Maintenance

ZAPI™ CONTROLLERS
MPB040-E [B827]

PART NO. 524154895 2200 YRM 1006

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

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks.

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

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

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

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

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

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

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

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

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

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

CAUTION
Indicates a condition that can cause property damage!
ZAPI™ Controllers Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
ZAPI™ Transistor Motor Controller ................................................................................................................. 1
Principles of Operation.................................................................................................................................... 2
Controller Safety.................................................................................................................................................. 2
Controller Adjustments ........................................................................................................................................ 3
Modes of Operation ............................................................................................................................................. 3
User-Selectable Operating Modes .................................................................................................................. 3
Programming ....................................................................................................................................................... 4
Custom Performance Mode ............................................................................................................................ 4
Controller Parameters ..................................................................................................................................... 4
Tester Menu .................................................................................................................................................... 5
Set Option Menu ............................................................................................................................................. 5
ZAPI™ Handset .............................................................................................................................................. 6
Troubleshooting ................................................................................................................................................... 10
ZAPI™ PC Interface ............................................................................................................................................ 28
Connecting PC to ZAPI™ Controller............................................................................................................... 28
File Menu ........................................................................................................................................................ 31
Open File .................................................................................................................................................... 31
TX From File ............................................................................................................................................... 32
Save File ..................................................................................................................................................... 34
Print Settings .............................................................................................................................................. 36
Exit.............................................................................................................................................................. 37
Connection Menu ............................................................................................................................................ 38
Function Menu ................................................................................................................................................ 38
Parameter ................................................................................................................................................... 38
Memory Menu............................................................................................................................................. 43
Set Options ................................................................................................................................................. 44
Tester .......................................................................................................................................................... 46
Data Logger ................................................................................................................................................ 48
Alarm Logbook............................................................................................................................................ 50
Alarms......................................................................................................................................................... 51
Repair .................................................................................................................................................................. 51
Remove ........................................................................................................................................................... 51
Install............................................................................................................................................................... 52
Repair.............................................................................................................................................................. 52

This section is for the following models:

MPB040-E [B827]

©2003 Yale Materials Handling Corp. i

2200 YRM 1006 Description

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

Figure 1. Controller MPB040-E

Description
ZAPI™ TRANSISTOR MOTOR valve, brake, and main contactor. Jumpers are used
CONTROLLER to configure the basic controller.

The ZAPI™ controller is a solid state DC motor con-
troller utilizing SEM technology. It controls the traction
motor, brake, and hydraulic system. The controller re-
ceives inputs from the control handle by serial commu-
nication, and direct inputs from the key switch and con-
trol handle arm position switch. The controller directly
controls the traction motor, lift pump motor, lowering
The controller software provides self diagnostics which
are accessed by means of a ZAPI™ handset or a PC
with specialized ZAPI™ software. The controller soft-
ware features a Test Menu for monitoring controller in-
puts and outputs, a Diagnostic Menu for viewing fault
code information, and a Programming Menu for cus-
tomizing the truck performance.

