Maintenance

ZAPI™ CONTROLLERS
MSW020/025-E [A895];
MSW030/040-E [C820];
MRW020/030-E [C821];
MCW025/030/040-E [C819]

PART NO. 524185045 2200 YRM 1064

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, 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 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!
ZAPI™ Controllers Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
ZAPI™ Transistor Motor Controller ................................................................................................................. 1
Principles of Operation.................................................................................................................................... 2
Controller Safety.................................................................................................................................................. 2
Controller Adjustments ........................................................................................................................................ 3
Modes of Operation ............................................................................................................................................. 3
User-Selectable Operating Modes .................................................................................................................. 3
Programming ....................................................................................................................................................... 4
Custom Performance Mode ............................................................................................................................ 4
Controller Parameters ..................................................................................................................................... 4
Tester Menu .................................................................................................................................................... 4
Set Option Menu ............................................................................................................................................. 6
ZAPI™ Handset .............................................................................................................................................. 6
Troubleshooting ................................................................................................................................................... 10
Auxiliary Hydraulics (MSW030/040-E, MRW020/030-E, MCW025/030/040-E) .............................................. 29
ZAPI™ PC Interface ............................................................................................................................................ 30
Connecting PC to ZAPI™ Controller............................................................................................................... 30
File Menu ........................................................................................................................................................ 33
Open File .................................................................................................................................................... 33
TX From File ............................................................................................................................................... 34
Save File ..................................................................................................................................................... 36
Print Settings .............................................................................................................................................. 38
Exit.............................................................................................................................................................. 39
Connection Menu ............................................................................................................................................ 40
Function Menu ................................................................................................................................................ 40
Parameter ................................................................................................................................................... 40
Memory Menu............................................................................................................................................. 45
Set Options ................................................................................................................................................. 46
Tester .......................................................................................................................................................... 48
Data Logger ................................................................................................................................................ 50
Alarm Logbook............................................................................................................................................ 54
Alarms......................................................................................................................................................... 55
Repair .................................................................................................................................................................. 56
Remove ........................................................................................................................................................... 56
Install............................................................................................................................................................... 56
Repair.............................................................................................................................................................. 56
Sideshift Setup With Auxiliary (MRW020/030-E) ............................................................................................ 56

This section is for the following models:

MSW020/025-E [A895];
MSW030/040-E [C820];
MRW020/030-E [C821];
MCW025/030/040-E [C819]

©2003 Yale Materials Handling Corp. i

2200 YRM 1064 Description

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

Figure 1. Controller

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

1
Controller Safety 2200 YRM 1064

PRINCIPLES OF OPERATION speed, acceleration rate, release braking, and braking

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

Controller Safety
WARNING
The ZAPI™ controllers can hold an electrical charge
for several minutes after the key switch has been
turned OFF. To prevent injury, discharge the con-
trollers 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. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
3. 200-OHM, 2-WATT RESISTOR
4. INSULATED JUMPER WIRES

