Maintenance

ZAPI™ CONTROLLERS
MSW020/025-E [A895];
MSW025/030-F [B895];
MCW025/030/040-E [C819, D819];
MSW030/040-E [C820, D820];
MRW020/030-E [C821, D821]

PART NO. 524185045 2200 YRM 1064

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:

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

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Description ................................................................................................................................................................2
ZAPI™ Transistor Motor Controller ...................................................................................................................... 2
Principles of Operation ......................................................................................................................................... 2
Controller Safety ....................................................................................................................................................... 3
Controller Adjustments ............................................................................................................................................. 3
Modes of Operation .................................................................................................................................................. 4
User-Selectable Operating Modes ....................................................................................................................... 4
Programming ............................................................................................................................................................ 5
Custom Performance Mode ..................................................................................................................................5
Controller Parameters .......................................................................................................................................... 5
Setting Drive Modes .........................................................................................................................................5
Tester Menu ......................................................................................................................................................... 7
Set Option Menu ...................................................................................................................................................7
ZAPI™ Handset ....................................................................................................................................................8
Alarm Code Diagnostics ......................................................................................................................................... 12
Alarm Code Diagnostic Procedure ..................................................................................................................... 12
Troubleshooting ...................................................................................................................................................... 14
Auxiliary Hydraulics (MSW030/040-E, MRW020/030-E, MCW025/030/040-E).................................................. 38
Control Card Functional Test ..................................................................................................................................43
Traction Motor Test .................................................................................................................................................45
ZAPI™ PC Interface ............................................................................................................................................... 46
Connecting PC to ZAPI™ Controller .................................................................................................................. 46
File Menu ............................................................................................................................................................50
Open File ........................................................................................................................................................50
TX From File .................................................................................................................................................. 52
Save File ........................................................................................................................................................ 54
Print Settings ..................................................................................................................................................56
Exit ................................................................................................................................................................. 57
Connection Menu ............................................................................................................................................... 58
Function Menu ....................................................................................................................................................58
Parameter ...................................................................................................................................................... 58
Memory Menu ................................................................................................................................................ 63
Set Options .................................................................................................................................................... 64
Tester ............................................................................................................................................................. 66
Data Logger ................................................................................................................................................... 68
Alarm Logbook ............................................................................................................................................... 71
Alarms ............................................................................................................................................................ 73
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) ....................................................................... 73
Repair ..................................................................................................................................................................... 74
Remove .............................................................................................................................................................. 74
Brass Stud Replacement ....................................................................................................................................74
Remove ..........................................................................................................................................................74
Install ..............................................................................................................................................................74
Install .................................................................................................................................................................. 74
Repair ................................................................................................................................................................. 75
Sideshift Setup With Auxiliary (MRW020/030-E).................................................................................................75

©2016 Yale Materials Handling Corp. i

Table of Contents

This section is for the following models:

(MSW020/025-E) [A895];
(MSW025/030-F) [B895];
(MCW025/030/040-E) [C819, D819];
(MSW030/040-E) [C820, D820];
(MRW020/030-E) [C821, D821]

ii
2200 YRM 1064 General

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

Figure 1. Controller

1
Description 2200 YRM 1064

Description
ZAPI™ TRANSISTOR MOTOR NOTE: The dash indicator will display the code: EP
CONTROLLER 107 (or a higher number) for 1 to 2 seconds every
time the key switch is turned to the ON position. The
The ZAPI™ controller is a solid-state DC motor con- ZAPI handset similarly displays V1.07 (or higher).
troller utilizing SEM technology. It controls the traction This code represents the EEPROM software version
motor, brake, and hydraulic system. The controller re- and DOES NOT INDICATE A FAULT CODE.
ceives inputs from the control handle by serial com-
munication, and direct inputs from the key switch and Troubleshoot the fault using a ZAPI™ handset or a
control handle arm position switch. The controller di- properly configured IBM compatible PC. On trucks
rectly controls the traction motor, lift pump motor, lift equipped with the optional dash display, the dash wir-
valve, proportional lowering valve, brake, and main ing harness plugs into the controller in place of the
contactor. Additional hydraulic functions, such as LED. The display also has a red LED, however, it
reach, sideshift, and tilt are controlled through an aux- does not flash codes. If a fault occurs, the red LED
iliary relay board mounted to the front of the control- blinks, the wrench LCD is shown, and "AL" followed
ler. Jumpers are used to configure the basic controller by the fault number is displayed.
and the controller with auxiliary relay board for differ-
ent truck models. PRINCIPLES OF OPERATION

The controller software provides self diagnostics The ZAPI™ transistor motor controller uses a sophis-
which are accessed by means of a ZAPI™ handset or ticated microprocessor to control the logic and opera-
a PC with specialized ZAPI™ software. The controller tion of the controller, eliminating the need for forward
software features a Test Menu for monitoring control- and reverse contactors. The SEM motor controller op-
ler inputs and outputs, a Diagnostic Menu for viewing erates on the principle of controlling the motor field
fault code information, and a Programming Menu for circuit and the motor armature circuit independently.
customizing the truck performance. The handset or The controller has many programmable features, in-
PC connect to the controller through a cable with a six cluding maximum speed, acceleration rate, release
pin connector which attaches to the 10 pin "D" con- braking, and braking current limit. The SEM controller
nector port on the bottom of the controller. The con- includes a full range of features, as well as diagnostic
nector is installed centered in the "D" port leaving two and setup capability.
pins on each end of the "D" port vacant. The connec-
tor retainer clip will align and secure the connector in NOTE: There are no user-serviceable parts in the
position. ZAPI™ controller. No attempt should be made to
open, repair, or otherwise modify the controller. Doing
The self diagnostics monitor the traction motor, brake so may damage the controller and will void the war-
coil, lowering valve coil, contactor coil, control handle ranty.
serial communications, controller temperature, and in-
ternal 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.

2
2200 YRM 1064 Controller Safety

Controller Safety

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

See Figure 2.

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

Figure 2. Discharging Controller

Controller Adjustments
The ZAPI™ transistor motor controller can store and the wrench symbol and red light are lit. The for-
display Error Codes (Alarms). It is also possible to mat is AL XX where XX is the error code. The
modify the controller Setup for individual preferences. software version is displayed on startup.
Communication with the controller is possible by four
methods: 3. ZAPI™ Handset - A diagnostic handset is availa-
ble through your Yale dealer. The handset makes
1. LED - An LED (light emitting diode) can be instal- it possible to diagnose faults and modify controller
led in trucks that do not use a display. The LED settings. See Programming, in this section.
flashes error codes to the technician for diagno-
4. Personal Computer - The controller can also be
sis. The LED would be installed on the bottom of
connected to a personal computer (PC) equipped
the ZAPI™ controller at connector port D. See
with special software and cables. The PC can
Figure 1.
read, store, and change settings on the controller.
2. Dash Display - Some trucks are equipped with
an optional dash display or MDI. Error codes are Proper use of these four methods and a list of diag-
shown on the LCD (liquid crystal display) when nostic codes are explained in Troubleshooting, in this
section.

