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 con-
tained 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 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 re-
move 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 man-
ual:

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 back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS

General ..................................................................................................................................................................... 1
Description ................................................................................................................................................................2
ZAPI™ Transistor Motor Controller ...................................................................................................................... 2
Principles of Operation ......................................................................................................................................... 2
Controller Safety ....................................................................................................................................................... 3
Controller Adjustments ............................................................................................................................................. 4
Modes of Operation .................................................................................................................................................. 4
User-Selectable Operating Modes ....................................................................................................................... 4
Programming ............................................................................................................................................................ 5
Custom Performance Mode ..................................................................................................................................5
Controller Parameters .......................................................................................................................................... 5
Tester Menu ......................................................................................................................................................... 6
Set Option Menu ...................................................................................................................................................7
ZAPI™ Handset ....................................................................................................................................................7
Troubleshooting ...................................................................................................................................................... 10
Control Card Functional Test ..................................................................................................................................34
ZAPI™ PC Interface ............................................................................................................................................... 36
Connecting PC to ZAPI™ Controller .................................................................................................................. 36
File Menu ............................................................................................................................................................39
Open File ........................................................................................................................................................39
TX From File .................................................................................................................................................. 41
Save File ........................................................................................................................................................ 43
Print Settings ..................................................................................................................................................45
Exit ................................................................................................................................................................. 46
Connection Menu ............................................................................................................................................... 47
Function Menu ....................................................................................................................................................48
Parameter ...................................................................................................................................................... 48
Memory Menu ................................................................................................................................................ 54
Set Options .................................................................................................................................................... 55
Tester ............................................................................................................................................................. 57
Data Logger ................................................................................................................................................... 59
Alarm Logbook ............................................................................................................................................... 62
Alarms ............................................................................................................................................................ 64
Repair ..................................................................................................................................................................... 64
Remove .............................................................................................................................................................. 64
Brass Stud Replacement ....................................................................................................................................65
Remove ..........................................................................................................................................................65
Install ..............................................................................................................................................................65
Install .................................................................................................................................................................. 65
Repair ................................................................................................................................................................. 65
Connector Pin Outs ................................................................................................................................................ 66

This section is for the following models:

(MPB040-E) [B827]

©2014 Yale Materials Handling Corp. i

2200 YRM 1006 General

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

1
Description 2200 YRM 1006

Description
ZAPI™ TRANSISTOR MOTOR the fault using a ZAPI™ handset or a properly config-
CONTROLLER ured IBM compatible PC. On trucks equipped with the
optional dash display, the dash wiring harness plugs
The ZAPI™ controller is a solid state DC motor con- into the controller in place of the LED. The display
troller utilizing SEM technology. It controls the traction also has a red LED, however it does not flash codes.
motor, brake, and hydraulic system. The controller re- If a fault occurs, the red LED blinks, the wrench LCD
ceives inputs from the control handle by serial com- is shown and "AL" followed by the fault number is dis-
munication, and direct inputs from the key switch and played.
control handle arm position switch. The controller di-
rectly controls the traction motor, lift pump motor, low- PRINCIPLES OF OPERATION
ering valve, brake, and main contactor. Jumpers are
used to configure the basic controller. The ZAPI™ Transistor Motor Controller uses a so-
phisticated microprocessor to control the logic and op-
The controller software provides self diagnostics eration of the controller, eliminating the need for for-
which are accessed by means of a ZAPI™ handset or ward and reverse contactors. The SEM motor control-
a PC with specialized ZAPI™ software. The controller ler operates on the principle of controlling the motor
software features a Test Menu for monitoring control- field circuit and the motor armature circuit independ-
ler inputs and outputs, a Diagnostic Menu for viewing ently. The controller has many programmable fea-
fault code information, and a Programming Menu for tures, including maximum speed, acceleration rate,
customizing the truck performance. release braking, and braking current limit. The SEM
controller includes a full range of features, as well as
The self diagnostics monitor the traction motor, brake diagnostic and setup capability.
coil, lowering valve coil, contactor coil, control handle
serial communications, controller temperature, and in- NOTE: There are no user-serviceable parts in the
ternal logic functions. The controllers on standard ZAPI™ controller. No attempt should be made to
trucks come equipped with a red LED fault indicator open, repair, or otherwise modify the controller. Doing
located at the bottom of the controller. In the event of so may damage the controller and will void the war-
a fault, the LED flashes a numeric code. Troubleshoot ranty.

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2200 YRM 1006 Controller Safety

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.

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

Figure 2. Discharging Controller MPB040-E

3
Controller Adjustments 2200 YRM 1006

Controller Adjustments
The ZAPI™ transistor motor controller can store and The format is AL XX where XX is the error code.
display Error Codes (Alarms). It is also possible to The software version is displayed on startup.
modify the controller Setup for individual preferences.
Communication with the controller is possible by four 3. ZAPI™ Handset - A diagnostic handset is availa-
methods: ble through your Yale dealer. The handset makes
it possible to diagnose faults and modify controller
1. LED - An LED may be installed in trucks that do settings. See Programming, in this section.
not use a dash display. The LED flashes error co-
4. Personal Computer - The controller can also be
des to the technician for diagnosis. The LED
connected to a personal computer (PC) equipped
would be installed on the bottom of the ZAPI™
with special software and cables. The PC can
controller. The LED is installed in connector port
read, store, and change settings on the controller.
B. See Figure 1.

