CALIBRATOR USE

HOW TO USE ZAPI CALIBRATOR

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 Presentation

Confirmation of the Exit or execute the

selection function

Option selection or Parameter increase or

previous step in the access to special
menu functions

Option selection or Parameter decrease or

following step in the access to special
menu functions

HOW TO USE ZAPI CALIBRATOR

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 Connection in the chassis
On hourmeter connector
NEW VERSION

PPC TYPE
OLD VERSION

NEW VERSION BOSCH PUMP UNIT HALDEX PUMP UNIT

COMPACT - OPTIMUM range

HOW TO USE ZAPI CALIBRATOR
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 Connection in lower control box

Hourmeter connector CNB connector

STAR range

TRIPLAT TYPE

HOW TO USE ZAPI CALIBRATOR

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 Standard menu
PPC CO 2.03 ALARM
24V 350A 0000 Alarms list

Parameters
Parameters PARAMETERS RESTORE restore from
adjustment CHANGE PARAMETER calibrator
towards variator

Not used by SAVE Save parameters

Haulotte MOTOR DATA PARAMETER in the calibrator

Not used by PROGRAM VACC TEST Function test

Haulotte

HOW TO USE ZAPI CALIBRATOR

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Special functions 1
PPC CO 2.03
24V 350A 0000

CONFIG MENU Model choice (Compact and

SET MODEL Optimum only)

CONFIG MENU
SET OPTION Option choice

Steering adjustment for Star range

ADJUSTMENT only and battery voltage for all
models

HOW TO USE ZAPI CALIBRATOR

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 Special functions 2
Alarms list ALARM

Variator
CLEAR EEPROM parameters reset

Special setting SPECIAL

access ADJUSTMENT

RAM parameters
READ RAM reeading ( not
used by
HAULOTTE)
HARDWARE
Special settings SETTINGS
EEPROM
parameters
READ EEPROM reading ( not
used by
HAULOTTE)
Calibrator CLEAR CONSOLE
memory reset

HOW TO USE ZAPI CALIBRATOR

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 Parameters setting COMPACT/OPTIMUM : circuit E614 – version PPC C02 V 2.03

PARAMETERS
CHANGE

CALIBRATOR DISPLAY DESIGNATION VALUE

ACCELER. DELAY Acceleration ramp for traction 9

DECELER. DELAY Decceleration ramp for traction 5 (OPTIMUM :0)
CUTBACK SPEED Speed reduction ( microspeed) 2 (OPTIMUM :1)
CREEP SPEED Minimum speed for traction 2
MAX SPEED FORW. Maximum speed for forward traction 9
MAX SPEES BACK Maximum speed for reverse speed 9

COMPENSATION Compensation between battery voltage and value read by the

variator 7
TRACTION I MAX Maximum current on traction motor 9
1ST SPEED COARSE Lifting Speed 9
1ST SPEED COMP. 5
STEERING SPEED Steering speed 1 (OPTIMUM :9)
ADJ TR + ST SPEED Traction and steering speed adjustment 2
ADJ ST VALVE DEL. 5
CREEP PUMP Minimum speed for pump for lifting 9
PU. ACCELER. DEL Acceleration ramp for lifting 5
PU. DECELER. DEL Deceleration ramp for lifting 4
EV. ACCELER. DEL Deceleration ramp for proportional valve (5) Not used by HAULOTTE
EV. DECELER. DEL Ramp de deceleration for proportional valve (5) Not used by HAULOTTE
MIN. VALVE VOLT Minimum voltage on proportional valve (5) Not used by HAULOTTE
MAX. VALVE VOLT Maximum voltage on proportional valve (5) Not used by HAULOTTE
AUX. CURRENT # 1 4 (OPTIMUM :2)

HOW TO USE ZAPI CALIBRATOR

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 Parameters setting COMPACT/OPTIMUM : circuit E614 – version PPC C02 V 2.07

PARAMETERS
CHANGE

CALIBRATOR DISPLAY DESIGNATION VALUE

ACCELER. DELAY Acceleration ramp for traction 9

DECELER. DELAY Decceleration ramp for traction 5 ( OPTIMUM:0)
CUTBACK SPEED Speed reduction ( microspeed) 5 ( OPTIMUM :6)
CREEP SPEED Minimum speed for traction 2
9 (with Bosch pump and all compact ) and 7 (
MAX SPEED FORW. Maximum speed for forward traction Optimum with Haldex pump)
9 (with Bosch pump and all compact ) and 7 (
MAX SPEED BACK Maximum speed for reverse speed Optimum with Haldex pump)