Figure 2. Discharging Controller

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2200 YRM 1064
Controller Adjustments
The ZAPI™ transistor motor controller can store and
display Error Codes (Alarms). It is also possible to mod-
ify the controller Setup for individual preferences. Com-
munication with the controller is possible by four meth-
ods:
1. LED - An LED (light emitting diode) can be installed
in trucks that do not use a display. The LED flashes
error codes to the technician for diagnosis. The
LED would be installed on the bottom of the ZAPI™
controller at connector port D. See Figure 1.
2. Dash Display - Some trucks are equipped with
an optional dash display or MDI. Error codes are
shown on the LCD (liquid crystal display) when the
Modes of Operation
It is possible to adjust the operating characteristics of
the lift truck. There are two basic ways to do this: User-
Selectable and Non-User-Selectable Operating Modes.
USER-SELECTABLE OPERATING MODES
The operator has a choice of three performance modes
that are selectable through the control handle. The
mode selection is made at startup or key ON. Perfor-
mance parameters that vary are acceleration, decel-
eration, regenerative (neutral) braking, and top travel
speed.
The three operator-selectable performance modes are
factory programmed per the following:
• Mode 1 - Economy mode (battery saver) - soft accel-
eration, reduced top speed with regenerative (neutral)
braking.
• Mode 2 - Performance with regenerative (neutral)
braking - medium acceleration, reduced top travel
speed with regenerative (neutral) braking.
• Mode 3 - Performance without regenerative (neutral)
braking - maximum acceleration, maximum top travel
speed with coast at throttle release.
The following procedure is used to access the user-se-
lectable operating modes:
1. The controller drive modes parameter must be ON.
This is the factory setting.
Modes of Operation
wrench symbol and red light are lit. The format is
AL XX where XX is the error code.
3. ZAPI™ Handset - A diagnostic handset is available
through your Yale dealer. The handset makes it
possible to diagnose faults and modify controller
settings. See Programming, in this section.
4. Personal Computer - The controller can also be
connected to a personal computer (PC) equipped
with special software and cables. The PC can read,
store, and change settings on the controller.
Proper use of these four methods and a list of diagnostic
codes are explained in Troubleshooting, in this section.
NOTE: You must use the handset or PC interface to
change this setting. Using the ZAPI™ handset or PC
connection, it is possible to set the drive mode parame-
ters to ON or OFF. In the ON mode, the user-selectable
rules are enabled. In the OFF mode, the lift truck will
only operate using the settings selected. The proce-
dure to alter or modify these settings is given in Pro-
gramming in this section.
2. Control handle must be in the full, upright position,
brake ON.
3. Press and hold the horn button while turning the key
switch to the ON position.
4. Release the horn button when the horn sounds.
5. Toggle through the modes by pressing the lift or
lower buttons to the desired mode.
6. The horn provides an audible indication as to the
mode selected. One beep indicates Mode 1, two
beeps indicate Mode 2, and three beeps indicate
Mode 3.
7. Lower the control handle to the operating position,
brake OFF, and begin operation.
8. The selected mode is maintained until the proce-
dure is repeated.
9. Turning the key OFF before lowering the control
handle will cancel the mode change.
3
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
Parameters are controller settings that can be adjusted
to alter the performance characteristics of the truck.
To adjust parameters and install custom drive settings,
Drive Modes must be OFF. To set Drive Modes to OFF,
use the following procedure:
1. Turn key switch OFF.
2. Remove drive unit compartment cover.
3. Connect adapter harness to handset.
NOTE: It may be necessary to remove the MDI harness
connector from the controller to install the adapter har-
ness.
NOTE: Connect and disconnect the handset only with
the key switch in the OFF position.
4. Connect adapter harness to controller.
5. Turn key switch ON.
6. The handset will turn ON. See Figure 3.
7. Press buttons 1 and 5 simultaneously.
Figure 3. ZAPI™ Handset
4
2200 YRM 1064
8. The screen will display CONFIG MENU.
9. Scroll through the menus using button 1 or 2 to the
SET OPTIONS menu.
10. Enter this menu by pressing button 3.
11. Press button 5 or 6 to set Drive Modes to OFF.
12. Press button 4 to exit this menu.
13. The handset will prompt, "Are you sure?"
14. Press ENTER (button 3) to retain settings.
15. Press OUT (button 4) to discard settings.
16. Turn the key switch OFF to save the drive modes
OFF parameter change.
17. Turn the key switch ON to enter the MAIN MENU
and change the parameters outlined in Table 1.
TESTER MENU
The most important input or output signals can be mea-
sured in real time using the TESTER function of the
handset. The handset acts as a multimeter to read volt-
age, current, temperature, switch state, and other func-
tions.
1. BATTERY VOLTAGE = battery voltage, nominal
value = 24V.
2. MOTOR VOLTAGE = armature voltage obtained,
shown in volts.
3. MOTOR CURRENT = armature current during trac-
tion (positive value) or braking (negative value) in
amps.
4. FIELD CURRENT = field current in the selected
traction direction in amps.
5. EVP VOLTAGE = proportional lowering valve coil
voltage.
6. TEMPERATURE = controller temperature, C.
7. ACCELERATOR = directional control voltage re-
ceived from control handle.
2200 YRM 1064 Programming

