ZAPI™ CONTROLLERS

W40Z [B218]

PART NO. 1511612 2200 SRM 1006

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

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

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!

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

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
ZAPI™ Transistor Motor Controller............................................................................................................. 2
Principles of Operation.................................................................................................................................. 2
Controller Safety ................................................................................................................................................ 3
Controller Adjustments ..................................................................................................................................... 3
Modes of Operation ............................................................................................................................................ 4
User-Selectable Operating Modes ................................................................................................................ 4
Programming...................................................................................................................................................... 4
Custom Performance Mode ........................................................................................................................... 4
Controller Parameters................................................................................................................................... 4
Tester Menu ................................................................................................................................................... 5
Set Option Menu............................................................................................................................................ 6
ZAPI™ Handset............................................................................................................................................. 6
Troubleshooting.................................................................................................................................................. 10
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 .................................................................................................................................................. 41
Memory Menu............................................................................................................................................ 45
Set Options ................................................................................................................................................ 46
Tester.......................................................................................................................................................... 48
Data Logger ............................................................................................................................................... 50
Alarm Logbook .......................................................................................................................................... 53
Alarms........................................................................................................................................................ 54
Repair ................................................................................................................................................................. 55
Remove ........................................................................................................................................................... 55
Brass Stud Replacement ............................................................................................................................... 55
Remove....................................................................................................................................................... 55
Install ......................................................................................................................................................... 55
Install ............................................................................................................................................................. 55
Repair ............................................................................................................................................................. 55

This section is for the following models:

W40Z [B218]

©2007 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1006 General

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

Figure 1. Controller W40Z

1
Description 2200 SRM 1006

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

2
2200 SRM 1006 Controller Adjustments

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

See Figure 2.

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

Figure 2. Discharging Controller W40Z

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

1. LED - An LED may be installed in trucks that 4. Personal Computer - The controller can also be
do not use a dash display. The LED flashes error connected to a personal computer (PC) equipped
codes to the technician for diagnosis. The LED with special software and cables. The PC can
would be installed on the bottom of the ZAPI™ read, store, and change settings on the controller.
controller. The LED is installed in connector port
B. See Figure 1. Proper use of these four methods and a list of diag-
nostic codes are explained in Troubleshooting, in this
2. Dash Display - Some trucks are equipped with section.
an optional dash display or MDI. Error codes are
shown on the LCD (liquid crystal display) when
the wrench symbol and red light are lit. The for-
mat is AL XX where XX is the error code.

3
Programming 2200 SRM 1006

Modes of Operation
It is possible to adjust the operating characteristics connection, it is possible to set the drive mode param-
of the lift truck. There are two basic ways to do this: eters to ON or OFF. In the ON mode, the user-se-
User-Selectable and Non-User-Selectable Operating lectable rules are enabled. In the OFF mode, the lift
Modes. truck will only operate using the settings selected.
The procedure to alter or modify these settings is
USER-SELECTABLE OPERATING MODES given in Programming in this section.

The operator has a choice of three performance 2. Control handle must be in the full, upright posi-
modes that are selectable through the control han- tion, brake ON.
dle. The mode selection is made at startup or key
ON. Performance parameters that vary are acceler- 3. Press and hold the horn button while turning the
ation, deceleration, regenerative (neutral) braking, key switch to the ON position.
and top travel speed.
4. Release the horn button when the horn sounds.
The three operator-selectable performance modes
5. Toggle through the modes by pressing the lift or
are factory programmed per the following:
lower buttons to the desired mode.
• Mode 1 - Economy mode (battery saver) - soft
acceleration, reduced top speed with regenerative 6. The horn provides an audible indication as to the
(neutral) braking. mode selected. One beep indicates Mode 1, two
• Mode 2 - Performance with regenerative (neutral) beeps indicate Mode 2, and three beeps indicate
braking - medium acceleration, reduced top travel Mode 3.
speed with regenerative (neutral) braking.
• Mode 3 - Performance without regenerative (neu- 7. Lower the control handle to the operating posi-
tral) braking - maximum acceleration, maximum tion, brake OFF, and begin operation.
top travel speed with coast at throttle release.
8. The selected mode is maintained until the proce-
The following procedure is used to access the user- dure is repeated.
selectable operating modes:
9. Turning the key OFF before lowering the control
1. The controller drive modes parameter must be handle will cancel the mode change.
ON. This is the factory setting.