COMPENSATION Compensation between battery voltage and value read by the

variator 7
TRACTION I MAX Maximum current on traction motor 9
1ST SPEED COARSE Lifting Speed 9
1ST SPEED COMP. 5
STEERING SPEED Steering speed 1 (OPTIMUM :9)
ADJ TR + ST SPEED 2
ADJ ST VALVE DEL. 5
CREEP PUMP Minimum speed for pump for lifting 9
PU. ACCELER. DEL Acceleration ramp for lifting 5
PU. DECELER. DEL Deceleration ramp for lifting 4
EV. ACCELER. DEL Deceleration ramp for proportional valve (5) Not used by HAULOTTE
EV. DECELER. DEL Ramp de deceleration for proportional valve (5) Not used by HAULOTTE
MIN. VALVE VOLT Minimum voltage on proportional valve (5) Not used by HAULOTTE
MAX. VALVE VOLT Maximum voltage on proportional valve (5) Not used by HAULOTTE
AUX. CURRENT # 1 4 (OPTIMUM :2)

HOW TO USE ZAPI CALIBRATOR

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 Test menu COMPACT/OPTIMUM

TEST

CALIBRATOR DISPLAY DESIGNATION VALUE

Voltage reading on B+ and B- variator plug

BATTERY VOLTAGE
BATTERY CHARGE Reading of % remaining charge value in battery
DEADMAN SWITCH Dead man switch state joystick HM
INCLINATION SWITCH Slope sensor state SQ10
PRESSURE SWITCH Overload pressure switch state SP1 ( if charge board option is not installed)
LEFT STEER SW Left steering switch state joystick G
RIGHT STEER SW Right steering switch state joystick D
SIDE GATES Pothole limit switches state SQ5 + SQ6
8M BLOCK SWITCH Stop driving limit switch state ( 8M cut ) SQ4
STOP DOWN SWITCH Lower limit switch state SQ1
STOP UP SWITCH Upper limit switch state SQ3
DESCENT SWITCH Contact switch state for descent (Joystick) SA3 + push on the joystick towards descent without trigger (HM)
LIFTING SWITCH Contact switch state for lifting (Joystick) SA3 + push on the joystick towards lift without trigger (HM)
CUTBACK SWITCH Switch state for speed reduction SA3 in LS ( low speed)
ENABLE SWITCH Emergency push button state SB2

BACKWARD SWITCH Reverse speed switch state (Joystick) Joystick to the back without trigger and SA3 in LS or HS

FORWARD SWITCH Forward speed switch state (Joystick) Joystick to the front without trigger and SA3 in LS or HS
ACCELERATOR Accelerator on joystick Without trigger( 5.00V) + 100% if trigger is pushed
TEMPERATURE Temperature inside the variator
EVP VOLTAGE Voltage on proportional valve
MOTOR CURRENT Current on pump motor
MOTOR VOLTAGE Voltage on motor

HOW TO USE ZAPI CALIBRATOR

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 Option setting COMPACT/OPTIMUM
CONFIG MENU
SET OPTION

CALIBRATOR DISPLAY DESIGNATION VALUE

HOUR COUNTER Selection for hour counter function KEYON on SB1contact / RUNNING on pump working

Possible choice
FLASHING LIGHT OPTION # 1 not programmed
# 1 to # 4 Flashing light option # 2 drive
# 3 all movements
# 4 when power is ON

OVER LEARNING validation of charge BPE board option + OFF if charge board option is installed ( BPE option)
pressure sensor G1and angle sensor A1 option

LOWERING BLOCK activation / cut for descent warning at SQ1 ON / OFF ( ON for EUR version )

SET BATTERY TYPE Voltage battery selection 24 V / 48 V ( 24V for compact)

CHECK UP DONE Maintenance program scheduled ON / OFF (OFF for HAULOTTE)

CHECK UP ENABLE Cut out selection for scheduled maintenance ON / OFF (OFF for HAULOTTE)

BUZZER OPTION # 2 Buzzer activation for all movements ABSENTE / PRESENTE

BUZZER OPTION Driver buzzer activation ABSENTE / PRESENTE

AUX FUNCTION # 2 EVP Not used by HAULOTTE (no proportional valve in Haulotte)

BATTERY CHECK Lift cut if batteries are discharged ON for HAULOTTE

CONFIG MENU
SET MODEL

NOTE : For COMPACT , select option # 1 and for OPTIMUM option # 2

( to be checked when exchanging the variator for microspeed adjustment

HOW TO USE ZAPI CALIBRATOR

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 Special setting COMPACT/OPTIMUM