3
Controller Adjustments 2200 YRM 1064

Modes of Operation
It is possible to adjust the operating characteristics of NOTE: You must use the handset or PC interface to
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-select-
able rules are enabled. In the OFF mode, the lift truck
USER-SELECTABLE OPERATING MODES will only operate using the settings selected. The pro-
cedure to alter or modify these settings is given in
The operator has a choice of three performance Programming in this section.
modes that are selectable through the control handle.
2. Control handle must be in the full, upright posi-
The mode selection is made at startup or key ON.
tion, brake ON.
Performance parameters that vary are acceleration,
deceleration, regenerative (neutral) braking, and top 3. Press and hold the horn button while turning the
travel speed. key switch to the ON position.

The three operator-selectable performance modes 4. Release the horn button when the horn sounds.
are factory programmed per the following:
5. Toggle through the modes by pressing the lift or
• Mode 1 - Economy mode (battery saver) - soft
lower buttons to the desired mode.
acceleration, reduced top speed with regenera-
tive (neutral) braking. 6. The horn provides an audible indication as to the
• Mode 2 - Performance with regenerative (neu- mode selected. One beep indicates Mode 1, two
tral) braking - medium acceleration, reduced beeps indicate Mode 2, and three beeps indicate
top travel speed with regenerative (neutral) Mode 3.
braking.
7. Lower the control handle to the operating position,
• Mode 3 - Performance without regenerative brake OFF, and begin operation.
(neutral) braking - maximum acceleration, max-
imum top travel speed with coast at throttle re- 8. The selected mode is maintained until the proce-
lease. dure is repeated.

The following procedure is used to access the user- 9. Turning the key OFF before lowering the control
selectable operating modes: handle will cancel the mode change.

1. The controller drive modes parameter must be

ON. This is the factory setting.

4
2200 YRM 1064 Programming

Programming
CUSTOM PERFORMANCE MODE 8. The screen will display CONFIG MENU.

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

In some instances, it may be preferable to disable the
the SET OPTIONS menu.
Drive Modes and use a custom setting. This controller
has adjustable parameters that may be modified to 10. Enter this menu by pressing button 3.
suit specific customer needs. There are two methods
used to adjust these parameters: the ZAPI™ handset 11. Press button 5 or 6 to set Drive Modes to OFF.
or the personal computer (PC) interface.
12. Press button 4 to exit this menu.
CONTROLLER PARAMETERS 13. The handset will prompt, "Are you sure?"
Parameters are controller settings that can be adjus- 14. Press ENTER (button 3) to retain settings or OUT
ted to alter the performance characteristics of the (button 4) to discard settings.
truck.
15. Press OUT (button 4) to exit to the main menu.
To adjust parameters and install custom drive set-
tings, Drive Modes must be OFF. To set Drive Modes 16. Turn the key switch OFF to save the "Drive
to OFF, use the following procedure: Modes OFF" parameter change. The key switch
must be cycled before attempting to make any ad-
ditional parameter changes.
Setting Drive Modes
17. Turn the key switch ON to confirm the Drive Mode
1. Turn key switch OFF.
is OFF. Then enter the MAIN MENU and change
2. Remove drive unit compartment cover. the parameters outlined in Table 1.

3. Connect adapter harness to handset.

NOTE: It may be necessary to remove the MDI har-

ness connector from the controller to install the
adapter harness.

NOTE: Connect and disconnect the handset only

with the key switch in the OFF position.

4. Connect adapter harness to controller.

5. Turn key switch ON. Figure 3. ZAPI™ Handset

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

7. Press buttons 1 and 5 simultaneously.

5
Programming 2200 YRM 1064

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 in 0 = minimum 4
forward direction, forks 9 = maximum
trailing.
MAX SPEED BACK Adjusts maximum speed in 0 = minimum 4
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 time 0 = minimum or approximately 5
for auxiliary hydraulic 1.5 seconds
functions. 9 = maximum or approximately 6
seconds

6
2200 YRM 1064 Programming

TESTER MENU 13. LOWERING SWITCH = lowering function request

from control handle card, proportional lowering
NOTE: The Tester function can be used to trouble- switch, ON/OFF.
shoot multiple systems simultaneously while the truck
is in operation. 14. FORK LIFT SWITCH = lifting function request
from control handle card, ON/OFF.
The most important input or output signals can be
15. FORK LOW SWITCH = lowering function request
measured in real time using the TESTER function of
from control handle card, ON/OFF.
the handset. The handset acts as a multimeter to read
voltage, current, temperature, switch state, and other 16. R-SHIFT SWITCH = sideshift right switch, ON/
functions. OFF.

1. BATTERY VOLTAGE = battery voltage, nominal 17. L-SHIFT SWITCH = sideshift left switch, ON/OFF.
value = 24V.
18. BELLY SWITCH = traction reversing switch to the
2. MOTOR VOLTAGE = armature voltage obtained, controller or traction reversing request from con-
shown in volts. trol handle card, ON/OFF.

3. MOTOR CURRENT = armature current during 19. SNAIL SWITCH = snail request from control han-
traction (positive value) or braking (negative dle card allows machine to drive with control han-
value) in amps. dle up, turtle speed switch, ON/OFF.

4. FIELD CURRENT = field current in the selected 20. HORN SWITCH = horn request from control han-
traction direction in amps. dle card, ON/OFF.

5. EVP VOLTAGE = proportional lowering valve coil 21. SW4-SW9 = auxiliary function jumper.
voltage.
22. BATTERY MODEL = battery-type of input switch,
6. TEMPERATURE = controller temperature, °C. ON/OFF. ON = flooded battery (input closed),
OFF = sealed battery (input open).
7. ACCELERATOR = directional control voltage re-
ceived from control handle. 23. BATTERY CHARGE = battery charge indication,
%.
8. LIFTING CONTROL = proportional lifting voltage
received from control handle. SET OPTION MENU
9. TILLER SWITCH = control handle switch input,
ON The truck has three performance
ON/OFF.
modes, each with a fixed set of
10. FORWARD SWITCH = forward direction request parameters. This function is
from control handle card, ON/OFF. enabled by setting DRIVE
DRIVE MODES = ON.
11. BACKWARD SWITCH = backward direction re- MODES OFF DRIVE MODES disabled.
quest from control handle card, ON/OFF.
Custom Performance Mode is
12. LIFTING SWITCH = lifting function request from enabled, the adjustable
control handle card, proportional lift switch, ON/ parameters on Table 1 can be
OFF. adjusted.

7
Programming 2200 YRM 1064

ZAPI™ HANDSET To navigate the menu options, numbers inside the tri-
angles in the following map correspond to the same
NOTE: The ZAPI handset will display the code: number on the handset keyboard buttons. The orien-
V1.07 (or a higher number) for 1 to 2 seconds every tation of the triangle indicates the way to the next
time the key switch is turned to the ON position. This function. See Figure 3.
code represents the EEPROM software version and
DOES NOT INDICATE A FAULT CODE. 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 For additional handset description, see Figure 4.
have an adapter harness to connect to the controller.
The handset and adapter harness are available from 1 Roll-Up Push to scroll up.
your Yale dealer. Connect the handset to plug D. The
handset can remain connected to the controller while 2 Roll-Down Push to scroll down.
running, and the parameters can be changed in real 3 Enter Push to enter a submenu
time. In this case, it is necessary to go in a standby or to confirm a change.
condition (truck at rest) before switching OFF the con-
4 Out Push to exit a selected
troller in order to store the new values in the EE-
menu or to refuse a
PROM.
change.
This section describes the ZAPI™ handset functions. 5 Set-Up Push to increase a
Six buttons provide the capability of changing or read- parameter value.
ing the parameters. 6 Set-Down Push to decrease a
parameter value.
NOTE: After a modification, save the new values by
pushing out, then enter to confirm. (Screen prompts
will guide the user.)