2. Dash Display - Some trucks are equipped with Proper use of these four methods and a list of diag-
an optional dash display or MDI. Error codes are nostic codes are explained in Troubleshooting, in this
shown on the LCD (liquid crystal display) when section.
the wrench symbol and red light are lit.

Modes of Operation
It is possible to adjust the operating characteristics of 1. The controller drive modes parameter must be
the lift truck. There are two basic ways to do this: ON. This is the factory setting.
User-Selectable and Non-User-Selectable Operating
Modes. NOTE: You must use the handset or PC interface to
change this setting. Using the ZAPI™ handset or PC
USER-SELECTABLE OPERATING MODES connection, it is possible to set the drive mode param-
eters to ON or OFF. In the ON mode, the user-select-
The operator has a choice of three performance able rules are enabled. In the OFF mode, the lift truck
modes that are selectable through the control handle. will only operate using the settings selected. The pro-
The mode selection is made at startup or key ON. cedure to alter or modify these settings is given in
Performance parameters that vary are acceleration, Programming in this section.
deceleration, regenerative (neutral) braking, and top
2. Control handle must be in the full, upright posi-
travel speed.
tion, brake ON.
The three operator-selectable performance modes 3. Press and hold the horn button while turning the
are factory programmed per the following: key switch to the ON position.
• Mode 1 - Economy mode (battery saver) - soft
acceleration, reduced top speed with regenera- 4. Release the horn button when the horn sounds.
tive (neutral) braking. 5. Toggle through the modes by pressing the lift or
• Mode 2 - Performance with regenerative (neu- lower buttons to the desired mode.
tral) braking - medium acceleration, reduced
top travel speed with regenerative (neutral) 6. The horn provides an audible indication as to the
braking. mode selected. One beep indicates Mode 1, two
beeps indicate Mode 2, and three beeps indicate
• Mode 3 - Performance without regenerative
Mode 3.
(neutral) braking - maximum acceleration, max-
imum top travel speed with coast at throttle re- 7. Lower the control handle to the operating position,
lease. brake OFF, and begin operation.

The following procedure is used to access the user- 8. The selected mode is maintained until the proce-
selectable operating modes: dure is repeated.

4
2200 YRM 1006 Programming

9. Turning the key OFF before lowering the control

handle will cancel the mode change.

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
Figure 3. ZAPI™ Handset
Parameters are controller settings that can be adjus-
ted to alter the performance characteristics of the
truck. 7. Press buttons 1 and 5 simultaneously.

To adjust parameters and install custom drive set- 8. The screen will display CONFIG MENU.
tings, Drive Modes must be OFF. To set Drive Modes
to OFF, use the following procedure: 9. Scroll through the menus using button 1 or 2 to
the SET OPTIONS menu.
1. Turn key switch OFF. 10. Enter this menu by pressing button 3.
2. Remove drive unit compartment cover. 11. Press button 5 or 6 to set Drive Modes to OFF.
3. Connect adapter harness to handset. 12. Press button 4 to exit this menu.
NOTE: It may be necessary to remove the MDI har- 13. The handset will prompt, "Are you sure?"
ness connector from the controller to install the
adapter harness. 14. Press ENTER (button 3) to retain settings.
NOTE: Connect and disconnect the handset only 15. Press OUT (button 4) to discard settings.
with the key switch in the OFF position.
16. Turn the key switch OFF to save the drive modes
4. Connect adapter harness to controller. OFF parameter change.
5. Turn key switch ON. 17. Turn the key switch ON to enter the MAIN MENU
and change the parameters outlined in Table 1.
6. The handset will turn ON. See Figure 3.

5
Programming 2200 YRM 1006

Table 1. Parameters

Parameter Description Value and Affect

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

10. BACKWARD SWITCH = backward direction re-

TESTER MENU quest from control handle card, ON/OFF.

The most important input or output signals can be 11. CUTBACK SWITCH 1 = speed reduction switch
measured in real time using the TESTER function of input, ON/OFF (closed switch = OFF = no speed
the handset. The handset acts as a multimeter to read reduction).
voltage, current, temperature, switch state, and other
functions. 12. LIFTING SWITCH = lifting function request from
control handle card, ON/OFF.
1. BATTERY VOLTAGE = battery voltage, nominal
13. LOWERING SWITCH = lowering function request
value = 24V, V.
from control handle card, ON/OFF.
2. MOTOR VOLTAGE = motor voltage obtained
14. FORK LIFT SWITCH = i - lift request from control
VBATT - VMN, V.
handle card, ON/OFF.
3. MOTOR CURRENT = armature current during
15. FORK LOW SWITCH = i - lift request from control
traction (positive value) or braking (negative
handle card, ON/OFF.
value).
16. BELLY SWITCH = belly input switch to the con-
4. FIELD CURRENT = field current in the selected
troller or belly request from control handle card,
traction direction.
ON/OFF.
5. TEMPERATURE = controller temperature, °C.
17. HARD & SOFT = snail request from control han-
6. ACCELERATOR = traction potentiometer value dle card allows machine to drive with control han-
received from control handle. dle up, ON/OFF.