1
Controller Safety
The self diagnostics monitor the traction motor, brake
coil, lowering valve coil, contactor coil, control handle
serial communications, controller temperature, and
internal logic functions. The controllers on standard
trucks come equipped with a red LED fault indicator
located at the bottom of the controller. In the event of a
fault, the LED flashes a numeric code. Troubleshoot the
fault using a ZAPI™ handset or a properly configured
IBM compatible PC. On trucks equipped with the op-
tional dash display, the dash wiring harness plugs into
the controller in place of the LED. The display also has
a red LED, however it does not flash codes. If a fault
occurs, the red LED blinks, the wrench LCD is shown
and "AL" followed by the fault number is displayed.
Controller Safety
WARNING
The ZAPI™ controllers can hold an electrical charge
for several minutes after the key switch has been
turned OFF. To prevent injury, discharge the con-
trollers by connecting a 200-ohm, 2-watt resistor
between the battery positive connector and battery
negative connector on the controller and hold there
for 5 seconds.
See Figure 2.
2
2200 YRM 1006
PRINCIPLES OF OPERATION
The ZAPI™ Transistor Motor Controller uses a sophisti-
cated microprocessor to control the logic and operation
of the controller, eliminating the need for forward and
reverse contactors. The SEM motor controller operates
on the principle of controlling the motor field circuit and
the motor armature circuit independently. The controller
has many programmable features, including maximum
speed, acceleration rate, release braking, and braking
current limit. The SEM controller includes a full range
of features, as well as diagnostic and setup capability.
NOTE: There are no user-serviceable parts in the
ZAPI™ controller. No attempt should be made to open,
repair, or otherwise modify the controller. Doing so
may damage the controller and will void the warranty.
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 2. Discharging Controller MPB040-E
2200 YRM 1006
Controller Adjustments
The ZAPI™ transistor motor controller can store and
display Error Codes (Alarms). It is also possible to mod-
ify the controller Setup for individual preferences. Com-
munication with the controller is possible by four meth-
ods:
1. LED - An LED may be installed in trucks that do not
use a dash display. The LED flashes error codes to
the technician for diagnosis. The LED would be in-
stalled on the bottom of the ZAPI™ controller. The
LED is installed in connector port B. See Figure 1.
2. Dash Display - Some trucks are equipped with
an optional Dash Display or MDI. Error codes are
shown on the LCD (liquid crystal display) when the
Modes of Operation
It is possible to adjust the operating characteristics of
the lift truck. There are two basic ways to do this: User-
Selectable and Non-User-Selectable Operating Modes.
USER-SELECTABLE OPERATING MODES
The operator has a choice of three performance modes
that are selectable through the control handle. The
mode selection is made at startup or key ON. Perfor-
mance parameters that vary are acceleration, decel-
eration, regenerative (neutral) braking, and top travel
speed.
The three operator-selectable performance modes are
factory programmed per the following:
• Mode 1 - Economy mode (battery saver) - soft accel-
eration, reduced top speed with regenerative (neutral)
braking.
• Mode 2 - Performance with regenerative (neutral)
braking - medium acceleration, reduced top travel
speed with regenerative (neutral) braking.
• Mode 3 - Performance without regenerative (neutral)
braking - maximum acceleration, maximum top travel
speed with coast at throttle release.
The following procedure is used to access the user-se-
lectable operating modes:
1. The controller drive modes parameter must be ON.
This is the factory setting.
Modes of Operation
wrench symbol and red light are lit. The format is
AL XX where XX is the error code.
3. ZAPI™ Handset - A diagnostic handset is available
through your Yale dealer. The handset makes it
possible to diagnose faults and modify controller
settings. See Programming.
4. Personal Computer - The controller can also be
connected to a personal computer (PC) equipped
with special software and cables. The PC can read,
store, and change settings on the controller.
Proper use of these four methods and a list of diagnostic
codes are explained in Troubleshooting, in this section.
NOTE: You must use the handset or PC interface to
change this setting. Using the ZAPI™ handset or PC
connection, it is possible to set the drive mode parame-
ters to ON or OFF. In the ON mode, the user-selectable
rules are enabled. In the OFF mode, the lift truck will
only operate using the settings selected. The proce-
dure to alter or modify these settings is given in Pro-
gramming.
2. Control handle must be in the full, upright position,
brake ON.
3. Press and hold the horn button while turning the key
switch to the ON position.
4. Release the horn button when the horn sounds.
5. Toggle through the modes by pressing the lift or
lower buttons to the desired mode.
6. The horn provides an audible indication as to the
mode selected. One beep indicates Mode 1, two
beeps indicate Mode 2, and three beeps indicate
Mode 3.
7. Lower the control handle to the operating position,
brake OFF, and begin operation.
8. The selected mode is maintained until the proce-
dure is repeated.
9. Turning the key OFF before lowering the control
handle will cancel the mode change.
3
Programming 2200 YRM 1006

Programming
CUSTOM PERFORMANCE MODE
In some instances, it may be preferable to disable the
Drive Modes and use a custom setting. This controller
has adjustable parameters that may be modified to suit
specific customer needs. There are two methods used
to adjust these parameters: the ZAPI™ handset or the
personal computer (PC) interface.

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

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

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

4
2200 YRM 1006 Programming

Table 1. Parameters (Continued)

Parameter Description Value and Affect

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

TESTER MENU 13. LOWERING SWITCH = lowering function request

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

12. LIFTING SWITCH = lifting function request from

control handle card, ON/OFF.

5
Programming 2200 YRM 1006

ZAPI™ HANDSET 1 Roll-Up Push to scroll up.