SPECIAL
ADJUSTMENT

CALIBRATOR DISPLAY CALIBRATOR DISPLAY DESIGNATION VALUE

HARDWARE SETTING SET CURRENT 350 A ( COMPACT)

I max setting on traction motor

AUX FUNCTION 1 Hours priority for the variator if set at OFF. OFF (normally)
Hours priority for the hourmeter is set at ON
(when one of this item is replaced)

ADJUSTMENT # 2 Hourmeter green led descent speed for

discharge

ADJUSTMENT # 1 Red led adjustment flashing light at the end of

the discharge or lift prevent step

SET TEMPERATURE Temperature adjustment value read by MOS

FET probe

OK FOR VERSION # 1 or # 2 Charge option (BPE board) # 2 : charge option validation

VERSION OPTION # 1 or # 2 Charge option (BPE board) # 2 :charge option validation

MAXIMUM CURRENT Field I max setting on traction motors 52 for COMPACT

CLEAR CONSOLE Calibrator parameters reset

CLEAR EEPROM Variator memory reset
READ EEPROM Parameters reading in EEPROM not used by HAULOTTE
READ RAM Parameters reading IN RAM not used by HAULOTTE

HOW TO USE ZAPI CALIBRATOR

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 Parameters setting STAR 8/10NG : circuit E621 – versionTRIP B NH H1.09

PARAMETERS CALIBRATOR DISPLAY DESIGNATION VALUE

CHANGE Acceler delay Acceleration ramp delay for drive 5
Max valve delay Not used by HAULOTTE 5
mini valve delay Not used by HAULOTTE 5
EV [Link] Not used by HAULOTTE 5
EV [Link] Not used by HAULOTTE 5
Basket cut back Not used by HAULOTTE 5
Creep pump Minimum speed on pump 5
Steering creep Minimum speed for steering 5
Steering speed Steering speed 5
Rotation speed Mast rotation speed 5
3RD speed coarse 5
2ND speed coarse 5
1ST speed coarse 5
PU deceler delay Pump motor deceleration ramp delay 5
PU acceler delay Pump motor acceleration ramp delay 5
Field norm curr Field current for drive 5
Field curr max Maximum field current for drive 5
Weak dropout Not used by HAULOTTE 5
Arm nom curr Normal current (stator drive ) 5
Traction I max Maximum current (rotor drive) 9
Max speed back Maximum speed on reverse drive 9
Max speed forw Maximum speed on forward drive 9
Creep speed Minimum speed for drive 5
Cutback speed Microspeed 5
Curve cutback Drive motion slow down with steering wheels function 5
Invers bracking Brakes power during inversion 5
Release bracking Brakes power when joystick is released 5
decceler delay Deceleration delay for drive 5

HOW TO USE ZAPI CALIBRATOR

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 Parameters check STAR 8/10NG

TEST 1/2

CALIBRATOR DISPLAY DESIGNATION VALUE

Batt voltage Voltage reading on B+ and B- applied on variator plug

Batt charge (in %) Remaining battery charge ( in % )

Dead man switch State of dead-man switch ( joystick) Upper control box : SB8

Security switch Not connected

Weighing card Charge option board installed with pressure sensor ON (if BPE charge board is installed)
G1 and angle sensor A1
Inclination switch Slope sensor switch state SQ1
Overvoltage SW Not used by HAULOTTE OFF
Basket CTB SW Not used by HAULOTTE OFF
Basket low block Not connected OFF
Left steer sw Left steering switch state ( on joystick) SA2 on traction selection + push on SB8 and SM2 towards left
Right steer sw Right steering switch state ( on joystick) SA2 on traction selection + push on SB8 and SM2 towards right
L Rotation sw State of the left rotation switch SA2 on mast rotation selection + push on SB8 and SM3 towards left
R Rotation sw State of the right rotation switch SA2 on mast rotation selection + push on SB8 and SM3 towards right
Basket lift block Not connected
Stop down cabin Mast descent limit switch state SQ4
Stop up cabin Lift mast limit witch state SQ10
Basket low sw Descent limit switch state for cage Not used by HAULOTTE
Basket lift sw Lift limit switch state for cage Not used by HAULOTTE
Descent switch Descent limit switch state SA2 on mast lift selection + push on SB8 and SM3 in descent mode