7. LIFTING CONTROL = lifting/lowering potentiome- 18. HORN SWITCH = horn request from control han-
ter value received from control handle. dle card, ON/OFF.

8. CONTROL HANDLE SWITCH = control handle 19. LIFTING BLOCK = lifting block input switch,
switch input, ON/OFF. ON/OFF (with LIFTING BLOCK option program-
med OFF).
9. FORWARD SWITCH = forward direction request
from control handle card, ON/OFF.

6
2200 YRM 1006 Programming

20. BATTERY MODEL = battery-type of input switch, 1 Roll-Up Push to scroll up.
ON/OFF. ON = flooded battery (input closed),
OFF = sealed battery (input open). 2 Roll-Down Push to scroll down.
3 Enter Push to enter a submenu
21. BATTERY CHARGE = battery charge indication, or to confirm a change.
%.
4 Out Push to exit a selected
SET OPTION MENU menu or to refuse a
change.
DRIVE ON The truck has three performance 5 Set-Up Push to increase a pa-
MODES modes, each with a fixed set of rameter value.
parameters. This function is ena-
bled by setting DRIVE MODES = 6 Set-Down Push to decrease a pa-
ON. rameter value.

OFF DRIVE MODES disabled. NOTE: After a modification, save the new values by
pushing out, then enter to confirm. (Screen prompts
ZAPI™ HANDSET will guide the user.)

The ZAPI™ handset must be connected to the con- To navigate the menu options, numbers inside the tri-
troller before turning on the key. The handset must angles in the following map correspond to the same
have an adapter harness to connect to the controller. number on the handset keyboard buttons. The orien-
The handset and adapter harness are available from tation of the triangle indicates the way to the next
your Yale dealer. Connect the handset to plug B. The function. See Figure 3.
handset can remain connected to the controller while
running, and the parameters can be changed in real NOTE: Connect and disconnect the handset only
time. In this case, it is necessary to go in a standby with the key switch in the OFF position.
condition (truck at rest) before switching OFF the con-
troller in order to store the new values in the EE- For additional handset description, see Figure 4.
PROM.

This section describes the ZAPI™ handset functions.

Six buttons provide the capability of changing or read-
ing the parameters.

7
Programming 2200 YRM 1006

8
2200 YRM 1006 Programming

Figure 4. ZAPI™ Handset Instructions

9
Troubleshooting 2200 YRM 1006

Troubleshooting

Dash Display Controller LED Handset or PC

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

CORRESPONDING SCHEMATIC SHOWING CIR-

CUITS TO BE CHECKED OR AFFECTED COMPO-
NENT(S)

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

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

10
2200 YRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

No LEDs or LCDs illu- LED OFF Handset does not operate
minated
CONDITION
Dash display, controller LED, and truck inop-
erative.
TRUCK RESPONSE
Travel and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCE-
DURES
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 batter-
ies negative (at battery) and -B
power wire connection (at con-
troller).
If no continuity, check:
Power wiring between battery
and controller.
Check for +24V at D-4, A-3, and
A-6.
If no continuity, check:
LOGIC
Fuse 2 for open.
Occurs when there is no power to the controller or the controller
Key switch continuity in ON po- is defective.
sition.
Wiring battery + to main contac-
tor 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.

11
Troubleshooting 2200 YRM 1006

Dash Display Controller LED Handset or PC

No LEDs or LCDs illumina- LED OFF No error codes present
ted
CONDITION
Dash display and/or controller LED inoperative.
TRUCK RESPONSE
Travel and hydraulic functions normal.
POSSIBLE CAUSES AND TEST PROCEDURES
Open connection between
• dash display and con-
troller.
Verify harness connections at MDI and
connector B on controller.
Verify continuity of wires between MDI
and controller.
Defective• dash display. LOGIC
Connect handset to controller and confirm Occurs when the MDI or LED receives no signal, or
communication to handset. MDI or LED are damaged.
If handset operates correctly, replace MDI.
Defective
• LED.
Disconnect LED and connect handset. If
handset works, replace LED.

12
2200 YRM 1006 Troubleshooting

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 revers-
ing 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 hy-
draulic 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 verti-
cal position. If steer handle is in vertical position
and reading is not OFF, check brake switch for
damage, interference, or shorts.
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. Re-
place damaged or faulty buttons.
Verify that the wiring to
• the tiller card is ok. Use
the handset to verify the belly switch is working
properly. For tiller card troubleshooting proce- LOGIC
dures, refer to Control Card Functional Test in Fault occurs when controller receives input that has not
this section. followed the proper operational sequence.

13
Troubleshooting 2200 YRM 1006

Dash Display Controller LED Handset or PC

SW Version 1.08: Last bat- Continuous Flashing BATTERY LOW
tery indicator light flashing.
Earlier SW Versions: AL66
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.
Controller voltage •calibration is incorrect.
Install handset, go to test menu, and se-
LOGIC
lect "Battery Voltage." Compare tester
Controller measures low battery voltage over multiple
voltage to voltage measured by an accu-
checks during traction or hydraulic operation.
rate digital voltmeter between B+ and B-
terminal. Pull down tiller handle to engage
contactor for this measurement. If these
two voltages are more than 1 volt differ-
ence, do the following:
Check for •shorts to frame
Check at •the connector
Check at•the contactor
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.