Table 1. Parameters

Parameter Description Value and Affect Factory

Default
ACCELERATION DELAY Adjusts truck acceleration. 0 = short or rapid acceleration 0
9 = long or slow acceleration
DECELERATION DELAY Adjusts truck deceleration 0 = short or rapid deceleration 5
according to throttle 9 = long or slow deceleration
position.
RELEASE BRAKING Adjusts motor braking 0 = soft braking 7
strength or regenerative 9 = strong braking
braking when throttle is
released. This determines
coast distance.
INVERSE BRAKING Adjusts plugging rate. 0 = long or soft plugging 9
9 = short or rapid plugging
CUTBACK SPEED Speed control for trucks in 0 = slow 9
optional mode. 9 = fast (not used)
MAX SPEED FORW Adjusts maximum speed 0 = minimum 4
in forward direction, forks 9 = maximum
trailing.
MAX SPEED BACK Adjusts maximum speed 0 = minimum 4
in reverse direction, forks 9 = maximum
leading.
LIFT MAX TIME Adjusts the maximum time 0 = minimum or approximately 5 9
for lifting forks. seconds
9 = maximum or approximately
65 seconds
AUXILIARY TIME Adjusts the maximum 0 = minimum or approximately 5
time for auxiliary hydraulic 1.5 seconds
functions. 9 = maximum or approximately
6 seconds

8. LIFTING CONTROL = proportional lifting voltage
received from control handle.
9. TILLER SWITCH = control handle switch input,
ON/OFF.
10. FORWARD SWITCH = forward direction request
from control handle card, ON/OFF.
11. BACKWARD SWITCH = backward direction re-
quest from control handle card, ON/OFF.
13. LOWERING SWITCH = lowering function request
from control handle card, proportional lowering
switch, ON/OFF.
14. FORK LIFT SWITCH = lifting function request from
control handle card, ON/OFF.
15. FORK LOW SWITCH = lowering function request
from control handle card, ON/OFF.
16. R-SHIFT SWITCH = sideshift right switch, ON/OFF.

12. LIFTING SWITCH = lifting function request from 17. L-SHIFT SWITCH = sideshift left switch, ON/OFF.
control handle card, proportional lift switch,
ON/OFF.

5
Programming 2200 YRM 1064

18. BELLY SWITCH = traction reversing switch to the In this case, it is necessary to go in a standby condition
controller or traction reversing request from control (truck at rest) before switching OFF the controller in or-
handle card, ON/OFF. der to store the new values in the EEPROM.

19. SNAIL SWITCH = snail request from control handle This section describes the ZAPI™ handset functions.
card allows machine to drive with control handle up, Six buttons provide the capability of changing or reading
turtle speed switch, ON/OFF. the parameters.

20. HORN SWITCH = horn request from control handle 1 Roll-Up Push to scroll up.
card, ON/OFF.
2 Roll-Down Push to scroll down.
21. SW4-SW9 = auxiliary function jumper. 3 Enter Push to enter a submenu
or to confirm a change.
22. BATTERY MODEL = battery-type of input switch,
ON/OFF. ON = flooded battery (input closed), OFF 4 Out Push to exit a selected
= sealed battery (input open). menu or to refuse a
change.
23. BATTERY CHARGE = battery charge indication, %.
5 Set-Up Push to increase a
SET OPTION MENU parameter value.
6 Set-Down Push to decrease a
DRIVE ON The truck has three performance
parameter value.
MODES modes, each with a fixed set
of parameters. This function
is enabled by setting DRIVE NOTE: After a modification, save the new values by
MODES = ON. pushing out, then enter to confirm. (Screen prompts
will guide the user.)
OFF DRIVE MODES disabled.
To navigate the menu options, numbers inside the trian-
Custom Performance Mode
gles in the following map correspond to the same num-
is enabled, the adjustable
ber on the handset keyboard buttons. The orientation of
parameters on Table 1 can be
the triangle indicates the way to the next function. See
adjusted.
Figure 3.