NOTE: You must use the handset or PC interface to

change this setting. Using the ZAPI™ handset or PC

Programming
CUSTOM PERFORMANCE MODE To adjust parameters and install custom drive set-
tings, Drive Modes must be OFF. To set Drive Modes
In some instances, it may be preferable to disable to OFF, use the following procedure:
the Drive Modes and use a custom setting. This
controller has adjustable parameters that may be 1. Turn key switch OFF.
modified to suit specific customer needs. There
are two methods used to adjust these parameters: 2. Remove drive unit compartment cover.
the ZAPI™ handset or the personal computer (PC)
3. Connect adapter harness to handset.
interface.
NOTE: It may be necessary to remove the MDI
CONTROLLER PARAMETERS harness connector from the controller to install the
adapter harness.
Parameters are controller settings that can be ad-
justed to alter the performance characteristics of the NOTE: Connect and disconnect the handset only with
truck. the key switch in the OFF position.

4
2200 SRM 1006 Programming

4. Connect adapter harness to controller. 9. Scroll through the menus using button 1 or 2 to
the SET OPTIONS menu.
5. Turn key switch ON.
10. Enter this menu by pressing button 3.
6. The handset will turn ON. See Figure 3.
11. Press button 5 or 6 to set Drive Modes to OFF.
7. Press buttons 1 and 5 simultaneously.
12. Press button 4 to exit this menu.
8. The screen will display CONFIG 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.
Figure 3. ZAPI™ Handset

Table 1. Parameters

Parameter Description Value and Affect

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

TESTER MENU 3. MOTOR CURRENT = armature current during

traction (positive value) or braking (negative
The most important input or output signals can be value).
measured in real time using the TESTER function
of the handset. The handset acts as a multimeter to 4. FIELD CURRENT = field current in the selected
read voltage, current, temperature, switch state, and traction direction.
other functions.
5. TEMPERATURE = controller temperature, C.
1. BATTERY VOLTAGE = battery voltage, nominal
value = 24V, V. 6. ACCELERATOR = traction potentiometer value
received from control handle.
2. MOTOR VOLTAGE = motor voltage obtained
VBATT - VMN, V.

5
Programming 2200 SRM 1006

7. LIFTING CONTROL = lifting/lowering poten- SET OPTION MENU

tiometer value received from control handle.
DRIVE ON The truck has three
8. CONTROL HANDLE SWITCH = control handle MODES performance modes, each
switch input, ON/OFF. with a fixed set of parameters.
This function is enabled by
9. FORWARD SWITCH = forward direction request setting DRIVE MODES = ON.
from control handle card, ON/OFF.
OFF DRIVE MODES disabled.
10. BACKWARD SWITCH = backward direction re-
quest from control handle card, ON/OFF.
ZAPI™ HANDSET
11. CUTBACK SWITCH 1 = speed reduction switch
The ZAPI™ handset must be connected to the con-
input, ON/OFF (closed switch = OFF = no speed
troller before turning on the key. The handset must
reduction).
have an adapter harness to connect to the controller.
12. LIFTING SWITCH = lifting function request The handset and adapter harness are available from
from control handle card, ON/OFF. your Hyster dealer. Connect the handset to plug B.
The handset can remain connected to the controller
13. LOWERING SWITCH = lowering function re- while running, and the parameters can be changed
quest from control handle card, ON/OFF. in real time. In this case, it is necessary to go in
a standby condition (truck at rest) before switching
14. FORK LIFT SWITCH = i - lift request from con- OFF the controller in order to store the new values
trol handle card, ON/OFF. in the EEPROM.
15. FORK LOW SWITCH = i - lift request from con- This section describes the ZAPI™ handset functions.
trol handle card, ON/OFF. Six buttons provide the capability of changing or
reading the parameters.
16. BELLY SWITCH = belly input switch to the con-
troller or belly request from control handle card, 1 Roll-Up Push to scroll up.
ON/OFF.
2 Roll-Down Push to scroll down.
17. HARD & SOFT = snail request from control 3 Enter Push to enter a submenu or
handle card allows machine to drive with control to confirm a change.
handle up, ON/OFF.
4 Out Push to exit a selected menu
18. HORN SWITCH = horn request from control or to refuse a change.
handle card, ON/OFF.
5 Set-Up Push to increase a
19. LIFTING BLOCK = lifting block input switch, parameter value.
ON/OFF (with LIFTING BLOCK option pro- 6 Set-Down Push to decrease a
grammed OFF). parameter value.
20. BATTERY MODEL = battery-type of input
switch, ON/OFF. ON = flooded battery (input NOTE: After a modification, save the new values by
closed), OFF = sealed battery (input open). pushing out, then enter to confirm. (Screen prompts
will guide the user.)
21. BATTERY CHARGE = battery charge indication,
%. To navigate the menu options, numbers inside the
triangles in the following map correspond to the same
number on the handset keyboard buttons. The ori-
entation of the triangle indicates the way to the next
function. See Figure 3.