14
2200 YRM 1006 Troubleshooting

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.
Disconnect battery and check voltage at
connector. Inspect battery for correct wa-
ter level and damage. Repair or replace
LOGIC
battery.
Battery voltage is much less than allowable.
Defective or damaged
• connection to battery.
Inspect cable crimps
- and cables from bat-
tery to connector.
Inspect cable crimps- and cables from bat-
tery contactor to controller and contactor.
Verify the voltage on• the controller when the
main contactor closes.
If voltage is less than
- 21V, check the bat-
tery, power connector, fuse, main contac-
tor.
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.

15
Troubleshooting 2200 YRM 1006

Dash Display Controller LED Handset or PC

AL01 1 Flash SERIAL ERROR #1
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. With control card disconnected, this
should be about 12V; with the card connected, it
should be about 3 to 9V.
If problem persists, check
• the functionality of the LOGIC
control card. Refer to Control Card Functional No information or incorrect information has been sent
Test in this section. from the control card to controller.

16
2200 YRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL21 1 Flash INPUT ERROR #1
Earlier SW Versions =
AL01
CONDITION
Connection/communication error between control card
and traction controller. Belly Switch is not communicat-
ing 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 se-
cure.
Check the shield wire •connections at the control-
LOGIC
ler and at the tiller card. Ensure connection be-
Traction reversing switch data signal is not present and
tween controller connector C, pin 2 and the tiller
hardwire signal is present.
card. Ensure voltage on A5 to alternate between
power and ground, when the switch is pressed
and released.
If problem persists, check
• the functionality of the
control card. Refer to Control Card Functional
Test in this section.
Test truck functionality• after completing the con-
trol card functional test. If all control card test
were successfully passed and truck still does not
function, then replace controller.

17
Troubleshooting 2200 YRM 1006

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 con-
tactor.
Verify the voltage on the
• connector D3 to be the
same as battery voltage. LOGIC
Problem in motor
• field circuit. Occurs when the controller detects a short in the main
contactor circuit.
Verify electrical connections between mo-
tor field and controller.
Check motor field for shorts to chassis.

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2200 YRM 1006 Troubleshooting

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.
Verify electrical connections between
valve coil and controller. The negative LOGIC
side of the coil should be the same volt- Occurs if electro-proportional valve is open before cir-
age as the positive side (24V) cuit is energized. Valve does not follow the supplied
signal from controller.
Lowering •coil damaged.
Check lowering valve coil for correct re-
sistance. Coil resistance should be ap-
proximately 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.

19
Troubleshooting 2200 YRM 1006

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 the brake coil is LOGIC
not open. Occurs when brake driver circuit is shorted or open cir-
Verify electrical connection between elec- cuit.
tric 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.

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2200 YRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

AL6 6 Flashes VFIELD NOT OK
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 dam-
aged.
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.

21
Troubleshooting 2200 YRM 1006

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 trac-
tion motor.
Verify electrical connections between trac-
tion motor and controller.
Check condition
• of brushes.
Replace if needed.
Check condition
• of commutator.
Stone if necessary.
Traction motor armature
• resistance is too low,
Check traction motor armature for shorts. LOGIC
Occurs if while driving, the motor current does not ex-
Check for F1 and F2• fuses, if an open fuse is
ceed a preset minimum value.
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 connec-
tions at tiller wire harness, if wire harness is
good, then replace controller.

22
2200 YRM 1006 Troubleshooting

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.
Failure of current sensor
• in controller or failure of
field current driver in controller. Replace control-
ler.
Check for resistance
• between A1 and A2 to LOGIC
case. Resistance should read approximately 0.5 Measured field current is too high.
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.

23
Troubleshooting 2200 YRM 1006

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL60 6 Flashes NO FIELD CURR
Earlier SW Versions = 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 dam-
aged.
Verify connection of field wires to motor
and controller.
Motor field winding
• is open or too high.
Check motor field for correct resistance
and continuity. It should measure less
than 2 ohms.
Main contactor circuit •damaged or disconnected.
Verify electrical connection between con-
troller and contactor. LOGIC
Check contactor coil for correct resistance Measured field current is too low.
of 45 to 55 ohms.
Failure of current sensor
• in controller or failure of
field current driver in controller. Replace control-
ler.
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.

24
2200 YRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL61 6 Flashes STBY I HIGH
Earlier SW 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
Occurs if controller detects motor currents during
standby mode.

25
Troubleshooting 2200 YRM 1006

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 tempera-
ture outside is -10 to 75°C (14 to 167°F).

26
2200 YRM 1006 Troubleshooting

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 shor-
ted connections to main contactor, brake,
and electric valve coils.
Check main contactor, brake, and electric
valve coils for correct resistance values.
Check contactor coil for correct resistance
of 45 to 55 ohms. LOGIC
Check the brake coil for the correct resist- Occurs when controller detects short circuit in compo-
ance. Resistance should be between 25 to nent driven by controller.
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 follow-
ing:
When the tiller switch
- close, the main con-
tactor coil is in short circuit.
When traction is commanded
- (throttle ac-
celeration), the electric brake coil is shor-
ted.
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 ac-
tive mode; but if the problem is always present,
then problem is the controller.