The ZAPI™ handset must be connected to the con- 2 Roll-Down Push to scroll down.
troller before turning on the key. The handset must have 3 Enter Push to enter a submenu
an adapter harness to connect to the controller. The or to confirm a change.
handset and adapter harness are available from your
Yale dealer. Connect the handset to plug B. The hand- 4 Out Push to exit a selected
set can remain connected to the controller while run- menu or to refuse a
ning, and the parameters can be changed in real time. change.
In this case, it is necessary to go in a standby condition 5 Set-Up Push to increase a
(truck at rest) before switching off the controller in order parameter value.
to store the new values in the EEPROM.
6 Set-Down Push to decrease a
This section describes the ZAPI™ handset functions. parameter value.
Six buttons provide the capability of changing or reading
the parameters. NOTE: After a modification, save the new values by
pushing out then enter to confirm. (Screen prompts will
guide the user.)

To navigate the menu options, numbers inside the trian-

gles in the following map correspond to the same num-
ber on the handset keyboard buttons. The orientation 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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7
Programming 2200 YRM 1006

8
2200 YRM 1006 Programming

Figure 4. ZAPI™ Handset Instructions

9
Troubleshooting 2200 YRM 1006

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

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

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

10
2200 YRM 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 connected
in run position.
Verify continuity between batteries nega-
tive (at battery) and B power wire con-
nection (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 connec-
tion.
• 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 power
If truck operates, check charger fuses, 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 YRM 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 controller.
Verify harness connections at MDI and connector B
on controller.
Verify continuity of wires between MDI and con-
troller.
• Defective dash display.
Connect handset to controller and confirm commu- LOGIC
nication to handset.
If handset operates correctly, replace MDI. Occurs when the MDI or
• Defective LED. LED receives no signal, or MDI 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 commu-
nication to handset.
If handset will not communicate with controller, re-
place controller.

LOGIC

Occurs when controller

does not send a signal to the MDI or LED.

12
2200 YRM 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. Return
throttle to neutral. Release all hydraulic function
controls.
If fault remains, attach handset and go to test menu. LOGIC
• Check brake switch, it should be off. If steer handle is
in vertical position and reading is not “off,” check brake Fault occurs when
switch for damage, interference, or shorts. controller receives input that has not followed
• Check accelerator - Should be 0 volts at neutral. If not, the proper operational sequence.
repeat control card calibration. If this does not correct
the problem, replace control card.
• Check hydraulic inputs – Should be 0 volts. If not, re-
calibrate tiller card. Follow auto-learn procedure listed
in steering. If this does not clear fault, check but-
tons for damage or interference. Replace damaged
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 voltage mea-
sured by an accurate digital voltmeter between B+
and B terminal. Pull down tiller handle to engage LOGIC
contactor for this measurement. If these two volt-
ages are more than 1.5 volts difference, replace Controller measures low
controller. battery voltage over multiple checks during
traction or hydraulic operation.

13
Troubleshooting 2200 YRM 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 connector.
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 >1 volt (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 YRM 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 switches LOGIC
and for smooth, linear operation. Replace dam-
aged switches. Occurs if the output of
• Control card lift/lower switch calibration is out of range. one on the hydraulic controls is higher
Install handset. Go to tester function. Check “Lift- than 1V (20%) at start.
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 YRM 1006

Dash Display Controller LED Handset or PC

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

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2200 YRM 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 making
Control card is not
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 YRM 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 and LOGIC
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 17.7 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 brake LOGIC
and controller.
• Check brake coil for correct coil resistance. Occurs when brake driver
Disconnect brake. Measure brake coil resistance in circuit is shorted or open circuit.
both directions. Coil resistance should be between
27.36 and 30.24 ohms.
• Damaged controller.
Activate the brake switch. Use voltmeter to mea-
sure voltage on wire 2B and 79 with brake con-
nected in circuit. If both measurements are 24V and
the alarm is displayed, then controller is damaged.

18
2200 YRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

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

Occurs if while driving, the

motor current does not exceed a
preset minimum value.

19
Troubleshooting 2200 YRM 1006

Dash Display Controller LED Handset or PC

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

LOGIC

Measured field current is

too high.

20
2200 YRM 1006 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 con-
troller.
• Motor field winding is open or too high.
Check motor field for correct resistance and conti-
nuity. It should measure approximately 1.5 ohms.
• Field current sensor in controller has failed.
Replace controller.
• Main contactor circuit damaged or disconnected.
Verify electrical connection between controller and
contactor.
Check contactor coil for correct resistance of 52 LOGIC
ohms.
• Field current drivers in controller are damaged. Measured field current
Replace controller. is too low.