8
2200 YRM 1064 Programming

THIS PAGE INTENTIONALLY LEFT BLANK

9/(9 blank)
Programming 2200 YRM 1064

10
2200 YRM 1064 Programming

Figure 4. ZAPI™ Handset Instructions

11
Alarm Code Diagnostics 2200 YRM 1064

Alarm Code Diagnostics

ALARM CODE DIAGNOSTIC
PROCEDURE Table 3. Example Controller Software Versions

NOTE: The dash indicator will display the code: EP MPB NA V 1.08
107 (or a higher number) for 1 to 2 seconds every 24 V - 180 A 000369
time the key switch is turned to the ON position. This
code represents the EEPROM software version and or
DOES NOT INDICATE A FAULT CODE. SC P18 V 1.04
24 V - 180 A 00369
When an alarm code(s) has been detected, the fol-
lowing procedure should be performed to properly or
read the codes and eliminate unnecessary proce- COMBI - USA4 V 1.06
dures during troubleshooting.
24 V - 180 A 000369

CAUTION NOTE: The lower right hand numbers represent the

Always turn the key switch to the OFF position hours since controller installation which may differ
when connecting and disconnecting the handset from total truck hours as shown on the digital dash in-
or laptop cable into the truck controller. dicator (DDI).
NOTE: If you are using a USB connection to your 3. Go to "Alarm Menu." Press Enter.
laptop, the cables and adaptors must be connected to
both the laptop and the lift truck controller before the 4. Write down both lines of the alarm code. Then
laptop is first started (booted) up. scroll to the next alarm code and record both lines
again. Continue until the alarm codes repeat with
1. Connect the Zapi™ Handset or laptop to the lift identical information. Example: You will see five
truck controller. Turn the handset or laptop on. alarm codes as you scroll if five alarms have been
Turn the lift truck key switch to the ON position generated, then they will repeat. The codes con-
and view the handset display. See Table 2. tain the actual alarm code (EVP NOT OK), con-
troller hours at time of last occurrence (1350h),
number or occurrences (#15), temperature at time
Table 2. Example Handset Software Versions
of last occurrence (in Celsius (35C)). See Table 4.
ZAPI
CONSOLE V 3.07 Table 4. Example Alarm Code

EVP NOT OK
NOTE: The handset will briefly display the handset
1350h #15 35C
software version for 1.5 seconds before changing to
the second screen. Wait for the second screen to ap-
pear with the controller software version. 5. After all the alarm codes have been written down,
then clear the log book by selecting "Clear the
2. Write down the controller software version infor-
Log." The Zapi handset will ask "Are You Sure?"
mation and hourmeter reading that is displayed
Press "Enter" then press "Out."
on the second screen of the handset. See Ta-
ble 3. NOTE: DO NOT disconnect or turn off the handset or
laptop at this time.

12
2200 YRM 1064 Alarm Code Diagnostics

6. Cycle the key switch to start the lift truck in the Remember to use the "Tester" function to check
normal mode. Operate the lift truck until the alarm switch input from the control handle to the control-
code reoccurs (faults out). Then, go back to the ler. This procedure will also alert you if the control-
Alarm Code menu and write down the alarm co- ler has been changed but the control handle card
des which are now present. These alarms should has not been reprogrammed.
be investigated first to isolate the most prominent
malfunctions. Zapi controller menu items:
• ACCELERATOR = Volts Percent % =
NOTE: If the THERMAL PROTECTION alarm codes Shows Variable Voltage From Traction
are generated, use the Tester Function = Tempera- Thumbwheel (FWD or REV)
ture. If the controller sees 75°C (175°F) or below
−10°C (14°F), it will reduce electrical current to the • FORWARD AND BACKWARD SWITCH =
motors and regular performance of the lift truck will "OFF to "ON"
slow down. • LIFTING CONTROL = Volts Percent % =
Lifting and Lowering = Proportional Switches
You can operate the truck with the Tester Function (Control Handle Card Must be Calibrated)
activated and monitor the controller's internal tem-
• LIFTING AND LOWERING SWITCH =
perature in real time. For additional heat dissipa-
"OFF" to "ON"
tion, fold up several layers of aluminum foil and
place it between the controller mounting base and • BELLY, HORN, SNAIL SWITCHES = "OFF"
the mounting plate to fill any air pockets in the mat- to "ON"
ing surfaces which will impede conductivity and • SW8 = Gray Button for Alt Functions =
prevent the heat from flowing from the controller "OFF" to "ON" (Reach and Counterbalance)
heat sink into the mounting plate of the controllers.
• ETC.
The use of "conductivity paste' is not recommen-
ded.

CAUTION
If the battery has been disconnected and recon-
nected with the key switch in the ON position, a
voltage spike can cause corruption of the Zapi
controller EPROM.

13
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 OR COMPONENTS
AFFECTED

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

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

NOTE: The dash indicator will display the code: EP 107 (or a higher number) for 1 to 2 seconds every time the
key switch is turned to the ON position. This code represents the EEPROM software version and DOES NOT IN-
DICATE A FAULT CODE.

14
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 position.
Verify continuity between batteries
negative (at battery) and -B power wire
connection (at controller). LOGIC
If no continuity, check: Occurs when there is no power to the controller or the
Power wiring between battery and controller is defective.
controller.
Verify continuity between battery positive
(at battery) and B-12 connection (at
controller).
If no continuity, check:
Fuse 3 for open.
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.
Refer to the section Electrical System 2200YRM1026
or Electrical System 2200YRM1007 for more
information on troubleshooting electrical system circuits
and components.

15
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 controller.
• Defective dash display.
Connect handset to controller and confirm
communication to handset. LOGIC
Occurs when the MDI or LED receives no signal, or
If handset operates correctly, replace MDI. MDI or LED is damaged.
• Defective LED.
Disconnect LED and connect handset. If
handset 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
communication 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.

16
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
• Check that all switches are in the neutral
position.
• 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 LOGIC
OFF, check brake switch for damage, Fault occurs when controller receives input that has not
interference, or shorts. followed the proper operational sequence.
• Check accelerator - Should be 0 volts at neutral.
If not, repeat control card calibration. If this does
not correct the problem, test the control card.
Refer to Control Card Functional Test in this
section.
• Check hydraulic inputs – Should be 0 volts. If
not, recalibrate tiller card. Follow auto-learn
procedure listed in steering. If this does not clear
fault, check buttons for damage or interference.
Replace damaged or faulty buttons.

17
Troubleshooting 2200 YRM 1064

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 switch is open,
recalibrate control card.
• Control card throttle damaged or Cam Magnetic
Holder not aligned with Alignment Window.
Replace control card if needed.

