Zapi AC-2 Service Manual

insert image hereWe build a better future11- Service guide: Hyundai -7 AC range -

1010

100100- Important adjustments, through display -

101101- 15/18/20BT-7, 16/18/20B-7 ZAPI Settings.

102102- 15/18/20BT-7, 16/18/20B-7 Traction Master (03) setup.PARAMETER CHANGEDESCRIPTION (Service level)E mode N mode H mode0ACCELER. DELAYLEVEL = 7 L

103103- 15/18/20BT-7, 16/18/20B-7 Traction Master (03) setup.CodeSET MODEL (service level) CONNECTED TOCodeSET OPTIONS (Service lev

104104- 15/18/20BT-7, 16/18/20B-7 Traction Master (03) Setup.CodeSET OPTIONS (Service level) 247STOP ON RAMP109AUX INPUT #1251PEDAL BRAKING

105105- 15/18/20BT-7, 16/18/20B-7 Traction Master (03) Setup.CodeADJUSTMENTS (Service level)245SET POT BRK MIN246SET POT BRK MAX145SET BATTERY TYPE1

106106- 15/18/20BT-7, 16/18/20B-7 Traction Master (03) Test .Motor VoltageVoltage supplied to the motor by the controller expressed in % of full batte

107107- 15/18/20BT-7, 16/18/20B-7 Pump (05) Parameter setup.PARAMETER CHANGEDESCRIPTION (Service level)E mode N modeH mode0ACCELER. DELAYDetermines th

108108- 15/18/20BT-7, 16/18/20B-7 Pump (05) Parameter setup.CODEADJUSTMENTS (service level)Parameter explanation.145SET BATTERY TYPETo selects the nom

109109- 15/18/20BT-7, 16/18/20B-7 Pump (05) Parameter Setup.CODEADJUSTMENTS (service level)Parameter explanation.248MIN TILT UPTilt up sensor minimum

1111Drive units and intergratedwet brake systems

110110- 15/18/20BT-7, 16/18/20B-7 Pump (05) Test.Motor VoltageVoltage supplied to the motor by the controller expressed in % of full battery voltage.F

11115/18/20BT-7, 16/18/20B-7 Pump (05)(Fingertip option)- Pump settings -- Mhyrio settings -PA R A M ETE R C H A N G EM IN E V P M A X E V P

11211215/18/20BT-7, 16/18/20B-7 Display (16) Parameter setup.Power selectorTrucks performances. Option 1:H / Option 2:N / Option 3:EHour counter Hours

113113- 22/25/30/32B-7 Zapi settings.

114114- 22/25/30/32B-7 Traction Master (03) setup -Code PARAMETER CHANGE E MODE N MODE H MODE0 A C C E L E R . D E L A Y L E V E L = 7 LE V E L =

115115- 22/25/30/32B-7 Traction Master (03) setup -Code SET OPTION E MODE N MODE H MODE1 2 5 H O U R C O U N T E R K E Y O N K E Y O N

116116- 22/25/30/32B-7 Traction Master (03) setup -Code ADJUSTMENTS E MODE N MODE H MODE2 4 5 S E T P O T B R K M IN 1 .0 V 1 .0 V 1 .0 V2 4

117117- 22/25/30/32B-7 Traction Slave (04) setup -Code PARAMETER CHANGE E MODE N MODE H MODE11 RELEASE BRAKING LEVEL = 2 LEVEL = 3 LEVEL = 4248 SEAT

118118- 22/25/30/32B-7 Pump (05) setup -Code PARAMETER CHANGE E MODE N MODE H MODE0 ACCELER. DELAY LEVEL = 0 LEVEL = 0 LEVEL = 05 DECELER. DELAY LEV

119119- 22/25/30/32B-7 Pump (05) setup -Code SET MODEL E MODE N MODE H MODE242 CONNECTED TO PUMP PUMP PUMP

1212- 15/18/20BT-7, 16/18/20B-7 Drive Unit.

120- 22/25/30BHA-7 Zapi settings.