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.

21
Troubleshooting 2200 YRM 1006

Dash Display Controller LED Handset or PC

AL7 7 Flashes THERMAL PROTECTION
CONDITION
Controller temperature is out of operating range.
TRUCK RESPONSE
Traction functions reduced below 10 C (14 F)
and above 75 C (167 F). Traction and hydraulic
functions disabled above 90 C (194 F).
POSSIBLE CAUSES AND TEST PROCEDURES
• Controller temperature is too hot/cold.
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 LOGIC
“temperature.” Controller and vehicle temperature
should be same as room temperature at initial This alarm is generated
startup. If these temperatures differ, replace con- when the controller temperature is outside
troller. 10 to 75 C (14 to 167 F).
• Controller temperature sensor damaged.
Replace controller.
• Controller damaged.
Replace controller.

Dash Display Controller LED Handset or PC

AL8 8 Flashes POWER FAILURE #1
CONDITION
Short circuit in device connected to controller.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Over current 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 the main contactor for correct resistance of
52 ohms.
LOGIC
Check the brake coil for the correct resistance. Re-
sistance should be between 27.36 and 30.24.
Occurs when controller
Check the electric valve coils for correct resistance
detects short circuit in component driven by controller.
of 17.7 ohms.

Value should be within ±10% at room temperature.

22
2200 YRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

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

LOGIC

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

23
Troubleshooting 2200 YRM 1006

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 damage wire connection.
Inspect and confirm wire connections at contactor,
pump motor, and traction motor.
• Short circuit in harness.
Disconnect main harness and check for shorts.
• Short circuit in component coil.
Disconnect battery. Disconnect all drive motor;
LOGIC
pump motor, solenoid, brake, and coil connections
at the component end of the harness. Tape or
Occurs when an internal
secure the wire ends to prevent shorts.
or external short or open prevents the main
Discharge controller by placing 200 ohm, 2W resis-
capacitors from charging at key ON.
tor 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 in-
crease to battery voltage, connect each accessory
one at a time until the fault occurs to identify dam-
aged component.
• Damaged controller.
Replace controller.

24
2200 YRM 1006 Troubleshooting

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) VMN NOT OK
CONDITION
Measured voltage at traction motor inputs does
not match battery voltage.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Loose or damaged cable connections to motor.
Verify motor armature cables and connections.
• Ground between motor windings and chassis.
Check for grounds between motor chassis and ter-
minals.
• Damaged controller.
Voltage at –T terminal on controller should be the
same as the +B terminal.
Replace controller.

LOGIC

Occurs when controller

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

25
Troubleshooting 2200 YRM 1006

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 1.5 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 between
B+ and B . LOGIC
Replace controller.
• Field current drivers in controller are damaged. This fault occurs when the
Replace controller Verify motor field cable connec- voltage measured at the field connections
tions. 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.

26
2200 YRM 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.

27
ZAPI™ PC Interface 2200 YRM 1006

ZAPI™ PC Interface
CONNECTING PC TO ZAPI™ 4. Connect the interface cable to the controller and the
CONTROLLER PC. See Figure 7 and Figure 8.

NOTE: Values used on the following figures are for ex-

ample only. For the correct values for your truck, see
Programming - in this section.

1. Turn the key switch to the OFF position.

2. Remove the drive unit compartment cover to ac-

cess the controller. Figure 7. Controller Connection
3. Locate the communications port on the controller.
(The port will have either a diagnostic LED, as in
Figure 5, or a connector for the display, as in Fig-
ure 6.)

Figure 8. PC Connection

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

and double-click on it. See Figure 9.
Figure 5. Diagnostic LED

Figure 9. ZAPI™ Icon

Figure 6. Display Connection

28
2200 YRM 1006 ZAPI™ PC Interface

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

ure 10.

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

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.

29
ZAPI™ PC Interface 2200 YRM 1006

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

30
2200 YRM 1006 ZAPI™ PC Interface

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

Figure 13. File - Open

31
ZAPI™ PC Interface 2200 YRM 1006

Note that the previously saved file has the .CSV exten- the Save File section of this manual for proper file sav-
sion, and observe how the file name was used. See ing 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

32
2200 YRM 1006 ZAPI™ PC Interface

Notice the Connection Status while the file is down-

loaded into the controller. See Figure 16.

