Document

Maintenance

ZAPI™ CONTROLLERS
MPB040-E [B827]

PART NO. 524154895 2200 YRM 1006

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow
instructions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and

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that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on
these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

NOTE:  The following symbols and words indicate safety information in this

manual:

  WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

  CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.

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TABLE
©2014 Yale OF
Materials CONTENTS
Handling Corp.

General
Description
ZAPI™ Transistor Motor Controller
Principles of Operation
Controller Safety
Controller Adjustments
Modes of Operation
User-Selectable Operating Modes
Programming
Custom Performance Mode
Controller Parameters
Tester Menu
Set Option Menu
ZAPI™ Handset
Troubleshooting
Control Card Functional Test
ZAPI™ PC Interface
Connecting PC to ZAPI™ Controller
File Menu
Open File
TX From File
Save File
Print Settings
Exit
Connection Menu
Function Menu
Parameter
Memory Menu
Set Options
Tester
Data Logger
Alarm Logbook
Alarms
Repair
Remove
Brass Stud Replacement
Remove
Install
Install
Repair
Connector Pin Outs

This section is for the following models:

(MPB040-E) [B827]

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General

This section describes the ZAPI™ transistor motor controller. Procedures are outlined for controller safety,
adjustments, troubleshooting, and repairs. See Figure 1.

Figure 1. Controller MPB040-E

Description

ZAPI™ TRANSISTOR MOTOR CONTROLLER

The ZAPI™ controller is a solid state DC motor controller utilizing SEM technology. It controls the traction
motor, brake, and hydraulic system. The controller receives inputs from the control handle by serial
communication, and direct inputs from the key switch and control handle arm position switch. The controller
directly controls the traction motor, lift pump motor, lowering valve, brake, and main contactor. Jumpers are
used to configure the basic controller.

The controller software provides self diagnostics which are accessed by means of a ZAPI™ handset or a PC
with specialized ZAPI™ software. The controller software features a Test Menu for monitoring controller

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inputs and outputs, a Diagnostic Menu for viewing fault code information, and a Programming Menu for
customizing the truck performance.

The self diagnostics monitor the traction motor, brake coil, lowering valve coil, contactor coil, control handle
serial communications, controller temperature, and internal logic functions. The controllers on standard
trucks come equipped with a red LED fault indicator located at the bottom of the controller. In the event of
a fault, the LED flashes a numeric code. Troubleshoot the fault using a ZAPI™ handset or a properly
configured IBM compatible PC. On trucks equipped with the optional dash display, the dash wiring harness
plugs into the controller in place of the LED. The display also has a red LED, however it does not flash
codes. If a fault occurs, the red LED blinks, the wrench LCD is shown and "AL" followed by the fault number
is displayed.

PRINCIPLES OF OPERATION

The ZAPI™ Transistor Motor Controller uses a sophisticated microprocessor to control the logic and
operation of the controller, eliminating the need for forward and reverse contactors. The SEM motor
controller operates on the principle of controlling the motor field circuit and the motor armature circuit
independently. The controller has many programmable features, including maximum speed, acceleration
rate, release braking, and braking current limit. The SEM controller includes a full range of features, as well
as diagnostic and setup capability.

NOTE:  There are no user-serviceable parts in the ZAPI™ controller. No attempt should be made to open,
repair, or otherwise modify the controller. Doing so may damage the controller and will void the warranty.

Controller Safety

  WARNING
The ZAPI™ controllers can hold an electrical charge for several minutes after the key switch has been
turned OFF. To prevent injury, discharge the controllers by connecting a 200-ohm, 2-watt resistor
between the battery positive connector and battery negative connector on the controller and hold
there for 5 seconds.

See Figure 2.

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1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR

Figure 2. Discharging Controller MPB040-E

Controller Adjustments

The ZAPI™ transistor motor controller can store and display Error Codes (Alarms). It is also possible to
modify the controller Setup for individual preferences. Communication with the controller is possible by four
methods:

1. LED - An LED may be installed in trucks that do not use a dash display. The LED flashes error codes
to the technician for diagnosis. The LED would be installed on the bottom of the ZAPI™ controller.
The LED is installed in connector port B. See Figure 1.

2. Dash Display - Some trucks are equipped with an optional dash display or MDI. Error codes are
shown on the LCD (liquid crystal display) when the wrench symbol and red light are lit. The format is
AL XX where XX is the error code. The software version is displayed on startup.

3. ZAPI™ Handset - A diagnostic handset is available through your Yale dealer. The handset makes it
possible to diagnose faults and modify controller settings. See Programming, in this section.

4. Personal Computer - The controller can also be connected to a personal computer (PC) equipped
with special software and cables. The PC can read, store, and change settings on the controller.

Proper use of these four methods and a list of diagnostic codes are explained in Troubleshooting, in this

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section.

Modes of Operation

It is possible to adjust the operating characteristics of the lift truck. There are two basic ways to do this:
User-Selectable and Non-User-Selectable Operating Modes.

USER-SELECTABLE OPERATING MODES

The operator has a choice of three performance modes that are selectable through the control handle. The
mode selection is made at startup or key ON. Performance parameters that vary are acceleration,
deceleration, regenerative (neutral) braking, and top travel speed.

The three operator-selectable performance modes are factory programmed per the following:
• Mode 1 - Economy mode (battery saver) - soft acceleration, reduced top speed with regenerative
(neutral) braking.
• Mode 2 - Performance with regenerative (neutral) braking - medium acceleration, reduced top travel
speed with regenerative (neutral) braking.
• Mode 3 - Performance without regenerative (neutral) braking - maximum acceleration, maximum top
travel speed with coast at throttle release.

The following procedure is used to access the user-selectable operating modes:

1. The controller drive modes parameter must be ON. This is the factory setting.

NOTE:   You must use the handset or PC interface to change this setting. Using the ZAPI™ handset or PC
connection, it is possible to set the drive mode parameters to ON or OFF. In the ON mode, the user-
selectable rules are enabled. In the OFF mode, the lift truck will only operate using the settings selected.
The procedure to alter or modify these settings is given in Programming in this section.

2. Control handle must be in the full, upright position, brake ON.

3. Press and hold the horn button while turning the key switch to the ON position.

4. Release the horn button when the horn sounds.

5. Toggle through the modes by pressing the lift or lower buttons to the desired mode.

6. The horn provides an audible indication as to the mode selected. One beep indicates Mode 1, two
beeps indicate Mode 2, and three beeps indicate Mode 3.

