2 2 8 8 2 8 5 3 4 3
+ 4
Sensor Power
6 GND
U4
U7
U6
U5
U5
U4
U3
U2
U1
U0
6 GND
Control Power
6 GND
6 GND
Ground
GND 6 GND
B 2 GND
E A
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5
C Radio Di 4 11
Lock Di 3 4
Di 2
Sensors
B Ctrl 5
Di 1
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2
C Spiral
Ai 1
Lock
El & hydraulschema Z2500 C14 Welding:
t E&H Schematic Z2500 C14 Surface finish:

Material Sheet
Tolerance:
1 /1
75914TL A2
2016-10-25 MB MB ME PS 1:1
ZEPRO
A CARGOTEC BRAND
6 5 4 3 2 1
45
Technical Manual
6 5 4 3 2 1
46
styrkortets jordpunkter / Indicates ground connection, A 2020-01-07 7804 ME 3412 MK
connect these to ground connection on controlcard.
3.2.2
D
4 + Deg
5 Sig
6 Gnd
Inclinometer
GND
C
GND
GND
GND
GND
GND
7 2 2 8 8 2 8 5 3 4 4 3
4 + 4
Z 2500 MA with electric autotilt
Sensor Power
6 GND
U7
U6
U5
U5
U4
U4
U3
U2
U1
U0
6 GND
Control Power
6 GND
6 GND
Ground
GND 2 GND
B 6 GND
E 6 GND A
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5 12
C Radio Di 4 11
Lock Di 3
Di 2
Sensors
Ctrl 5
3 + Deg
B
Di 1 4 4 Sig
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2 GND 2 Gnd
C Spiral
Ai 1 5
Lock
El & hydraulschema Z2500 EATilt C14 Welding:
t E&H Schematic Z2500 EATiltC14 Surface finish:

Material Sheet
Tolerance:
1 /1
77651TL A2
2018-10-05 MB OE MB MK 1:1
ZEPRO
A CARGOTEC BRAND
Z-Lyften Produktion AB Z54831 A
6 5 4 3 2 1
Technical Manual
www.zepro.com
6 5 4 3 2 1
4 Sig C 2018-10-25 7599 OE - MK
3.2.3
2 Gnd
2 GND
www.zepro.com
Z 2500 DA
C
GND
GND
GND
7 2 8 2 8 5 3 4 3
+ 4
Sensor Power
6 GND
U7
U6
U5
U5
U4
U4
U3
U2
U1
U0
GND
6 GND
Control Power
6 GND
2 GND
Ground
B
E A
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5
C Radio Di 4 11
Lock Di 3 4
Di 2
Sensors
B Ctrl 5
Di 1
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2
C Spiral
Ai 1
Lock
El & hydraulschema Z1500/2000 Dvx4 C16 Welding:
t E&H Schematic Z1500/2000 Dvx4 C16 Surface finish:

Material Sheet
Tolerance:
1 /1
75938TL A2
2016-10-31 MB MB PS PS 1:1
ZEPRO
A CARGOTEC BRAND
6 5 4 3 2 1
47
Technical Manual
6 5 4 3 2 1
48
A 2019-06-19 7702 OE - MK
3.2.4
B 2020-11-20 7908 DN - MK
C 2021-10-22 8045 DN - MK
D
Sensor Power
U7
U4
U4
U2
U0
U6
U5
U5
U3
U1
Outputs
Control Power
Ground
B
E
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in B
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5
C Radio Di 4
Lock Di 3
Di 2
Sensors
B Ctrl 5
Di 1
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2
C Spiral
Ai 1
Lock
Ytjämnhet/
Surface finish:
Toleranser/
Tolerance: 1 /1
6 5 4 3 2 1
Technical Manual
www.zepro.com
6 5 4 3 2 1
3.2.5
D
www.zepro.com
C
4 4
4 4
+
11 +
11
B
U7
U5
U5
U4
U4
U3
U2
U1
U0
U4
U0
U6
U7
U6
U5
U5
U4
U3
U2
U1
Control Power
Control Power
Ground
Ground
B B
E E
Ctrl 1 Ctrl 1
C IN OUT C IN OUT
2H1 2H1
Se appendix in
Ctrl 2 Ctrl 2
C CSPWR C CSPWR