Figure 16. Connection Status

33
ZAPI™ PC Interface 2200 YRM 1006

Save File
The ZAPI™ PC software can save configurations for up
to 500 controllers. When saving a configuration to the
PC, the following steps could be followed to help track
which file goes with each controller. See Figure 17.

Figure 17. File - Save

34
2200 YRM 1006 ZAPI™ PC Interface

1. Try to use the actual truck serial number and put Save_Date=Thu Apr 04 15:58:15 2002
the word "settings" after it. (This is to keep the con-
troller settings file separate from the tester function [Code;Name;Position;Menu;Value;Scaled Value]
save file.) See Figure 18. 0;ACCELER.DELAY;0;0;0;LEVEL=0
5;DECELER.DELAY;1;0;9;LEVEL=9
2. Once you select a file name and hit save, you will 11;RELEASE BRAKING;2;0;0;LEVEL=9
see the screen shown in Figure 19. 12;INVERS.BRAKING;3;0;9;LEVEL=9
30;MAX SPEED FORW;4;0;9;LEVEL=9
3. Under the "enter a comment" box, you can either
31;MAX SPEED BACK;5;0;9;LEVEL=9
describe what is different with the settings or per-
248;DRIVE MODES ;01;1;ON
haps enter a customer name.
[End]
Here is what a saved parameter file looks like:
[Info] [Validation]
Chopper_Name=MPB NA V1.01 Code=FFDA
User_Comment=modified mode 4 to lower speed [Stop]
and coast more

Figure 18. Save: In

Figure 19. Enter a Comment

35
ZAPI™ PC Interface 2200 YRM 1006

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

Figure 20. File - Print

36
2200 YRM 1006 ZAPI™ PC Interface

Exit
This selection will exit the ZAPI™ PC console software.
See Figure 21.

Figure 21. File - Exit

37
ZAPI™ PC Interface
CONNECTION MENU
There are two selections under this menu:
1. Start - Starts the connection between the controller
and PC (operates the same as the main start but-
ton on the right-hand side of the display screen).
Figure 22. Connection Menu
FUNCTION MENU
There are seven selections under this menu:
1. Parameter - Allows the performance and configu-
ration of the controller to be adjusted. Refer to Pa-
rameter.
2. Tester - Allows the testing of various inputs and
operations of the controller. Refer to Tester.
3. Alarm Logbook - Stores alarms the controller
sees. Refer to Alarm Logbook.
4. Program VACC - Not Used.
5. Motor Data - Not Used.
6. Ram Function - Only Factory Use.
Figure 23. Parameter
You will now see a screen like Figure 24 while the data
are being downloaded.
38
2200 YRM 1006
2. Stop - Stops the connection between the controller
and PC (operates the same as the main stop button
on the right-hand side of the display screen).
See Figure 22.
7. EEPROM Function - Only Factory Use.
Parameter
When you first activate this selection, the screen will
look as indicated in Figure 23. In order to see the pa-
rameters of the controller, you have to download them
to the PC. This can be done by 1 of 2 ways.
1. Receive menu - This will only download the current
selected tab.
2. Receive - This will download all parameters and
configurations to the PC so you can adjust them.
2200 YRM 1006 ZAPI™ PC Interface

Figure 24. Downloading Screen

39
ZAPI™ PC Interface 2200 YRM 1006

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

Figure 25. Drive Mode

40
2200 YRM 1006 ZAPI™ PC Interface

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

1. ACCEL DELAY - Amount of "ramp up" to full speed. 4. INVERSE BRAKING - Amount of braking when the
• Level 0 - Large acceleration curve up to full lift truck is "plugged."
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 lower • Level 0 - Minimum speed.
speed (coasting). • Level 9 - Maximum speed.
• Level 9 - Short deceleration curve to a lower
speed (aggressive). 6. MAX SPEED BACK - Maximum speed of the lift
truck in the forks direction.
3. RELEASE BRAKING - Amount of braking when • Level 0 - Minimum speed.
the accelerator is released. • Level 9 - Maximum speed.

Figure 26. Adjustable Parameters

41
ZAPI™ PC Interface 2200 YRM 1006

Notice that the ACCEL DELAY function has been ad- NOTE: If the STORE button is not pressed before turn-
justed. The parameter settings are "live," which means ing off the lift truck, then all changed parameters will be
as they are being adjusted. The lift truck will react to lost.
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

42
2200 YRM 1006 ZAPI™ PC Interface

Memory Menu 2. Store - Same as Store button.

