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User Manual for HHC-200-ZP Handset

Universal Handheld Console for ZAPI controllers

(Last updated in (04/2014))

Date Description Rev.nr

29/04/2014 Initial release A

© 2014 Universal Machine Solution Pte Ltd. All Rights Reserved. This user manual (one or more parts of it) may only be
reproduced, distributed or translated with explicit written and prior permission by Universal Machine Solution.
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Table of Contents
1 Introduction............................................................................................................................................ 3
1.1 Use................................................................................................................................................. 3
1.2 Warnings ........................................................................................................................................ 3
2 General description ............................................................................................................................... 3
2.1 Technical features .......................................................................................................................... 3
2.2 Components ................................................................................................................................... 3
2.2.1 Handset ................................................................................................................................... 3
2.2.2 Cables ..................................................................................................................................... 3
3 Intended use.......................................................................................................................................... 3
3.1 Correct operating conditions ........................................................................................................... 4
3.2 Discouraged use ............................................................................................................................ 4
4 Commissioning and safety..................................................................................................................... 4
4.1 Warnings for each use.................................................................................................................... 4
5 Installation instructions .......................................................................................................................... 4
6 Operating instructions............................................................................................................................ 4
6.1 Brand selection............................................................................................................................... 4
6.2 Compatible devices ........................................................................................................................ 5
7 Adapter cables ...................................................................................................................................... 6
8 Maintenance .......................................................................................................................................... 6
9 Storage.................................................................................................................................................. 6
10 Solving problems ................................................................................................................................... 6
11 Transport ............................................................................................................................................... 6
12 Warranty................................................................................................................................................ 6

© 2014 Universal Machine Solution Pte Ltd. All Rights Reserved. This user manual (one or more parts of it) may only be
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1 Introduction
1.1 Use
The HHC-200-ZP Handset enables the user to amend the factory settings of certain industrial trucks.

The HHC-200-ZP must be used together with the cables supplied by UMS. Any other use is not authorized.

Remark: Drawings and images in this HHC-200-ZP Handset Manual may differ from your model

1.2 Warnings
Amending factory settings of an industrial truck can cause material and physical injury. Therefore, the HHC-
200-ZP Handset must only be used by skilled, trained and authorized staff.

The users of the HHC-200-ZP Handset must have access to the user manual at all times.

Read this HHC-200-ZP Handset Manual carefully before connecting, maintaining or using the HHC-200-ZP
Handset. Strictly follow the safety instructions in the truck manufacturer’s maintenance manual prior to
connecting the HHC-200-ZP Handset to the truck.

Warning: Failure to comply with the instructions and warnings in this manual could result in serious injury to
the user or other persons in the vicinity of the truck.

People working with the HHC-200-ZP Handset, and using procedures, work methods or tools that are not
described in this manual, are solely responsible for the safe and good operation of the HHC-200-ZP
handset.

2 General description
2.1 Technical features

2.2 Components
The HHC-200-ZP Handset consists of 2 component types: the Handset itself and the cables. Each
component is described in this manual.

2.2.1 Handset
The Handset has a display, a 6-key keyboard and a rotary switch on the front.

2.2.2 Cables
The HHC-200-ZP includes 6 separate cables

3 Intended use
The HHC-200-ZP Handset is a diagnostic device that allows a qualified repairer of industrial trucks to
perform diagnostics on certain types of industrial trucks.

Although we have made efforts to support as many truck types as possible, it could be that certain trucks
are not supported.

Only use the HHC-200-ZP Handset as described in this Manual. Read the ‘Solve Problems’ section at the
end of this Manual when encountering problems.

© 2014 Universal Machine Solution Pte Ltd. All Rights Reserved. This user manual (one or more parts of it) may only be
reproduced, distributed or translated with explicit written and prior permission by Universal Machine Solution.
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3.1 Correct operating conditions

The HHC-200-ZP Handset may only be used with an ambient temperature between 0°C and 40°C (32°F –
104°F).

The user has to be a qualified repairer of industrial trucks.

The user must always have sufficient working space, in order to prevent him from getting stuck between the
industrial truck and a wall or other object.

The values on the rating sticker must under no circumstances be exceeded. If the data on the type of
sticker is unreadable, please immediately order a new rating sticker at UMS through www.ums.sg. Always
specify the serial number on the sticker.

3.2 Discouraged use

Do not use the HHC-200-ZP Handset on industrial trucks which show severe signs of damage.

4 Commissioning and safety

4.1 Warnings for each use
Be sure that the HHC-200-ZP Handset is only used by trained staff. People that have insufficient
knowledge of the truck on which the HHC-200-ZP Handset is connected, can make changes as such that
the safe working of the truck can no longer be guaranteed.

Prior to each use, all parts of the HHC-200-ZP Handset must be checked for cracks or other damages.
Don’t forget to check the cables: they cannot show any signs of deformation. Only use the HHC-200-ZP
Handset when it is in a perfect condition.

When connecting the HHC-200-ZP Handset to the truck, both devices must be switched off. Connecting the
devices when powered on can lead to malfunction and possibly dangerous situations.

5 Installation instructions
When connecting the HHC-200-ZP Handset to the truck, following sequence must ALWAYS be used:

- Make sure that the truck is blocked up, and no wheels touch the ground
- Make sure that the industrial truck is powered off
- Connect the appropriate cable to the HHC-200-ZP Handset
- Connect the cable to the service connector of the truck. Refer to the service manual of your truck for
the location of the service connector.

