ZAPI™ CONTROLLERS

W45Z [C215];
W50Z [D215]

PART NO. 1540377 2200 SRM 1067

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 Mainte-
nance 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 HYSTER 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause 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.
ZAPI™ Controllers Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
ZAPI™ Transistor Motor Controller............................................................................................................. 2
Principles of Operation.................................................................................................................................. 3
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............................................................................................................................................ 6
ZAPI™ Handset............................................................................................................................................. 7
Troubleshooting.................................................................................................................................................. 10
ZAPI™ PC Interface .......................................................................................................................................... 33
Connecting PC to ZAPI™ Controller............................................................................................................ 33
File Menu ....................................................................................................................................................... 36
Open File.................................................................................................................................................... 36
TX From File ............................................................................................................................................. 37
Save File .................................................................................................................................................... 39
Print Settings ............................................................................................................................................ 41
Exit............................................................................................................................................................. 42
Connection Menu ........................................................................................................................................... 43
Function Menu............................................................................................................................................... 43
Parameter .................................................................................................................................................. 44
Memory Menu............................................................................................................................................ 48
Set Options ................................................................................................................................................ 49
Tester.......................................................................................................................................................... 51
Data Logger ............................................................................................................................................... 53
Alarm Logbook .......................................................................................................................................... 56
Alarms........................................................................................................................................................ 57
Repair ................................................................................................................................................................. 58
Remove ........................................................................................................................................................... 58
Brass Stud Replacement ............................................................................................................................... 58
Remove....................................................................................................................................................... 58
Install ......................................................................................................................................................... 58
Install ............................................................................................................................................................. 58
Repair ............................................................................................................................................................. 58

This section is for the following models:

W45Z [C215];
W50Z [D215]

©2007 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1067 General

General
This section describes the ZAPI™ transistor motor safety, adjustments, troubleshooting, and repairs.
controller. Procedures are outlined for controller See Figure 2.

Figure 1. Controller W40Z

1
Description 2200 SRM 1067

Figure 2. Controller W45Z and W50Z

Description
ZAPI™ TRANSISTOR MOTOR controller inputs and outputs, a Diagnostic Menu for
CONTROLLER viewing fault code information, and a Programming
Menu for customizing the truck performance.
The ZAPI™ controller is a solid-state DC motor
controller utilizing SEM technology. It controls the The self diagnostics monitor the traction motor,
traction motor, brake, and hydraulic system. The brake coil, lowering valve coil, contactor coil, control
controller receives inputs from the control handle by handle serial communications, controller tempera-
serial communication, and direct inputs from the key ture, and internal logic functions. The controllers on
switch and control handle arm position switch. The standard trucks come equipped with a red LED fault
controller directly controls the traction motor, lift indicator located at the bottom of the controller. In
pump motor, lift valve, proportional lowering valve, the event of a fault, the LED flashes a numeric code.
brake, and main contactor. Additional hydraulic Troubleshoot the fault using a ZAPI™ handset or a
functions, such as reach, sideshift, and tilt are con- properly configured IBM compatible PC. On trucks
trolled through an auxiliary relay board mounted equipped with the optional dash display, the dash
to the front of the controller. Jumpers are used to wiring harness plugs into the controller in place of
configure the basic controller and the controller with the LED. The display also has a red LED, however,
auxiliary relay board for different truck models. it does not flash codes. If a fault occurs, the red LED
blinks, the wrench LCD is shown, and "AL" followed
The controller software provides self diagnostics by the fault number is displayed.
which are accessed by means of a ZAPI™ handset
or a PC with specialized ZAPI™ software. The con-
troller software features a Test Menu for monitoring

2
2200 SRM 1067 Controller Safety

PRINCIPLES OF OPERATION acceleration rate, release braking, and braking

current limit. The SEM controller includes a full
The ZAPI™ transistor motor controller uses a so- range of features, as well as diagnostic and setup
phisticated microprocessor to control the logic and capability.
operation of the controller, eliminating the need for
forward and reverse contactors. The SEM motor NOTE: There are no user-serviceable parts in the
controller operates on the principle of controlling ZAPI™ controller. No attempt should be made to
the motor field circuit and the motor armature open, repair, or otherwise modify the controller.
circuit independently. The controller has many Doing so may damage the controller and will void
programmable features, including maximum speed, the warranty.

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

See Figure 3.

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

Figure 3. Discharging Controller W45Z and

W45Z

3
Modes of Operation 2200 SRM 1067

Controller Adjustments
The ZAPI™ transistor motor controller can store 3. ZAPI™ Handset - A diagnostic handset is avail-
and display Error Codes (Alarms). It is also pos- able through your Hyster dealer. The handset
sible to modify the controller Setup for individual makes it possible to diagnose faults and mod-
preferences. Communication with the controller is ify controller settings. See Programming, in this
possible by four methods: section.