B Di 6 B Di 6
E Ctrl 3
A
E Ctrl 3 Di 5 Di 5
Lock Di 3 Lock Di 3
Di 2 Di 2
Sensors
Sensors
Ctrl 5 B Ctrl 5
B
Di 1 Di 1
E Ctrl 4 E Ctrl 4
Out
GND/Spk-
LLED/Spk+
Out
GND/Spk-
LLED/Spk+
In
In
Ai 2 Ai 2
C Spiral C Spiral
Ai 1 Ai 1
Lock Lock

Material Sheet
Tolerance:
1 /1
77752TL A2
2018-11-21 MB OE MB MK 1:1
ZEPRO
A CARGOTEC BRAND
6 5 4 3 2 1
49
Technical Manual
6 5 4 3 2 1
Rev.Tag
50
Date Rev. number Revised by Checked Approved
A 2006-01-20 5278 UB MW,JE CL
3.3
B 2009-01-09 5983 MB MW CL
C 2013-02-22 6755 ME - CL
3.3.1
D 2016-02-26 7231 MB - PS
E 2017-09-07 7444 OE - MK
D
Z 45/75
Z 45/75
C
+
Sensor Power
U7
U6
U5
U5
U4
U4
U3
U2
U1
U0
Outputs
Control Power
Ground
B
E
Ctrl 1
C IN OUT
2H1 A
B Indication PA-
Se appendix in
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5
C Radio Di 4
Lock Di 3
Di 2
Sensors
B Ctrl 5
Di 1
E Ctrl 4 Out
Spk-
Spk+
CR
CT
In
I-
I+
Ai 2
C Spiral
Ai 1
Lock
Ytjämnhet/
Surface finish:
Material Blad/Sheet
Toleranser/
Tolerance: 1 /1
6 5 4 3 2 1
Technical Manual
www.zepro.com
6 5 4 3 2 1
A 2006-01-20 5278 UB MW,JE CL
B 2009-01-09 5983 MB MW CL 3.3.2
C 2009-03-20 6054 MW MB CL
D 2013-02-22 6755 ME - CL
E 2013-03-14 6774 TH - CL
F 2014-04-03 6954 TH CL D
G 2014-06-24 7025 TH 207 TH
H 2016-01-15 7213 ME - PS
I 2016-02-29 7231 MB - PS
J 2017-09-07 7444 OE - MK
www.zepro.com
C
+
Sensor Power
U7
U6
U5
U5
U4
U4
U3
U2
U1
U0
Outputs
Z 45/75 with hydraulic autotilt
Control Power
Ground
B
E
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in A
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5
C Radio Di 4
Lock Di 3
Di 2
Sensors
B Ctrl 5
Di 1
E Ctrl 4
Out
Spk-
Spk+
CR
CT
I-
In
I+
Ai 2
C Spiral
Ai 1
Lock
Ytjämnhet/
Surface finish:
Material Blad/Sheet
Toleranser/
Tolerance: 1 /1
6 5 4 3 2 1
51
Technical Manual
6 5 4 3 2 1
52
3.3.3
D
C
4 4
4 4
+
11 +
11
B
U7
U5
U5
U4
U4
U3
U2
U1
U0
U4
U0
U6
U7
U6
U5
U5
U4
U3
U2
U1
Control Power
Control Power
Ground
Ground
B B
E E
Ctrl 1 Ctrl 1
C IN OUT C IN OUT
2H1 2H1
Se appendix in
Ctrl 2 Ctrl 2
C CSPWR C CSPWR

B Di 6 B Di 6
E Ctrl 3
A
E Ctrl 3 Di 5 Di 5
Lock Di 3 Lock Di 3
Di 2 Di 2
Sensors
Sensors
Ctrl 5 B Ctrl 5
B
Di 1 Di 1
E Ctrl 4 E Ctrl 4
Out
GND/Spk-
LLED/Spk+
Out
GND/Spk-
LLED/Spk+
In
In
Ai 2 Ai 2
C Spiral C Spiral
Ai 1 Ai 1
Lock Lock