121- 22/25/30BHA-7 Traction Master (03) setup -PARAMETER CHANGEE MODE N MODE H MODEACCELER. DELAY LEVEL = 6 LEVEL = 6 LEVEL = 1RELEASE BRAKING LEVEL

122- 22/25/30BHA-7 Traction Master (03) setup -SET OPTIONHOUR COUNTER KEYON KEYON KEYON BATTERY CHECK ON ON ON

123ADJUSTMENTSSET POT BRK MIN 1.0 V 1.0 V 1.0 VSET POT BRK MAX 9.0 V 9.0 V 9.0 VSET BATTERY TYPE 80V 80V 80V ADJUST BATTERY

124- 22/25/30BHA-7 Traction Slave (04) setup -PARAMETER CHANGEE MODE N MODE H MODERELEASE BRAKING LEVEL = 2 LEVEL = 2 LEVEL = 4SEAT DELAY TIME 2 2

125PARAMETER CHANGEE MODE N MODE H MODEACCELER. DELAY LEVEL = 0 LEVEL = 0 LEVEL = 0DECELER. DELAY LEVEL = 0 LEVEL = 0 LEVEL = 0MAX SPEED UP 74

126- 22/25/30BHA-7 Pump (05) (Fingertip option) - Pump settings -- Mhyrio settings -PARAMETER CHANGEMIN EVP 25,10%MAX EVP 85,10%MIN EVP1

127- 22/25/30BHA-7 Display (16) settings. SET OPTION E MODE N MODE H MODEPOWER SELECTOR OPTION #3 OPTION #2 OPTION #1 HOUR COUNTER OPT

128128- 35/40/45/50B-7 Zapi settings.

129129- 35/40/45/50B-7 Traction Master (03) setup -Code PARAMETER CHANGE E MODE N MODE H MODE0 ACCELER. DELAY LEVEL = 3 LEVEL = 2 LEVEL = 111 RELEASE

1313- 15/18/20BT-7, 16/18/20B-7 Brake Structure.1 Brake pedal & bracket assy.2 Parking lever assy.3 Reservoir tank assy.4 Brake master cylinder.Pr

130130- 35/40/45/50B-7 Traction Master (03) setup -Code SET OPTION E MODE N MODE H MODE125 HOUR COUNTER KEYON KEYON KEYON 121 BATT

131131- 35/40/45/50B-7 Traction Master (03) setup -Code ADJUSTMENTS E MODE N MODE H MODE245 SET POT BRK MIN 0.5 V 0.5 V 0.5 V246 SET POT BRK MAX

132132- 35/40/45/50B-7 Traction Slave (04) setup -CODE PARAMETER CHANGE E MODE N MODE H MODE63 MAXIMUM CURRENT LEVEL = 4 LEVEL = 4 LEVEL = 4Code SET

133133- 35/40/45/50B-7 Pump (05) setup -Code PARAMETER CHANGE E MODE N MODE H MODE0 ACCELER. DELAY LEVEL = 0 LEVEL = 0 LEVEL = 05 DECELER. DELAY LEV

134134Code SET MODEL E MODE N MODE H MODE250 CONNECTED TO 5 5 5Code ADJUSTMENTS E MODE N MODE H MODE145 SET BATTERY TYPE 80V 80V 80

135135- Parameter setting variables -THROTTLE 0 ZONEIt establishes a dead band in the accelerator input curve.THROTTLE X POINTThis parameter changes t

136136- Parameter setting variables -- Smooth parameters setup -ACC. SMOOTHIt gives a different form to the acceleration curve in the frequency range

137137- Parameter setting variables -The following table shows the different values at which the parameters can be set.(*) The acceleration time shown

138138- Failure codes -

139139- Failure codes -

1414- 15/18/20BT-7, 16/18/20B-7 Drive Unit + Brake.1 Housing2 Disc carrier3 Internal gear4 Planet gear5 Shim6 Fixing plate7 Wheel bolt8 Breather filte

140140MaintenanceRecommendations

141141- Maintenance diagram.

142142- (15)16/18/20B(T)-7Maintenance diagram.

143143- 22/25/30/32B-7 Maintenance diagram.