NOTE: Connect and disconnect the handset only with

the key switch in the OFF position.

For additional handset description, see Figure 4.

6
 NOTES

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Programming 2200 SRM 1006

8
2200 SRM 1006 Programming

Figure 4. ZAPI™ Handset Instructions

9
Troubleshooting 2200 SRM 1006

Troubleshooting
Dash Display Controller LED Handset or PC
LCD display Red LED
Red LED Fault Indicator Located at base of motor Error codes stored under Main Menu Alarms
controller.
(Trucks equipped with (Trucks without dash Message displayed on Handset or PC
optional dash display) display)
CORRESPONDING SCHEMATIC SHOWING
CIRCUITS TO BE CHECKED

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

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

10
2200 SRM 1006 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.
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 con-
nected in run position.
Verify continuity between batteries
negative (at battery) and B power
wire connection (at controller).
If no continuity, check:
Power wiring between battery and con-
troller.
Check for +24V at D-4, A-3, and A-6.
If no continuity, check:
Fuse 2 for open.
Key switch continuity in ON position.
Wiring battery + to main contactor to
fuse 2 to key switch, to controller A-6
connection.
• Defective battery charger.
Disconnect wires 2D and 12 from leads LOGIC
to battery charger.
Use test lead to connect 2D and 12. Occurs when there is no
If truck operates, check charger fuses, power to the controller or the controller is defective.
repair or replace battery charger.
• Defective motor controller.
Check for battery voltage between A-6
and B power wire connection at con-
troller.
If correct battery voltage, replace con-
troller.

11
Troubleshooting 2200 SRM 1006

Dash Display Controller LED Handset or PC

No LEDs or LCDs LED OFF No error codes present
illuminated
CONDITION
Dash display and/or controller LED inoperative.
TRUCK RESPONSE
Travel and hydraulic functions normal.
POSSIBLE CAUSES AND TEST PROCEDURES
• Open connection between dash display and con-
troller.
Verify harness connections at MDI and connector
B on controller.
Verify continuity of wires between MDI and con-
troller.
• Defective dash display. LOGIC
Connect handset to controller and confirm com-
munication to handset. Occurs when the MDI or
If handset operates correctly, replace MDI. LED receives no signal, or MDI
• Defective LED. or LED are damaged.
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 com-
munication to handset.
If handset will not communicate with controller,
replace controller.

LOGIC

Occurs when controller

does not send a signal to the MDI or LED.

12
2200 SRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

No Alarm LED OFF - No Flashes INCORRECT START
CONDITION
Improper startup sequence by operator.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Throttle or hydraulic function selected at key ON.
Steer handle in run position at key ON.
Return steer handle to full upright position. Re-
turn throttle to neutral. Release all hydraulic
function controls.
If fault remains, attach handset and go to test LOGIC
menu.
• Check brake switch, it should be off. If steer handle Fault occurs when
is in vertical position and reading is not OFF, check controller receives input that has not followed
brake switch for damage, interference, or shorts. 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, replace control card.
• 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 dam-
aged or faulty buttons.

Dash Display Controller LED Handset or PC

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

13
Troubleshooting 2200 SRM 1006

Dash Display Controller LED Handset or PC

AL99 Continuous Flash BATTERY KO
CONDITION
Improper battery connection or defective battery.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Incorrect battery selected.
Verify correct battery voltage for truck.
• Damaged or extremely discharged battery.
Disconnect battery and check voltage at connec-
tor. Inspect battery for correct water level and
damage. Repair or replace battery.
• Defective or damaged connection to battery. LOGIC
Inspect cable crimps and cables from battery to
connector. Battery voltage is much
Inspect cable crimps and cables from battery con- less than allowable.
tactor to controller and contactor.