1. LED - An LED may be installed in trucks that 4. Personal Computer - The controller can also be
do not use a display. The LED can flash error connected to a personal computer (PC) equipped
codes to the technician for diagnosis. The LED with special software and cables. The PC can
would be installed on the bottom of the ZAPI™ read, store, and change settings on the controller.
controller. On the W45Z and W50Z, connector
port D is used. See Figure 2. Proper use of these four methods and a list of diag-
nostic codes are explained in Troubleshooting, in this
2. Dash Display - Some trucks are equipped with section.
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 for-
mat is AL XX where XX is the error code.

Modes of Operation
It is possible to adjust the operating characteristics NOTE: You must use the handset or PC interface to
of the lift truck. There are two basic ways to do this: change this setting. Using the ZAPI™ handset or PC
User-Selectable and Non-User-Selectable Operating connection, it is possible to set the drive mode param-
Modes. eters to ON or OFF. In the ON mode, the user-se-
lectable rules are enabled. In the OFF mode, the lift
USER-SELECTABLE OPERATING MODES truck will only operate using the settings selected.
The procedure to alter or modify these settings is
The operator has a choice of three performance given in Programming in this section.
modes that are selectable through the control han-
dle. The mode selection is made at startup or key 2. Control handle must be in the full, upright posi-
ON. Performance parameters that vary are acceler- tion, brake ON.
ation, deceleration, regenerative (neutral) braking,
and top travel speed. 3. Press and hold the horn button while turning the
key switch to the ON position.
The three operator-selectable performance modes
are factory programmed per the following: 4. Release the horn button when the horn sounds.
• Mode 1 - Economy mode (battery saver) - soft
5. Toggle through the modes by pressing the lift or
acceleration, reduced top speed with regenerative
lower buttons to the desired mode.
(neutral) braking.
• Mode 2 - Performance with regenerative (neutral) 6. The horn provides an audible indication as to the
braking - medium acceleration, reduced top travel mode selected. One beep indicates Mode 1, two
speed with regenerative (neutral) braking. beeps indicate Mode 2, and three beeps indicate
• Mode 3 - Performance without regenerative (neu- Mode 3.
tral) braking - maximum acceleration, maximum
top travel speed with coast at throttle release. 7. Lower the control handle to the operating posi-
tion, brake OFF, and begin operation.
The following procedure is used to access the user-
selectable operating modes: 8. The selected mode is maintained until the proce-
dure is repeated.
1. The controller drive modes parameter must be
ON. This is the factory setting. 9. Turning the key OFF before lowering the control
handle will cancel the mode change.

4
2200 SRM 1067 Programming

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 4. ZAPI™ Handset

Parameters are controller settings that can be ad- 7. Press buttons 1 and 5 simultaneously.
justed to alter the performance characteristics of the
truck. 8. The screen will display CONFIG MENU.

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

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 0 = soft braking
regenerative braking when throttle 9 = strong braking
is released. This determines coast
distance.
INVERSE BRAKING Adjusts plugging rate. 0 = long or soft plugging
9 = short or rapid plugging

5
Programming 2200 SRM 1067

Table 1. Parameters (Continued)

Parameter Description Value and Affect

MAX SPEED FORW Adjusts maximum speed in forward 0 = minimum
direction, forks trailing. 9 = maximum
MAX SPEED BACK Adjusts maximum speed in reverse 0 = minimum
direction, forks leading. 9 = maximum

TESTER MENU 13. LOWERING SWITCH = lowering function re-

quest from control handle card, ON/OFF.
The most important input or output signals can be
measured in real time using the TESTER function 14. FORK LIFT SWITCH = i - lift request from con-
of the handset. The handset acts as a multimeter to trol handle card, ON/OFF.
read voltage, current, temperature, switch state, and
other functions. 15. FORK LOW SWITCH = i - lift request from con-
trol handle card, ON/OFF.
1. BATTERY VOLTAGE = battery voltage, nominal
value = 24V, V. 16. BELLY SWITCH = belly input switch to the con-
troller or belly request from control handle card,
2. MOTOR VOLTAGE = motor voltage obtained ON/OFF.
VBATT - VMN, V.
17. HARD & SOFT = snail request from control
3. MOTOR CURRENT = armature current during handle card allows machine to drive with control
traction (positive value) or braking (negative handle up, ON/OFF.
value).
18. HORN SWITCH = horn request from control
4. FIELD CURRENT = field current in the selected handle card, ON/OFF.
traction direction.
19. LIFTING BLOCK = lifting block input switch,
5. TEMPERATURE = controller temperature, C. ON/OFF (with LIFTING BLOCK option pro-
grammed OFF).
6. ACCELERATOR = traction potentiometer value
received from control handle. 20. BATTERY MODEL = battery-type of input
switch, ON/OFF. ON = flooded battery (input
7. LIFTING CONTROL = lifting/lowering poten- closed), OFF = sealed battery (input open).
tiometer value received from control handle.
21. BATTERY CHARGE = battery charge indication,
8. CONTROL HANDLE SWITCH = control handle %.
switch input, ON/OFF.
SET OPTION MENU
9. FORWARD SWITCH = forward direction request
from control handle card, ON/OFF. DRIVE ON The truck has three
MODES performance modes, each
10. BACKWARD SWITCH = backward direction re-
with a fixed set of parameters.
quest from control handle card, ON/OFF.
This function is enabled by
11. CUTBACK SWITCH 1 = speed reduction switch setting DRIVE MODES = ON.
input, ON/OFF (closed switch = OFF = no speed OFF DRIVE MODES disabled.
reduction).