ZAPI™ HANDSET NOTE: Connect and disconnect the handset only with
the key switch in the OFF position.
The ZAPI™ handset must be connected to the con-
troller before turning on the key. The handset must have For additional handset description, see Figure 4.
an adapter harness to connect to the controller. The
handset and adapter harness are available from your
Yale dealer. Connect the handset to plug D. The hand-
set can remain connected to the controller while run-
ning, and the parameters can be changed in real time.

6
 NOTES

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7
Programming 2200 YRM 1064

8
2200 YRM 1064 Programming

Figure 4. ZAPI™ Handset Instructions

9
Troubleshooting 2200 YRM 1064

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 controller.
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 1064 Troubleshooting

Dash Display Controller LED Handset or PC

No LEDs or LCDs LED OFF Handset does not operate
illuminated
CONDITION
Dash display, controller LED, and truck inoperative
with key switch in ON position.
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 voltage.
Verify key switch is ON.
Verify brake override circuit is connected in run po-
sition.
Verify continuity between batteries negative (at bat-
tery) and B power wire connection (at controller).
If no continuity, check:
Power wiring between battery and controller.
Verify continuity between battery positive (at bat- LOGIC
tery) and B-12 connection (at controller).
If no continuity, check: Occurs when there is no
Fuse 3 for open. power to the controller or the controller is defective.
Key switch continuity in ON position.
Wiring battery + to main contactor to fuse 3 to key
switch, to controller B-12 connection.
• Defective motor controller.
Check for battery voltage between B-12 and B
power wire connection at controller.
If correct battery voltage, replace controller.

11
Troubleshooting 2200 YRM 1064

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 controller.
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 commu-
nication to handset.
If handset operates correctly, replace MDI. LOGIC
• Defective LED.
Disconnect LED and connect handset. If handset Occurs when the MDI or
works, replace LED. LED receives no signal, or MDI or LED is damaged.

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 commu-
nication to handset.
If handset will not communicate with controller, re-
place controller.

LOGIC

Occurs when controller

does not send a signal to the MDI or LED.

12
2200 YRM 1064 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 at key ON. Steer
handle in run position at key ON.
Return steer handle to full upright position. Return
throttle to neutral. Release all hydraulic function
controls.
If fault remains, attach handset and go to test menu.
• Check 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 correct
the problem, replace control card. LOGIC
• Check hydraulic inputs – Should be 0 volts. If not, re-
calibrate tiller card. Follow auto-learn procedure listed Fault occurs when
in steering. If this does not clear fault, check but- controller receives input that has not followed
tons for damage or interference. Replace damaged the proper operational sequence.
or faulty buttons.

13
Troubleshooting 2200 YRM 1064

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 voltage mea-
sured by an accurate digital voltmeter between B+
and B terminals. Pull down tiller handle to en-
gage contactor for this measurement. If these two
voltages are more than 1.5 volts difference, replace
controller. LOGIC

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 connector.
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.
Inspect cable crimps and cables from battery con- LOGIC
tactor to controller and contactor.
Battery voltage is much
less than allowable.

14
2200 YRM 1064 Troubleshooting

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 lift-
ing control and EVP voltage.” Check on/off switches LOGIC
and proportional switches for smooth, linear opera-
tion. Replace damaged switches. Occurs if the output of
• Control card lift/lower switch calibration is out of range. one on the hydraulic controls is higher
Install handset. Go to tester function. Check lifting than 1V (20%) at start.
control and EVP voltage. Output of proportional
hydraulic controls should be less than 1V (20%) at
neutral.
Recalibrate control card.
• Control card is damaged or defective.
Replace card.

15
Troubleshooting 2200 YRM 1064

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 same LOGIC
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 con-
trol card and controller.
Verify connection at controller.
Verify wire harness connection at base of steer han-
dle.
Verify connection at control card.
• Damaged or defective control card.
Measure voltage at pin 5, connector C, on the con-
troller. With control card disconnected, this should LOGIC
be about 12V; with the card connected, it should be
about 5V. 0V or 12V with the card connected means No information or incorrect
that the card is damaged. information has been sent from the
Replace control card. control card to controller.

