Z-LYFTEN PRODUKTION AB

55614TL

INSTALLATION INSTRUCTION

Radio control unit

with angle sensor

2016-10-06

Försäljning/Sales/Verkauf
Mossvägen 8, 641 49 KATRINEHOLM,SWEDEN
Telephone: +46 150 - 489550
Telefax: +46 150 - 489551
E-mail: zepro@zepro.com
Fabrik/Factory/Fabrik
Allévägen 4, 840 73 BISPGÅRDEN, SWEDEN
Telephone: +46 696 - 17200
Telefax: +46 696 - 17244
E-mail: info@zepro.com
Internet: www.zepro.com
Content
1. Important....................................................................................... 4

2. General information..................................................................... 4

3. Installation Zepro T60 receiver................................................... 4

4. Installation of angle sensor......................................................... 5

5. Electric- and hydraulic diagram ................................................ 6

6. Zepro T60 - 4 channel radio......................................................... 10

6. Zepro T60 - 8 channel radio......................................................... 11

7. Circuit card, 4 channel radio....................................................... 12

7. Circuit card 8 channel radio ....................................................... 13

8. Programming: New transmitter to T60 receiver ...................... 14

9. Troubleshooting........................................................................... 16

3
 1. Important
In order to use your system at optimum way, it´s important that you take some time to read the manual be-
fore you install your equipment.
Equipment that is correct installed gives both longer life and better reach.

At delivery the box contains following:

1 pce. Transmitter inc. battery (premounted)

1 pce. Receiver incl. cable set
1 pce. Angle sensor
1 pce. Guarantee form
1 pce. Installation manual

If something would be missing in the box, please contact your dealer as soon as possible.

2. General information
Zepro T60 works at frequency 433,92MHz.

Zepro T60 consists of 2 parts: transmitter and receiver including cables. The receiver is equipped with brack-
ets which simplifies the installation of the equipment. The capsule of the receiver doesn’t require opening in
order to install the equipment.

The transmitter and the receiver are encoded from a factory. Encoded means that each transmitter and re-
ceiver in a pair from factory has received a code that´s specific for just this pair. There are 24 millions differ-
ent program variations (codes). No adjustments isn´t necessary on your new equipment. Encoding prevents
that some unauthorized by mistake can maneuver you’re tail lift

3. Installation of Zepro T60 receiver

In order to maximum function on your radio control equipment, the following must be considered at installa-
tion:

* The cables must be turned downwards at installation.

* The receiver must be installed on trucks framework, NOT in a box. See a picture below.

At installation the voltage must be disconnected.

Note!

The old Zepro T60 6-channel occurs in 2 versions, a DA and a DC version. If your receiver is a new 8-chan-
nel, it´s a DF. One way to check which version that is available, is to remove the cap on the receiver and
read on sticker. See page 9.

4
 4. Installation of angle sensor
NOTE! Angle sensor is not needed on slider lifts.
NOTE! Supplied angle sensor is not needed on Z3N lifts. Existing angle sensor on Z3N for fast opening may
also be used for the radio control.

Important:
The angle sensor constitutes a safety function for the radio control units. This should under no circumstance be
modify or disconnected. This is to prevent that the tail lift is being used intentionally or unintentionally when the
user don’t have control over the working area. Bypass of this function ceases the CE marking from Zepro.

See different options of mounting below.

ZHD 2500 ZHD 1500/2000

Fasten angle sensor on the existing welding screw
with a nut as shown in the picture below.
NOTE! Make sure to position the sensor correctly
with its cable facing in the correct direction and in 45°
angle towards the platform to get proper function.
Drill a 7,4 mm hole and fasten the bracket for angle
sensor. NOTE! Make sure to position the sensor
correctly with its cable facing in the correct direction
and in 45° angle towards the platform to get proper
function.

Other models
Fasten angle sensor according to the picture below. NOTE! Make sure to position the sensor correctly with its
cable facing in the correct direction and in 45° angle towards the platform to get proper function.