12. LIFTING SWITCH = lifting function request

from control handle card, ON/OFF.

6
2200 SRM 1067 Programming

ZAPI™ HANDSET 4 Out Push to exit a selected

menu or to refuse a
The ZAPI™ handset must be connected to the con-
change.
troller before turning on the key. The handset must
have an adapter harness to connect to the controller. 5 Set-Up Push to increase a
The handset and adapter harness are available from parameter value.
your Hyster dealer. Connect the handset to plug B. 6 Set-Down Push to decrease a
The handset can remain connected to the controller parameter value.
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 NOTE: After a modification, save the new values by
OFF the controller in order to store the new values pushing out, then enter to confirm. (Screen prompts
in the EEPROM. will guide the user.)

This section describes the ZAPI™ handset functions. To navigate the menu options, numbers inside the
Six buttons provide the capability of changing or triangles in the following map correspond to the same
reading the parameters. number on the handset keyboard buttons. The ori-
entation of the triangle indicates the way to the next
1 Roll-Up Push to scroll up. function. See Figure 4.
2 Roll-Down Push to scroll down. NOTE: Connect and disconnect the handset only with
3 Enter Push to enter a the key switch in the OFF position.
submenu or to confirm For additional handset description, see Figure 5.
a change.

7
Programming 2200 SRM 1067

8
2200 SRM 1067 Programming

Figure 5. ZAPI™ Handset Instructions

9
Troubleshooting 2200 SRM 1067

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 (Trucks without dash Message displayed on Handset or PC
optional dash display) display)
CORRESPONDING SCHEMATIC SHOWING
CIRCUITS TO BE CHECKED

CONDITION OR
TRUCK RESPONSE AFFECTED COMPONENT
POSSIBLE CAUSES AND TEST PROCEDURES LOGIC

NOTE: General error code information is provided by the Dash Display and Red LED at the base of the con-
troller. 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 SRM 1067 Troubleshooting

Dash Display Controller LED Handset or PC - 12V

No LEDs or LCDs LED OFF Handset does not operate
illuminated
CONDITION
Dash display, controller LED, and truck inoperative.
TRUCK RESPONSE
Travel and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• B+ and/or B missing at controller.
Confirm battery is connected and of proper volt-
age.
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 con-
troller).
If no continuity, check:
Power wiring between battery and controller.
Verify continuity between battery positive (at
battery) and B-1 and B-12 connection (at con-
troller).
If no continuity, check:
Fuse 2 for open.
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.
• Defective motor controller. LOGIC
Check for battery voltage between A-6 and B
power wire connection at controller. Occurs when there is no
If correct battery voltage, replace controller. power to the controller or the controller is defective.

11
Troubleshooting 2200 SRM 1067

Dash Display Controller LED Handset or PC - 24V

No LEDs or LCDs LED OFF Handset does not operate
illuminated
CONDITION
Dash display, controller LED, and truck inoperative.
TRUCK RESPONSE
Travel and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• B+ and/or B missing at controller.
Confirm battery is connected and of proper volt-
age.
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 con-
troller).
If no continuity, check:
Power wiring between battery and controller.
Verify continuity between battery positive (at
battery) and B-1 and B-12 connection (at con-
troller).
If no continuity, check:
Fuse 2 for open.
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. LOGIC
Use test lead to connect 2D and 12.
If truck operates, check charger fuses, repair or Occurs when there is no
replace battery charger. power to the controller or the controller is defective.
• Defective motor controller.
Check for battery voltage between A-6 and B
power wire connection at controller.
If correct battery voltage, replace controller.

12
2200 SRM 1067 Troubleshooting

Dash Display Controller LED Handset or PC

No LEDs or LCDs LED OFF No error codes present
illuminated
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
D on controller.
Verify continuity of wires between MDI and con-
troller.
• Defective dash display.
Connect handset to controller and confirm com- LOGIC
munication to handset.
If handset operates correctly, replace MDI. Occurs when the MDI or
• Defective LED. LED receives no signal, or MDI
Disconnect LED and connect handset. If handset or LED are damaged.
works, replace LED.

Dash Display Controller LED Handset or PC

No LEDs or LCDs LED OFF NO COMMUNICATION
illuminated
CONDITION
Dash display and/or controller LED inoperative.
TRUCK RESPONSE
Travel and hydraulic functions normal.
POSSIBLE CAUSES AND TEST PROCEDURES
• Defective controller.
Connect handset to controller and confirm com-
munication to handset.
If handset will not communicate with controller,
replace controller.

LOGIC

Occurs when controller

does not send a signal to the MDI or LED.