16
2200 YRM 1064 Troubleshooting

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. Traction Reversing Switch
• Damaged or defective control card. data signal is not present and hadwire
Replace control card. signal is present.

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 control handle card. LOGIC
Replace control card.
Traction Reversing Switch
hadwire signal is not present and
data signal is present.

17
Troubleshooting 2200 YRM 1064

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
• Connector E is loose at base of controller or defective.
Inspect connector E. Check wire 100 between po-
sition E6 and E16 for continuity.

LOGIC

Controller inputs indicate

a battery charger is connected.

Dash Display Controller LED Handset or PC

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
and controller.
Check motor field for shorts to chassis.
• Controller is damaged.
Replace controller. LOGIC

Occurs when the

controller detects a short in the main contactor circuit.

18
2200 YRM 1064 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 electrical connection to propor-
tional lowering valve.
Verify electrical connections between proportional
valve coil and controller.
• Lowering coil damaged.
Check lowering valve coil for correct resistance.
Coil resistance should be approximately 17.8
ohms.
Replace coil if damaged.
• Lowering valve cartridge is damaged. LOGIC
Replace lowering valve cartridge.
Occurs if electropropor-
tional valve is open before circuit is energized. Valve
does not follow the supplied signal from controller.

19
Troubleshooting 2200 YRM 1064

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 14.3 LOGIC
ohms.
• Damaged fly-back diode at brake. Occurs when brake driver
Check coil resistance. Short circuit measured at circuit is shorted or open circuit.
brake connector may indicate a damaged diode.
Cut one lead of diode and check with meter. If dam-
aged, replace diode.
• Damaged controller.
Activate the brake switch. Use voltmeter to mea-
sure voltage on wire 2B and 79 with brake con-
nected in circuit. If both measurements are 24V and
the alarm is displayed, then controller is damaged.

20
2200 YRM 1064 Troubleshooting

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, replace con- LOGIC
troller.
Occurs if while driving, the
motor current does not exceed a
preset minimum value.

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 conti-
nuity. 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.

21
Troubleshooting 2200 YRM 1064

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 conti-
nuity. 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 and
contactor. LOGIC
Check contactor coil for correct resistance of 12.5
ohms. Measured field current
• Field current drivers in controller are damaged. is too low.
Replace controller.

Dash Display Controller LED Handset or PC

AL6 6 Flashes STBY I HIGH
CONDITION
Controller detects motor current during standby
mode. Standby mode occurs while the truck is
at rest with the contactor closed.
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.

22
2200 YRM 1064 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 allow
controller to return to operating temperature.
• Controller temperature miscalibrated.
Install handset. Go to tester function and check
temperature. Controller and vehicle temperature
should be same as room temperature at initial LOGIC
startup. If these temperatures differ, replace con-
troller. This alarm is generated
• Controller temperature sensor damaged. when the controller temperature is outside
Replace controller. 10 to 75 C (14 to 167 F).
• Controller damaged.
Replace controller.

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 proportional low-
ering solenoid for correct resistance values.

Value should be within ±10% at room temperature. LOGIC

Main contactor = 12.5 ohms Occurs when controller

Brake coil = 14.3 ohms detects short circuit in component driven by controller.
Proportional lowering valve coil (EV1) = 17.8 ohms
Lifting solenoid (EV2) = 22.2 ohms
A/B directional valve coil (EV3, EV4) = 40.2 ohms

23
Troubleshooting 2200 YRM 1064

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) EEPROM KO
CONDITION
Fault in the memory area where parameters are stored.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Controller damaged.
Cycle key switch OFF and ON. If fault remains, re-
place controller.