HOW TO USE ZAPI CALIBRATOR

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 Parameters check STAR 8/10NG

TEST 2/2

Lifting switch Lift limit switch state SA2 on mast lift selection + push on SB8 and SM3 in lift mode

Backward switch Reverse drive limit switch state SA2 on drive selection + push on SB8 and SM3 to the back

Forward switch Forward drive limit switch SA2 on drive selection + push on SB8 and SM3 to the front

Enable switch main switch SB3

Steer angle Steering wheels angle potentiometer value reading %

2 possible test with upper control box ( without SB8 then with SB8 +
Lifting control Accelerator % + lifting voltage push on SM3) and on lower control box ( without SB6 then
with SB6 + push on SM1)

Accelerator Accelerator % + drive voltage SA2 on drive selection then test without SB8 then with SB8 + push
on SM3

Temperature Temperature measured inside the MOS transistor

EVP Voltage Voltage applied on proportional valve Battery voltage value

Field current Current reading inside the traction motor stator

L I motor R Current reading inside the traction motor rotor

L Vmotor R Voltage reading inside the traction motors rotor

HOW TO USE ZAPI CALIBRATOR

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 Parameters setting STAR 8/10NG
CONFIG MENU
SET OPTION 1/2

CALIBRATOR DISPLAY CALIBRATOR DISPLAY DESIGNATION VALUE

SET MODEL Not available Not used by HAULOTTE

SET OPTION Hour counter Counter is running with motor pump RUNNING
Counter is running when power is ON Key ON

Possible choices
# 1 not programmed
# 2 drive
# 3 all movements
Flashing light option # 1 to # 4 Flashing light at ON # 4 when power is ON
Flashing light at OFF OFF

Possible choices
#1 on drive
#2 all movements
Buzzer option Buzzer at ON NONE not programmed
Buzzer at OFF OFF
Check up done ON
OFF
Scheduled maintenance ( not used by HAULOTTE)
Check up enable ON
OFF

Not used by HAULOTTE ( no proportional valve)

Aux FUNCTION 2 ABSENT
Battery check ON
Battery test selection
OFF

HOW TO USE ZAPI CALIBRATOR

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 Parameters setting STAR 8/10NG
CONFIG MENU
SET OPTION 2/2

ADJUSTMENT Set steer min Left steering setting position

Set steer max Right steering setting position

Set steer 0 POS Middle point steering position

Adjust battery Battery voltage value setting ( value read by the variator)

5 possible choices :

0 40% discharged
Activation of the variator input in case the voltage booster 1 50% discharged
option is installed , the value set will define the battery
Set voltage level =0 charge threshold from which , the operator might not use 2 60% discharged
electronic devices on cage (this in order to avoid to be
stuck in the air) 3 70% discharged
4 80% discharged

HOW TO USE ZAPI CALIBRATOR

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 Parameters setting STAR 8/10NG
SPECIAL
ADJUSTMENT

CALIBRATOR DISPLAY CALIBRATOR DISPLAY DESIGNATION VALUE

HARDWARE SETTING SET CURRENT 270 A ( STAR 10)

Maximum current on variator ( main power)

AUX FUNCTION 1 Variator hours counting if set at OFF. Hourmeter OFF (normally)
hours counting if set at ON (when one of these parts
has been replaced)

ADJUSTMENT # 02 Hourmeter green led descent speed for discharge 5

ADJUSTMENT # 01 Red led adjustment flashing light at the end of the

discharge or lift prevent step

SET FIELD CURRENT Maximum field current setting in the traction motors value 50 for STAR 10

COMPENSATION LEVEL Not used by HAULOTTE 5

SET TEMPERATURE Temperature setting read by the MOS FET

transistors inside the variator

CLEAR CONSOLE Calibrator parameters reset

CLEAR EEPROM Variator memory reset
READ EEPROM Parameters reading in EEPROM Not used by HAULOTTE
READ RAM Parameters reading IN RAM Not used by HAULOTTE

HOW TO USE ZAPI CALIBRATOR

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 Save parameter function COMPACT-
COMPACT-STAR 8/10NG

SAVE
PARAMETER

d
PROCESS :
● Select a free channel in order to register the parameters (from 00 to 31)
( an existing channel could be selected but in this case the previous values will be erased )
● Push on Enter in order to launch the parameters registration process in the calibrator
● At the end of the copy , exit by “OUT”
● Switch off the machine in order to save the validation