45° 45º
45°

5
 6 5 4 3 2 1

2-3 Knappsdon
--- Jord anslutning finns ej på alla manöverdon / Earth connection is not present on all controls
2-3 Button Control
3

Ctrl 1
D
+

Sensor Power

U4
6

U7
U6
U5
U5
U4
U3
U2
U1
U0
Outputs Not in use 6
4 6

Control Power
2-3 Knappsdon 4
4

Ground
--- 4
2-3 Button Control 3 B
8 E 3
Ctrl 1 Se anslutningstabell nedan var
2 C IN OUT

Ctrl 2
2H1
vinkelgivare ska monteras /
Indication 2 See connectiontable below
3 B PA-
Se appendix in where to connect anglesensor
8 E installation manual PA+
Ctrl 2 4
2 C CSPWR C
2H2 Ctrl 6 CS
3 B Di 6
Radiomanöverdon 8 E Ctrl 3 Di 5
2 C Radio Di 4 4
--- Lock
9 Di 3

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.
Radiocontrol Di 2

Sensors
B Ctrl 5

6
3 Di 1
E Ctrl 4

Out
GND/Spk-

Ctrl 3
LLED/Spk+
CR
CT

In
I-
I+
8 Ai 2 Anslutningstabell / Connectiontable
2 C Spiral
Ai 1
10 Lock Exempel på lyftmodeller (inte alla) /
Config Input
Examples of liftmodels (not all)
1 Di2 ZHD,Z45,Z75,ZAHD,ZKZ,ZS,ZD,ZT
2 - Se anteckningar / See notes***
Spiralmanöverdon Slädmanöverdons Manöverdon 3 - Se anteckningar / See notes***
B
--- anslutning* låsindikering** 6 Di3 SZHS
Spiral cable controller --- --- 8 Di6 Z100
Sledcontroller Controller lock 9 Di3 Z3N
connection* indication**

Ctrl 4
12 - Se anteckningar / See notes***
13 Di3 ZHDN
5. Electric- and hydraulic diagram

- Ingen vinkelgivare / No anglesensor

Connection without connection card (ZePro1 controlercard, firmware 8.0 or later.

Information
Beror på typ av lyft / Depends on the type of lift. Title Used on: Drawing interpretation unless otherwise All measures intends finished product
* specified. IS0 tolerances and drawing rules
El & hydraulschema Lyftar med 2H vinkelgivare Welding:
Anslutning av LED jord för manöverdon på CTRL1, 2 E&H Schematic Lifts with 2H anglesensor
** Surface finish: -
med låsindikering (ej spiral) / Connection for LED earth Material Sheet A
- Tolerance: -
used for controls connected to CTRL1,2 with LED 1 /1
Dimension Weigh(kg) Stock nr. Size
indicating lock (not spiral) - - 75530TL A2
Date Designer Drawn Checked by Approved by Scale Drawing nr. Revision

*** Vissa ZHD varianter främst som byggs med ett annat 2016-07-04 MB MB PS PS 1:1
arbetssätt på hydraulik / Certain ZHD variants that are

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
built on a different type of hydraulic design ZEPRO
A CARGOTEC BRAND
Z-Lyften Produktion AB Z53534
6 5 4 3 2 1
 6 5 4 3 2 1

För anslutning av manöverdon mot +

kopplingskort, se ritning Z47616 / Sensor Power
6

U7
U5
U5
U4
U4
U3
U2
U1
U0

U6
For connection of control devices to the 4 Outputs Not in use
connection card, see drawing Z47616

Control Power
Ground
B
E C
Ctrl 1
C IN OUT
2H1
B Indication PA-
Se appendix in
E installation manual PA+
Ctrl 2
C CSPWR

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.
2H2 Ctrl 6 CS
B Di 6

7
E Ctrl 3 Di 5
C Radio Di 4
Lock
Connection of connection card to ZePro1 controlercard

Di 3
Di 2
Sensors

B Ctrl 5
3 Di 1
E Ctrl 4
Out
Spk-
Spk+
CT
CR

I-

In
I+

8 Ai 2
2 C Spiral
Ai 1
Lock B

Man.don 5 Släde /
Controller 5 Sled
5. Electric- and hydraulic diagram

Title Used on: Drawing interpretation unless otherwise All measures intends finished product
specified. IS0 tolerances and drawing rules
El & hydraulschema Styrkort med kopplingskort Welding:

E&H schematic Control card w. conn.-card Surface finish: -

Material Sheet A
- Tolerance: - 1 /1
Dimension Weigh(kg) Stock nr. Size
- - 75279TL A3
Date Designer Drawn Checked by Approved by Scale Drawing nr. Revision
2016-04-29 ME ME MB PS 1:1

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
ZEPRO
A CARGOTEC BRAND
Z-Lyften Produktion AB Z53275
6 5 4 3 2 1
Connection card is required when connecting Radio on ZePro1 controler card with firmware 7.0 or earlier.
 8
Denna ritning är Z-Lyftens egendom och skyddad enligt internationellt gällande lag för copyright This drawing is property of Z-Lyften Produktion AB and is loaned subject to return upon demand. It is not
och får ej utan Z-Lyftens skriftliga medgivande kopieras, delges eller obehörigen användas. to be reproduced or used directly or indirectly in any way detrimental to the interest of Z-Lyften Produktion AB.
6

6
5

5
4

4
3

3
Material

Dimension

A CARGOTEC BRAND
ZEPRO
2

2
F
E
B
A

H
D
C

G
Rev.Tag
Date

2015-08-24
2014-04-02
2013-03-01
2013-01-11
2011-08-31
2011-08-18
2011-02-18
2009-03-24
1

1
7152
6947
6761
6719
6482
6469
6373
6056
Rev. number

TH
TH
TH

ME
MB
MB
MB
MW
Revised

1 /1
-
TH
TH
ECR

MB
MB
MB
MB

177

Revision
CL
CL
CL
CL
CL
CL
CL

MJ
Approved

B
D

A
C
Connection on a lift with connection card (Order. no. 55027TL), all controls
5. Electric- and hydraulic diagram
 5. Electric- and hydraulic diagram

Connection on a lift with connection card (Order. no. 55027TL), radio only

OBS! Bygel på kretskort ska tas bort

innan vinkelgivare monteras
NOTE! The circuit card jumper must be
removed before angle sensor is installed

9
 6. Zepro T60 - 4 channel radio

Colour of cable and function.

1. White: Earth (marked with a - minus sign)

2. Black: 12 V DC or 24 V AC/DC (or black marked with a + plus sign)
3. Brown: UP function
4. Blue: TILT function
5. Yellow/Green: DOWN function
6. Grey Lock/Unlock function

The lock/ unlock function

Press button 4 to lock. Press button 2 to unlock.
Note! When the transmitter is locked, button 1 and 3 cannot be activated.

When the transmitter is locked, button 2 unlocks the transmitter. When the
transmitter is unlocked, button 2 activates the tilt function.

Applies only control system with software version 9.0 or later:

Locking is maintained if the lift loses power and then is started up again, the
number 7 is flashing on the control board display. Unlocking is done by turning
operating power Off/On using the cabin switch (CS).

10
 6. Zepro T60 - 8 channel radio

Colour of cable and function

1. White: Earth (marked with - minus)

2. Black: 12 V DC or 24 V AC/DC (marked with a plus sign)
3. Brown: UP function
4. Blue: TILT function
5. Yellow/Green: DOWN function
6. Grey: LOCK / UNLOCK-function
7. Brown: SLIDE OUT function
8. Blue: SLIDE IN function

The lock/ unlock function

Press button 7 to lock. Press button 8 to unlock.
Note! When the transmitter is locked, button 1 to 6 cannot be activated.

Applies only control system with software version 9.0 or later:

Locking is maintained if the lift loses power and then is started up again,
the number 7 is flashing on the control board display. Unlocking is done
by turning operating power Off/On using the cabin switch (CS).

11
 7. Circuit card - 4 channel radio.

Circuit card: explanation

1. Yellow LED indicates correct voltage.

2. Green LED indicates receiving of radio signal.
3. Red LED off = no transmitter programmed.
Red LED blinks = transmitter programmed.
Red LED shines = receiver in program mode.
4. Not in use.
5. Not in use
6. Indicates that UP function is activated (shine when button is pushed)
7. Indicates that TILT function is activated (shine when button is pushed)
8. Indicates that DOWN function is activated (shine when button is pushed)
9. In use at programming new transmitter
10. Indicates that LOCK function is activated

12
 7. Circuit card - 8 channel radio.