Material Sheet
Tolerance:
1 /1
77752TL A2
2018-11-21 MB OE MB MK 1:1
ZEPRO
A CARGOTEC BRAND
6 5 4 3 2 1
Technical Manual
www.zepro.com
6 5 4 3 2 1
A 2019-06-19 7702 OE - MK 3.3.4
B 2020-11-20 7908 DN - MK
C 2021-10-22 8045 DN - MK
www.zepro.com
Sensor Power
U7
U4
U4
U2
U0
U6
U5
U5
U3
U1
Outputs
Control Power
Ground
B
E
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in B
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5
C Radio Di 4
Lock Di 3
Di 2
Sensors
B Ctrl 5
Di 1
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2
C Spiral
Ai 1
Lock
Ytjämnhet/
Surface finish:
Toleranser/
Tolerance: 1 /1
6 5 4 3 2 1
53
Technical Manual
6 5 4 3 2
54
1
GND Indikerar jordanslutningar, koppla dessa till någon av Rev.Tag Date Rev. number Revised by Checked Approved
3.4
styrkortets jordpunkter / Indicates ground connection, A 2015-01-27 7089 TH - PL
connect these to ground connection on controlcard. B 2015-12-21 7206 ME - MJ
C 2016-02-26 7231 MB - PS
D 2016-04-20 7258 DS MB PS
E 2018-10-17 7591 SSB - MB
F 2019-10-29 7773 ME - MJ D
GND
GND GND GND
C
5 2 2 8 4 3 4 3
+ 4
Sensor Power
B
U7
U6
U5
U5
U4
U4
U3
U2
U1
U0
Outputs
Z3N, Z3NU, Z3NW, Z3NWU
Control Power
6 GND
Ground 6 GND
B 6 GND
E 2 GND
GND Ctrl 1
C IN OUT 6 GND
2H1 6 GND
B Indication
Se appendix in
PA-
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5 A
C Radio Di 4 10
Lock Di 3 4
Sensors
Ctrl 5
Di 2
B
Di 1
E Ctrl 4 Out
GND/Spk-
LLED/Spk+
In
Ai 2
C Spiral
Ai 1
GND Lock
Ytjämnhet/
Surface finish:
Material Blad/Sheet
Toleranser/
Tolerance: 1 /1
6 5 4 3 2 1
Technical Manual
www.zepro.com
6 5 4 3 2 1
GND Indikerar jordanslutningar, koppla dessa till någon av Rev.Tag Date Rev. number Revised by Checked Approved
styrkortets jordpunkter / Indicates ground connection, A 2015-12-21 7206 ME - MJ
connect these to ground connection on controlcard. B 2016-02-26 7231 MB - PS 3.4.1
C 2017-08-08 7435 ME 735 PS
D 2018-10-17 7591 SSB - MB
E 2019-10-29 7773 ME - MJ
D
GND
www.zepro.com
GND
GND GND GND
C
5 2 2 8 4 3 9 4 4 3
+ 4
Sensor Power B
U7
U5
U5
U4
U4
U3
U2
U1
U0
U6
Outputs
Control Power
6 GND
6 GND
Ground
6 GND
B 3 GND
E 2 GND
Ctrl 1
GND C IN OUT
6 GND
2H1 6 GND
B Indication PA-
Se appendix in
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5 6 A
C Radio Di 4 10
Lock Di 3 4
Di 2
Sensors
Ctrl 5 2
B
Di 1
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2
C Spiral
Ai 1
GND Lock
Z3N, Z3NU, Z3NW, Z3NWU with electric autotilt
Ytjämnhet/
Surface finish:
Material Blad/Sheet
Toleranser/
Tolerance: 1 /1
6 5 4 3 2 1
55
Technical Manual
6 5 4 3 2 1
56
3.4.2
D
C
4 4
4 4
+
11 +
11
B
U7
U5
U5
U4
U4
U3
U2
U1
U0
U4
U0
U6
U7
U6
U5
U5
U4
U3
U2
U1
Control Power
Control Power
Ground
Ground
B B
E E
Ctrl 1 Ctrl 1
C IN OUT C IN OUT
2H1 2H1
Se appendix in
Ctrl 2 Ctrl 2
C CSPWR C CSPWR