7. Lower the control handle to the operating position, brake OFF, and begin operation.

8. The selected mode is maintained until the procedure is repeated.

9. Turning the key OFF before lowering the control handle will cancel the mode change.

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Programming

CUSTOM PERFORMANCE MODE

In some instances, it may be preferable to disable the Drive Modes and use a custom setting. This controller
has adjustable parameters that may be modified to suit specific customer needs. There are two methods
used to adjust these parameters: the ZAPI™ handset or the personal computer (PC) interface.

CONTROLLER PARAMETERS

Parameters are controller settings that can be adjusted to alter the performance characteristics of the truck.

To adjust parameters and install custom drive settings, Drive Modes must be OFF. To set Drive Modes to
OFF, use the following procedure:

1. Turn key switch OFF.

2. Remove drive unit compartment cover.

3. Connect adapter harness to handset.

NOTE:  It may be necessary to remove the MDI harness connector from the controller to install the adapter
harness.

NOTE:  Connect and disconnect the handset only with the key switch in the OFF position.

4. Connect adapter harness to controller.

5. Turn key switch ON.

6. The handset will turn ON. See Figure 3.

Figure 3. ZAPI™ Handset

7. Press buttons 1 and 5 simultaneously.

8. The screen will display CONFIG MENU.

9. Scroll through the menus using button 1 or 2 to the SET OPTIONS menu.

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10. Enter this menu by pressing button 3.

11. Press button 5 or 6 to set Drive Modes to OFF.

12. Press button 4 to exit this menu.

13. The handset will prompt, "Are you sure?"

14. Press ENTER (button 3) to retain settings.

15. Press OUT (button 4) to discard settings.

16. Turn the key switch OFF to save the drive modes OFF parameter change.

17. Turn the key switch ON to enter the MAIN MENU and change the parameters outlined in Table 1.

Table 1.  Parameters

Parameter Description Value and Affect

ACCELERATION Adjusts truck acceleration. 0 = short or rapid
DELAY acceleration
9 = long or slow
acceleration
DECELERATION Adjusts truck deceleration according to throttle position. 0 = short or rapid
DELAY deceleration
9 = long or slow
deceleration
RELEASE Adjusts motor braking strength or regenerative braking when throttle 0 = soft braking
BRAKING is released. This determines coast distance. 9 = strong
braking
INVERSE Adjusts plugging rate. 0 = long or soft
BRAKING plugging
9 = short or rapid
plugging
MAX SPEED Adjusts maximum speed in forward direction, forks trailing. 0 = minimum
FORW 9 = maximum
MAX SPEED Adjusts maximum speed in reverse direction, forks leading. 0 = minimum
BACK 9 = maximum

TESTER MENU

The most important input or output signals can be measured in real time using the TESTER function of the
handset. The handset acts as a multimeter to read voltage, current, temperature, switch state, and other
functions.

1. BATTERY VOLTAGE = battery voltage, nominal value = 24V, V.

2. MOTOR VOLTAGE = motor voltage obtained VBATT - VMN, V.

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3. MOTOR CURRENT = armature current during traction (positive value) or braking (negative value).

4. FIELD CURRENT = field current in the selected traction direction.

5. TEMPERATURE = controller temperature, °C.

6. ACCELERATOR = traction potentiometer value received from control handle.

7. LIFTING CONTROL = lifting/lowering potentiometer value received from control handle.

8. CONTROL HANDLE SWITCH = control handle switch input, ON/OFF.

9. FORWARD SWITCH = forward direction request from control handle card, ON/OFF.

10. BACKWARD SWITCH = backward direction request from control handle card, ON/OFF.

11. CUTBACK SWITCH 1 = speed reduction switch input, ON/OFF (closed switch = OFF = no speed
reduction).

12. LIFTING SWITCH = lifting function request from control handle card, ON/OFF.

13. LOWERING SWITCH = lowering function request from control handle card, ON/OFF.

14. FORK LIFT SWITCH = i - lift request from control handle card, ON/OFF.

15. FORK LOW SWITCH = i - lift request from control handle card, ON/OFF.

16. BELLY SWITCH = belly input switch to the controller or belly request from control handle card,
ON/OFF.

17. HARD & SOFT = snail request from control handle card allows machine to drive with control handle
up, ON/OFF.

18. HORN SWITCH = horn request from control handle card, ON/OFF.

19. LIFTING BLOCK = lifting block input switch, ON/OFF (with LIFTING BLOCK option programmed OFF).

20. BATTERY MODEL = battery-type of input switch, ON/OFF. ON = flooded battery (input closed), OFF
= sealed battery (input open).

21. BATTERY CHARGE = battery charge indication, %.

SET OPTION MENU

DRIVE ON The truck has three performance modes, each with a fixed set of parameters. This
MODES function is enabled by setting DRIVE MODES = ON.
OFF DRIVE MODES disabled.

ZAPI™ HANDSET

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The ZAPI™ handset must be connected to the controller before turning on the key. The handset must have
an adapter harness to connect to the controller. The handset and adapter harness are available from your
Yale dealer. Connect the handset to plug B. The handset can remain connected to the controller while
running, and the parameters can be changed in real time. In this case, it is necessary to go in a standby
condition (truck at rest) before switching OFF the controller in order to store the new values in the
EEPROM.

This section describes the ZAPI™ handset functions. Six buttons provide the capability of changing or
reading the parameters.

1 Roll-Up Push to scroll up.

2 Roll-Down Push to scroll down.
3 Enter Push to enter a submenu or to confirm a change.
4 Out Push to exit a selected menu or to refuse a change.
5 Set-Up Push to increase a parameter value.
6 Set-Down Push to decrease a parameter value.

NOTE:  After a modification, save the new values by pushing out, then enter to confirm. (Screen prompts
will guide the user.)

To navigate the menu options, numbers inside the triangles in the following map correspond to the same
number on the handset keyboard buttons. The orientation of the triangle indicates the way to the next
function. See Figure 3.

NOTE:  Connect and disconnect the handset only with the key switch in the OFF position.

For additional handset description, see Figure 4.

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Figure 4. ZAPI™ Handset Instructions

Troubleshooting

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Dash Display Controller LED Handset or PC

LCD display Red LED
Red LED Fault Indicator Located at base of Error codes stored under Main Menu Alarms
motor controller.
(Trucks equipped with (Trucks without Message displayed on Handset or PC
optional dash display) dash display)

CORRESPONDING SCHEMATIC SHOWING CIRCUITS TO

BE CHECKED OR AFFECTED COMPONENT(S)

CONDITION
TRUCK RESPONSE
POSSIBLE CAUSES AND TEST LOGIC (Brief description of the reason behind truck
PROCEDURES exhibited malfunction.)