LOGIC
Occurs when accelerator voltage from serial control
card is higher than 1V (20%) before neutral switch is
closed.

18
2200 YRM 1064 Troubleshooting

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

19
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 time, card may be
damaged.
Replace the control card if needed.

LOGIC
Occurs if controller receives signal for forward and
reverse directions simultaneously.

20
2200 YRM 1064 Troubleshooting

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 LOGIC
the controller. With control card No information or incorrect information has been sent
disconnected, this should be about 12V; from the control card to controller.
with the card connected, it should be
about 5V. 0V or 12V with the card
connected means that the card may be
damaged.
Test the control card. Refer to Control
Card Functional Test in this section.

21
Troubleshooting 2200 YRM 1064

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.
Verify that traction reversing switch cover
is making contact with switch on control
card.
• Possible damaged or defective control card.
Replace the control card if needed.

LOGIC
Traction Reversing Switch data signal is not present
and hardware 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 LOGIC
connections or broken wires. Traction Reversing Switch hardware signal is not
present and data signal is present.
• Damaged or defective control handle card.
Replace control card if needed.

22
2200 YRM 1064 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
• Connector E is loose at base of controller or
defective.
Inspect connector E. Check wire 100
between position 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. LOGIC
Check motor field for shorts to chassis. Occurs when the controller detects a short in the main
See Traction Motor Test. contactor circuit.
• Controller is damaged.
Replace controller.
Refer to the section Electrical System 2200YRM1026
or Electrical System 2200YRM1007 for more
information on troubleshooting electrical system circuits
and components.

23
Troubleshooting 2200 YRM 1064

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
proportional 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. LOGIC
• Lowering valve cartridge is damaged. Occurs if electro-proportional valve is open before
Replace lowering valve cartridge. circuit is energized. Valve does not follow the supplied
signal from controller.
Refer to the section Electrical System 2200YRM1026
or Electrical System 2200YRM1007 for more
information on troubleshooting electrical system circuits
and components.

24
2200 YRM 1064 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 LOGIC
resistance should be 14.3 ohms. Occurs when brake driver circuit is shorted or open
circuit.
• Damaged fly-back diode at brake.
Check coil resistance. Short circuit
measured at 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.

25
Troubleshooting 2200 YRM 1064

Dash Display Controller LED Handset or PC

AL6 6 Flashes I = 0 EVER
CONDITION
Motor current levels do not exceed a preset minimum
value while driving.
TRUCK RESPONSE
Traction and hydraulic function disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Damaged or loose electrical connections to trac-
tion motor.
Verify electrical connections between trac-
tion motor and controller.
• Traction motor armature resistance is too low.
Check traction motor armature for shorts.
Perform traction motor test. See Traction
Motor Test in this section.
• Controller is damaged.
LOGIC
Cycle key switch. Place steer handle in Occurs if while driving, the motor current does not ex-
drive position and select throttle. If the ceed a preset minimum value.
truck starts to drive but then stops and
presents code AL6, replace controller.

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 controller.
• Motor field winding is shorted or too low.
Check motor field for correct resistance
and continuity. It should measure approxi-
mately 0.5 ohms. Perform traction motor
test. See Traction Motor Test in this sec-
tion.
• Failure of current sensor in controller.
LOGIC
Replace controller. Measured field current is too high.
• Failure of field current driver in controller.
Replace controller.

26
2200 YRM 1064 Troubleshooting

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 controller.
• Motor field winding is open or too high.
Check motor field for correct resistance
and continuity. It should measure
approximately 0.5 ohms. Perform traction
motor test. See Traction Motor Test in this
section.
LOGIC
• Field current sensor in controller has failed.
Measured field current is too low.
Replace controller.
• Main contactor circuit damaged or disconnected.
Verify electrical connection between
controller and contactor.
Check contactor coil for correct resistance
of 22.0 ohms (12.5 ohms for models
MSW020/025-E).
• Field current drivers in controller are damaged.
Replace controller.
Refer to the section Electrical System 2200YRM1026
or Electrical System 2200YRM1007 for more
information on troubleshooting electrical system circuits
and components.

27
Troubleshooting 2200 YRM 1064

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.

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 LOGIC
temperature should be same as room This alarm is generated when the controller
temperature at initial startup. If these temperature is outside -10 to 75°C (14 to 167°F).
temperatures differ, replace controller.
• Controller temperature sensor damaged.
Replace controller.
• Controller damaged.
Replace controller.

28
2200 YRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

AL8 8 Flashes POWER FAILURE #1
CONDITION
Short circuit in device connected to controller.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Overcurrent detected in driven component.
Check main harness for damaged or
shorted connections to main contactor,
brake, and electric valve coils.
Check main contactor, brake, and
proportional lowering solenoid for correct
resistance values.
LOGIC
Value should be within ±10% at room
Occurs when controller detects short circuit in
temperature.
component driven by controller.
Main Contactor for truck with Aux functions and
300 amp contactor = 15 ohms, No Aux functions
and 80 amp contactor = 22 ohms.
Brake coil = 14.3 ohms
Proportional lowering valve coil (EV1) = 17.8
ohms
Lifting solenoid (EV2) = 22.2 ohms
A/B directional valve coil (EV3, EV4) = 40.2
ohms
Refer to the section Electrical System 2200YRM1026
or Electrical System 2200YRM1007 for more
information on troubleshooting electrical system circuits
and components.

29
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.
Clear fault log and recycle key switch OFF
and ON. Operate lift truck to test. If fault
reoccurs, replace controller.

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

30
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.
See Traction Motor Test in this section.
• 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 LOGIC
the harness. Tape or secure the wire ends Occurs when an internal or external short or open
to prevent shorts. prevents the main capacitors from charging at key ON.
Discharge controller by placing 200?, 2W
resistor across B+ and B- terminals.
Reconnect battery and turn key ON. Use
voltmeter to observe voltage across B+
and B-. If there is no voltage increase,
replace controller. If there is a steady
voltage increase to battery voltage,
connect each accessory one at a time
until the fault occurs to identify damaged
component.
• If traction motor malfunction suspected, test for
proper operation.
Perform traction motor test. See Traction
Motor Test in this section.
• Damaged controller.
Replace controller.

31
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 terminals. See Traction Motor Test in
this section.
• Check for traction motor malfunction.
Perform traction motor test. See Traction LOGIC
Motor Test in this section. Occurs when controller observes differences between
• Damaged controller. battery voltage and voltage supplied to the traction
motor.
Voltage at –T terminal on controller should
be the same as the +B terminal.
Replace controller.

32
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 controller.
• 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?.
• Check for traction motor malfunction.
Perform traction motor test. See Traction LOGIC
Motor Test in this section. This fault occurs when the voltage measured at the
field connections is not the expected value.
• 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 B+ and
B-.
Replace controller.
• Field current drivers in controller are damaged.
Replace controller Verify motor field cable
connections.

33
Troubleshooting 2200 YRM 1064

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.
Clear the fault log and recycle key switch
OFF, then ON. Operate truck to test. If
alarm returns, replace controller.

LOGIC
Occurs if the watchdog hardware circuit is damaged.