27
Troubleshooting 2200 YRM 1006

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 re-
mains, replace controller.
Check battery, contactor,
• relay, and fuses, en-
sure appropriate battery voltage, clean and tight
connections.
LOGIC
Occurs if controller discovers fault in the area of mem-
ory where parameters are stored.

28
2200 YRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL11 LED ON (No Flashing) CAPACITOR CHARGE
Earlier SW Versions =
AL10
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 mo-
tor.
Failure of current sensor
• in controller or failure of
field current driver in controller.
Check for F1 and F2 not
• to be open, and to have LOGIC
clean and tight connections. Occurs when an internal or external short or open pre-
Short circuit
• in harness. vents the main capacitors from charging at key ON.
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, re-
place controller. If there is a steady volt-
age increase to battery voltage, connect
each accessory one at a time until the
fault occurs to identify damaged compo-
nent.
Ensure hydraulic• motor is not shorted.

29
Troubleshooting 2200 YRM 1006

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL12 LED ON (No Flashing) VMN NOT OK
Earlier SW Versions =
AL10
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 connec-
tions.
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 connec-
tions.
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 mo-
tor.

30
2200 YRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL13 LED ON (No Flashing) VFIELD NOT OK
Earlier SW Versions =
AL10
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 dam-
aged.
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 connec-
tions.
Failure of current sensor
• in controller or failure of
field current driver in controller. Replace control-
ler. LOGIC
Check for resistance
• between A1 and A2 to This fault occurs when the voltage measured at the
case, it should have approximately 0.5 mega field connections is not the expected value.
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.

31
Troubleshooting 2200 YRM 1006

Dash Display Controller LED Handset or PC

SW Version 1.08 = AL15 LED ON (No Flashing) WATCHDOG
Earlier SW Versions =
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 LED Handset or PC

SW Version 1.08 = AL14 LED ON (No Flashing) Driver Shorted
Earlier SW Versions =
AL10
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 dam-
aged.
Verify connection of field wires to motor
and controller.
Motor field winding• is shorted to chassis.
Check motor field for shorts to chassis.
Main contactor• coil shorted/open.
Check contactor coil for correct resistance
of 45 to 55 ohms.

LOGIC
This fault occurs when the voltage measured at the
field connections is not the expected value.

32
2200 YRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

AL94 OFF NONE
CONDITION
Controller is installing hourmeter memory from MDI dis-
play 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 sec-
onds.

LOGIC
Synchronize hourmeter data between MDI and control-
ler.

33
Control Card Functional Test 2200 YRM 1006

Control Card Functional Test

Refer to Control Card Functional Test for the following (2) If Proportional lift/lower switches doesn’t
procedures. behave as expected, swap the proportional
switch with other proportional switch avail-
1. Follow all safety precautions as listed at the be- able within tiller head to verify if problem
ginning of this section prior to performing any follow the switch.
electrical checks.
6. If handset test are not passed, open tiller head
2. Ensure Battery is fully charged. and verify connection at control card:

a. Verify continuity between battery negative (at a. Power off the forklift and measure continuity
battery) and -B terminal (at controller). between pin 2, on JP2, on the control card and
B- at the controller.
3. Check for loose connections or damaged wiring
between control card and controller. (1) If an open or high resistance is measured,
trace problem source and refer to Trouble-
a. Verify connection at the controller. shooting in this section.
b. Very wire harness connection at the base of b. Power on the forklift and check for 7- segment
the steer handle. LED to light on.
4. Connect ZAPI handset and go to tester function. (1) If the LED is not lit then check to have
Refer to ZAPI™ PC Interface in this section. power on JP2, between pin 1 and pin 2.
NOTE: If ZAPI Handset cannot be connected, con- i. JP2 voltage reading shall be 14V or
sult LED OFF. See Troubleshooting in this section. more, if not, then the tiller card is not
receiving power from controller. Dis-
5. With ZAPI Handset connected, check the follow- connect the connection at JP1 and
ing: verify the voltage between harness
pins 1 and 2 is more than 14V.
a. Look for battery voltage to be 25 ±0.5 volts.
a. Check the wiring between the
b. Check for accelerator output to be 95% or controller and the tiller card,
more at full throttle, and to be at 0% and 0V on as well as the controller out-
neutral position. put.
b. Measure voltage at pin 5, on
c. Check for lift switch, fork low switch, belly
connector C, on the ZAPI
switch, and horn switch to alternate between
controller. The voltage should
on and off when switch is pressed and re-
be 12V with card disconnec-
leased. (Ensure belly switch is properly
ted and 3V to 9V with control
seated.)
card connected. If voltage is
(1) If ON-OFF lift/lower switches doesn’t be- different, please refer to
have as expected, swap the On-Off switch Troubleshooting, LED Off
with other On-Off switch available within sections.
tiller head to verify if problem follow the c. Measure voltage at pin 7, on
switch. connector C, on ZAPI control-
ler. It should have 22V or
d. Check lifting control to be more than 90%. greater with card disconnec-
ted. If voltage is different,
(1) Output of proportional hydraulic controls
please refer to Troubleshoot-
should be less than 10% at neutral.
ing, LED Off sections.