144144- 22/25/30BHA-7 Maintenance diagram.

145145- 35/40/45/50B-7 Maintenance diagram.

146146- Questions or remarks.

1515- 15/18/20BT-7, 16/18/20B-7 Brake Adjustment.- Adjusting dimension "A" for thebrake lever is between 0.4 ~ 1.0mm.-The adjusting dimensio

1616- 22/25/30/32B-7, 22/25/30BHA-7 Drive Unit

171722/25/30/32B-7, 22/25/30BHA-7 Brake Structure.1 Brake pedal & bracket.2 Parking lever assy.3 Reservoir tank assy.4 Brake master cylinder.SAE 1

1818- 22/25/30/32B-7, 22/25/30BHA-7 Drive Unit.1 Brake housing.2 Drive gear (electro motor input).3 Parking brake lever (adjustable).4 Brake port (bra

19191 Wheel hub2 Hub bolt3 Needle bearing4 Gamma seal5 Taper roller bearing6 Spacer7 Bolt8 Air breather9 Socket screw10 Housing-LH11 Housing-RH12 Plug

22- Introduction Hyundai’s production plant (Ulsan).

202019 Bleeder fitting26 Retaining ring27 Needle cage28 Input pinion29 Outer cover-LH30 Outer cover-RH32 Socket screw33 Ball bearing34 Retaining ring3

21212. Assemble an adapter (pump) to pressurized the brake system.3. Put 2-5Bar into the system and measure stroke with a dial gauge.4. Set piston sto

2222By external pump or pushing the brake pedal.Handbrake released.22/25/30/32B-7, 22/25/30BHA-7 Brake adjustment= Hydraulic pressure

2323- 35/40/45/50B-7 Drive Unit + Brake.

2424- 35/40/45/50B-7 Brake Structure.1 Brake pedal & bracket assy.2 Parking lever assy.3 Reservoir tank assy.4 Brake master cylinder.Pressure at

2525- 35/40/45/50B-7 Drive Unit + Brake.1 Spacer2 Wheel hub3 Wheel fixing screw4 Needle cage5 Shaft seal6 Taper roller bearing7 Spacer8 Breather plug

2626- 35/40/45/50B-7 Drive Unit + Brake.35 Helix pinion36 Ball bearing37 Retaining ring38 Retaining ring39 Locking pin40 Sun pinion41 Feather key42 E

2727- 35/40/45/50B-7 Brake Adjustment.- It’s recommendable checking every 2000 working hours if the stroke of the brake piston (pos 54 on page 2

2828General Brake and Drive Unit’s Oil Quality Overview

2929Hydraulicsystems

33- Table of contents.- General AC machine’s introduction.- New AC Battery models: - 15/18/20BT-7 - 16/18/20B-7 - 22/25/30/32B-7 - 22/25/30BHA-7 - 35

3030- 15/18/20BT-7, 16/18/20B-7 Hydraulics.

3131- 15/18/20BT-7 Hydraulic Diagram (Non OPSS).80Bar1 Hydraulic gear pump2 Priority valve3 Main control valve4 Steering unit5 Steering hydraulic moto

32- 15/18/20BT-7 Hydraulic Diagram (OPSS).Holding valve OPSS valve- Steering: 80Bar- Main: 15BT-7=160Bar18BT-7=180Bar20BT-7=190Bar - Auxiliary:

33- 15/18/20BT-7 Hydraulic Diagram (OPSS+ fing).

3434- 16/18/20B-7 Hydraulic Diagram (Non OPSS).1 Hydraulic gear pump2 Priority valve3 Main control valve4 Steering unit5 Steering cylinder6 Tilt cylin

35- 16/18/20B-7 Hydraulic Diagram (OPSS).- Steering: 100Bar- Main: 16B-7=160Bar18B-7=180Bar20B-7=190Bar - Auxiliary: +/- 130BarHolding valve OP

3636- 15/18/20BT-7, 16/18/20B-7 MCV (OPSS).