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.

14
2200 SRM 1006 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 LOGIC
switches and for smooth, linear operation. Re-
place damaged switches. Occurs if the output of
• Control card lift/lower switch calibration is out of one on the hydraulic controls is higher
range. than 1V (20%) at start.
Install handset. Go to tester function. Check lift-
ing control and EVP voltage. Output of hydraulic
controls should be less than 1V (20%) at neutral.
Recalibrate control card.
• Control card is damaged or defective.
Replace card.

Dash Display Controller LED Handset or PC

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

15
Troubleshooting 2200 SRM 1006

Dash Display Controller LED Handset or PC

AL01 1 Flash SERIAL ERROR #1
CONDITION
Connection/communication error between control
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Loose or damaged electrical connection between
control card and controller.
LOGIC
Verify connection at controller.
Verify wire harness connection at base of steer
No information or
handle.
incorrect information has been sent from
Verify connection at control card.
the control card to controller.
• Damaged or defective control card.
Measure voltage at pin 5, connector C, on the
controller. With control card disconnected, this
should be about 12V; with the card connected, it
should be about 5V. 0V or 12V with the card con-
nected means that the card is damaged.
Replace control card.

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
Check wires in control handle arm are secure. data signal is not present and
• Damaged or defective control card. hardwire signal is present.
Replace control card.

16
2200 SRM 1006 Troubleshooting

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
LOGIC
operation of traction reversing switch.
Verify that traction reversing switch cover is
Control card is not
making contact with switch on control card.
sending hard-wired signal from
• Damaged or defective cable.
traction-reversing switch to controller.
Check steer handle control cable for loose connec-
tions or broken wires.
• Damaged or defective tiller card.
Replace control card.

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.
LOGIC
• Controller is damaged.
Replace controller.
Occurs when the
controller detects a short in the
main contactor circuit.

17
Troubleshooting 2200 SRM 1006

Dash Display Controller LED Handset or PC

AL4 4 Flashes EVP NOT OK
CONDITION
Lowering valve will not operate correctly.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Damaged or loose electrical connection to lowering
valve.
Verify electrical connections between valve coil LOGIC
and controller.
• Lowering coil damaged. Occurs if electro-propor-
Check lowering valve coil for correct resistance. tional valve is open before circuit is energized. Valve
Coil resistance should be approximately 33 ohms. does not follow the supplied signal from controller.
Replace coil if damaged.
• Lowering valve cartridge is damaged.
Replace lowering valve cartridge.

Dash Display Controller LED Handset or PC

AL5 5 Flashes EB DRIVER KO
CONDITION
Electric brake does not release or remains
released at all times.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Damaged or loose electrical connection to brake.
Verify electrical connection between electric LOGIC
brake and controller.
• Check brake coil for correct coil resistance. Occurs when brake
Disconnect brake. Measure brake coil resistance driver circuit is shorted or open circuit.
in both directions. Coil resistance should be be-
tween 27.36 and 30.24 ohms.
• 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.

18
2200 SRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

AL6 6 Flashes VFIELD NOT OK
CONDITION
Voltage measured at field connections is not correct.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Cable connection to motor field is loose or damaged.
Verify connection of field wires to motor and con-
troller.
• Check condition of crimps on wires connecting to F1
and F2.

LOGIC

This fault occurs when

the voltage measured at the field connections
is not the expected value.

19
Troubleshooting 2200 SRM 1006

Dash Display Controller LED Handset or PC

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

Occurs if while driving,

the motor current does not exceed
a preset minimum value.

20
2200 SRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

AL6 6 Flashes HIGH FIELD CURR, BW HIGH FLD CURR,
FW HIGH FLD CURR
CONDITION
High field current values measured by controller.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Field wires are loose, damaged, or shorted.
Verify connection of field wires to motor and con-
troller.
• Motor field winding is shorted or too low.
Check motor field for correct resistance and
continuity. It should measure approximately 0.5
ohms.
• Failure of current sensor in controller.
Replace controller.
• Failure of field current driver in controller.
Replace controller.
LOGIC

Measured field current

is too high.

