ZAPI™ CONTROLLERS MSW020/025-E [A895]; MSW025/030-F [B895]; MSW030/040-E [C820]; MRW020/030-E [C821]; MCW025/030/040-E [C819]
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 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 hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.
TABLE OF CONTENTS General Description ZAPI™ Transistor Motor Controller Principles of Operation Controller Safety Controller Adjustments Modes of Operation User-Selectable Operating Modes Programming Custom Performance Mode Controller Parameters Setting Drive Modes Tester Menu Set Option Menu ZAPI™ Handset Alarm Code Diagnostics Alarm Code Diagnostic Procedure Troubleshooting
Auxiliary Hydraulics (MSW030/040-E, MRW020/030-E, MCW025/030/040-E) Control Card Functional Test Traction Motor Test ZAPI™ PC Interface Connecting PC to ZAPI™ Controller File Menu Open File TX From File Save File Print Settings Exit Connection Menu Function Menu Parameter Memory Menu Set Options Tester Data Logger Alarm Logbook Alarms Programming Tilt and Sideshift on the ZAPI Controller (Laptop) Repair Remove Brass Stud Replacement Remove Install Install Repair Sideshift Setup With Auxiliary (MRW020/030-E) This section is for the following models: MSW020/025-E [A895]; MSW025/030-F [B895]; MSW030/040-E [C820]; MRW020/030-E [C821]; MCW025/030/040-E [C819]
General This section describes the ZAPI™ transistor motor controller. Procedures are outlined for controller safety, adjustments, troubleshooting, and repairs. See Figure 1.
Figure 1. Controller
Description ZAPI™ TRANSISTOR MOTOR CONTROLLER The ZAPI™ controller is a solid-state DC motor controller utilizing SEM technology. It controls the traction motor, brake, and hydraulic system. The controller receives inputs from the control handle by serial communication, and direct inputs from the key switch and control handle arm position switch. The controller directly controls the traction motor, lift pump motor, lift valve, proportional lowering valve, brake, and main contactor. Additional hydraulic functions, such as reach, sideshift, and tilt are controlled through an auxiliary relay board mounted to the front of the controller. Jumpers are used to configure the basic controller and the controller with auxiliary relay board for different truck models. The controller software provides self diagnostics which are accessed by means of a ZAPI™ handset or a PC with specialized ZAPI™ software. The controller software features a Test Menu for monitoring controller inputs and outputs, a Diagnostic Menu for viewing fault code information, and a Programming Menu for customizing the truck performance. The handset or PC connect to the controller through a cable with a six pin connector which attaches to the 10 pin "D" connector port on the bottom of the controller. The connector is installed centered in the "D" port leaving two pins on each end of the "D" port vacant. The connector retainer clip will align and secure the connector in position. 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. NOTE: The dash indicator will display the code: EP 107 (or a higher number) for 1 to 2 seconds every time the key switch is turned to the ON position. The ZAPI handset similarly displays V1.07 (or higher). This code represents the EEPROM software version and DOES NOT INDICATE A FAULT CODE. Troubleshoot the fault using a ZAPI™ handset or a properly configured IBM compatible PC. On trucks equipped with the optional 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.
PRINCIPLES OF OPERATION The ZAPI™ transistor motor controller uses a sophisticated 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.
Controller Safety WARNING The ZAPI™ controllers can hold an electrical charge for several minutes after the key switch has been turned OFF. To prevent injury, discharge the controllers by connecting a 200-ohm, 2-watt resistor between the battery positive connector and battery negative connector on the controller and hold there for 5 seconds. See Figure 2.
1. NEGATIVE CONNECTION 2. POSITIVE CONNECTION 3. 200-OHM, 2-WATT RESISTOR 4. INSULATED JUMPER WIRES Figure 2. Discharging Controller
Controller Adjustments The ZAPI™ transistor motor controller can store and display Error Codes (Alarms). It is also possible to modify the controller Setup for individual preferences. Communication with the controller is possible by four methods: 1. LED - An LED (light emitting diode) can be installed in trucks that do not use a display. The LED flashes error codes to the technician for diagnosis. The LED would be installed on the bottom of the ZAPI™ controller at connector port D. See Figure 1.
2. Dash Display - Some trucks are equipped with an optional dash display or MDI. Error codes are shown on the LCD (liquid crystal display) when the wrench symbol and red light are lit. The format is AL XX where XX is the error code. The software version is displayed on startup. 3. ZAPI™ Handset - A diagnostic handset is available through your Yale dealer. The handset makes it possible to diagnose faults and modify controller settings. See Programming, in this section. 4. Personal Computer - The controller can also be connected to a personal computer (PC) equipped with special software and cables. The PC can read, store, and change settings on the controller. Proper use of these four methods and a list of diagnostic codes are explained in Troubleshooting, in this section.