3737- 15/18/20BT-7, 16/18/20B-7 Hydraulic MCV.Main pressure check point 190Bar Priority valveAUX. relief valveMain relief valve

3838- 15/18/20BT-7 Hydraulic Steering.1 Hydraulic gear pump2 Priority valve4 Steering unit5 Steering hydraulic motor8 Suction strainer11 Hydraulic oil

3939- 16/18/20B-7 Hydraulic Steering.1 Hydraulic gear pump2 Priority valve4 Steering unit5 Steering cylinder8 Suction strainer12 Hydraulic tankSteerin

44General machinesintroductions

4040- 22/25/30/32B-7, 22/25/30BHA-7 Hydraulics

4141- 22/25/30/32B-7 Hydraulic Diagram.130 Bar1 Gear pump + priority valve2 Main control valve3 Steering unit4 Steering cylinder5 Tilt cylinder6 Lift

4242- 22/25/30BHA-7 Hydraulic Diagram.- Steering: 100Bar- Main:22BHA-7=160Bar 25BHA-7=185Bar 30BHA-7=180Bar - Auxiliary: +/- 130Bar

4343- 22/25/30/32B-7, 20/25/30BHA-7 MCV.PLift positionPLower position Tilt forward position Tilt backwards positionLoad check valveLoad check valveLoa

4444Emergency descending valve turn counterclockwise (10mm spanner) OPSS section- 22/25/30/32B-7, 20/25/30BHA-7 MCV.

4545Priority valve installed on pumpsSteering pressure checkpointMain relief valveAux relief valve- 22/25/30/32B-7 Component location.Main pressure ch

4646- 22/25/30/32B-7 Hydraulic Steering.1 Gear pump with priority valve3 Steering unit4 Steering cylinder7 Suction strainer10 Return filter11 Hydrauli

4747- 22/25/30BHA-7 Hydraulic Steering.1 Hydraulic gear pump2 Priority valve3 Steering unit4 Steering cylinder7 Suction strainer10 Return filter11 Hyd

4848- 35/40/45/50B-7 Hydraulics.

4949- 35/40/45/50B-7 Hydraulic Diagram.1 Hydraulic gear pump2 Priority valve3 Main control valve4 Steering unit5 Steering cylinder6 Lift cylinder7 Til

55- 15/18/20BT-7, 16/18/20B-7 Model introduction.-ZAPI AC Dual AC2 drive controller (48V).-ZAPI AC 2 Flash inverter (Hydr.) (48V).-2 x Sauer Danfoss d

5050- 35/40/45/50B-7 Main Control Valve.- When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed.-

5151- When the tilt control lever is pushed forward, the spool moves to the left and closes the neutral passage.-Oil supplied from the pump pushes the

5252Steering pressure: 120Bar Aux. relief valve Hydrostat valve Main pressure gaugeOPSS section- 35/40/45/50B-7 MCV and Priority valve.

5353- 35/40/45/50B-7 Hydraulic Steering.1 Hydraulic gear pump2 Priority valve4 Steering unit5 Steering cylinder10 Suction strainer11 Return filter12 H

5454Electricsystems

5555- 15/18/20BT-7, 16/18/20B-7 Electric System.

5656-15/18/20BT-7, 16/18/20B-7 Component location.1 Combination switch2 Display3 Working lamp switch (opt)4 Beacon switch (opt)5 DC-DC converter6 Beac

5757- 15/18/20BT-7, 16/18/20B-7 Traction Motor.51 Stator220 Terminal222 Hexagon screw223 Hexagon nut224 Disk225 Hexagon nut226 Disk300 Drive end cover

5858- 15/18/20BT-7, 16/18/20B-7 Pump Motor.51 Stator220 Terminal221 Cylinder screw222 Hexagon screw223 Hexagon nut224 Disk225 Hexagon nut240 Terminal

5959- 15/18/20BT-7, 16/18/20B-7 Electric Diagram.

66

6060- 15/18/20BT-7, 16/18/20B-7 DC System. (Behind converter)+Flasher relay Lamp relay TNRFan TNRLamps sw.Zapi input

6161- 15/18/20BT, 16/18/20B-7 AC System.