LOGIC

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

24
2200 YRM 1064 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 contactor,
pump motor, and traction motor.
• Short circuit in harness.
Disconnect main harness and check for shorts.
• Short circuit in component coil.
Disconnect battery. Disconnect all drive motor,
pump motor, solenoid, brake, and coil connections
at the component end of the harness. Tape or
secure the wire ends to prevent shorts.
Discharge controller by placing 200 , 2W resistor
across B+ and B terminals. Reconnect battery
and turn key ON. Use voltmeter to observe voltage
LOGIC
across B+ and B . If there is no voltage increase,
replace controller. If there is a steady voltage in-
Occurs when an internal
crease to battery voltage, connect each accessory
or external short or open prevents the main
one at a time until the fault occurs to identify dam-
capacitors from charging at key ON.
aged component.
• Damaged controller.
Replace controller.

25
Troubleshooting 2200 YRM 1064

Dash Display Controller LED Handset or PC

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 ter-
minals.
• 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.

26
2200 YRM 1064 Troubleshooting

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 .
• 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 between LOGIC
B+ and B .
Replace controller. This fault occurs when the
• Field current drivers in controller are damaged. voltage measured at the field connections
Replace controller Verify motor field cable connec- is not the expected value.
tions.

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.

27
Troubleshooting 2200 YRM 1064

Dash Display Controller LED Handset or PC

AL94 OFF NONE
CONDITION
Controller is installing hourmeter memory to MDI
display if controller or MDI 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.

28
2200 YRM 1064 Troubleshooting

AUXILIARY HYDRAULICS (MSW030/040-E,

MRW020/030-E, MCW025/030/040-E)
When experiencing a malfunction with the auxiliary op-
erations of the lift truck, different components may be at
fault. To accurately determine where the fault is occur-
ring, you must test the circuits responsible for delivering
the desired function. See Figure 5.

For detailed auxiliary hydraulics troubleshooting, see

Electrical System 2200 YRM 1026.

Figure 5. Auxiliary Hydraulic Logic

29
ZAPI™ PC Interface 2200 YRM 1064

ZAPI™ PC Interface
CONNECTING PC TO ZAPI™
CONTROLLER
NOTE: Values used on the following figures are for ex-
ample 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 8. Controller Connection
Figure 6, or a connector for the display, as in Fig-
ure 7.)

Figure 9. PC Connection
Figure 6. Diagnostic LED
5. Locate the icon for the ZAPI™ software on the PC
and double-click on it. See Figure 10.

Figure 10. ZAPI™ Icon

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

ure 11.
Figure 7. Display Connection

4. Connect the interface cable to the controller and the

PC. See Figure 8 and Figure 9.

30
2200 YRM 1064 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

31
ZAPI™ PC Interface 2200 YRM 1064

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

32
2200 YRM 1064 ZAPI™ PC Interface

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

Figure 15. Look In:

33
ZAPI™ PC Interface 2200 YRM 1064

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

34
2200 YRM 1064 ZAPI™ PC Interface

Notice the CONNECTION STATUS while the file is

downloaded into the controller. See Figure 17.

Figure 17. Connection Status

35
ZAPI™ PC Interface 2200 YRM 1064

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

Figure 18. File - Save

36
2200 YRM 1064 ZAPI™ PC Interface

1. Try to use the actual truck serial number and put 2. Once you select a file name and click on Save, you
the word "settings" after it. (This is to keep the con- will see the screen shown in Figure 20.
troller settings file separate from the tester function
Save file.) See Figure 19.