13
Troubleshooting 2200 SRM 1067

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 at key ON.
Steer handle in run position at key ON.
Return steer handle to full upright position. Re-
turn throttle to neutral. Release all hydraulic
function controls.
If fault remains, attach handset and go to test
menu.
• Check brake switch, it should be off. 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 LOGIC
correct the problem, replace control card.
• Check hydraulic inputs – Should be 0 volts. If not, Fault occurs when
recalibrate tiller card. Follow auto-learn procedure controller receives input that has not followed
listed in steering. If this does not clear fault, check the proper operational sequence.
buttons for damage or interference. Replace dam-
aged or faulty buttons.

14
2200 SRM 1067 Troubleshooting

Dash Display Controller LED Handset or PC

AL66 Continuous Flashing BATTERY LOW
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.
• Controller voltage calibration is incorrect.
Install handset. Go to test menu and select
Battery Voltage. Compare tester voltage to volt-
age measured by an accurate digital voltmeter
between B+ and B terminals. Pull down tiller
handle to engage contactor for this measure-
ment. If these two voltages are more than 1.5 LOGIC
volts difference, replace controller.
Controller measures low
battery voltage over multiple checks during
traction or hydraulic operation.

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 connec-
tor. Inspect battery for correct water level and
damage. Repair or replace battery.
• Defective or damaged connection to battery.
Inspect cable crimps and cables from battery to
connector. LOGIC
Inspect cable crimps and cables from battery con-
tactor to controller and contactor. Battery voltage is much
less than allowable.

15
Troubleshooting 2200 SRM 1067

Dash Display Controller LED Handset or PC

AL01 1 Flash VACC NOT OK
CONDITION
Connection/communication error between tiller
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Control card throttle calibration is out of range.
Install handset. Go to tester function of handset.
If accelerator output is >1V (20%) and the enable LOGIC
switch is open, recalibrate control card.
• Control card throttle damaged or defective. Occurs when accelerator
If card cannot be recalibrated, replace card. voltage from serial control card is higher than
1V (20%) before neutral switch is closed.

Dash Display Controller LED Handset or PC

AL01 1 Flash PUMP VACC NOT OK
CONDITION
Connection/communication error between control
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• A lift/lower switch is damaged or defective.
Install handset. Go to tester function. Check
lifting control and EVP voltage. Check on/off LOGIC
switches and proportional switches for smooth,
linear operation. Replace damaged switches. Occurs if the output of
• Control card lift/lower switch calibration is out of one on the hydraulic controls is higher
range. than 1V (20%) at start.
Install handset. Go to tester function. Check lift-
ing control and EVP voltage. Output of propor-
tional hydraulic controls should be less than 1V
(20%) at neutral.
Recalibrate control card.
• Control card is damaged or defective.
Replace card.

16
2200 SRM 1067 Troubleshooting

Dash Display Controller LED Handset or PC

AL01 1 Flash FORW + BACK
CONDITION
Connection/communication error between control
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Control card throttle device is damaged or defective.
Install handset. Go to tester function. If forward
switch and backward switch are both on at the LOGIC
same time, card is damaged.
Replace control card. Occurs if controller
receives signal for forward and reverse
directions simultaneously.

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.
• Damaged or defective control card.
Measure voltage at pin 5, connector C, on the
controller. With control card disconnected, this LOGIC
should be about 12V; with the card connected, it
should be about 5V. 0V or 12V with the card con- No information or
nected means that the card is damaged. incorrect information has been sent from
Replace control card. the control card to controller.

17
Troubleshooting 2200 SRM 1067

Dash Display Controller LED Handset or PC

AL01 1 Flash INPUT ERROR #1
CONDITION
Connection/communication error between control
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions 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. LOGIC
Verify that traction reversing switch cover is
making contact with switch on control card. Control card is not
Check wires in control handle arm are secure. sending digital signal for the
• Damaged or defective control card. traction-reversing switch.
Replace control card.

Dash Display Controller LED Handset or PC

AL01 1 Flash INPUT ERROR #2
CONDITION
Connection/communication error between control
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions 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.
• Damaged or defective cable.
Check steer handle control cable for loose connec-
tions or broken wires.
• Damaged or defective tiller card. LOGIC
Replace control card.
Control card is not
sending hard-wired signal from
traction-reversing switch to controller.

18
2200 SRM 1067 Troubleshooting

Dash Display Controller LED Handset or PC

AL01 1 Flash BATTERY CHARGING
CONDITION
Controller waits in standby mode while a
battery charger is connected.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• A battery charger is connected.
Disconnect or shut down battery changer. LOGIC
• Controller is damaged.
Install handset. Go to tester function. Look at Controller inputs
SW7 while installing and removing connector E. indicate a battery charger is connected.
This input should cycle between ON and OFF. If
this does not occur, replace controller.

Dash Display Controller LED Handset or PC - 12V

AL02 2 Flashes CONTACTOR CLOSED
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.
• Problem in motor field circuit.
Verify electrical connections between motor field LOGIC
and controller.
Check motor field for shorts to chassis. Occurs when the
• Controller is damaged. controller detects a short in the
Replace controller. main contactor circuit.

19
Troubleshooting 2200 SRM 1067

Dash Display Controller LED Handset or PC - 24V

AL02 2 Flashes CONTACTOR CLOSED
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.
• Problem in motor field circuit.
Verify electrical connections between motor field LOGIC
and controller.
Check motor field for shorts to chassis. Occurs when the
• Controller is damaged. controller detects a short in the
Replace controller. main contactor circuit.