NOTE:  General error code information is provided by the Dash Display and Red LED at the base of the
controller. In most instances, it will be necessary to use a handset or a PC to further define the possible
causes and test procedures.

Dash Display Controller LED Handset or PC

No LEDs or LCDs illuminated LED OFF Handset does not operate
CONDITION
Dash display, controller LED, and truck inoperative.
TRUCK RESPONSE
Travel and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Verify battery charger is not plugged into wall

socket.
• B+ and/or B- missing at controller.
Confirm battery is connected and of proper
voltage.
Verify key switch is ON.
Verify brake override circuit is connected in
run position.
Verify continuity between batteries negative
(at battery) and -B power wire connection (at
controller).
If no continuity, check:

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Power wiring between battery and controller.

Check for +24V at D-4, A-3, and A-6.
If no continuity, check: LOGIC
Occurs when there is no power to the
Fuse 2 for open. controller or the controller is defective.
Key switch continuity in ON position.
Wiring battery + to main contactor to fuse 2
to key switch, to controller A-6 connection.

• Defective battery charger.

Disconnect wires 2D and 12 from leads to
battery charger.
Use test lead to connect 2D and 12.
If truck operates, check charger fuses, repair
or replace battery charger.

Dash Display Controller LED Handset or PC

No LEDs or LCDs illuminated LED OFF No error codes present
CONDITION
Dash display and/or controller LED inoperative.
TRUCK RESPONSE
Travel and hydraulic functions normal.

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POSSIBLE CAUSES AND TEST PROCEDURES

• Open connection between dash display and

controller.
Verify harness connections at MDI and
connector B on controller.
LOGIC
Verify continuity of wires between MDI
Occurs when the MDI or LED receives no signal, or
and controller.
MDI or LED are damaged.
• Defective dash display.
Connect handset to controller and
confirm communication to handset.
If handset operates correctly, replace
MDI.

• Defective LED.
Disconnect LED and connect handset. If
handset works, replace LED.

Dash Display Controller LED Handset or PC

No Alarm LED OFF - No Flashes INCORRECT START
CONDITION
Improper startup sequence by operator.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Throttle or hydraulic function selected or reversing switch

pressed at key ON. Steer handle in run position at key ON.
Return steer handle to full upright position. Return
throttle to neutral. Release all hydraulic function
controls.
If fault remains, attach handset and go to test
menu.

• Check the control handle proximity sensor, it should be off

when the control arm is in the vertical position. If steer
handle is in vertical position and reading is not OFF, check
brake switch for damage, interference, or shorts.

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• Check accelerator - Should be 0 volts at neutral. If not,

repeat control card calibration. If this does not correct the
problem, check the functionality of the control card. Refer
to Control Card Functional Test in this section.
• Check hydraulic inputs – Should be OFF. If not, check
buttons for damage or interference. Replace damaged or
faulty buttons. LOGIC
• Verify that the wiring to the tiller card is ok. Use the Fault occurs when controller receives
handset to verify the belly switch is working properly. For input that has not followed the proper
tiller card troubleshooting procedures, refer to Control Card operational sequence.
Functional Test in this section.

Dash Display Controller Handset or PC

LED
SW Version 1.08: Last battery indicator light flashing. Continuous BATTERY LOW
Earlier SW Versions: AL66 Flashing
CONDITION
Battery discharged and requires charging.
TRUCK RESPONSE
Hydraulic lift function disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Battery voltage is low.

Charge or replace battery. The battery generally needs 8
hours to charge when fully discharged.
LOGIC
• Controller voltage calibration is incorrect. Controller measures low
Install handset, go to test menu, and select "Battery Voltage." battery voltage over multiple
Compare tester voltage to voltage measured by an accurate checks during traction or
digital voltmeter between B+ and B- terminal. Pull down tiller hydraulic operation.
handle to engage contactor for this measurement. If these
two voltages are more than 1 volt difference, do the following:
• Check for shorts to frame
• Check at the connector
• Check at the contactor

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• check if contactor engaged.

• check the battery parameters with handset

Refer to the section Electrical System 2200YRM1007 for

more information on troubleshooting electrical system circuits
and components.

• If none of previous components solved problem, then replace

controller.

Dash Display Controller LED Handset or PC

AL99 Continuous Flash BATTERY KO
CONDITION
Improper battery connection or defective battery.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Incorrect battery selected.

Verify correct battery voltage for truck.

• Damaged or extremely discharged battery. LOGIC

Disconnect battery and check voltage at connector. Inspect Battery voltage is much less
battery for correct water level and damage. Repair or replace than allowable.
battery.

• Defective or damaged connection to battery.

- Inspect cable crimps and cables from battery to connector.
- Inspect cable crimps and cables from battery contactor to
controller and contactor.

• Verify the voltage on the controller when the main contactor closes.
- If voltage is less than 21V, check the battery, power
connector, fuse, main contactor.
- If is higher than 22V, most likely is the controller.
Refer to the section Electrical System 2200YRM1007 for
more information on troubleshooting electrical system circuits
and components.

Dash Display Controller LED Handset or PC

AL01 1 Flash SERIAL ERROR #1

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CONDITION
Connection/communication error between control card and
traction controller.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Loose or damaged electrical connection between control

card and controller.
Verify connection at controller.
Verify wire harness connection at base of steer
handle.
Verify connection at control card.

• Measure voltage at pin 5, connector C, on the controller. LOGIC

With control card disconnected, this should be about 12V; No information or incorrect information
with the card connected, it should be about 3 to 9V. has been sent from the control card to
controller.
• If problem persists, check the functionality of the control
card. Refer to Control Card Functional Test in this section.

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL21 Earlier SW Versions = 1 Flash INPUT ERROR #1
AL01
CONDITION
Connection/communication error between control card and
traction controller. Belly Switch is not communicating properly.
TRUCK RESPONSE
Traction function disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Traction reversing switch is not connected.

Install handset. Go to tester function. Check for
operation of traction reversing switch.
Verify that traction reversing switch cover is making
contact with switch on control card.
Check wires in control handle arm are secure.

• Check the shield wire connections at the controller and at LOGIC

the tiller card. Ensure connection between controller Traction reversing switch data signal is
connector C, pin 2 and the tiller card. Ensure voltage on not present and hardwire signal is
A5 to alternate between power and ground, when the present.
switch is pressed and released.
• If problem persists, check the functionality of the control
card. Refer to Control Card Functional Test in this section.

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• Test truck functionality after completing the control card

functional test. If all control card test were successfully
passed and truck still does not function, then replace
controller.