21
Troubleshooting 2200 SRM 1006

Dash Display Controller LED Handset or PC

AL6 6 Flashes NO FIELD CURR
CONDITION
Low field current values measured by controller.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Cable connection to motor field is loose or damaged.
Verify connection of field wires to motor and con-
troller.
• Motor field winding is open or too high.
Check motor field for correct resistance and
continuity. It should measure approximately 0.5
ohms.
• Field current sensor in controller has failed.
Replace controller.
• Main contactor circuit damaged or disconnected.
Verify electrical connection between controller
and contactor. LOGIC
Check contactor coil for correct resistance of 53.4
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.
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 SRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

AL7 7 Flashes THERMAL PROTECTION
CONDITION
Controller temperature is out of operating range.
TRUCK RESPONSE
Traction functions reduced below 10 C (14 F)
and above 75 C (167 F). Traction and hydraulic
functions disabled above 90 C (194 F).
POSSIBLE CAUSES AND TEST PROCEDURES
• Controller temperature is too hot/cold.
Move truck to cooler or warmer location and al-
low controller to return to operating tempera-
ture.
• Controller temperature miscalibrated. LOGIC
Install handset. Go to tester function and check
temperature. Controller and vehicle tempera- This alarm is generated
ture should be same as room temperature at ini- when the controller temperature outside
tial startup. If these temperatures differ, replace is 10 to 75 C (14 to 167 F).
controller.
• Controller temperature sensor damaged.
Replace controller.
• Controller damaged.
Replace controller.

23
Troubleshooting 2200 SRM 1006

Dash Display Controller LED Handset or PC

AL8 8 Flashes POWER FAILURE #1
CONDITION
Short circuit in device connected to controller.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Overcurrent detected in driven component.
Check main harness for damaged or shorted con-
nections to main contactor, brake, and electric
valve coils.
Check main contactor, brake, and electric valve
coils for correct resistance values.
Check contactor coil for correct resistance of 53.4
ohms.
LOGIC
Check the brake coil for the correct resistance.
Resistance should be between 27.36 and 30.24
Occurs when controller
ohms.
detects short circuit in component
Check the electric valve coils for correct resis-
driven by controller.
tance of 17.7 ohms.

Value should be within ±10% at room temperature.

Dash Display Controller LED Handset or PC

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

LOGIC

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

24
2200 SRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) CAPACITOR CHARGE
CONDITION
Main controller capacitors did not charge
within 500 ms of key ON.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Loose or damaged wire connection.
Inspect and confirm wire connections at contac-
tor, pump motor, and traction motor.
• Short circuit in harness.
Disconnect main harness and check for shorts.
• Short circuit in component coil.
Disconnect battery. Disconnect all drive motor,
LOGIC
pump motor, solenoid, brake, and coil connec-
tions at the component end of the harness. Tape
Occurs when an internal
or secure the wire ends to prevent shorts.
or external short or open prevents the main
Discharge controller by placing 200 ohm, 2W re-
capacitors from charging at key ON.
sistor across B+ and B terminals. Reconnect
battery and turn key ON. Use voltmeter to ob-
serve voltage across B+ and B . If there is no
voltage increase, replace controller. If there is a
steady voltage increase to battery voltage, con-
nect each accessory one at a time until the fault
occurs to identify damaged component.
• Damaged controller.
Replace controller.

25
Troubleshooting 2200 SRM 1006

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.
• 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 SRM 1006 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 ohms.
• Field current driver circuit has failed.
Use a voltmeter to measure between F1 and B
and F2 and B with battery connected and key
ON. Voltage should measure 1/2 the voltage be-
tween B+ and B . LOGIC
Replace controller.
• Field current drivers in controller are damaged. This fault occurs when
Replace controller. Verify motor field cable con- the voltage measured at the field connections
nections. is not the expected value.

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 SRM 1006

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) Driver Shorted
CONDITION
Voltage measured at field connections is not correct.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Cable connection to motor field is loose or damaged.
Verify connection of field wires to motor and con-
troller.
• Motor field winding is shorted to chassis.
Check motor field for shorts to chassis.
Measure motor field resistance. Motor field
should be approximately 0.5 ohms.
• Main contactor coil shorted/open.
Check contactor coil for correct resistance of 53.4
ohms.
• Field current driver circuit has failed.
Use a voltmeter to measure between F1 and B LOGIC
and F2 and B with battery connected and key
ON. Voltage should measure 1/2 the voltage be- This fault occurs when
tween B+ and B . the voltage measured at the field connections
Replace controller. is not the expected value.
• Field current drivers in controller are damaged.
Replace controller. Verify motor field cable con-
nections.