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 electrical connection to lowering
valve.
Verify electrical connections between valve coil
and controller.
• Lowering coil damaged.
Check lowering valve coil for correct resistance.
Coil resistance should be approximately 33 ohms.
Replace coil if damaged.
• Lowering valve cartridge is damaged.
Replace lowering valve cartridge. LOGIC

Occurs if electro-propor-
tional valve is open before circuit is energized. Valve
does not follow the supplied signal from controller.

20
2200 SRM 1067 Troubleshooting

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.
Verify electrical connection between electric
brake and controller.
• Check brake coil for correct coil resistance.
Disconnect brake. Measure brake coil resistance
in both directions. Coil resistance should be be- LOGIC
tween 28-32 ohms.
• Damaged fly-back diode at brake. Occurs when brake
Check coil resistance. Short circuit measured at driver circuit is shorted or open circuit.
brake connector may indicate a damaged diode.
Cut one lead of diode and check with meter. If
damaged, replace diode.
• 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.

21
Troubleshooting 2200 SRM 1067

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 damaged.
Verify connection of field wires to motor and con-
troller.
• 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.
• Traction motor armature resistance is too low.
Check traction motor armature for shorts.
• Controller is damaged.
Cycle key switch. Place steer handle in drive po-
sition and select throttle. If the truck starts to
drive but then stops and presents code AL6, re- LOGIC
place controller.
Occurs if while driving,
the motor current does not exceed
a preset minimum value.

22
2200 SRM 1067 Troubleshooting

Dash Display Controller LED Handset or PC

AL6 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 con-
troller.
• Motor field winding is shorted or too low.
Check motor field for correct resistance and
continuity. It should measure approximately 0.5
ohms.
• Failure of current sensor in controller.
Replace controller.
• Failure of field current driver in controller.
Replace controller. LOGIC

Measured field current

is too high.

23
Troubleshooting 2200 SRM 1067

Dash Display Controller LED Handset or PC

AL6 6 Flashes NO FIELD CURR
CONDITION
Low field current values measured by controller.
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 con-
troller.
• Motor field winding is open or too high.
Check motor field for correct resistance and
continuity. It should measure approximately 0.5
ohms.
• Field current sensor in controller has failed.
Replace controller.
• Main contactor circuit damaged or disconnected.
Verify electrical connection between controller LOGIC
and contactor.
Check contactor coil for correct resistance of 22.0 Measured field current
ohms. is too low.
• Field current drivers in controller are damaged.
Replace controller.

Dash Display Controller LED Handset or PC

AL6 6 Flashes STBY I HIGH
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.

24
2200 SRM 1067 Troubleshooting

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.
Move truck to cooler or warmer location and al-
low controller to return to operating tempera-
ture.
• Controller temperature miscalibrated.
Install handset. Go to tester function and check
temperature. Controller and vehicle tempera- LOGIC
ture should be same as room temperature at ini-
tial startup. If these temperatures differ, replace This alarm is generated
controller. when the controller temperature outside
• Controller temperature sensor damaged. is 10 to 75 C (14 to 167 F).
Replace controller.
• Controller damaged.
Replace controller.

25
Troubleshooting 2200 SRM 1067

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 con-
nections to main contactor, brake, and electric
valve coils.
Check main contactor, brake, and electric valve LOGIC
coils for correct resistance values.
Check contactor coil for correct resistance of 22.0 Occurs when controller
ohms. detects short circuit in component
Check the brake coil for the correct resistance. driven by controller.
Resistance should be between 27.36 and 30.24
ohms.
Check the electric valve coils for correct resis-
tance of 17.7 ohms.

Value should be within ±10% at room temperature.

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) EEPROM KO
CONDITION
Fault in the memory area where param-
eters 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

Occurs if controller
discovers fault in the area of memory
where parameters are stored.

26
2200 SRM 1067 Troubleshooting

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) CAPACITOR CHARGE
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 contac-
tor, pump motor, and traction motor.
• Short circuit in harness. LOGIC
Disconnect main harness and check for shorts.
• Short circuit in component coil. Occurs when an internal
Disconnect battery. Disconnect all drive motor, or external short or open prevents the main
pump motor, solenoid, brake, and coil connec- capacitors from charging at key ON.
tions at the component end of the harness. Tape
or secure the wire ends to prevent shorts.
Discharge controller by placing 200 ohm, 2W re-
sistor across B+ and B terminals. Reconnect
battery and turn key ON. Use voltmeter to ob-
serve voltage across B+ and B . If there is no
voltage increase, replace controller. If there is a
steady voltage increase to battery voltage, con-
nect each accessory one at a time until the fault
occurs to identify damaged component.
• Damaged controller.
Replace controller.

27
Troubleshooting 2200 SRM 1067

Dash Display Controller LED Handset or PC - 12V

AL10 LED ON (No Flashing) VMN NOT OK
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.
• Damaged controller.
Voltage at –T terminal on controller should be the
same as the +B terminal.
Replace controller.