Dash Display Controller LED Handset or PC

AL02 2 Flashes CONTACTOR CLOSED OR CONTACTOR
DRIVER
CONDITION
Main contactor circuit is damaged.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Main contactor tips are welded closed.

Disconnect power leads at contactor. Use meter
to confirm open circuit across power terminals.
If short circuit is measured, replace contactor.
LOGIC
• Verify the voltage on the connector D3 to be the same Occurs when the controller detects a
as battery voltage. short in the main contactor circuit.
• Problem in motor field circuit.
Verify electrical connections between motor field
and controller.
Check motor field for shorts to chassis.

Dash Display Controller LED Handset or PC

AL4 4 Flashes EVP NOT OK
CONDITION
Lowering valve will not operate correctly.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Damaged or loose wiring harness or electrical

connection to lowering valve. LOGIC
Occurs if electro-proportional valve is open
Verify electrical connections between valve
before circuit is energized. Valve does not
coil and controller. The negative side of the
follow the supplied signal from controller.
coil should be the same voltage as the
positive side (24V)

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• Lowering coil damaged.

Check lowering valve coil for correct
resistance. Coil resistance should be
approximately 33 ohms (for 24V trucks) or 8
to 10 ohms (for 12V trucks).
Replace coil if damaged.

• F1 and F2 should not be open. Check for clean tips.

• Lowering valve cartridge is damaged.
Replace lowering valve cartridge.

Dash Display Controller LED Handset or PC

AL5 5 Flashes EB DRIVER KO
CONDITION
Electric brake does not release or remains released at all times.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Damaged or loose electrical connection to brake. The voltage on

the electric brake coil negative side is not correct. Ensure that LOGIC
the brake coil is not open. Occurs when brake driver circuit
is shorted or open circuit.
Verify electrical connection between electric brake and
controller.

• Check brake coil for correct coil resistance.

Ensure brake is not dragging. Disconnect brake. Measure
brake coil resistance in both directions. Coil resistance
should be between 25 and 35 ohms (on 24V trucks) or 8
to 10 ohms (on 12V trucks).

• Damaged controller.
Activate the brake switch. Use voltmeter to measure
voltage on wire 2C and 17 with brake connected in circuit.
If both measurements are 24V and the alarm is displayed,
then controller is damaged.

Dash Display Controller LED Handset or PC

AL6 6 Flashes VFIELD NOT OK
CONDITION
Voltage measured at field connections is
not correct.

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TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST
PROCEDURES

• Cable connection to motor field is

loose or damaged.
Verify connection of field wires
to motor and controller.

• Check condition of crimps on wires

connecting to F1 and F2.
LOGIC
This fault occurs when the voltage measured at the field
connections is not the expected value.

Dash Display Controller LED Handset or PC

AL6 6 Flashes I = 0 EVER
CONDITION
Motor current levels do not exceed a preset minimum value while
driving.
TRUCK RESPONSE
Traction and hydraulic function disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Damaged or loose electrical connections to traction motor.

Verify electrical connections between traction motor
and controller.

• Check condition of brushes.

Replace if needed.

• Check condition of commutator. LOGIC

Occurs if while driving, the motor
Stone if necessary. current does not exceed a preset
minimum value.
• Traction motor armature resistance is too low, Check
traction motor armature for shorts.
• Check for F1 and F2 fuses, if an open fuse is found,
replace it. Ensure fuse connections are tight and clean.
• Check for controller damage. Cycle key switch. Place steer
handle in drive position and select throttle. If the truck
starts to drive, but then stops and presents code AL6;
check for loose connections at tiller wire harness, if wire

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harness is good, then replace controller.

Dash Display Controller LED Handset or PC

AL10 6 Flashes HIGH FIELD CURR, BW HIGH FLD
CURR, FW HIGH FLD CURR
CONDITION
High field current values measured by controller.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Field wires are loose, damaged, or shorted.

Verify connection of field wires to motor and
controller.

• Check for shorts between field and chassis.

• Motor field winding is shorted or too low. Check motor field
for correct resistance and continuity. It should measure
approximately 0.5 to 2.0 ohms.
LOGIC
• Failure of current sensor in controller or failure of field Measured field current is too high.
current driver in controller. Replace controller.
• Check for resistance between A1 and A2 to case.
Resistance should read approximately 0.5 mega ohms.
• Check for F1 and F2 not to be open, and to have clean
and tight connections. The resistance across F1 and F2
should be between 0.5 and 2.5 ohms.

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL60 Earlier SW Versions 6 Flashes NO FIELD CURR
= AL6
CONDITION
Low field current values measured by controller.
TRUCK RESPONSE
Traction function disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and
controller.

• Motor field winding is open or too high.

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Check motor field for correct resistance and

continuity. It should measure less than 2 ohms.

• Main contactor circuit damaged or disconnected. LOGIC

Measured field current is too low.
Verify electrical connection between controller and
contactor.
Check contactor coil for correct resistance of 45 to
55 ohms.

• Failure of current sensor in controller or failure of field

current driver in controller. Replace controller.
• Check for resistance between A1 and A2 to case, it should
have approximately 0.5 mega ohms.
• Check the relay.
• Check for F1 and F2 not to be open, and to have clean
and tight connections. The resistance across F1 and F2
should be between 0.5 and 2.5 ohms.

Dash Display Controller Handset or PC

LED
SW Version 1.08 = AL61 Earlier SW 6 Flashes STBY I HIGH
Versions = AL6
CONDITION
Controller detects motor current during standby mode.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Damaged controller.
Replace controller.

LOGIC

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Occurs if controller detects motor currents during

standby mode.

Dash Display Controller LED Handset or PC

AL7 7 Flashes THERMAL PROTECTION
CONDITION
Controller temperature is out of operating range.
TRUCK RESPONSE
Traction functions reduced below -10°C (14°F) and above
75°C (167°F). Traction and hydraulic functions disabled
above 90°C (194°F).
POSSIBLE CAUSES AND TEST PROCEDURES

• Controller temperature is too hot/cold.

If too hot, allow the unit to cool off.
LOGIC
This alarm is generated when the
controller temperature outside is -10 to
75°C (14 to 167°F).

Dash Display Controller LED Handset or PC

AL8 8 Flashes POWER FAILURE #1
CONDITION
Short circuit in device connected to controller.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Overcurrent detected in driven component.