B Di 6 B Di 6
E Ctrl 3
A
E Ctrl 3 Di 5 Di 5
Lock Di 3 Lock Di 3
Di 2 Di 2
Sensors
Sensors
Ctrl 5 B Ctrl 5
B
Di 1 Di 1
E Ctrl 4 E Ctrl 4
Out
GND/Spk-
LLED/Spk+
Out
GND/Spk-
LLED/Spk+
In
In
Ai 2 Ai 2
C Spiral C Spiral
Ai 1 Ai 1
Lock Lock

Material Sheet
Tolerance:
1 /1
77752TL A2
2018-11-21 MB OE MB MK 1:1
ZEPRO
A CARGOTEC BRAND
6 5 4 3 2 1
Technical Manual
www.zepro.com
6 5 4 3 2 1
A 2019-06-19 7702 OE - MK 3.4.3
B 2020-11-20 7908 DN - MK
C 2021-10-22 8045 DN - MK
www.zepro.com
Sensor Power
U7
U4
U4
U2
U0
U6
U5
U5
U3
U1
Outputs
Control Power
Ground
B
E
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in B
Ctrl 2
C CSPWR
2H2 Ctrl 6 CS
B Di 6
E Ctrl 3 Di 5
C Radio Di 4
Lock Di 3
Di 2
Sensors
B Ctrl 5
Di 1
E Ctrl 4
Out
GND/Spk-
LLED/Spk+
In
Ai 2
C Spiral
Ai 1
Lock
Ytjämnhet/
Surface finish:
Toleranser/
Tolerance: 1 /1
6 5 4 3 2 1
57
Technical Manual
www.zepro.se
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
of our customers' operations and to shape the future of intelligent load handling.

79072TL - EN - Technical Manual ZePRO1 211116

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79072TL - EN - Technical Manual ZePRO1 211116

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Technical Manual

ZePRO1 Control System

1.2 Power save mode

1.3 Operating information

1.3.1 Information codes

J 01-99 _ 1-9 Firmware version number

Example of sequence with information codes:

Configuration 1 Voltage detected 12V Firmware 9.0

Example of sequence with sensor indication:

Example of sequence with control device indication:

1.3.2 Fault codes

Example of sequence of fault codes:

1.3.3 Fault codes control card

E5 Lysdiod blinkar när

1.3.4 Control device

Coil control device LED

1.4 Supply voltage

The lift is not working.

1.5 Minimum recommended battery capacity

Minimum recommended battery capacity

Lifting capacity < 1000 kg. 140 Ah

1.6 Minimum recommended conductor cross-sectional area

Minimum recommended conductor cross-sectional area

1.7 Power consumption

2.2 Models - Configurations

Model Configuration Page

Z/ZL 1500/2000/2500, ZDK 250, Z/ZN 2500 - MA 14 14

Designation Position Function Description

Di6 Not used in this configuration

"2.2 Models - Configurations" on page 13

2.3.2 Functional diagram

p Di2 p U2 Open from 89º down to p Ctrl 2 45º

p Di6 p U6** p Ctrl 6

p Di2 p U2 p Ctrl 2 45º

"2.2 Models - Configurations" on page 13

Sensor name with /-symbol in front = 0, i.e., no signal.

"2.2 Models - Configurations" on page 13

2.3.3 Restriction in use of control device

Ctrl 1 & 2 Ctrl 3 & 6 Ctrl 4

2.3.4 Quick opening - activation zone

"2.2 Models - Configurations" on page 13

2.4 Configuration 14 - MA Autotilt

Designation Position Function Description

Di6 Not used in this configuration

"2.2 Models - Configurations" on page 13

2.4.2 Functional diagram

"2.2 Models - Configurations" on page 13

"2.2 Models - Configurations" on page 13

2.4.3 Restriction in use of control device

Ctrl 1 & 2 Ctrl 3, 4 & 6

2.4.4 Quick opening zone

"2.2 Models - Configurations" on page 13

2.4.5 Foot controls and warning lights

2.4.6 Inclinometer - voltage

Image 8. Approximate voltage at various angles

"2.2 Models - Configurations" on page 13

Designation Position Function Description

Di6 Not used in this configuration

"2.2 Models - Configurations" on page 13