34
2200 YRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) Driver Shorted
CONDITION
Voltage measured at field connections is not correct. LOGIC
This fault occurs when the voltage measured at the
TRUCK RESPONSE field connections is not the expected value.
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Cable connection to motor field is loose or
damaged.
Verify connection of field wires to motor
and controller.
• Main contactor coil shorted/open.
Check contactor coil for correct resistance
of 22.0 ohms (53.4 ohms for models
MPB040-E).
• 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.
• Check for traction motor malfunction.
Perform traction motor test. See Traction
Motor Test in this section.
• 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 B+ and
B-.
Replace controller.
• Field current drivers in controller are damaged.
Replace controller. Verify motor field cable
connections.
Refer to the section Electrical System 2200YRM1026
or Electrical System 2200YRM1007 for more
information on troubleshooting electrical system circuits
and components.

35
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 measured by an
accurate digital voltmeter between B+ and
B- terminals. Pull down tiller handle to
engage contactor for this measurement. If
these two voltages are more than 1.5 volts LOGIC
difference, replace controller. Controller measures low battery voltage over multiple
checks during traction or hydraulic operation.

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.

36
2200 YRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

AL99 Continuous Flash BATTERY KO
CONDITION
Improper battery connection or defective battery.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Incorrect battery selected.
Verify correct battery voltage for truck.
• Damaged or extremely discharged battery.
Disconnect battery and check voltage at
connector. Inspect battery for correct
water level and damage. Repair or replace
battery.
• Defective or damaged connection to battery.
Inspect cable crimps and cables from LOGIC
battery to connector. Battery voltage is much less than allowable.
Inspect cable crimps and cables from
battery contactor to controller and
contactor.
Refer to the section Electrical System 2200YRM1026
or Electrical System 2200YRM1007 for more
information on troubleshooting electrical system circuits
and components.

37
Troubleshooting 2200 YRM 1064

AUXILIARY HYDRAULICS (MSW030/040-

E, MRW020/030-E, MCW025/030/040-E)

When experiencing a malfunction with the auxiliary

operations of the lift truck, different components may
be at fault. To accurately determine where the fault is
occurring, you must test the circuits responsible for
delivering the desired function. See Figure 5.

For detailed auxiliary hydraulics troubleshooting, see

Electrical System 2200YRM1026.

Figure 5. Auxiliary Hydraulic Logic

38
2200 YRM 1064 Troubleshooting

Table 5. Auxiliary Module - MRW020/030-E (With Tilt)

Auxiliary Function Reach (In) Reach (Out) Tilt (Up) Tilt (Down)
Push Button 5 6 5 6
Selector Button 7
H1 L L H H
H2 H H H H
H5 L L L L
H6 L L L L
Auxiliary Board
H7 H H L L
Inputs
H8 L L H H
H9 L H L H
H10 H L H L
H12 L L L L
F1 H H H H
F2 H H H H
F3 H H H H
F4 H H H H
F5 L H L H
F6 H L H L
F7 L L L L
Auxiliary Board
F8 L L L L
Outputs
G1 L L L L
G2 H H L L
G3 H H L L
G4 L L H H
G5 H H H H
G6 H H H H
H11 L L H H

39
Troubleshooting 2200 YRM 1064

Table 6. Auxiliary Module - MRW020/030-E (With Tilt and Sideshift)

Auxiliary Function Sideshift Reach Tilt

Right Left In Out Up Down
Push Button 3 4 5 6 5 6
Selector Button 7
H1 L L L L H H
H2 H H H H H H
H5 L L L L L L

Auxiliary H6 L L L L H H
Board H7 H H H H L L
Inputs H8 H H L L H H
H9 L H L H L H
H10 H L H L H L
H12 L L L L L L
F1 H H H H H H
F2 H H H H H H
F3 H H H H H H
F4 H H H H H H
F5 L H L H L H
F6 H L H L H L

Auxiliary F7 L L L L L L
Board F8 L L L L L L
Outputs G1 L L H H H H
G2 H H H H L L
G3 H H L L H H
G4 H H L L H H
G5 H H H H H H
G6 H H H H H H
H11 L L L L H H

40
2200 YRM 1064 Troubleshooting

Table 7. Auxiliary Module - MCW025/030/040-E (With Tilt)

Auxiliary Function Tilt (Up) Tilt (Down)

Push Button 5 6
H1 L L
H2 H H
H5 L L
H6 L L
Auxiliary Board Inputs H7 L L
H8 H H
H9 L H
H10 H L
H12 L L
F1 H H
F2 H H
F3 H H
F4 H H
F5 L H
F6 H L
F7 L L
Auxiliary Board Outputs F8 L L
G1 L L
G2 L L
G3 H H
G4 H H
G5 H H
G6 H H
H11 L L

41
Troubleshooting 2200 YRM 1064

Table 8. Auxiliary Module - MCW025/030/040-E (With Tilt and Sideshift)

Auxiliary Function Sideshift (Right) Sideshift (Left) Tilt (Up) Tilt (Down)
Push Button 3 4 5 6
H1 L L L L
H2 H H H H
H5 L L L L
H6 L L L L
Auxiliary Board
H7 H H H H
Inputs
H8 L L H H
H9 L H L H
H10 H L H L
H12 H H L L
F1 H H H H
F2 H H H H
F3 H H H H
F4 H H H H
F5 H H L H
F6 H H H L
F7 L H H H
Auxiliary Board F8 H L H H
Outputs
G1 L L L L
G2 H H H H
G3 H H H H
G4 L L H H
G5 L L H H
G6 H H H H
H11 L L L L

42
2200 YRM 1064 Control Card Functional Test

Control Card Functional Test

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

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

43
Control Card Functional Test 2200 YRM 1064

d. Reconnect and measure volt- • The proper setting for these models
age on JP2 again. is number 4.
ii. If voltage reading is achieved on i. If not, proceed to reconfigure card
JP2, and the 7 segment display is through teach mode following auto-
not lit, replace the tiller card. Refer learning procedure listed in the
to the section Electrical System Electrical System 2200YRM1026
2200YRM1026 or Electrical Sys- or Electrical System
tem 2200YRM1007. 2200YRM1007{xxx 1006 1064
&1067 all reference electrical 1007
(2) Ensure jumper on SV2 is not on Diagnose, verified B.Cole--1064 also referen-
Teach or Configuration mode. SV2 jumper ces 1026 electrical for C820 et. al.
can be either seated on parking position BCole 7/27/10} section.
(P) or not present at all.
7. If speed is other than desired, refer to Trouble-
(3) Ensure 7 segment LED displays the proper shooting in this section.
control handle card setting:

NOTE: ENSURE THAT THE CAM MAGNETIC HOLDER IS ALIGNED WITH THE ALIGNMENT WINDOW; OTH-
ERWISE TRACTION FUNCTIONS WILL NOT OPERATE IN ONE OF THE DIRECTIONS.