LOGIC

Occurs when controller

observes differences between battery voltage
and voltage supplied to the traction motor.

28
2200 SRM 1067 Troubleshooting

Dash Display Controller LED Handset or PC - 24V

AL10 LED ON (No Flashing) VMN NOT OK
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.
• Damaged controller.
Voltage at –T terminal on controller should be the
same as the +B terminal.
Replace controller.

LOGIC

Occurs when controller

observes differences between battery voltage
and voltage supplied to the traction motor.

29
Troubleshooting 2200 SRM 1067

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) 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 damaged.
Verify connection of field wires to motor and con-
troller.
• Motor field winding is shorted to chassis.
Check motor field for shorts to chassis.
Measure motor field resistance. Motor field
should be approximately 0.5 ohms.
• Field current driver circuit has failed.
Use a voltmeter to measure between F1 and B
and F2 and B with battery connected and key
ON. Voltage should measure 1/2 the voltage be- LOGIC
tween B+ and B .
Replace controller. This fault occurs when
• Field current drivers in controller are damaged. the voltage measured at the field connections
Replace controller. Verify motor field cable con- is not the expected value.
nections.

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) WATCHDOG
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,
replace controller.

LOGIC

Occurs if the watchdog

hardware circuit is damaged.

30
2200 SRM 1067 Troubleshooting

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) Driver Shorted
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 con-
troller.
• Motor field winding is shorted to chassis.
Check motor field for shorts to chassis.
Measure motor field resistance. Motor field
should be approximately 0.5 ohms.
• Main contactor coil shorted/open.
Check contactor coil for correct resistance of 22.0
ohms.
• Field current driver circuit has failed. LOGIC
Use a voltmeter to measure between F1 and B
and F2 and B with battery connected and key This fault occurs when
ON. Voltage should measure 1/2 the voltage be- the voltage measured at the field connections
tween B+ and B . is not the expected value.
Replace controller.
• Field current drivers in controller are damaged.
Replace controller. Verify motor field cable con-
nections.

31
Troubleshooting 2200 SRM 1067

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.

32
2200 SRM 1067 ZAPI™ PC Interface

ZAPI™ PC Interface
CONNECTING PC TO ZAPI™ 4. Connect the interface cable to the controller and
CONTROLLER the PC. See Figure 8 and Figure 9.

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 con-

troller. (The port will have either a diagnostic
LED, as in Figure 6, or a connector for the dis-
play, as in Figure 7.)
Figure 8. Controller Connection

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 7. Display Connection Figure 10. ZAPI™ Icon

33
ZAPI™ PC Interface 2200 SRM 1067

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

ure 11.

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

34
2200 SRM 1067 ZAPI™ PC Interface

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
revision.
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 Status: CONNECTED Indicates if the software is
communicating with the PC.

Figure 13. ZAPI™ Software Version Screen

35
ZAPI™ PC Interface 2200 SRM 1067

FILE MENU
Open File
When you select this function, you will be able to
open a previously saved file that contains parame-
ter settings for the controller. See Figure 14.

Figure 14. File - Open

36
2200 SRM 1067 ZAPI™ PC Interface

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

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

37
ZAPI™ PC Interface 2200 SRM 1067

Notice the CONNECTION STATUS while the file is

downloaded into the controller. See Figure 17.

Figure 17. Connection Status

38
2200 SRM 1067 ZAPI™ PC Interface

Save File to the PC, the following steps should be followed to

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

Figure 18. File - Save

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

Figure 19. Save: In

39
ZAPI™ PC Interface 2200 SRM 1067

2. Once you select a file name and click on Save, you 0;ACCELER.DELAY;0;0;0;LEVEL=0
will see the screen shown in Figure 20. 5;DECELER.DELAY;1;0;9;LEVEL=9
11;RELEASE BRAKING;2;0;0;LEVEL=9
3. Under the Enter a Comment box, you can either 12;INVERS.BRAKING;3;0;9;LEVEL=9
describe what is different with the settings or en- 30;MAX SPEED FORW;4;0;9;LEVEL=9
ter a customer name. 31;MAX SPEED BACK;5;0;9;LEVEL=9
248;DRIVE MODES ;01;1;ON
Here is what a saved parameter file looks like:
[End]
[Info]
Chopper_Name=MPB NA V1.01
[Validation]
User_Comment=modified mode 4 to lower
Code=FFDA
speed and coast more
[Stop]
Save_Date=Thu Apr 04 15:58:15 2002

[Code;Name;Position;Menu;Value;Scaled
Value]

Figure 20. Enter a Comment

40
2200 SRM 1067 ZAPI™ PC Interface

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

Figure 21. File - Print

41
ZAPI™ PC Interface 2200 SRM 1067

Exit
This selection will exit the ZAPI™ PC console soft-
ware. See Figure 22.

Figure 22. File - Exit

42
2200 SRM 1067 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 display
1. Start - Starts the connection between the con- screen).
troller and PC (operates the same as the main See Figure 23.
Start button on the right-hand side of the display
screen).