6 Operating instructions
6.1 Brand selection
Select the correct truck brand by turning the knob on the bottom to the corresponding number.

Never change the brand when the handset is connected with a controller. Always disconnect before
changing to another brand.

© 2014 Universal Machine Solution Pte Ltd. All Rights Reserved. This user manual (one or more parts of it) may only be
reproduced, distributed or translated with explicit written and prior permission by Universal Machine Solution.
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6.2 Compatible devices

This HHC-200-ZP Handset contains the software for most available Zapi controllers.

Warning: The HHC-200-ZP Handset does not fully support all truck configurations, in particular less
common configurations. The HHC-200-ZP Handset is under constant scrutiny, development and
improvement and feedback of user experiences is extremely valuable. In case of doubt or concern, please
contact UMS.

Some truck brands use the same protocol. Below is a list with compatible brands:

Brand Description
BT Used for BT trucks with Zapi controllers
Cesab Used for BT and Cesab trucks with Zapi controllers.
Clark AC For newer Clark trucks with AC controllers
Clark DC Used for old Zapi controllers in Clark trucks. Truck types as CTM-CEM10-20 or
CEM20-35MEGA AC.
Crown Only used for Zapi controller in Crown trucks
Jungheinrich Used for Jungheinrich trucks with Zapi controllers
Linde 1.0 Used for Linde trucks with Zapi Controllers
Linde OM Used for Linde trucks with Zapi controllers
Montini Used for Montini trucks with Zapi controllers, for example Montini 1203-H
Nacco AC Used for Nacco trucks with Zapi AC controllers
OM Fiat Triplo Used for B1 controllers in Fiat trucks. Also used in OM trucks, series 4016 and 4017,
truck types XE12³ - XE18³ and XE15 – XE18
OM Pimespo Used for several types of trucks of OM, Pimespo, Linde, Komatsu and Still. Depends
on the original brand of the truck. For example some truck types use the same
electronics, but they only have a different color (Still vs OM). Adapter cables are
different for some Linde controllers (Female instead of male AMP connector)
OM Thesi Used for Thesi trucks with Zapi controllers
Toyota Used for Toyota trucks with Zapi controllers
Yale Used for Yale trucks with Zapi controllers
Zapi Used for all standard Zapi controllers. Compatible with brands as Rocla, Yale, Hyster,
OMG, Haulotte, Atlet, Lafis, Mitsubishi …

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7 Adapter cables
Depending on the truck, a different adapter cable is necessary. Below you can find the references for the
available adapter cables.

Reference Description
HHA-ZP-CS1 For Combisem 1 controllers (Zapi, Hyster/Yale, Rocla)
HHA-ZP-ACx For Zapi AC3 and AC4 controllers, 1-1 to 8pin molex connector
HHA-ZP-KM For use with Komatsu and Pimespo Handsets. 6pin SAAB connector
HHA-ZP-LI For use with Linde machines
HHA-ZP-HL For use with Haulotte machines
HHA-ZP-STD Cable with standard Zapi connector

8 Maintenance
The HHC-200-ZP Handset (including interfaces, accessories and cables) is an electronic device and can
be damaged by contact with liquids. Keep the device away from liquids when using or storing it.

Only clean the device with a damp cloth. Do not use any solvents, gasoline, strong detergents and other.

All warning symbols and labels must be readable at all times. Change broken/unreadable labels. Contact
UMS to obtain new labels.

9 Storage
Store the HHC-200-ZP and accessories and cables in a dry frost-free room.

10 Solving problems
Problem Solution
A cable is damaged All cables (except the spiral cable connected to
the console) can be ordered on www.ums.sg
Never attempt to repair the cables!
I can’t find the service connector on the Please refer to the service manual of the
machine machine to locate the service connector.

11 Transport
When transporting the HHC-200-ZP Handset, make sure all cables towards the truck are disconnected to
prevent damage.

12 Warranty
UMS warrants the HHC-200-ZP Handset for a period of six (6) months from the date of purchase. The
warranty is strictly limited to the replacement or the repair of the HHC-200-ZP Handset, or parts thereof,
showing a manufacturing defect according to the final judgment of UMS.

UMS shall never accept a warranty claim if the user has carried out repairs or modifications to the HHC-
200-ZP Handset; or if the defect results from assembly, maintenance, storage, or use in a manner which is
inconsistent with the indications and recommendations by UMS, or from use for purposes other than those

© 2014 Universal Machine Solution Pte Ltd. All Rights Reserved. This user manual (one or more parts of it) may only be
reproduced, distributed or translated with explicit written and prior permission by Universal Machine Solution.
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described in the User Manual, abnormal use, overloading, or normal wear; or if the original UMS
identification, label or serial number has been removed; or if the warranty period has lapsed.

The warranty excludes all costs for transportation.

Warranty claims are administered through Universal Machine Solution Pte. Ltd., company registration
number 201201400E

Contact: www.ums.sg

© 2014 Universal Machine Solution Pte Ltd. All Rights Reserved. This user manual (one or more parts of it) may only be
reproduced, distributed or translated with explicit written and prior permission by Universal Machine Solution.
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