28
2200 SRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

AL94 OFF NONE
CONDITION
Controller is installing hourmeter memory from
MDI display if controller has been replaced.
TRUCK RESPONSE
Traction and hydraulic functions disabled
for 1 minute.
POSSIBLE CAUSES AND TEST PROCEDURES
• No fault is occurring.
Controller will send hourmeter data to MDI and
truck will operate as soon as transfer is complete.
Wait approximately 60 seconds.

LOGIC

Synchronize hourmeter
data between MDI and controller.

29
ZAPI™ PC Interface 2200 SRM 1006

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

1. Turn the key switch to the OFF position.

2. Remove the drive unit compartment cover to ac-

cess the controller.

3. Locate the communications port on the con-

troller. (The port will have either a diagnostic Figure 7. Controller Connection
LED, as in Figure 5, or a connector for the dis-
play, as in Figure 6.)

Figure 8. PC Connection
Figure 5. Diagnostic LED
5. Locate the icon for the ZAPI™ software on the
PC and double-click on it. See Figure 9.

Figure 9. ZAPI™ Icon

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

ure 10.
Figure 6. Display Connection

4. Connect the interface cable to the controller and

the PC. See Figure 7 and Figure 8.

30
2200 SRM 1006 ZAPI™ PC Interface

Figure 10. ZAPI™ Software Screen

7. Click on the START button first and then turn

the key switch to ON. See Figure 11.

Figure 11. Start Button

31
ZAPI™ PC Interface 2200 SRM 1006

8. If the connection was successful, you should now

see the screen shown in Figure 12. 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 12. ZAPI™ Software Version Screen

32
2200 SRM 1006 ZAPI™ PC Interface

FILE MENU
Open File
When you select this function, you will be able to
open a previously saved file that contains parame-
ter settings for the controller. See Figure 13.

Figure 13. File - Open

33
ZAPI™ PC Interface 2200 SRM 1006

Note that the previously saved file has the .csv exten- the Save File section of this manual for proper file
sion, and observe how the file name was used. See saving techniques. See Figure 14.

Figure 14. Look In:

TX From File
This selection in the file menu is similar to the File
Open selection. See Figure 15.

Figure 15. File - TX From File

34
2200 SRM 1006 ZAPI™ PC Interface

Notice the CONNECTION STATUS while the file is

downloaded into the controller. See Figure 16.

Figure 16. Connection Status

35
ZAPI™ PC Interface 2200 SRM 1006

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

help track which file goes with each controller. See
The ZAPI™ PC software can save configurations for Figure 17.
up to 500 controllers. When saving a configuration

Figure 17. File - Save

1. Try to use the actual truck serial number and put controller settings file separate from the tester
the word "settings" after it. (This is to keep the function Save file.) See Figure 18.

Figure 18. Save: In

36
2200 SRM 1006 ZAPI™ PC Interface

2. Once you select a file name and click on Save, you 0;ACCELER.DELAY;0;0;0;LEVEL=0
will see the screen shown in Figure 19. 5;DECELER.DELAY;1;0;9;LEVEL=9
11;RELEASE BRAKING;2;0;0;LEVEL=9
3. Under the Enter a Comment box, you can either 12;INVERS.BRAKING;3;0;9;LEVEL=9
describe what is different with the settings or en- 30;MAX SPEED FORW;4;0;9;LEVEL=9
ter a customer name. 31;MAX SPEED BACK;5;0;9;LEVEL=9
248;DRIVE MODES ;01;1;ON
Here is what a saved parameter file looks like:
[End]
[Info]
Chopper_Name=MPB NA V1.01
[Validation]
User_Comment=modified mode 4 to lower
Code=FFDA
speed and coast more
[Stop]
Save_Date=Thu Apr 04 15:58:15 2002

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

Figure 19. Enter a Comment

37
ZAPI™ PC Interface 2200 SRM 1006

Print Settings
This selection allows you to print out your current
parameter settings in the controller. See Figure 20.

Figure 20. File - Print

38
2200 SRM 1006 ZAPI™ PC Interface

Exit
This selection will exit the ZAPI™ PC console soft-
ware. See Figure 21.