Figure 19. Save: In

Figure 20. Enter a Comment

3. Under the Enter a Comment box, you can either 5;DECELER.DELAY;1;0;9;LEVEL=9

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

37
ZAPI™ PC Interface 2200 YRM 1064

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

Figure 21. File - Print

38
2200 YRM 1064 ZAPI™ PC Interface

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

Figure 22. File - Exit

39
ZAPI™ PC Interface
CONNECTION MENU
There are two selections under this menu:
1. Start - Starts the connection between the controller
and PC (operates the same as the main Start button
on the right-hand side of the display screen).
Figure 23. Connection Menu
FUNCTION MENU
There are seven selections under this menu:
1. Parameter - Allows the performance and configu-
ration of the controller to be adjusted. Refer to Pa-
rameter, in this section.
2. Tester - Allows the testing of various inputs and
operations of the controller. Refer to Tester, in this
section.
3. Alarm Logbook - Stores alarms that the controller
sees. Refer to Alarm Logbook, in this section.
4. Program VACC - Not Used.
5. Motor Data - Not Used.
40
2200 YRM 1064
2. Stop - Stops the connection between the controller
and PC (operates the same as the main Stop button
on the right-hand side of the display screen).
See Figure 23.
6. Ram Function - Only Factory Use.
7. EEPROM Function - Only Factory Use.
Parameter
When you first activate this selection, the screen will
look as indicated in Figure 24. In order to see the pa-
rameters of the controller, you have to download them
to the PC. This can be done by 1 of 2 ways.
1. Receive menu - This will only download the current
selected tab.
2. Receive - This will download all parameters and
configurations to the PC so you can adjust them.
2200 YRM 1064 ZAPI™ PC Interface

Figure 24. Parameter

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

Figure 25. Downloading Screen

41
ZAPI™ PC Interface 2200 YRM 1064

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

Figure 26. Drive Mode

42
2200 YRM 1064
There are six parameters that can be adjusted to affect
the performance of the lift truck. See Figure 27.
1. ACCELER. DELAY - Amount of ramp-up to full
speed.
• Level 0 - Large acceleration curve, up to full
speed.
• Level 9 - Short acceleration curve, up to full
speed.
2. DECELER. DELAY - Amount of ramp-down to a
lower speed.
• Level 0 - Large deceleration curve, to a lower
speed (coasting).
• Level 9 - Short deceleration curve, to a lower
speed (aggressive).
3. RELEASE BRAKING - Amount of braking when
the accelerator is released.
Figure 27. Adjustable Parameters
ZAPI™ PC Interface
• Level 0 - Minimum braking (coasting).
• Level 9 - Maximum braking (aggressive).
4. INVERSE BRAKING - Amount of braking when the
lift truck is "plugged."
• Level 0 - Minimum braking.
• Level 9 - Maximum braking.
5. MAX SPEED FORW - Maximum speed of the lift
truck in the handle direction.
• Level 0 - Minimum speed.
• Level 9 - Maximum speed.
6. MAX SPEED BACK - Maximum speed of the lift
truck in the forks direction.
• Level 0 - Minimum speed.
• Level 9 - Maximum speed.
43
ZAPI™ PC Interface 2200 YRM 1064

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

Figure 28. Store Button

44
2200 YRM 1064 ZAPI™ PC Interface

Memory Menu 2. Store - Same as Store button.

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

Figure 29. Memory Menu

45
ZAPI™ PC Interface 2200 YRM 1064

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

Figure 30. Set Options

46
2200 YRM 1064
Highlight Drive Modes and then click on the scroll bar
to the right and select OFF. See Figure 31.
Do the following steps once this has been done:
1. Press the Store button to save the change into the
controller.
2. Press the Close button to go to the main screen of
the ZAPI™ PC software.
Figure 31. Turn Off Drive Modes
ZAPI™ PC Interface
3. Press the Stop button to disconnect the communi-
cation between the PC and the controller.
4. Turn the key switch on the lift truck to OFF; then do
the reconnect procedure.
5. Now the parameters in the Function Menu can be
adjusted to a custom configuration (Mode 4).
47
ZAPI™ PC Interface 2200 YRM 1064

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

bility to further assist the technician and the factory with
This selection allows the technician to monitor up to four problems.
items at a time to help troubleshoot problems. See Fig-
ure 32.

Figure 32. Tester

48
2200 YRM 1064 ZAPI™ PC Interface

The PC software can test the following (four selections 12. Lowering Switch - refers to switch on right side of
at a time). See Figure 33. tiller head.
1. Battery Voltage - voltage across the battery. 13. Fork Lift Switch - refers to switch on left side of
2. Motor Voltage - voltage across the traction motor. tiller head.
3. Motor Current - current through the traction motor. 14. Fork Lower Switch - refers to switch on left side of
4. Field Current - current through the fields in the 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" from 18. Cutback Switch
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 battery.
9. Forward Switch - directional input.
10. Backward Switch - directional input.
11. Lifting Switch - refers to switch on right side of tiller
head.