Figure 23. Connection Menu

FUNCTION MENU 3. Alarm Logbook - Stores alarms that the con-

troller detects. Refer to Alarm Logbook, in this
There are seven selections under this menu: section.
1. Parameter - Allows the performance and config- 4. Program VACC - Not Used.
uration of the controller to be adjusted. Refer to 5. Motor Data - Not Used.
Parameter, in this section. 6. Ram Function - Only Factory Use.
2. Tester - Allows the testing of various inputs and 7. EEPROM Function - Only Factory Use.
operations of the controller. Refer to Tester, in
this section.

43
ZAPI™ PC Interface 2200 SRM 1067

Parameter 1. Receive menu - This will only download the cur-

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

Figure 24. Parameter

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

Figure 25. Downloading Screen

44
2200 SRM 1067 ZAPI™ PC Interface

Now that the parameters have downloaded, you You will also notice that there are six tabs along the
should see a screen as indicated in Figure 26. top to choose from:
1. Parameter Change - Allows the performance of
Please note that the current drive mode the lift truck the truck to be adjusted.
was in will be displayed. (There are three modes that 2. Set Options - Allows the technician to turn on or
cannot be adjusted.) In order to make any changes to off mode 4 for personalized performance settings.
the parameters, you must turn on Mode 4, which is See Set Options.
covered in Set Options, in this section. 3. Set Model - Not Used.
4. Adjustment - Not Used.
Adjustments can be made by first highlighting the
5. Special Adjust - Not Used.
parameter to be modified and then using the scroll
6. Hardware settings - Not Used.
bar on the right side of the screen to adjust it.

Figure 26. Drive Mode

45
ZAPI™ PC Interface 2200 SRM 1067

There are six parameters that can be adjusted to af- • Level 0 - Minimum braking (coasting).
fect the performance of the lift truck. See Figure 27. • Level 9 - Maximum braking (aggressive).

1. ACCELER. DELAY - Amount of ramp-up to full 4. INVERSE BRAKING - Amount of braking

speed. when the lift truck is "plugged."
• Level 0 - Large acceleration curve, up to full • Level 0 - Minimum braking.
speed. • Level 9 - Maximum braking.
• Level 9 - Short acceleration curve, up to full
speed. 5. MAX SPEED FORW - Maximum speed of the
lift truck in the handle direction.
2. DECELER. DELAY - Amount of ramp-down to • Level 0 - Minimum speed.
a lower speed. • Level 9 - Maximum speed.
• Level 0 - Large deceleration curve, to a lower
speed (coasting). 6. MAX SPEED BACK - Maximum speed of the lift
• Level 9 - Short deceleration curve, to a lower truck in the forks direction.
speed (aggressive). • Level 0 - Minimum speed.
• Level 9 - Maximum speed.
3. RELEASE BRAKING - Amount of braking
when the accelerator is released.

Figure 27. Adjustable Parameters

46
2200 SRM 1067 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
settings into the controller. See Figure 28.

Figure 28. Store Button

47
ZAPI™ PC Interface 2200 SRM 1067

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 what they were before adjustments were made.
prior to pressing the Store button, then you can select Note this will not work if the settings were stored
the Memory menu to see the screen in Figure 29. before using this function.
This menu has three selections:
1. Receive - Same as Receive menu and Receive
button.

Figure 29. Memory Menu

48
2200 SRM 1067 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

49
ZAPI™ PC Interface 2200 SRM 1067

Highlight Drive Modes and then click on the scroll 3. Press the Stop button to disconnect the commu-
bar to the right and select OFF. See Figure 31. nication between the PC and the controller.
4. Turn the key switch on the lift truck to OFF; then
Do the following steps once this has been done: 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 4).
2. Press the Close button to go to the main screen
of the ZAPI™ PC software.

Figure 31. Turn Off Drive Modes

50
2200 SRM 1067 ZAPI™ PC Interface

Tester The Tester function also features a data-logging ca-

pability to further assist the technician and the fac-
This selection allows the technician to monitor up to tory with problems.
four items at a time to help troubleshoot problems.
See Figure 32.

Figure 32. Tester

51
ZAPI™ PC Interface 2200 SRM 1067

The PC software can test the following (four selec- 11. Lifting Switch - refers to switch on right side of
tions at a time). See Figure 33. tiller head.
1. Battery Voltage - voltage across the battery. 12. Lowering Switch - refers to switch on right side
2. Motor Voltage - voltage across the traction mo- of tiller head.
tor. 13. Fork Lift Switch - refers to switch on left side
3. Motor Current - current through the traction of tiller head.
motor. 14. Fork Lower Switch - refers to switch on left
4. Field Current - current through the fields in the side of tiller head.
traction motor. 15. Belly Switch
5. Temperature - current temperature of the con- 16. Snail Switch
troller. 17. Horn Switch
6. Accelerator - voltage and percent of "throw" 18. Cutback Switch
from the traction thumbwheel. 19. Lifting Block
7. Lifting Control 20. Battery Model
8. Tiller Switch - position of tiller handle. 21. Battery Charge - remaining charge on the bat-
9. Forward Switch - directional input. tery.
10. Backward Switch - directional input.