Check main harness for damaged or shorted
connections to main contactor, brake, and electric
valve coils.
Check main contactor, brake, and electric valve coils
for correct resistance values. LOGIC
Occurs when controller detects short
Check contactor coil for correct resistance of 45 to circuit in component driven by
55 ohms. controller.
Check the brake coil for the correct resistance.
Resistance should be between 25 to 35 ohms.
Check the electric valve coils for correct resistance of
27 to 29 ohms. Value should be within ±10% at
room temperature.

• One load is in short circuit. Check for the following:

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- When the tiller switch close, the main contactor coil

is in short circuit.
- When traction is commanded (throttle acceleration),
the electric brake coil is shorted.
- When lowering the forks, the electric valve coil is
shorted.

• If the short is intermittent, the problem can arise in every

time the function is commanded or in active mode; but if
the problem is always present, then problem is the
controller.

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) EEPROM KO
CONDITION
Fault in the memory area where parameters are stored.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Controller damaged.
Cycle key switch OFF and ON. If fault
remains, replace controller.
LOGIC
• Check battery, contactor, relay, and fuses, ensure Occurs if controller discovers fault in the area
appropriate battery voltage, clean and tight of memory where parameters are stored.
connections.

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL11 Earlier SW LED ON (No CAPACITOR CHARGE
Versions = AL10 Flashing)
CONDITION
Main controller capacitors did not charge within 500 ms of key
ON.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Loose or damaged wire connection.

Inspect and confirm wire connections at contactor,
pump motor, and traction motor.

• Failure of current sensor in controller or failure of field LOGIC

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current driver in controller. Occurs when an internal or external

short or open prevents the main
• Check for F1 and F2 not to be open, and to have clean and capacitors from charging at key ON.
tight connections.
• Short circuit in harness.
Disconnect main harness and check for shorts.

• Short circuit in component coil.

Disconnect battery. Disconnect all drive motor, pump
motor, solenoid, brake, and coil connections at the
component end of the harness. Tape or secure the
wire ends to prevent shorts.
Discharge controller by placing 200 ohm, 2W resistor
across B+ and B- terminals. Reconnect battery and
turn key ON. Use voltmeter to observe voltage
across B+ and B-. If there is no voltage increase,
replace controller. If there is a steady voltage
increase to battery voltage, connect each accessory
one at a time until the fault occurs to identify
damaged component.

• Ensure hydraulic motor is not shorted.

Dash Display Controller Handset or PC

LED
SW Version 1.08 = AL12 Earlier SW LED ON (No VMN NOT OK
Versions = AL10 Flashing)
CONDITION
Measured voltage at traction motor inputs does not
match battery voltage.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Loose or damaged cable connections to motor.

Verify motor armature cables and
connections.

• Ground between motor windings and chassis.

Check for grounds between motor
chassis and terminals.

• Voltage at –T terminal on controller should be

the same as the +B terminal. If not, check
cables and traction motor.
• Verify battery condition, charge, and

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connections.
• Check for F1 and F2 connections, if fuse is
found open, replace fuse.
LOGIC
Occurs when controller observes differences
between battery voltage and voltage supplied to
the traction motor.

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL13 Earlier SW Versions LED ON (No VFIELD NOT OK
= AL10 Flashing)
CONDITION
Voltage measured at field connections is not correct.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and
controller.

• Motor field winding is shorted to chassis.

Motor field should be less than 2 ohms.

• Verify battery condition, charge, and connections.

LOGIC

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• Failure of current sensor in controller or failure of field This fault occurs when the voltage
current driver in controller. Replace controller. measured at the field connections is
not the expected value.
• Check for resistance between A1 and A2 to case, it should
have approximately 0.5 mega ohms.
• Check for F1 and F2 not to be open, and to have clean
and tight connections. The resistance across F1 and F2
should be between 0.5 and 2.5 ohms.

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL15 Earlier SW Versions = LED ON (No Flashing) WATCHDOG
AL10
CONDITION
Watchdog hardware circuit is not OK.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES

• Watchdog hardware circuit is damaged.

Cycle key switch OFF then ON. If alarm returns, controller
may be at fault. Contact Resident Service Engineering through
the Contact Management System.
LOGIC
Occurs if the watchdog
hardware circuit is damaged.

Dash Display Controller Handset or PC

LED
SW Version 1.08 = AL14 Earlier LED ON (No Driver Shorted
SW Versions = AL10 Flashing)
CONDITION
Voltage measured at field connections is not
correct.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST
PROCEDURES

• Cable connection to motor field is loose

or damaged.
Verify connection of field wires to
motor and controller.

• Motor field winding is shorted to

chassis.
LOGIC

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Check motor field for shorts to This fault occurs when the voltage measured at the field
chassis. connections is not the expected value.

• Main contactor coil shorted/open.

Check contactor coil for correct
resistance of 45 to 55 ohms.

Dash Display Controller LED Handset or PC

AL94 OFF NONE
CONDITION
Controller is installing hourmeter memory from MDI display
if controller has been replaced.
TRUCK RESPONSE
Traction and hydraulic functions disabled for 1 minute.
POSSIBLE CAUSES AND TEST PROCEDURES

• No fault is occurring.
Controller will send hourmeter data to MDI and
truck will operate as soon as transfer is
complete. Wait approximately 60 seconds.

LOGIC
Synchronize hourmeter data between MDI
and controller.

Control Card Functional Test

Refer to Control Card Functional Test for the following procedures.

1. Follow all safety precautions as listed at the beginning of this section prior to performing any
electrical checks.

2. Ensure Battery is fully charged.

a. Verify continuity between battery negative (at battery) and -B terminal (at controller).

3. Check for loose connections or damaged wiring between control card and controller.

a. Verify connection at the controller.

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b. Very wire harness connection at the base of the steer handle.

4. Connect ZAPI handset and go to tester function. Refer to ZAPI™ PC Interface in this section.

NOTE:  If ZAPI Handset cannot be connected, consult LED OFF. See Troubleshooting in this section.

5. With ZAPI Handset connected, check the following:

a. Look for battery voltage to be 25 ±0.5 volts.

b. Check for accelerator output to be 95% or more at full throttle, and to be at 0% and 0V on neutral
position.

c. Check for lift switch, fork low switch, belly switch, and horn switch to alternate between on and off
when switch is pressed and released. (Ensure belly switch is properly seated.)

(1) If ON-OFF lift/lower switches doesn’t behave as expected, swap the On-Off switch with other On-
Off switch available within tiller head to verify if problem follow the switch.

d. Check lifting control to be more than 90%.

(1) Output of proportional hydraulic controls should be less than 10% at neutral.

(2) If Proportional lift/lower switches doesn’t behave as expected, swap the proportional switch with
other proportional switch available within tiller head to verify if problem follow the switch.