1. JUMPER TERMINALS (SV2)

2. HORN SWITCH (S1)
3. THUMBWHEEL SWITCH (CAM MAGNETIC HOLDER)
4. LED DISPLAY SCREEN
5. BELLY SWITCH (S)
6. TURTLE SWITCH (S2)
7. ALIGNMENT WINDOW (CAM MAGNETIC HOLDER)

Figure 6. Control Card

44
2200 YRM 1064 Traction Motor Test

Traction Motor Test

After troubleshooting the alarm codes per the trouble- 6. Connect the battery BUT LEAVE THE KEY
shooting section, some problems may be isolated to SWITCH IN THE OFF POSITION. Press the re-
either the controller or the traction motor. There is no mote start switch for 1/2 second then release.
test that can be performed on the controller to deter- Note the direction of rotation of the drive tire and
mine if it is faulty. However, the traction motor can be noise of the motor, bearings and gearbox.
eliminated as the problem by testing it to confirm
proper operation. If the traction motor performs prop- 7. Disconnect the battery then reconfigure the
erly during the test, and all the other troubleshooting jumper wires as follows:
steps have been checked thoroughly, the controller is
a. Connect a jumper wire from B+ (battery posi-
more likely to be functioning improperly. Use the fol-
tive) before it enters the controller to F2 termi-
lowing procedure to test the traction motor.
nal on the traction motor.
1. Position the lift truck drive end on blocks to se- b. Connect a jumper wire from F1 to A2 on the
curely suspend the drive tire off the floor. traction motor.
2. Turn the key switch to the OFF position and dis- NOTE: A remote starter switch is a jumper wire with
connect the battery. Remove the drive unit com- an in-line momentary switch.
partment cover and discharge the capacitors in
the controller. c. Connect a remote starter switch from B− on the
controller to A1 on the traction motor.
NOTE: Locate the brake override connector on the
main wiring harness between the MDU and the con-
troller. It is a normally unconnected wiring connector
positioned near where the brake wiring harness and
main wiring harness connect.

3. Disconnect the brake wiring harness connector

from the main wiring harness and then connect
the brake override connector into the brake wiring
harness. With the key switch in the OFF position,
connect the battery connector and listen for a
"click" indicating that the brake has been released
and the override function is working properly. Dis-
connect the battery and continue. See Figure 7.

4. Tag, identify, and then disconnect the field wires

(F1 and F2) and motor leads (A1 and A2) from
the traction motor.

5. Connect jumper wires as follows:

a. Connect a jumper wire from B+ (battery posi-

tive) before it enters the controller to F2 termi-
nal on the traction motor.

b. Connect a jumper wire from F1 to A1 on the

traction motor.
1. BRAKE WIRING HARNESS
NOTE: A remote starter switch is a jumper wire with 2. MAIN WIRING HARNESS
an in-line momentary switch. 3. BRAKE OVERRIDE CONNECTOR

c. Connect a remote starter switch from B− on the Figure 7. Brake Override Connector
controller to A2 on the traction motor.

45
Traction Motor Test 2200 YRM 1064

8. Connect the battery BUT LEAVE THE KEY b. Clear the alarm log.
SWITCH IN THE OFF POSITION. Press the re-
mote start switch for 1/2 second then release. c. Disconnect the brake override and reconnect
Note the direction of rotation of the drive tire the break wiring harness to the main wiring
(should be opposite of the first test) and noise of harness.
the motor, bearings and gearbox.
d. Retest the lift truck.
9. Disconnect the battery.
11. If the alarm code NO TRACTION FWD OR REV
10. If the test proves the motor is not operating prop- or alarm code V FIELD NOT OK is generated, re-
erly, repair the traction motor, bearings, or gear- place the controller. Calibrate the control handle
box as necessary. If the test show the motor is card to the new controller.
operating properly:

a. Remove the jumpers and reconnect the field

wiring as removed.

ZAPI™ PC Interface
CONNECTING PC TO ZAPI™
CONTROLLER
NOTE: Values used on the following figures are for
example only. For the correct values for your truck,
see Controller Parameters in this section.

1. Turn the key switch to the OFF position.

2. Remove the drive unit compartment cover to ac-

cess the controller.

3. Locate the communications port on the controller.

(The port will have either a diagnostic LED, as in
Figure 8, or a connector for the display, as in Fig- Figure 9. Display Connection
ure 9.)

4. Connect the interface cable to the controller and

the PC. See Figure 10 and Figure 11.

Figure 8. Diagnostic LED

Figure 10. Controller Connection

46
2200 YRM 1064 ZAPI™ PC Interface

Figure 12. ZAPI™ Icon

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

Figure 11. PC Connection ure 13.

5. Locate the icon for the ZAPI™ software on the PC

and double-click on it. See Figure 12.

Figure 13. ZAPI™ Software Screen

47
ZAPI™ PC Interface 2200 YRM 1064

7. Click on the START button first and then turn the

key switch to ON. See Figure 14.

Figure 14. Start Button

48
2200 YRM 1064 ZAPI™ PC Interface

8. If the connection was successful, you should now

see the screen shown in Figure 15. If you get an
error message, go back to Step 7 and try again.

Figure 15. ZAPI™ Software Version Screen

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.

49
ZAPI™ PC Interface 2200 YRM 1064

FILE MENU

Open File

When you select this function, you will be able to

open a previously saved file that contains parameter
settings for the controller. See Figure 16.

Figure 16. File - Open

50
2200 YRM 1064 ZAPI™ PC Interface

Note that the previously saved file has the .csv exten-
sion, and observe how the file name was used. See
the Save File section of this manual for proper file
saving techniques. See Figure 17.

Figure 17. Look In:

51
ZAPI™ PC Interface 2200 YRM 1064

TX From File

This selection in the file menu is similar to the File

Open selection. See Figure 18.

Figure 18. File - TX From File

52
2200 YRM 1064 ZAPI™ PC Interface

Notice the CONNECTION STATUS while the file is

downloaded into the controller. See Figure 19.

Figure 19. Connection Status

53
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 Fig-
ure 20.

Figure 20. File - Save

54
2200 YRM 1064 ZAPI™ PC Interface

1. Try to use the actual truck serial number and put

the word "settings" after it. (This is to keep the
controller settings file separate from the tester
function Save file.) See Figure 21.

Figure 21. Save: In

2. Once you select a file name and click on Save,

you will see the screen shown in Figure 22.

Figure 22. Enter a Comment

55
ZAPI™ PC Interface 2200 YRM 1064

3. Under the Enter a Comment box, you can either BRAKING;2;0;0;LEVEL=9 12;INVERS.BRAKING;
describe what is different with the settings or en- 3;0;9;LEVEL=9 30;MAX SPEED FORW;
ter a customer name. 4;0;9;LEVEL=9 31;MAX SPEED BACK;
5;0;9;LEVEL=9 248;DRIVE MODES ;01;1;ON [End]
Here is what a saved parameter file looks like: [Info] [Validation] Code=FFDA [Stop]
Chopper_Name=MPB NA V1.01 User_Com-
ment=modified mode 4 to lower speed and coast Print Settings
more Save_Date=Thu Apr 04 15:58:15 2002
[Code;Name;Position;Menu;Value;Scaled Value] This selection allows you to print out your current pa-
0;ACCELER.DELAY;0;0;0;LEVEL=0 5;DE- rameter settings in the controller. See Figure 23.
CELER.DELAY;1;0;9;LEVEL=9 11;RELEASE

Figure 23. File - Print

56
2200 YRM 1064 ZAPI™ PC Interface

Exit

This selection will exit the ZAPI™ PC console soft-

ware. See Figure 24.