Figure 33. Test Name

52
2200 SRM 1067 ZAPI™ PC Interface

Data Logger 1. Advanced - Allows the user to select sample

rates and length of recording.
In addition to "live testing" of the controller, the 2. Start Rec. - Starts the data logger.
ZAPI™ PC software also includes a data-logging 3. Stop Rec. - Stops the data logger.
capability. See Figure 34. There are four buttons 4. Save Rec. - Saves the log to a file.
associated with this, as listed below.

Figure 34. Data Logger

The Advanced button allows the user to select time

increments and the number of samples. See Fig-
ure 35.

Figure 35. Tester Advanced

53
ZAPI™ PC Interface 2200 SRM 1067

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

Figure 36. Logging Process

54
2200 SRM 1067 ZAPI™ PC Interface

Once the data logger is done, you can save the log Once the log file has been saved, the user can either
using the Save Rec. button. See Figure 37. analyze the data him/herself or e-mail the file to the
factory for analysis.

Figure 37. Save As

The raw data file looks like this (see Figure 38): 30;0;0.00 0;80;0.0;
[Info]
40;0;0.00 0;80;0.0;
Chopper_Name=CS P20 V1.00
Save_Date=Thu Apr 04 13:32:24 2002 50;0;0.00 0;80;7.2;
TIME;MOTOR CURRENT;ACCELERATOR;BAT- 60;3;0.00 0;80;7.2;
TERY CHARGE ;FIELD CURRENT;
70;3;0.27 10;80;7.2;
0;0;0.00 0;80;0.0;
80;3;0.27 10;80;12.7;
10;0;0.00 0;80;0.0;
90;8;0.53 16;80;12.7;
20;0;0.00 0;80;0.0;

Figure 38. Test Data

55
ZAPI™ PC Interface 2200 SRM 1067

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

56
2200 SRM 1067 ZAPI™ PC Interface

The display screen (Figure 40) will display any 5. SERIAL ERROR #1
current "live" alarms. Note the display ACTUAL 6. WATCHDOG
ALARM that indicates a current "live" alarm condi- 7. EEPROM KO
tion. 8. FORW + BACK
9. VMN NOT OK
The PC software will provide the alarm name and 10. CONTACTOR CLOSED
the number of times it has occurred, the tempera- 11. I=0 EVER
ture of the controller when the alarm occurred, and 12. STBY I HIGH
the hourmeter reading (internal to the controller) of 13. HIGH FIELD CURRENT
when the alarm occurred. 14. NO FIELD CURRENT
15. CAPACITOR CHARGE
The user can check for new alarms by pressing the
16. LOW BATTERY
Update key or clear out the alarm log by pressing the
17. THERMAL PROTECTION
Clear key.
18. CHARGING BATTERY
The following list consists of possible alarms. 19. POWER FAILURE #1
20. DRIVER SHORTED
Alarms 21. CONTACTOR DRIVER
22. VACC NOT OK
1. EVP NOT OK 23. INCORRECT START
2. BRAKE DRIVER KO 24. INPUT ERROR #2
3. VFIELD NOT OK 25. INPUT ERROR #1
4. PUMP VACC NOT OK

Figure 40. Actual Alarm

57
Repair 2200 SRM 1067

Repair
REMOVE 2. Remove brass stud from controller.

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

2. Block drive wheel to prevent lift truck from mov- The stud must be installed in the correct orientation
ing. with regard to the relief groove.
3. Connect handset or PC and download parame- 1. Install brass stud onto controller and tighten to
ters, if possible. 10 to 11 N•m (92 to 97 lbf in).
4. Turn key to OFF. 2. Install brass washer, power fuse, brass washer,
flat washer, lockwasher, and M8 nut to brass
5. Disconnect battery.
stud. Tighten M8 nut to 10 to 11 N•m (92 to
6. Remove cover. 97 lbf in).

INSTALL
WARNING
The capacitors in the controller remain 1. Align controller to plate and capscrews. Tighten
charged for several minutes after operation. capscrews.
To prevent personal injury and/or damage
to equipment, the controller should be dis- 2. Connect all power cables and wires connected to
charged. To discharge the controller, connect controller.
a 200-ohm, 2- to 3-watt resistor between the
3. Connect battery.
battery positive and negative terminals on
the controller for at least 5 seconds. Refer to 4. Connect handset or PC.
Figure 2 in the General section of this manual.
5. Turn key to ON.
7. Discharge controller.
6. Upload parameters.
8. Identify and tag all power cables and wires con-
nected to controller for later installation. 7. Remove blocks from drive wheel.

9. Remove all power cables and wires connected to 8. Test lift truck in a safe, level area away from
controller. other personnel and equipment.

10. Loosen both capscrews retaining controller to 9. Install cover.

plate.
REPAIR
11. Remove controller.
1. Replace fuses.
BRASS STUD REPLACEMENT
2. Replace controllers by following the remove and
Remove install procedures listed above.

1. Remove M8 nut, lockwasher, flat washer, brass

washer, power fuse, and brass washer from brass
stud.

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2200 SRM 1067 11/07 (8/05)(7/03) Printed in U.S.A.