6. If handset test are not passed, open tiller head and verify connection at control card:

a. Power off the forklift and measure continuity between pin 2, on JP2, on the control card and B- at
the controller.

(1) If an open or high resistance is measured, trace problem source and refer to Troubleshooting in
this section.

b. Power on the forklift and check for 7- segment LED to light on.

(1) If the LED is not lit then check to have power on JP2, between pin 1 and pin 2.
i. JP2 voltage reading shall be 14V or more, if not, then the tiller card is not receiving power
from controller. Disconnect the connection at JP1 and verify the voltage between harness
pins 1 and 2 is more than 14V.
a. Check the wiring between the controller and the tiller card, as well as the controller
output.
b. Measure voltage at pin 5, on connector C, on the ZAPI controller. The voltage
should be 12V with card disconnected and 3V to 9V with control card connected. If
voltage is different, please refer to Troubleshooting, LED Off sections.
c. Measure voltage at pin 7, on connector C, on ZAPI controller. It should have 22V or
greater with card disconnected. If voltage is different, please refer to
Troubleshooting, LED Off sections.
d. Reconnect and measure voltage on JP2 again.

ii. If voltage reading is achieved on JP2, and the 7 segment display is not lit, replace the tiller

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card. Refer to the section Electrical System 2200YRM1007.

(2) Ensure jumper on SV2 is not on Diagnose, Teach or Configuration mode. SV2 jumper can be
either seated on parking position (P) or not present at all.

(3) Ensure 7 segment LED displays the proper control handle card setting:
• The proper setting for these models is number 3.
i. If not, proceed to reconfigure card through teach mode following auto-learning procedure
listed in the Electrical System 2200YRM1007 section.

7. If speed is other than desired, refer to Troubleshooting in this section.

NOTE: ENSURE THAT THE CAM MAGNETIC HOLDER IS ALIGNED WITH THE ALIGNMENT WINDOW;
OTHERWISE TRACTION FUNCTIONS WILL NOT OPERATE IN ONE OF THE DIRECTIONS.
1. JUMPER TERMINALS (SV2)
2. HORN SWITCH (S1)
3. THUMBWHEEL SWITCH (CAM MAGNETIC HOLDER)
4. LED DISPLAY SCREEN
5. BELLY SWITCH (S)
6. TURTLE SWITCH (S2)
7. ALIGNMENT WINDOW (CAM MAGNETIC HOLDER)

Figure 5. Control Card

ZAPI™ PC Interface

CONNECTING PC TO ZAPI™ CONTROLLER

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NOTE:  Values used on the following figures are for example only. For the correct values for your truck, see
Controller Parameters in this section.

1. Turn the key switch to the OFF position.

2. Remove the drive unit compartment cover to access the controller.

3. Locate the communications port on the controller. (The port will have either a diagnostic LED, as in
Figure 6, or a connector for the display, as in Figure 7.)

Figure 6. Diagnostic LED

Figure 7. Display Connection

4. Connect the interface cable to the controller and the PC. See Figure 8 and Figure 9.

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Figure 8. Controller Connection

Figure 9. PC Connection

5. Locate the icon for the ZAPI™ software on the PC and double-click on it. See Figure 10.

Figure 10. ZAPI™ Icon

6. You should now see a screen as shown in Figure 11.

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Figure 11. ZAPI™ Software Screen

7. Click on the START button first and then turn the key switch to ON. See Figure 12.

Figure 12. Start Button

8. If the connection was successful, you should now see the screen shown in Figure 13. If you get an
error message, go back to Step 7 and try again.

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Explanation of Screen
Connected To: MPB NA This tells the current software revision.
V1.01
Nominal Voltage: 24V Voltage of the controller installed.
Nominal Current: 180A Maximum operating current of the controller.
Hour: 0h Internal hourmeter of the controller.
Alarm: If there is a current "live" error in the controller, the alarm code will
appear here.
Connection CONNECTED Indicates if the software is communicating with the PC.
Status:

Figure 13. ZAPI™ Software Version Screen

FILE MENU

Open File

When you select this function, you will be able to open a previously saved file that contains parameter
settings for the controller. See Figure 14.

Figure 14. File - Open

Note that the previously saved file has the .csv extension, and observe how the file name was used. See the
Save File section of this manual for proper file saving techniques. See Figure 15.

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Figure 15. Look In:

TX From File

This selection in the file menu is similar to the File Open selection. See Figure 16.

Figure 16. File - TX From File

Notice the CONNECTION STATUS while the file is downloaded into the controller. See Figure 17.

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Figure 17. Connection Status

Save File

The ZAPI™ PC software can save configurations for up to 500 controllers. When saving a configuration to
the PC, the following steps should be followed to help track which file goes with each controller. See
Figure 18.

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Figure 18. File - Save

1. Try to use the actual truck serial number and put the word "settings" after it. (This is to keep the
controller settings file separate from the tester function Save file.) See Figure 19.

Figure 19. Save: In

2. Once you select a file name and click on Save, you will see the screen shown in Figure 20.

Figure 20. Enter a Comment

3. Under the Enter a Comment box, you can either describe what is different with the settings or enter a
customer name.

Here is what a saved parameter file looks like: [Info] Chopper_Name=MPB NA V1.01
User_Comment=modified mode 4 to lower speed and coast more Save_Date=Thu Apr 04
15:58:15 2002 [Code;Name;Position;Menu;Value;Scaled Value]
0;ACCELER.DELAY;0;0;0;LEVEL=0 5;DECELER.DELAY;1;0;9;LEVEL=9 11;RELEASE
BRAKING;2;0;0;LEVEL=9 12;INVERS.BRAKING;3;0;9;LEVEL=9 30;MAX SPEED
FORW;4;0;9;LEVEL=9 31;MAX SPEED BACK;5;0;9;LEVEL=9 248;DRIVE MODES ;01;1;ON [End]
[Validation] Code=FFDA [Stop]

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Print Settings

This selection allows you to print out your current parameter settings in the controller. See Figure 21.

Figure 21. File - Print

Exit

This selection will exit the ZAPI™ PC console software. See Figure 22.

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Figure 22. File - Exit

CONNECTION MENU

There are two selections under this menu:

1. Start - Starts the connection between the controller and PC (operates the same as the main Start
button on the right-hand side of the display screen).
2. Stop - Stops the connection between the controller and PC (operates the same as the main Stop
button on the right-hand side of the display screen).
See Figure 23.