34
2200 YRM 1006 Control Card Functional Test

d. Reconnect and measure volt- (3) Ensure 7 segment LED displays the proper
age on JP2 again. control handle card setting:
ii. If voltage reading is achieved on • The proper setting for these models
JP2, and the 7 segment display is is number 3.
not lit, replace the tiller card. Refer i. If not, proceed to reconfigure card
to the section Electrical System through teach mode following auto-
2200YRM1007. learning procedure listed in the
Electrical System 2200YRM1007
(2) Ensure jumper on SV2 is not on Diagnose,
section.
Teach or Configuration mode. SV2 jumper
can be either seated on parking position 7. If speed is other than desired, refer to Trouble-
(P) or not present at all. shooting in this section.

NOTE: ENSURE THAT THE CAM MAGNETIC HOLDER IS ALIGNED WITH THE ALIGNMENT WINDOW; OTH-
ERWISE 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

35
ZAPI™ PC Interface 2200 YRM 1006

ZAPI™ PC Interface
CONNECTING PC TO ZAPI™
CONTROLLER
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 ac-

cess 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 Fig- Figure 8. Controller Connection
ure 7.)

Figure 6. Diagnostic LED

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

Figure 7. Display Connection

6. You should now see a screen as shown in Fig-

4. Connect the interface cable to the controller and ure 11.
the PC. See Figure 8 and Figure 9.

36
2200 YRM 1006 ZAPI™ PC Interface

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

37
ZAPI™ PC Interface 2200 YRM 1006

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.

Explanation of Screen
Connected To: MPB NA V1.01 This tells the current software revi-
sion.
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 ap-
pear here.
Connection Status: CONNECTED Indicates if the software is communi-
cating with the PC.

Figure 13. ZAPI™ Software Version Screen

38
2200 YRM 1006 ZAPI™ PC Interface

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

39
ZAPI™ PC Interface 2200 YRM 1006

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

Figure 15. Look In:

40
2200 YRM 1006 ZAPI™ PC Interface

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

41
ZAPI™ PC Interface 2200 YRM 1006

Notice the CONNECTION STATUS while the file is

downloaded into the controller. See Figure 17.

Figure 17. Connection Status

42
2200 YRM 1006 ZAPI™ PC Interface

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 Fig-
ure 18.

Figure 18. File - Save

43
ZAPI™ PC Interface 2200 YRM 1006

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 [Link];1;0;9;LEVEL=9 11;RELEASE
describe what is different with the settings or en- BRAKING;2;0;0;LEVEL=9 12;[Link];
ter a customer name. 3;0;9;LEVEL=9 30;MAX SPEED FORW;
4;0;9;LEVEL=9 31;MAX SPEED BACK;
Here is what a saved parameter file looks like: [Info] 5;0;9;LEVEL=9 248;DRIVE MODES ;01;1;ON [End]
Chopper_Name=MPB NA V1.01 User_Com- [Validation] Code=FFDA [Stop]
ment=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;[Link];0;0;0;LEVEL=0 5;DE-

44
2200 YRM 1006 ZAPI™ PC Interface

Print Settings

This selection allows you to print out your current pa-

rameter settings in the controller. See Figure 21.

Figure 21. File - Print

45
ZAPI™ PC Interface 2200 YRM 1006

Exit

This selection will exit the ZAPI™ PC console soft-

ware. See Figure 22.

Figure 22. File - Exit

46
2200 YRM 1006 ZAPI™ PC Interface

CONNECTION MENU 2. Stop - Stops the connection between the con-

troller and PC (operates the same as the main
There are two selections under this menu: Stop button on the right-hand side of the dis-
1. Start - Starts the connection between the con- play screen).
troller and PC (operates the same as the main See Figure 23.
Start button on the right-hand side of the dis-
play screen).

Figure 23. Connection Menu

47
ZAPI™ PC Interface 2200 YRM 1006

FUNCTION MENU 6. RAM Function - Only Factory Use.

7. EEPROM Function - Only Factory Use.
There are seven selections under this menu:
1. Parameter - Allows the performance and con- Parameter
figuration of the controller to be adjusted. Refer
to Parameter, in this section. When you first activate this selection, the screen will
2. Tester - Allows the testing of various inputs look as indicated in Figure 24. In order to see the pa-
and operations of the controller. Refer to rameters of the controller, you have to download them
Tester, in this section. to the PC. This can be done by 1 of 2 ways.

3. Alarm Logbook - Stores alarms that the con- 1. Receive menu - This will only download the
troller detects. Refer to Alarm Logbook, in this current selected tab.
section. 2. Receive - This will download all parameters
4. Program VACC - Not Used. and configurations to the PC so you can adjust
them.
5. Motor Data - Not Used.

Figure 24. Parameter

48
2200 YRM 1006 ZAPI™ PC Interface

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

Figure 25. Downloading Screen

49
ZAPI™ PC Interface 2200 YRM 1006

Now that the parameters have downloaded, you

should see a screen as indicated in Figure 26.