RESTORE
PARAMETER

PROCESS :
● look for the channel to be copied into the variator ( from 00 to 31)
● Validate by ENTER and confirm ( message “ARE YOU SURE”?)
● At the end of automatic transfer , exit by “OUT”
● Switch off the machine in order to validate the copy process

●Note : in order the machine will keep the hour meter values , don’t forget before the process to select the
parameter “AUX FUNCTION 1” to ON

HOW TO USE ZAPI CALIBRATOR

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 Battery voltage setting COMPACT-
COMPACT-STAR 8/10NG

ADJUSTMENT

SYMPTOM :
The batteries are discharged although the hour meter indicate some charge level
PROCESS :
● Look for the parameter « ADJUST BATTERY »
● Put a low value ( i.e. 22.5VDC) then switch off in order that the variator will register a fault
● Switch ON again and enter in the calibrator the value read on voltmeter
● Switch OFF , remove the calibrator and connect again the hour meter
● When power is back , the battery charge indicator on hour meter must correspond to the real battery voltage value
Note : if the value didn’t change , proceed to a “CLEAR EEPROM” and make again the process described just above

HOW TO USE ZAPI CALIBRATOR

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 How to get back the machines hours COMPACT-
COMPACT-STAR 8/10NG

HARDWARE
SETTINGS

SYMPTOM :
When the variator or hour meter has been changed , the machines ‘ hours are lost
( select the function « AUX FUNCTION 1 » to OFF in order to keep the variator’s hours and to ON in order to keep the
hour meter's hours)

CLEAR EEPROM

PROCESS :
● Proceed to a « CLEAR EEPROM » then switch off the machine
●Re program the function « AUX FUNCTION 1 » to OFF then switch off again , remove the calibrator and connect the
hour meter
● Adjust again the right parameters according to the model and software version ( MENU PARAMETER CHANGE)
● When power is back , the alarm AL98 will appear
● Then after 5 mns the hour meter will automatically update the running hours
Note : after this , it will be necessary to check all parameters and models ( especially between Compact and Optimum)

HOW TO USE ZAPI CALIBRATOR

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 Steering potentiometer setting STAR 8/10NG

HARDWARE
SETTINGS

SYMPTOM :
When the wheels reach the maximum steer left or right position , the pump should stop
In the same time, it’s possible to check that the motor located on the side where the wheels are turning will decrease the
speed so the current and voltage applied on it (menu TESTER / see parameters « L I motor R » et « L V motor R »

ADJUSTMENT

PROCESS :
● In the menu « ADJUSTMENT » , push « ENTER »
● Look for the parameter «STEER MIN »
● From upper control box , steer the wheels to the maximum left side and validate the position by pushing
« ENTER » then « OUT »
● Look for the parameter « STEER MAX »
● Steer the wheels to the maximum right position and validate the position by pushing « ENTER » then « OUT »
● Look for parameter « STEER POS 0 POSITION »
● Put back the wheels perfectly aligned and validate by « ENTER » then « OUT »
● Switch the key-switch off then on to confirm setting.

CHECK :
● Check that the pump will stop working when the wheels reach the maximum position left or right
● It’s also possible to check the steering potentiometer setting according to the wheels’ alignment
( menu TESTER then look for parameter « STEER ANGLE » : it must indicate 0°° with wheels in straight position , then
+ 45 ° and – 45°° for the extreme position.

HOW TO USE ZAPI CALIBRATOR

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 Serial card initialisation COMPACT-
COMPACT- STAR 8/10NG

TEST

SYMPTOM :
If the machine is weak and especially in ramp , the signal sent to the variator must be checked and should correspond to
inclination joystick angle .
Look inside the menu « TESTER » , the following function « ACCELERATOR »
Push full forward the joystick with the trigger or validation button , on the calibrator display it should indicate 5.00 V and
100% , if not proceed to the serial card initialization as described below .

INITIALISATION :
● Emergency button not pushed
● Put the key selector in « OFF » position
● Put a jumper on the connector J1 on serial card
● Put the key selector to « ON » position
( all following operations should be done smoothly without stop)
● Push the joystick completely to the front ( FWD)
● Come back to neutral position and release the joystick
J1
● Pull the joystick completely to the back ( REV)
● Come back in neutral position and release the joystick
● Push the joystick fully up ( lift)
● Come back to neutral position and release it
● Pull the joystick fully down ( descent)
● Come back to neutral position and release it
● Put the key selector to « OFF » position and remove the jumper on J1
● Wait for 5 seconds then switch ON again and check the movements

HOW TO USE ZAPI CALIBRATOR

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