Figure 21. File - Exit

39
ZAPI™ PC Interface 2200 SRM 1006

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

troller and PC (operates the same as the main
There are two selections under this menu: Stop button on the right-hand side of the display
1. Start - Starts the connection between the con- screen).
troller and PC (operates the same as the main See Figure 22.
Start button on the right-hand side of the display
screen).

Figure 22. Connection Menu

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

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

40
2200 SRM 1006 ZAPI™ PC Interface

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

rent selected tab.
When you first activate this selection, the screen will 2. Receive - This will download all parameters and
look as indicated in Figure 23. In order to see the configurations to the PC so you can adjust them.
parameters of the controller, you have to download
them to the PC. This can be done by 1 of 2 ways.

Figure 23. Parameter

You will now see a screen like Figure 24, while the
data are being downloaded.

Figure 24. Downloading Screen

41
ZAPI™ PC Interface 2200 SRM 1006

Now that the parameters have downloaded, you You will also notice that there are six tabs along the
should see a screen as indicated in Figure 25. top to choose from:
1. Parameter Change - Allows the performance of
Please note that the current drive mode the lift truck the truck to be adjusted.
was in will be displayed. (There are three modes that 2. Set Options - Allows the technician to turn on or
cannot be adjusted.) In order to make any changes to off mode 4 for personalized performance settings.
the parameters, you must turn on Mode 4, which is See Set Options.
covered in Set Options, in this section. 3. Set Model - Not Used.
4. Adjustment - Not Used.
Adjustments can be made by first highlighting the
5. Special Adjust - Not Used.
parameter to be modified and then using the scroll
6. Hardware settings - Not Used.
bar on the right side of the screen to adjust it.

Figure 25. Drive Mode

42
2200 SRM 1006 ZAPI™ PC Interface

There are six parameters that can be adjusted to af- • Level 0 - Minimum braking (coasting).
fect the performance of the lift truck. See Figure 26. • Level 9 - Maximum braking (aggressive).

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

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

Figure 26. Adjustable Parameters

43
ZAPI™ PC Interface 2200 SRM 1006

Notice that the ACCELER. DELAY function has been NOTE: If the Store button is not pressed before turn-
adjusted. The parameter settings are "live," which ing off the lift truck, then all changed parameters will
means as they are being adjusted. The lift truck will be lost.
react to the setting. Once the lift truck is performing
as wanted, the Store button is pressed to save the
settings into the controller. See Figure 27.

Figure 27. Store Button

44
2200 SRM 1006 ZAPI™ PC Interface

Memory Menu 2. Store - Same as Store button.

3. Restore - Will revert the parameter settings to
If you wish to start all over with your adjustments what they were before adjustments were made.
prior to pressing the Store button, then you can select Note this will not work if the settings were stored
the Memory menu to see the screen in Figure 28. before using this function.
This menu has three selections:
1. Receive - Same as Receive menu and Receive
button.

Figure 28. Memory Menu

45
ZAPI™ PC Interface 2200 SRM 1006

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 29.

Figure 29. Set Options

46
2200 SRM 1006 ZAPI™ PC Interface

Highlight Drive Modes and then click on the scroll 3. Press the Stop button to disconnect the commu-
bar to the right and select OFF. See Figure 30. nication between the PC and the controller.
4. Turn the key switch on the lift truck to OFF; then
Do the following steps once this has been done: do the reconnect procedure.
1. Press the Store button to save the change into 5. Now the parameters in the Function Menu can
the controller. be adjusted to a custom configuration (Mode 4).
2. Press the Close button to go to the main screen
of the ZAPI™ PC software.

Figure 30. Turn Off Drive Modes

47
ZAPI™ PC Interface 2200 SRM 1006

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

pability to further assist the technician and the fac-
This selection allows the technician to monitor up to tory with problems.
four items at a time to help troubleshoot problems.
See Figure 31.