Figure 24. File - Exit

57
ZAPI™ PC Interface 2200 YRM 1064

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

troller and PC (operates the same as the main
There are two selections under this menu: Stop button on the right-hand side of the dis-
play screen).
1. Start - Starts the connection between the con-
troller and PC (operates the same as the main See Figure 25.
Start button on the right-hand side of the dis-
play screen).

Figure 25. Connection Menu

FUNCTION MENU 4. Program VACC - Not Used.

5. Motor Data - Not Used.
There are seven selections under this menu:
6. RAM Function - Only Factory Use.
1. Parameter - Allows the performance and con-
7. EEPROM Function - Only Factory Use.
figuration of the controller to be adjusted. Refer
to Parameter, in this section.
Parameter
2. Tester - Allows the testing of various inputs
and operations of the controller. Refer to When you first activate this selection, the screen will
Tester, in this section. look as indicated in Figure 26. In order to see the pa-
3. Alarm Logbook - Stores alarms that the con- rameters of the controller, you have to download them
troller detects. Refer to Alarm Logbook, in this to the PC. This can be done by 1 of 2 ways.
section.

58
2200 YRM 1064 ZAPI™ PC Interface

1. Receive menu - This will only download the 2. Receive - This will download all parameters
current selected tab. and configurations to the PC so you can adjust
them.

Figure 26. Parameter

You will now see a screen like Figure 27, while the
data is being downloaded.

Figure 27. Downloading Screen

59
ZAPI™ PC Interface 2200 YRM 1064

Now that the parameters have downloaded, you

should see a screen as indicated in Figure 28.

Figure 28. Drive Mode

Please note that the current drive mode the lift truck 2. Set Options - Allows the technician to turn on
was in will be displayed. (There are three modes that or off mode 4 for personalized performance
cannot be adjusted.) In order to make any changes to settings. See Set Options.
the parameters, you must turn on Mode 4, which is 3. Set Model - Not Used.
covered in Set Options, in this section.
4. Adjustment - Not Used.
Adjustments can be made by first highlighting the pa- 5. Special Adjust - Not Used.
rameter to be modified and then using the scroll bar 6. Hardware settings - Not Used.
on the right side of the screen to adjust it.
There are six parameters that can be adjusted to af-
You will also notice that there are six tabs along the fect the performance of the lift truck. See Figure 29.
top to choose from:
1. Parameter Change - Allows the performance
of the truck to be adjusted.

60
2200 YRM 1064 ZAPI™ PC Interface

Figure 29. Adjustable Parameters

1. ACCELER. DELAY - Amount of ramp-up to full • Level 9 - Maximum braking (aggressive).

speed.
4. INVERSE BRAKING - Amount of braking when
• Level 0 - Large acceleration curve, up to the lift truck is "plugged."
full speed.
• Level 0 - Minimum braking.
• Level 9 - Short acceleration curve, up to
full speed. • Level 9 - Maximum braking.

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

61
ZAPI™ PC Interface 2200 YRM 1064

Notice that the ACCELER. DELAY function has been react to the setting. Once the lift truck is performing as
adjusted. The parameter settings are "live," which wanted, the Store button is pressed to save the set-
means as they are being adjusted. The lift truck will tings into the controller. See Figure 30.

Figure 30. Store Button

NOTE: If the Store button is not pressed before turn-

ing off the lift truck, then all changed parameters will
be lost.

62
2200 YRM 1064 ZAPI™ PC Interface

Memory Menu

If you wish to start all over with your adjustments prior

to pressing the Store button, then you can select the
Memory menu to see the screen in Figure 31.

Figure 31. Memory Menu

This menu has three selections: 3. Restore - Will revert the parameter settings to
1. Receive - Same as Receive menu and Re- what they were before adjustments were
ceive button. made. Note this will not work if the settings
were stored before using this function.
2. Store - Same as Store button.

63
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 custom configuration. See Figure 32.

Figure 32. Set Options

64
2200 YRM 1064 ZAPI™ PC Interface

Highlight Drive Modes and then click on the scroll bar

to the right and select OFF. See Figure 33.

Figure 33. Turn Off Drive Modes

Do the following steps once this has been done: 4. Turn the key switch on the lift truck to OFF;
1. Press the Store button to save the change into then do the reconnect procedure.
the controller. 5. Now the parameters in the Function Menu can
2. Press the Close button to go to the main be adjusted to a custom configuration (Mode
screen of the ZAPI™ PC software. 4).

3. Press the Stop button to disconnect the com-

munication between the PC and the controller.

65
ZAPI™ PC Interface 2200 YRM 1064

Tester

This selection allows the technician to monitor up to

four items at a time to help troubleshoot problems.
See Figure 34.

Figure 34. Tester

The Tester function also features a data-logging ca-

pability to further assist the technician and the factory
with problems.

66
2200 YRM 1064 ZAPI™ PC Interface

The PC software can test the following (four selec- 11. Lifting Switch - refers to switch on right side
tions at a time). See Figure 35. of tiller head.
1. Battery Voltage - voltage across the battery. 12. Lowering Switch - refers to switch on right
2. Motor Voltage - voltage across the traction side of tiller head.
motor. 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 35. Test Name

67
ZAPI™ PC Interface 2200 YRM 1064

Data Logger

Figure 36. Data Logger

In addition to "live testing" of the controller, the The Advanced button allows the user to initiate a ser-
ZAPI™ PC software also includes a data-logging ca- ies of samples to be taken for the 4 items you have
pability. See Figure 36. There are four buttons associ- selected in the tester menu. Users can select the de-
ated with this, as listed below. sired time intervals between samples (time steps) and
1. Advanced - Allows the user to select sample the number of samples to be taken (samples). Time
rates and length of recording. steps are in increments equal to 0.1 seconds. There-
fore a selection of 20 time steps and 50 samples
2. Start Rec. - Starts the data logger. would result in a sample being taken every two sec-
3. Stop Rec. - Stops the data logger. onds until 50 samples have been recorded. See Fig-
4. Save Rec. - Saves the log to a file. ure 37.

Figure 37. Tester Advanced

68
2200 YRM 1064 ZAPI™ PC Interface

Figure 38. Logging Process

69
ZAPI™ PC Interface 2200 YRM 1064

As the data logger is running, the screen will look like Once the data logger is done, you can save the log
what is shown in Figure 38. During the logging proc- using the Save Rec. button. See Figure 39.
ess, you will still be able to see the values changing in
the display menu.

Figure 39. Save As

Once the log file has been saved, the user can either 0;0;0.00 0;80;0.0;
analyze the data him/herself or e-mail the file to the
factory for analysis. 10;0;0.00 0;80;0.0;
20;0;0.00 0;80;0.0;
The raw data file looks like this (see Figure 40): [Info] 30;0;0.00 0;80;0.0;
Chopper_Name=CS P20 V1.00 Save_Date=Thu Apr
04 13:32:24 2002 TIME;MOTOR CURRENT;ACCEL- 40;0;0.00 0;80;0.0;
ERATOR;BATTERY CHARGE ;FIELD CURRENT; 50;0;0.00 0;80;7.2;
60;3;0.00 0;80;7.2;
70;3;0.27 10;80;7.2;
80;3;0.27 10;80;12.7;
90;8;0.53 16;80;12.7;

70
2200 YRM 1064 ZAPI™ PC Interface

Figure 40. Test Data

Alarm Logbook

The ZAPI™ controller can record up to five unique

alarms and store them in a logbook that the PC can
access. See Figure 41.