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Figure 23. Connection Menu

FUNCTION MENU

There are seven selections under this menu:

1. Parameter - Allows the performance and configuration of the controller to be adjusted. Refer to
Parameter, in this section.
2. Tester - Allows the testing of various inputs and operations of the controller. Refer to Tester, in this
section.
3. Alarm Logbook - Stores alarms that the controller detects. Refer to Alarm Logbook, in this section.

4. Program VACC - Not Used.

5. Motor Data - Not Used.

6. RAM Function - Only Factory Use.

7. EEPROM Function - Only Factory Use.

Parameter

When you first activate this selection, the screen will look as indicated in Figure 24. In order to see the
parameters of the controller, you have to download them to the PC. This can be done by 1 of 2 ways.
1. Receive menu - This will only download the current selected tab.

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2. Receive - This will download all parameters and configurations to the PC so you can adjust them.

Figure 24. Parameter

You will now see a screen like Figure 25, while the data is being downloaded.

Figure 25. Downloading Screen

Now that the parameters have downloaded, you should see a screen as indicated in Figure 26.

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Figure 26. Drive Mode

Please note that the current drive mode the lift truck was in will be displayed. (There are three modes that
cannot be adjusted.) In order to make any changes to the parameters, you must turn on Mode 4, which is
covered in Set Options, in this section.

Adjustments can be made by first highlighting the parameter to be modified and then using the scroll bar
on the right side of the screen to adjust it.

You will also notice that there are six tabs along the top to choose from:
1. Parameter Change - Allows the performance of the truck to be adjusted.

2. Set Options - Allows the technician to turn on or off mode 4 for personalized performance settings.
See Set Options.
3. Set Model - Not Used.

4. Adjustment - Not Used.

5. Special Adjust - Not Used.

6. Hardware settings - Not Used.

There are six parameters that can be adjusted to affect the performance of the lift truck. See Figure 27.

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Figure 27. Adjustable Parameters

1. ACCELER. DELAY - Amount of ramp-up to full speed.

• Level 0 - Large acceleration curve, up to full speed.
• Level 9 - Short acceleration curve, up to full speed.

2. DECELER. DELAY - Amount of ramp-down to a lower speed.

• Level 0 - Large deceleration curve, to a lower speed (coasting).
• Level 9 - Short deceleration curve, to a lower speed (aggressive).

3. RELEASE BRAKING - Amount of braking when the accelerator is released.

• Level 0 - Minimum braking (coasting).
• Level 9 - Maximum braking (aggressive).

4. INVERSE BRAKING - Amount of braking when the lift truck is "plugged."

• Level 0 - Minimum braking.
• Level 9 - Maximum braking.

5. MAX SPEED FORW - Maximum speed of the lift truck in the handle direction.
• Level 0 - Minimum speed.
• Level 9 - Maximum speed.

6. MAX SPEED BACK - Maximum speed of the lift truck in the forks direction.
• Level 0 - Minimum speed.

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• Level 9 - Maximum speed.

Notice that the ACCELER. DELAY function has been adjusted. The parameter settings are "live," which
means as they are being adjusted. The lift truck will react to the setting. Once the lift truck is performing as
wanted, the Store button is pressed to save the settings into the controller. See Figure 28.

Figure 28. Store Button

NOTE:  If the Store button is not pressed before turning off the lift truck, then all changed parameters will
be lost.

Memory Menu

If you wish to start all over with your adjustments prior to pressing the Store button, then you can select
the Memory menu to see the screen in Figure 29.

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Figure 29. Memory Menu

This menu has three selections:

1. Receive - Same as Receive menu and Receive button.

2. Store - Same as Store button.

3. Restore - Will revert the parameter settings to what they were before adjustments were made. Note
this will not work if the settings were stored before using this function.

Set Options

This selection will allow Mode 4 to be activated, so that the performance parameters can be adjusted for a
custom configuration. See Figure 30.

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Figure 30. Set Options

Highlight Drive Modes and then click on the scroll bar to the right and select OFF. See Figure 31.

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Figure 31. Turn Off Drive Modes

Do the following steps once this has been done:

1. Press the Store button to save the change into the controller.

2. Press the Close button to go to the main screen of the ZAPI™ PC software.

3. Press the Stop button to disconnect the communication between the PC and the controller.

4. Turn the key switch on the lift truck to OFF; then do the reconnect procedure.

5. Now the parameters in the Function Menu can be adjusted to a custom configuration (Mode 4).

Tester

This selection allows the technician to monitor up to four items at a time to help troubleshoot problems. See
Figure 32.

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Figure 32. Tester

The Tester function also features a data-logging capability to further assist the technician and the factory
with problems.

The PC software can test the following (four selections at a time). See Figure 33.
1. Battery Voltage - voltage across the battery.

2. Motor Voltage - voltage across the traction motor.

3. Motor Current - current through the traction motor.

4. Field Current - current through the fields in the traction motor.

5. Temperature - current temperature of the controller.

6. Accelerator - voltage and percent of "throw" from the traction thumbwheel.

7. Lifting Control

8. Tiller Switch - position of tiller handle.

9. Forward Switch - directional input.

10. Backward Switch - directional input.

11. Lifting Switch - refers to switch on right side of tiller head.

12. Lowering Switch - refers to switch on right side of tiller head.

13. Fork Lift Switch - refers to switch on left side of tiller head.

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14. Fork Lower Switch - refers to switch on left side of tiller head.

15. Belly Switch

16. Snail Switch

17. Horn Switch

18. Cutback Switch

19. Lifting Block

20. Battery Model

21. Battery Charge - remaining charge on the battery.

Figure 33. Test Name

Data Logger

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Figure 34. Data Logger

In addition to "live testing" of the controller, the ZAPI™ PC software also includes a data-logging capability.
See Figure 34. There are four buttons associated with this, as listed below.
1. Advanced - Allows the user to select sample rates and length of recording.

2. Start Rec. - Starts the data logger.

3. Stop Rec. - Stops the data logger.

4. Save Rec. - Saves the log to a file.

The Advanced button allows the user to initiate a series of samples to be taken for the 4 items you have
selected in the tester menu. Users can select the desired time intervals between samples (time steps) and
the number of samples to be taken (samples). Time steps are in increments equal to 0.1 seconds. Therefore
a selection of 20 time steps and 50 samples would result in a sample being taken every two seconds until
50 samples have been recorded. See Figure 35.

Figure 35. Tester Advanced

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Figure 36. Logging Process

As the data logger is running, the screen will look like what is shown in Figure 36. During the logging
process, you will still be able to see the values changing in the display menu.

Once the data logger is done, you can save the log using the Save Rec. button. See Figure 37.