Figure 31. Tester

48
2200 SRM 1006 ZAPI™ PC Interface

The PC software can test the following (four selec- 11. Lifting Switch - refers to switch on right side of
tions at a time). See Figure 32. tiller head.
1. Battery Voltage - voltage across the battery. 12. Lowering Switch - refers to switch on right side
2. Motor Voltage - voltage across the traction mo- of tiller head.
tor. 13. Fork Lift Switch - refers to switch on left side
3. Motor Current - current through the traction of tiller head.
motor. 14. Fork Lower Switch - refers to switch on left
4. Field Current - current through the fields in the side of tiller head.
traction motor. 15. Belly Switch
5. Temperature - current temperature of the con- 16. Snail Switch
troller. 17. Horn Switch
6. Accelerator - voltage and percent of "throw" 18. Cutback Switch
from the traction thumbwheel. 19. Lifting Block
7. Lifting Control 20. Battery Model
8. Tiller Switch - position of tiller handle. 21. Battery Charge - remaining charge on the bat-
9. Forward Switch - directional input. tery.
10. Backward Switch - directional input.

Figure 32. Test Name

49
ZAPI™ PC Interface 2200 SRM 1006

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

rates and length of recording.
In addition to "live testing" of the controller, the 2. Start Rec. - Starts the data logger.
ZAPI™ PC software also includes a data-logging 3. Stop Rec. - Stops the data logger.
capability. See Figure 33. There are four buttons 4. Save Rec. - Saves the log to a file.
associated with this, as listed below.

Figure 33. Data Logger

The Advanced button allows the user to select time

increments and the number of samples. See Fig-
ure 34.

Figure 34. Tester Advanced

50
2200 SRM 1006 ZAPI™ PC Interface

As the data logger is running, the screen will look process, you will still be able to see the values chang-
like what is shown in Figure 35. During the logging ing in the display menu.

Figure 35. Logging Process

51
ZAPI™ PC Interface 2200 SRM 1006

Once the data logger is done, you can save the log
using the Save Rec. button. See Figure 36.

Figure 36. Save As

Once the log file has been saved, the user can either 20;0;0.00 0;80;0.0;
analyze the data him/herself or e-mail the file to the
30;0;0.00 0;80;0.0;
factory for analysis.
40;0;0.00 0;80;0.0;
The raw data file looks like this (see Figure 37):
[Info] 50;0;0.00 0;80;7.2;
Chopper_Name=CS P20 V1.00 60;3;0.00 0;80;7.2;
Save_Date=Thu Apr 04 13:32:24 2002
70;3;0.27 10;80;7.2;
TIME;MOTOR CURRENT;ACCELERATOR;BAT-
TERY CHARGE ;FIELD CURRENT; 80;3;0.27 10;80;12.7;

0;0;0.00 0;80;0.0; 90;8;0.53 16;80;12.7;

10;0;0.00 0;80;0.0;

Figure 37. Test Data

52
2200 SRM 1006 ZAPI™ PC Interface

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 38.

Figure 38. Alarm Logbook

53
ZAPI™ PC Interface 2200 SRM 1006

The display screen (Figure 39) will display any 5. SERIAL ERROR #1
current "live" alarms. Note the display ACTUAL 6. WATCHDOG
ALARM that indicates a current "live" alarm condi- 7. EEPROM KO
tion. 8. FORW + BACK
9. VMN NOT OK
The PC software will provide the alarm name and 10. CONTACTOR CLOSED
the number of times it has occurred, the tempera- 11. I=0 EVER
ture of the controller when the alarm occurred, and 12. STBY I HIGH
the hourmeter reading (internal to the controller) of 13. HIGH FIELD CURRENT
when the alarm occurred. 14. NO FIELD CURRENT
15. CAPACITOR CHARGE
The user can check for new alarms by pressing the
16. LOW BATTERY
Update key or clear out the alarm log by pressing the
17. THERMAL PROTECTION
Clear key.
18. CHARGING BATTERY
The following list consists of possible alarms. 19. POWER FAILURE #1
20. DRIVER SHORTED
Alarms 21. CONTACTOR DRIVER
22. VACC NOT OK
1. EVP NOT OK 23. INCORRECT START
2. BRAKE DRIVER KO 24. INPUT ERROR #2
3. VFIELD NOT OK 25. INPUT ERROR #1
4. PUMP VACC NOT OK

Figure 39. Actual Alarm

54
2200 SRM 1006 Repair

Repair
REMOVE 2. Remove brass stud from controller.

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

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

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

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

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

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

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

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

55
 NOTES

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56
 TECHNICAL PUBLICATIONS

2200 SRM 1006 11/07 (8/05)(3/04)(7/03)(4/02)(1/02) Printed in U.S.A.