Figure 41. Alarm Logbook

71
ZAPI™ PC Interface 2200 YRM 1064

The display screen (Figure 42) will display any current

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

Figure 42. Actual Alarm

The PC software will provide the alarm name and the The user can check for new alarms by pressing the
number of times it has occurred, the temperature of Update key or clear out the alarm log by pressing the
the controller when the alarm occurred, and the hour- Clear key.
meter reading (internal to the controller) of when the
alarm occurred.

72
2200 YRM 1064 ZAPI™ PC Interface

The following list consists of possible alarms. d. Turn the key switch to the ON position and
then POWER ON the laptop.
Alarms
e. Launch the ZAPI Laptop Software program
1. EVP NOT OK from the desktop icon or the start menu.

2. BRAKE DRIVER KO 2. ON the drop down menu, click on "Configuration,"

3. VFIELD NOT OK "COM Port."
4. PUMP VACC NOT OK a. Select the COM port "ComPort2."
5. SERIAL ERROR #1
b. Select the Baud Rate "1200 bps."
6. WATCHDOG
7. EEPROM KO c. Click "OK" then "Start" in the console window.

8. FORW + BACK d. Verify the connection status reads "CONNEC-

9. VMN NOT OK TED."
10. CONTACTOR CLOSED
11. I=0 EVER CAUTION
This procedure will access High Level Program-
12. STBY I HIGH
ming of the ZAPI controller.
13. HIGH FIELD CURRENT
14. NO FIELD CURRENT 3. On the drop down menu, click on "Configuration,"
"Enter Password."
15. CAPACITOR CHARGE
16. LOW BATTERY a. Enter the password ZAPI (in all capital letters).
The password can only be entered if the Com
17. THERMAL PROTECTION Configuration was properly connected in the
18. CHARGING BATTERY previous steps.
19. POWER FAILURE #1
b. Click "OK."
20. DRIVER SHORTED
4. On the drop down menu, click on "Function," "EE-
21. CONTACTOR DRIVER
PROM Function."
22. VACC NOT OK
23. INCORRECT START a. Delete the value in the address box and enter
F000.
24. INPUT ERROR #2
25. INPUT ERROR #1 b. Click "Start Write."

c. Verify that the new console window states

PROGRAMMING TILT AND SIDESHIFT ON "WRITE EEPROM CELL."
THE ZAPI CONTROLLER (LAPTOP)
d. Delete the value in the address box and enter
1. Connect the laptop to the ZAPI Controller: F000.
a. If equipped with sideshift, make sure controller e. Click "Start Write" again.
connector "E" on the main wiring harness has a
jumper wire installed between E3 to E13. f. Verify that the new console states "READ EE-
PROM CELL."
b. Turn the key switch to the OFF position. SHUT
DOWN the laptop. Make certain the laptop was g. Click "Stop Write."
powered off as opposed to restarted or in
standby mode. h. Delete the value in the "Value" box and enter
1234.
c. Connect the laptop to the controller using the
appropriate cables and connectors. i. Click "Start Write" again.

73
ZAPI™ PC Interface 2200 YRM 1064

j. Verify the values in the ADDRESS box and the e. Change the parameter value to PRESENT us-
VALUE box. ing the drop box in the upper right corner of the
console.
k. Click the "Close" button.
f. Click the "Store" button in the lower left of the
5. On the drop down menu, click on "Function," "Pa- window to save. Verify the value has changed
rameters." in the "Parameter Value" column.
a. Select the "Parameter Change" tab. 6. Verify all settings and click the "Close" button in
the lower right of the window to return to the Main
b. Click "Receive."
Menu.
c. Click the "Set Options" tab.

d. Select the parameter name "AUX INPUT #1."

Repair
REMOVE 11. Remove controller.

1. Park lift truck in a safe, level area. BRASS STUD REPLACEMENT

2. Block drive wheel to prevent lift truck from mov- Remove
ing.
1. Remove M8 nut, lockwasher, flat washer, brass
3. Connect handset or PC and download parame- washer, power fuse, and brass washer from brass
ters, if possible. stud.
4. Turn key to OFF. 2. Remove brass stud from controller.
5. Disconnect battery.
Install
6. Remove cover.
The stud must be installed in the correct orientation
with regard to the relief groove.
WARNING
The capacitors in the controller remain charged 1. Install brass stud onto controller and tighten to 10
for several minutes after operation. To prevent to 11 N•m (92 to 97 lbf in).
personal injury and/or damage to equipment, the
controller should be discharged. To discharge the 2. Install brass washer, power fuse, brass washer,
controller, connect a 200-ohm, 2- to 3-watt resis- flat washer, lockwasher, and M8 nut to brass
tor between the battery positive and negative ter- stud. Tighten M8 nut to 10 to 11 N•m (92 to
minals on the controller for at least 5 seconds. 97 lbf in).
Refer to Figure 1 in the General section of this
manual. INSTALL
7. Discharge controller. 1. Align controller to plate and capscrews. Tighten
capscrews.
8. Identify and tag all power cables and wires con-
nected to controller for later installation. 2. Connect all power cables and wires connected to
controller.
9. Remove all power cables and wires connected to
controller. 3. Connect battery.

10. Loosen both capscrews retaining controller to 4. Connect handset or PC.

plate.

74
2200 YRM 1064 Repair

5. Turn key to ON. 2. Connect ZAPI™ handset.

6. Upload parameters. 3. When main menu appears, press ENTER.

7. Remove blocks from drive wheel. 4. Scroll to ALARMS.

8. Test lift truck in a safe, level area away from other 5. Press buttons 5 and 6 at the same time.
personnel and equipment.
6. Scroll to READ EEPROM" Press ENTER.
9. Install cover.
7. Using ROLL and SET keys, change address to
REPAIR F000 1234.

1. Check and replace fuses as necessary. 8. Press ENTER. Press OUT until the main menu
appears.
2. Check and repair wiring (see troubleshooting
guide). 9. Press buttons 1 and 5 at the same time.

3. Check the battery pack. 10. Scroll to the SET OPTION menu. Press ENTER.

4. Check the motors and motor connections. 11. Scroll to AUX INPUT #1. Set to PRESENT.

5. Replace controllers when necessary by following 12. Press OUT. Handset will ask, ARE YOU SURE?.
the remove and install procedures listed above. Press ENTER.

SIDESHIFT SETUP WITH AUXILIARY 13. Press OUT until the main menu appears.
(MRW020/030-E) 14. Turn key OFF and ON to retain settings.

To enable the sideshift function on the MRW020/030- 15. Confirm operation of sideshift function.
E stacker trucks with auxiliary board, follow the follow-
ing procedure:

1. Jumper must be installed in connector E - posi-

tions 3 and 13.

75
 NOTES

76
2200 YRM 1064 8/16 (5/14)(5/12)(9/08)(4/08)(11/07)