14

Tele Radio
R60 XX
V x.x

Circuit card: explanation

1. Yellow LED indicates correct voltage.

2. Green LED indicates receiving of radio signal.
3. Red LED off = no transmitter programmed.
Red LED blinks = transmitter programmed.
Red LED shines = receiver in program mode.
4. Not in use.
5. Not in use
6. Indicates that UP function is activated (shine when button is pushed)
7. Indicates that TILT function is activated (shine when button is pushed)
8. Indicates that DOWN function is activated (shine when button is pushed)
9. Indicates that SLIDE IN function is activated (shine when button is pushed)
10. Indicates that SLIDE OUT function is activated (shine when button is pushed)
11. Indicates that LOCK/UNLOCK function is activated (shine when button is pushed)
12. In use at programming new transmitter
13. In use at programming new transmitter (only for DA recievers)
14. Sticker stating version of reciever(R60 DA, DC or DF).

13
 8. Programming: New transmitter to T60 receiver.

Applies all 3 / 4 - channel radio and DC / DF varieties of T60 receiver

Erase old transmitters

Note! All steps below must be carried out

1. Open lid at receiver.

2. Push button on receiver circuit card for programming new transmitter (see page 8 and
9), whereupon red LED (3) shines with a permanent light. Keep button down at least 6 sec.
until red LED stops shining.
3. All old memorized transmitters are now erased from the memory in the receiver.

Program new transmitters

4. Push button on receiver circuit card for programming new transmitter (see page 8 and
9), whereupon red LED (3) shines with a permanent light.
5. Release the button.
6. When button is released, the red LED (3) shines with a permanent light.
7. When the red LED (3) shines permanent, push an optional button on the new transmit-
ter until red LED (3) blinks. This must be started within 6 sec.
8. The transmitter is now programmed at the receiver, perform a test by push one or some
buttons.

If you contrary to expectations not get your system to function. Please contact your
dealer.

14
 8. Programming: New transmitter to T60 receiver.

Applies DA variety of 6 - channel radio.

Erase old transmitters

1. Open lid at receiver.

2. Push-button (12 & 13) at the same time,

red LED shines with a permanent light. Keep 1
button down until red LED stops shining.
The erase is completed.

Program new transmitters

3. Push button (12) red LED is lit. Release

the button, red LED shines with a permanent
light. 2
4. Push button(13) 3 times in a row, this must
be started before red LED (3) stops shining
(5 sec.) Red LED (3) blinks.
5. Push button (1) at your new transmitter,
red LED (3) blinks 3 times.

The receiver is now programmed! 3

6. Perform a test by push one or some but-

tons.

If you contrary to expectations not get

your system to function. Please contact
your dealer.
4

15

Malfunction
The receiver does not func-
tion at transmitting.
The green LED no:2 on the
receiver shines at transmit-
ting, but the relay doesn’t
functioning.
The green LED no:2 on
the receiver shines despite
there’s no transmitting.
The green LED no:2 on the
receiver doesn’t shine at
transmitting.
The range is to short.
It seems that the transmit-
ter is functioning normally.
The relay inside the receiver
clicks, but the tail lift re-
mains still.
9. Troubleshooting.
Possible cause
The receiver isn’t properly
installed. The receiver has
got wrong operating voltage.
The code in the transmit-
ter isn’t the same as in the
receiver.
There is an another radio
control unit in the area at the
same frequency in use
The battery in the receiver is
finished. The transmitter is
broken.
The battery is poor. The
system isn’t installed prop-
erly according to installation
instructions.
+ and - is mixed up at instal-
lation.
16
Correction
Check installation of the
receiver.
Contact your dealer.
Test the system at a another
place. If the problem re-
mains, contact your dealer.
Change the battery or con-
tact your dealer.
Check out that the system is
installed properly according
to installation instruction.
Shift + and -