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

Figure 28. Memory Menu

43
ZAPI™ PC Interface 2200 YRM 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

44
2200 YRM 1006
Highlight Drive Modes and then click on the scroll bar
to the right and select off. See Figure 30.
Do the following steps once this has been done:
1. Press the Store button to save the change into the
controller.
2. Press the Close button to go to main screen of the
ZAPI™ PC software.
Figure 30. Turn Off Drive Modes
ZAPI™ PC Interface
3. Press the Stop button to disconnect the communi-
cation between the PC and the controller.
4. Turn the key switch on the lift truck to OFF; then do
the reconnect procedure.
5. Now the parameters in the function menu can be
adjusted to a custom configuration "mode 4."
45
ZAPI™ PC Interface 2200 YRM 1006

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

bility to further assist the technician and the factory with
This selection allows the technician to monitor up to four problems.
items at a time to help troubleshoot problems. See Fig-
ure 31.

Figure 31. Tester

46
2200 YRM 1006 ZAPI™ PC Interface

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

Figure 32. Test Name

47
ZAPI™ PC Interface 2200 YRM 1006

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

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

Figure 33. Data Logger

The Advanced button allows the user to select time in- As the data logger is running, the screen will look like
crements and the number of samples. See Figure 34. what is shown in Figure 35. During the logging process,
you will still be able to see the values changing in the
display menu.

Figure 34. Tester Advanced

Figure 35. Logging Process

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

48
2200 YRM 1006 ZAPI™ PC Interface

Figure 36. 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
10;0;0.00 0;80;0.0;
factory for analysis.
20;0;0.00 0;80;0.0;
The raw data file looks like this (see Figure 37):
[Info] 30;0;0.00 0;80;0.0;
Chopper_Name=CS P20 V1.00 40;0;0.00 0;80;0.0;
Save_Date=Thu Apr 04 13:32:24 2002
50;0;0.00 0;80;7.2;
TIME;MOTOR CURRENT;ACCELERATOR;BATTERY
CHARGE ;FIELD CURRENT; 60;3;0.00 0;80;7.2;
70;3;0.27 10;80;7.2;
80;3;0.27 10;80;12.7;
90;8;0.53 16;80;12.7;

Figure 37. Test Data

49
ZAPI™ PC Interface 2200 YRM 1006

Alarm Logbook
The ZAPI™ controller can record up to five unique
alarms and store them in a logbook that the PC can
access. See Figure 38.

Figure 38. Alarm Logbook

50
2200 YRM 1006 Repair

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

Figure 39. Actual Alarm

Repair
There are no repairable parts in the controller, and the 2. Block drive wheel to prevent lift truck from moving.
controller must be replaced if it is defective. The contac-
tor mounted to the controller is a serviceable/repairable 3. Connect handset or PC and download parameters,
component. In some instances, it may be desired to if possible.
disable the drive modes. Follow the remove and install
4. Turn key to OFF.
controller procedures listed below.
5. Disconnect battery.
REMOVE
6. Remove cover.
1. Park lift truck in a safe, level area.

51
Repair 2200 YRM 1006

2. Connect all power cables and wires connected to

WARNING controller.
The capacitors in the controller remain charged for
several minutes after operation. To prevent per- 3. Connect battery.
sonal injury and/or damage to equipment, the con-
troller should be discharged. To discharge the con- 4. Connect handset or PC.
troller, connect a 200-ohm, 2- to 3-watt resistor be- 5. Turn key to ON.
tween the battery positive and negative terminals
on the controller for at least 5 seconds. Refer to 6. Upload parameters.
Figure 1 in the General section of this manual.
7. Remove blocks from drive wheel.
7. Discharge controller.
8. Test lift truck in a safe, level area away from other
8. Identify and tag all power cables and wires con- personnel and equipment.
nected to controller for later installation.
9. Install cover.
9. Remove all power cables and wires connected to
controller. REPAIR
10. Loosen both capscrews retaining controller to plate. 1. Replace fuses.
11. Remove controller. 2. Replace controllers by following the remove and in-
stall procedures listed above.
INSTALL
1. Align controller to plate and capscrews. Tighten
capscrews.

52
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 1006 7/03 (12/02)(11/02)(4/02)(1/02) Printed in U.S.A.