Figure 26. Drive Mode

50
2200 YRM 1006 ZAPI™ PC Interface

Please note that the current drive mode the lift truck • Level 9 - Short acceleration curve, up to
was in will be displayed. (There are three modes that full speed.
cannot be adjusted.) In order to make any changes to
the parameters, you must turn on Mode 4, which is 2. DECELER. DELAY - Amount of ramp-down to a
covered in Set Options, in this section. lower speed.
• Level 0 - Large deceleration curve, to a
Adjustments can be made by first highlighting the pa- lower speed (coasting).
rameter to be modified and then using the scroll bar • Level 9 - Short deceleration curve, to a
on the right side of the screen to adjust it. lower speed (aggressive).
You will also notice that there are six tabs along the 3. RELEASE BRAKING - Amount of braking when
top to choose from: the accelerator is released.
1. Parameter Change - Allows the performance • Level 0 - Minimum braking (coasting).
of the truck to be adjusted.
• Level 9 - Maximum braking (aggressive).
2. Set Options - Allows the technician to turn on
or off mode 4 for personalized performance 4. INVERSE BRAKING - Amount of braking when
settings. See Set Options. the lift truck is "plugged."
3. Set Model - Not Used. • Level 0 - Minimum braking.
4. Adjustment - Not Used. • Level 9 - Maximum braking.
5. Special Adjust - Not Used. 5. MAX SPEED FORW - Maximum speed of the lift
6. Hardware settings - Not Used. truck in the handle direction.
• Level 0 - Minimum speed.
There are six parameters that can be adjusted to af-
fect the performance of the lift truck. See Figure 27. • Level 9 - Maximum speed.

6. MAX SPEED BACK - Maximum speed of the lift

1. ACCELER. DELAY - Amount of ramp-up to full truck in the forks direction.
speed.
• Level 0 - Minimum speed.
• Level 0 - Large acceleration curve, up to
full speed. • Level 9 - Maximum speed.

51
ZAPI™ PC Interface 2200 YRM 1006

Figure 27. Adjustable Parameters

52
2200 YRM 1006 ZAPI™ PC Interface

Notice that the ACCELER. DELAY function has been NOTE: If the Store button is not pressed before turn-
adjusted. The parameter settings are "live," which ing off the lift truck, then all changed parameters will
means as they are being adjusted. The lift truck will be lost.
react to the setting. Once the lift truck is performing as
wanted, the Store button is pressed to save the set-
tings into the controller. See Figure 28.

Figure 28. Store Button

53
ZAPI™ PC Interface 2200 YRM 1006

Memory Menu 2. Store - Same as Store button.

3. Restore - Will revert the parameter settings to
If you wish to start all over with your adjustments prior what they were before adjustments were
to pressing the Store button, then you can select the made. Note this will not work if the settings
Memory menu to see the screen in Figure 29. were stored before using this function.

This menu has three selections:

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

Figure 29. Memory Menu

54
2200 YRM 1006 ZAPI™ PC Interface

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.

Figure 30. Set Options

55
ZAPI™ PC Interface 2200 YRM 1006

Highlight Drive Modes and then click on the scroll bar 3. Press the Stop button to disconnect the com-
to the right and select OFF. See Figure 31. munication between the PC and the controller.
4. Turn the key switch on the lift truck to OFF;
Do the following steps once this has been done: then do the reconnect procedure.
1. Press the Store button to save the change into 5. Now the parameters in the Function Menu can
the controller. be adjusted to a custom configuration (Mode
2. Press the Close button to go to the main 4).
screen of the ZAPI™ PC software.

Figure 31. Turn Off Drive Modes

56
2200 YRM 1006 ZAPI™ PC Interface

Tester

This selection allows the technician to monitor up to

four items at a time to help troubleshoot problems.
See Figure 32.

Figure 32. Tester

The Tester function also features a data-logging ca- 6. Accelerator - voltage and percent of "throw"
pability to further assist the technician and the factory from the traction thumbwheel.
with problems. 7. Lifting Control

The PC software can test the following (four selec- 8. Tiller Switch - position of tiller handle.
tions at a time). See Figure 33. 9. Forward Switch - directional input.
1. Battery Voltage - voltage across the battery. 10. Backward Switch - directional input.
2. Motor Voltage - voltage across the traction 11. Lifting Switch - refers to switch on right side
motor. of tiller head.
3. Motor Current - current through the traction 12. Lowering Switch - refers to switch on right
motor. side of tiller head.
4. Field Current - current through the fields in the 13. Fork Lift Switch - refers to switch on left side
traction motor. of tiller head.
5. Temperature - current temperature of the con- 14. Fork Lower Switch - refers to switch on left
troller. side of tiller head.

57
ZAPI™ PC Interface 2200 YRM 1006

15. Belly Switch 19. Lifting Block

16. Snail Switch 20. Battery Model
17. Horn Switch 21. Battery Charge - remaining charge on the bat-
18. Cutback Switch tery.

Figure 33. Test Name

58
2200 YRM 1006 ZAPI™ PC Interface

Data Logger

Figure 34. Data Logger

In addition to "live testing" of the controller, the The Advanced button allows the user to initiate a ser-
ZAPI™ PC software also includes a data-logging ca- ies of samples to be taken for the 4 items you have
pability. See Figure 34. There are four buttons associ- selected in the tester menu. Users can select the de-
ated with this, as listed below. sired time intervals between samples (time steps) and
1. Advanced - Allows the user to select sample the number of samples to be taken (samples). Time
rates and length of recording. steps are in increments equal to 0.1 seconds. There-
fore a selection of 20 time steps and 50 samples
2. Start Rec. - Starts the data logger. would result in a sample being taken every two sec-
3. Stop Rec. - Stops the data logger. onds until 50 samples have been recorded. See Fig-
4. Save Rec. - Saves the log to a file. ure 35.