Figure 37. Save As

Once the log file has been saved, the user can either analyze the data him/herself or e-mail the file to the

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factory for analysis.

The raw data file looks like this (see Figure 38): [Info] Chopper_Name=CS P20 V1.00 Save_Date=Thu Apr
04 13:32:24 2002 TIME;MOTOR CURRENT;ACCELERATOR;BATTERY CHARGE ;FIELD CURRENT;

0;0;0.00 0;80;0.0;
10;0;0.00 0;80;0.0;
20;0;0.00 0;80;0.0;
30;0;0.00 0;80;0.0;
40;0;0.00 0;80;0.0;
50;0;0.00 0;80;7.2;
60;3;0.00 0;80;7.2;
70;3;0.27 10;80;7.2;
80;3;0.27 10;80;12.7;
90;8;0.53 16;80;12.7;

Figure 38. Test Data

Alarm Logbook

The ZAPI™ controller can record up to five unique alarms and store them in a logbook that the PC can
access. See Figure 39.

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Figure 39. Alarm Logbook

The display screen (Figure 40) will display any current "live" alarms. Note the display ACTUAL ALARM that
indicates a current "live" alarm condition.

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Figure 40. Actual Alarm

The PC software will provide the alarm name and the number of times it has occurred, the temperature of
the controller when the alarm occurred, and the hourmeter reading (internal to the controller) of when the
alarm occurred.

The user can check for new alarms by pressing the Update key or clear out the alarm log by pressing the
Clear key.

The following list consists of possible alarms.

Alarms

1. EVP NOT OK

2. BRAKE DRIVER KO

3. VFIELD NOT OK

4. PUMP VACC NOT OK

5. SERIAL ERROR #1

6. WATCHDOG

7. EEPROM KO

8. FORW + BACK

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9. VMN NOT OK
10. CONTACTOR CLOSED

11. I=0 EVER

12. STBY I HIGH

13. HIGH FIELD CURRENT

14. NO FIELD CURRENT

15. CAPACITOR CHARGE

16. LOW BATTERY

17. THERMAL PROTECTION

18. CHARGING BATTERY

19. POWER FAILURE #1

20. DRIVER SHORTED

21. CONTACTOR DRIVER

22. VACC NOT OK

23. INCORRECT START

24. INPUT ERROR #2

25. INPUT ERROR #1

Repair

REMOVE

1. Park lift truck in a safe, level area.

2. Block drive wheel to prevent lift truck from moving.

3. Connect handset or PC and download parameters, if possible.

4. Turn key to OFF.

5. Disconnect battery.

6. Remove cover.

  WARNING
The capacitors in the controller remain charged for several minutes after operation. To prevent
personal injury and/or damage to equipment, the controller should be discharged. To discharge the
controller, connect a 200-ohm, 2- to 3-watt resistor between the battery positive and negative
terminals on the controller for at least 5 seconds. Refer to Figure 1 in the General section of this

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manual.

7. Discharge controller.

8. Identify and tag all power cables and wires connected to controller for later installation.

9. Remove all power cables and wires connected to controller.

10. Loosen both capscrews retaining controller to plate.

11. Remove controller.

BRASS STUD REPLACEMENT

Remove

1. Remove M8 nut, lockwasher, flat washer, brass washer, power fuse, and brass washer from brass
stud.

2. Remove brass stud from controller.

Install

The stud must be installed in the correct orientation with regard to the relief groove.

1. Install brass stud onto controller and tighten to 10 to 11 N•m (92 to 97 lbf in).

2. Install brass washer, power fuse, brass washer, flat washer, lockwasher, and M8 nut to brass stud.
Tighten M8 nut to 10 to 11 N•m (92 to 97 lbf in).

INSTALL

1. Align controller to plate and capscrews. Tighten capscrews.

2. Connect all power cables and wires connected to controller.

3. Connect battery.

4. Connect handset or PC.

5. Turn key to ON.

6. Upload parameters.

7. Remove blocks from drive wheel.

8. Test lift truck in a safe, level area away from other personnel and equipment.

9. Install cover.

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REPAIR

1. Check and replace fuses as necessary.

2. Check and repair wiring (see troubleshooting guide).

3. Check the battery pack.

4. Check the motors and motor connections.

5. Replace controllers when necessary by following the remove and install procedures listed above.

Connector Pin Outs

Connector A
Connects all the inputs and actuators present on the frame to the controller.
Pin Description
1 Lowering Electrovalve Negative
2 Electrobrake Positive
3 Battery Positive Out to the Key Switch (this is a feed through directly from D2/D4)
4 Horn Negative
5 Electrobrake Negative
6 Key Input
7 Horn Positive
8 Speed Reduction Switch.
9 Lowering Electrovalve Positive
10 Battery Select Bridge (Flooded or Sealed)
11 Optional Lift Stop Switch
12 24V Common for Input Switches

Connector B
This connector is used for the programming console, handset, or the MDI connection. The
controller will function without either of the prior mentioned devices connected.
Pin Description
1 Positive Serial Data Reception
2 Battery Negative
3 12V
4 Negative Serial Data Transmission

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5 Positive Serial Data Transmission

6 Negative Serial Data Reception

Connector C
Tiller connection port. All tiller commands are routed through the tiller card, which
communicates to the controller via serial interface.
Pin Description
1 Negative Battery
2 Belly Switch
3 Hard & Soft (This function is known as "Snail" speed, and allows the truck to be maneuvered at slow
speed with the tiller handle up. It is useful for moving the truck in tight quarters.)
4 Tiller Switch
5 Data Received From Tiller
6 Negative Battery
7 Key Out (24V to power the tiller)
8 Key Out (24V to power the tiller)

Connector D
This connector is used for the main contactor connection. It is factory installed because the
contactor is part of the assembly.
Pin Description
1 Positive MC Coil
2 Battery Positive After Logic Fuse
3 Negative MC Coil
4 Battery Positive After Logic Fuse

Other Connections
Name Symbol Description
Connect to Negative Battery. (Cable is fixed to the post by an M8 bolt (13-
Batt Negative (−B)
13.5 Nm torque))
Batt Possitive (+B) Connect to the Main Contactor. (Use an M6 bolt (4.2 - 4.8 Nm torque)
Pump Negative (−P) Connect to Negative Pump. M8 bolt (13-13.5 Nm)
A2 Connecto to Negative Armature. M8 bolt (13-13.5 Nm)
A1 and Pump Connect After the Power Fuse. M8 bolt (10-11 Nm)
Positive
Field Connect to AMP Receptacle Housing (2 position)

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