6262- 15/18/20BT-7, 16/18/20B-7 Traction Config.

6363-15/18/20BT-7, 16/18/20B-7 Pump Configuration.

6464- 22/25/30/32B-7, 22/25/30BHA-7 Electric system.

6565- 22/25/30/32B-7 Electric Component location.1 Combination switch2 Accelerator assy.3 Parking micro switch4 High horn5 Drive motor6 Pump motor7 Fa

6666- 22/25/30/32B-7 Electric Diagram.

6767- 22/25/30/32B-7 DC System. (Behind converter)Flasher relay Lamp relay Fan TNR Zapi inputLamps sw.+

6868- 22/25/30/32B-7 AC System.

6969 - 22/25/30/32B-7 Traction Con. Configuration.

77- 22/25/30/32B-7, 22/25/30BHA-7 Model intro.-ZAPI AC Dual AC2 drive controller (48/80V).-ZAPI AC 2 Flash inverter (Hydr.) (48/80V).-2 x Sauer Danfos

7070 - 22/25/30/32B-7 Pump Con. Configuration.

7171- 22/25/30BHA-7 Electric Component location.1 Combination switch2 Accelerator assy3 Parking micro switch4 High horn5 Drive motor6 Pump motor7 Fan

7272- 22/25/30BHA-7 Electric Diagram.

7373 - 22/25/30BHA-7 Traction Con. Configuration.

7474 - 22/25/30BHA-7 Pump Con. Configuration.

7575- 35/40/45/50B-7 Electric systems.

7676- 35/40/45/50B-7 Component location.1 Combination switch2 Accelerator assy.3 Drive motor4 Pump motor5 High horn6 Relay7 Flasher unit8 Fuse box ass

7777- 35/40/45/50B-7 Electric Diagram.

7878- 35/40/45/50B-7 DC System. (Behind converter)Zapi inputBrake lamp sw.Flasher relay Lamp relay

7979- 35/40/45/50B-7 AC System.

88

8080- 35/40/45/50B-7 Traction Master Configuration.

8181- 35/40/45/50B-7 Traction Slave Configuration.

8282- 35/40/45/50B-7 Pump Con. Configuration.

8383ZAPI controllersystems

8484- Some basics.DC Motor AC Motor- DC motors consist of rotor-mounted windings (armature) and stationary windings (field poles). In all DC motors, e

8585- Some basics.DC controller system AC controller system- In a close loop speed control system a feedback signal is returned from the motor to the

8686- Zapi Dual AC2 inverter / AC2 and AC3 inverter.- Can drive (control) 2 traction motors.- Controllers control voltage and frequency.- Limited slip

8787- Entering the system by Console.- Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CKULTRA, minimum &q

8888- Enter the system with calibrator / Set Model – Option menu.

8989- Enter the system with calibrator / Saving – Restoring settings.

99- 35/40/45/50B-7 Model introduction.-ZAPI AC Dual AC3 drive controller(80V).-ZAPI AC 3 Flash inverter (Hydr.)(80V).-2 x Sauer Danfoss drive motor(8,

9090- Enter the system with calibrator / Test – Alarm menu.

9191- Enter the system through the machines display.1 Oil level warning lamp (option)2 Wrench warning lamp3 Thermometer warning lamp4 Seat warning lam

9292- Program menus: Traction master and Slave.MasterSlave- Only through the calibrator -

9393- Program menus: Pump and DisplayPumpDisplay- Only through the calibrator -

9494- Important adjustments -Accelerator pedal adjustment:1. Opening Zapi display.2. Connect to the DUAL MASTER (03)3. Press ENTER to go into the gen

9595- Important adjustments -Steering pot. teach-in :1. Opening Zapi display.2. Connect to the DUAL MASTER (03)3. Press ROLL UP and SET UP to enter C

9696- Important adjustments, through display -

9797- Important adjustments, through display -+ ENTER.+ OUT and YES.+ ENTER.+ ENTER.+ OUT and YES.the steering sensoror controller

9898- Important adjustments, through display -+ OUT and YES.Repeat from (3) and but select reverse direction.

9999- Important adjustments, through display -