Figure 35. Tester Advanced

59
ZAPI™ PC Interface 2200 YRM 1006

As the data logger is running, the screen will look like Once the data logger is done, you can save the log
what is shown in Figure 36. During the logging proc- using the Save Rec. button. See Figure 37.
ess, you will still be able to see the values changing in
the display menu.

Figure 36. Logging Process

60
2200 YRM 1006 ZAPI™ PC Interface

Figure 37. Save As

Once the log file has been saved, the user can either 0;0;0.00 0;80;0.0;
analyze the data him/herself or e-mail the file to the
factory for analysis. 10;0;0.00 0;80;0.0;
20;0;0.00 0;80;0.0;
The raw data file looks like this (see Figure 38): [Info] 30;0;0.00 0;80;0.0;
Chopper_Name=CS P20 V1.00 Save_Date=Thu Apr
04 13:32:24 2002 TIME;MOTOR CURRENT;ACCEL- 40;0;0.00 0;80;0.0;
ERATOR;BATTERY CHARGE ;FIELD CURRENT; 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

61
ZAPI™ PC Interface 2200 YRM 1006

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.

Figure 39. Alarm Logbook

62
2200 YRM 1006 ZAPI™ PC Interface

The display screen (Figure 40) will display any current

"live" alarms. Note the display ACTUAL ALARM that
indicates a current "live" alarm condition.

Figure 40. Actual Alarm

63
Repair 2200 YRM 1006

The PC software will provide the alarm name and the 9. VMN NOT OK
number of times it has occurred, the temperature of 10. CONTACTOR CLOSED
the controller when the alarm occurred, and the hour-
meter reading (internal to the controller) of when the 11. I=0 EVER
alarm occurred. 12. STBY I HIGH
13. HIGH FIELD CURRENT
The user can check for new alarms by pressing the
Update key or clear out the alarm log by pressing the 14. NO FIELD CURRENT
Clear key. 15. CAPACITOR CHARGE
16. LOW BATTERY
The following list consists of possible alarms.
17. THERMAL PROTECTION
Alarms 18. CHARGING BATTERY
19. POWER FAILURE #1
1. EVP NOT OK
20. DRIVER SHORTED
2. BRAKE DRIVER KO
21. CONTACTOR DRIVER
3. VFIELD NOT OK
22. VACC NOT OK
4. PUMP VACC NOT OK
23. INCORRECT START
5. SERIAL ERROR #1
24. INPUT ERROR #2
6. WATCHDOG
25. INPUT ERROR #1
7. EEPROM KO
8. FORW + BACK

Repair
REMOVE controller should be discharged. To discharge the
controller, connect a 200-ohm, 2- to 3-watt resis-
1. Park lift truck in a safe, level area. tor between the battery positive and negative ter-
minals on the controller for at least 5 seconds.
2. Block drive wheel to prevent lift truck from mov-
Refer to Figure 1 in the General section of this
ing.
manual.
3. Connect handset or PC and download parame-
7. Discharge controller.
ters, if possible.
8. Identify and tag all power cables and wires con-
4. Turn key to OFF.
nected to controller for later installation.
5. Disconnect battery.
9. Remove all power cables and wires connected to
6. Remove cover. controller.

10. Loosen both capscrews retaining controller to

WARNING plate.
The capacitors in the controller remain charged
11. Remove controller.
for several minutes after operation. To prevent
personal injury and/or damage to equipment, the

64
2200 YRM 1006 Repair

BRASS STUD REPLACEMENT 3. Connect battery.

Remove 4. Connect handset or PC.

1. Remove M8 nut, lockwasher, flat washer, brass 5. Turn key to ON.

washer, power fuse, and brass washer from brass
6. Upload parameters.
stud.
7. Remove blocks from drive wheel.
2. Remove brass stud from controller.
8. Test lift truck in a safe, level area away from other
Install personnel and equipment.

The stud must be installed in the correct orientation 9. Install cover.

with regard to the relief groove.
REPAIR
1. Install brass stud onto controller and tighten to 10
1. Check and replace fuses as necessary.
to 11 N•m (92 to 97 lbf in).
2. Check and repair wiring (see troubleshooting
2. Install brass washer, power fuse, brass washer,
guide).
flat washer, lockwasher, and M8 nut to brass
stud. Tighten M8 nut to 10 to 11 N•m (92 to 3. Check the battery pack.
97 lbf in).
4. Check the motors and motor connections.
INSTALL
5. Replace controllers when necessary by following
1. Align controller to plate and capscrews. Tighten the remove and install procedures listed above.
capscrews.

2. Connect all power cables and wires connected to

controller.

65
Connector Pin Outs 2200 YRM 1006

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
5 Positive Serial Data Transmission
6 Negative Serial Data Reception

66
2200 YRM 1006 Connector Pin Outs

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 (13-13.5 Nm
Batt Negative (−B)
torque))
Batt Possitive (+B) Connect to the Main Contactor. (Use an M6 bolt (4.2 - 4.8 Nm torque)
Pump Nega-
(−P) Connect to Negative Pump. M8 bolt (13-13.5 Nm)
tive
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)

67
 NOTES

68
2200 YRM 1006 3/14 (8/10)(12/09)(9/09)(11/07)(8/05)