Figure 33. Test Name

49
ZAPI™ PC Interface 2200 YRM 1064

Data Logger 2. Start Rec. - Starts the data logger.

3. Stop Rec. - Stops the data logger.
In addition to "live testing" of the controller, the ZAPI™ 4. Save Rec. - Saves the log to a file.
PC software also includes a data-logging capability.
See Figure 34. There are four buttons associated with The Advanced button allows the user to select time in-
this, as listed below. crements and the number of samples. See Figure 35.
1. Advanced - Allows the user to select sample rates
and length of recording.

Figure 34. Data Logger

Figure 35. Tester Advanced

50
2200 YRM 1064 ZAPI™ PC Interface

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

Figure 36. Logging Process

51
ZAPI™ PC Interface 2200 YRM 1064

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

Figure 37. Save As

52
2200 YRM 1064 ZAPI™ PC Interface

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 fac-
tory 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 40;0;0.00 0;80;0.0;
Save_Date=Thu Apr 04 13:32:24 2002
TIME;MOTOR CURRENT;ACCELERATOR;BATTERY 50;0;0.00 0;80;7.2;
CHARGE ;FIELD CURRENT; 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

53
ZAPI™ PC Interface 2200 YRM 1064

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

54
2200 YRM 1064 ZAPI™ PC Interface

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

Figure 40. Actual Alarm

55
Repair 2200 YRM 1064

Repair
There are no repairable parts in the controller, and the INSTALL
controller must be replaced if it is defective. The contac-
tor mounted to the controller is a serviceable/repairable 1. Align controller to plate and capscrews. Tighten
component. In some instances, it may be desired to capscrews.
disable the drive modes. Follow the remove and install
2. Connect all power cables and wires connected to
controller procedures listed below.
controller.
REMOVE 3. Connect battery.
1. Park lift truck in a safe, level area. 4. Connect handset or PC.
2. Block drive wheel to prevent lift truck from moving. 5. Turn key to ON.
3. Connect handset or PC and download parameters, 6. Upload parameters.
if possible.
7. Remove blocks from drive wheel.
4. Turn key to OFF.
8. Test lift truck in a safe, level area away from other
5. Disconnect battery. personnel and equipment.
6. Remove cover. 9. Install cover.

WARNING REPAIR
The capacitors in the controller remain charged for
1. Replace fuses.
several minutes after operation. To prevent per-
sonal injury and/or damage to equipment, the con- 2. Replace controllers by following the remove and in-
troller should be discharged. To discharge the con- stall procedures listed above.
troller, connect a 200-ohm, 2- to 3-watt resistor be-
tween the battery positive and negative terminals SIDESHIFT SETUP WITH AUXILIARY
on the controller for at least 5 seconds. Refer to
(MRW020/030-E)
Figure 1 in the General section of this manual.
To enable the sideshift function on the MRW020/030-E
7. Discharge controller.
stacker trucks with auxiliary board, follow the following
8. Identify and tag all power cables and wires con- procedure:
nected to controller for later installation.
1. Jumper must be installed in connector E - positions
9. Remove all power cables and wires connected to 3 and 13.
controller.
2. Connect ZAPI™ handset.
10. Loosen both capscrews retaining controller to plate.
3. When main menu appears, press ENTER.
11. Remove controller.
4. Scroll to ALARMS.

56
2200 YRM 1064 Repair

5. Press buttons 5 and 6 at the same time. 11. Scroll to AUX INPUT #1. Set to PRESENT.

6. Scroll to READ EEPROM" Press ENTER. 12. Press OUT. Handset will ask, ARE YOU SURE?.
Press ENTER.
7. Using ROLL and SET keys, change address to
F000 1234. 13. Press OUT until the main menu appears.

8. Press ENTER. Press OUT until the main menu ap- 14. Turn key OFF and ON to retain settings.
pears.
15. Confirm operation of sideshift function.
9. Press buttons 1 and 5 at the same time.

10. Scroll to the SET OPTION menu. Press ENTER.

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 NOTES

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58
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 1064 7/03 (5/03)(4/03)(2/03) Printed in U.S.A.