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. Performance parameters that vary are acceleration, deceleration, 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 acceleration, 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-selectable operating modes: 1. The controller drive modes parameter must be 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 connection, it is possible to set the drive mode parameters to ON or OFF. In the ON mode, the userselectable rules are enabled. In the OFF mode, the lift truck will only operate using the settings selected. The procedure to alter or modify these settings is given in Programming in this section. 2. Control handle must be in the full, upright position, brake ON. 3. Press and hold the horn button while turning the key switch to the ON position. 4. Release the horn button when the horn sounds. 5. Toggle through the modes by pressing the lift or lower buttons to the desired mode. 6. The horn provides an audible indication as to the mode selected. One beep indicates Mode 1, two beeps indicate Mode 2, and three beeps indicate Mode 3. 7. Lower the control handle to the operating position, brake OFF, and begin operation. 8. The selected mode is maintained until the procedure is repeated. 9. Turning the key OFF before lowering the control handle will cancel the mode change.
Programming CUSTOM PERFORMANCE MODE In some instances, it may be preferable to disable the Drive Modes and use a custom setting. This controller has adjustable parameters that may be modified to suit specific customer needs. There are two methods used to adjust these parameters: the ZAPI™ handset or the personal computer (PC) interface.
CONTROLLER PARAMETERS Parameters are controller settings that can be adjusted to alter the performance characteristics of the truck. To adjust parameters and install custom drive settings, Drive Modes must be OFF. To set Drive Modes to OFF, use the following procedure:
Setting Drive Modes
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 harness. NOTE: Connect and disconnect the handset only with the key switch in the OFF position. 4. Connect adapter harness to controller. 5. Turn key switch ON. 6. The handset will turn ON. See Figure 3.
Figure 3. ZAPI™ Handset 7. Press buttons 1 and 5 simultaneously. 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 or OUT (button 4) to discard settings. 15. Press OUT (button 4) to exit to the main menu. 16. Turn the key switch OFF to save the "Drive Modes OFF" parameter change. The key switch must be cycled before attempting to make any additional parameter changes. 17. Turn the key switch ON to confirm the Drive Mode is OFF. Then enter the MAIN MENU and change the parameters outlined in Table 1.
Table 1. Parameters Parameter
Description
Value and Affect
Factory Default
ACCELERATION DELAY
Adjusts truck acceleration.
0 = short or rapid acceleration 9 = long or slow acceleration
0
DECELERATION DELAY
Adjusts truck deceleration according to throttle position.
0 = short or rapid deceleration 9 = long or slow deceleration
5
RELEASE BRAKING
Adjusts motor braking strength or regenerative braking when throttle is released. This determines coast distance.
0 = soft braking 9 = strong braking
7
INVERSE BRAKING
Adjusts plugging rate.
0 = long or soft plugging 9 = short or rapid plugging
9
CUTBACK SPEED
Speed control for trucks in optional mode.
0 = slow 9 = fast (not used)
9
MAX SPEED FORW
Adjusts maximum speed in forward direction, forks trailing.
0 = minimum 9 = maximum
4
MAX SPEED BACK
Adjusts maximum speed in reverse direction, forks leading.
0 = minimum 9 = maximum
4
LIFT MAX TIME
Adjusts the maximum time for lifting forks.
0 = minimum or approximately 5 seconds 9 = maximum or approximately 65 seconds
9
AUXILIARY TIME
Adjusts the maximum time for auxiliary hydraulic functions.
0 = minimum or approximately 1.5 seconds 9 = maximum or approximately 6 seconds
5
TESTER MENU NOTE: The Tester function can be used to troubleshoot multiple systems simultaneously while the truck is in operation. The most important input or output signals can be measured in real time using the TESTER function of the handset. The handset acts as a multimeter to read voltage, current, temperature, switch state, and other functions. 1. BATTERY VOLTAGE = battery voltage, nominal value = 24V. 2. MOTOR VOLTAGE = armature voltage obtained, shown in volts. 3. MOTOR CURRENT = armature current during traction (positive value) or braking (negative value) in amps. 4. FIELD CURRENT = field current in the selected traction direction in amps. 5. EVP VOLTAGE = proportional lowering valve coil voltage. 6. TEMPERATURE = controller temperature, °C. 7. ACCELERATOR = directional control voltage received from control handle. 8. LIFTING CONTROL = proportional lifting voltage received from control handle. 9. TILLER SWITCH = control handle switch input, ON/OFF. 10. FORWARD SWITCH = forward direction request from control handle card, ON/OFF. 11. BACKWARD SWITCH = backward direction request from control handle card, ON/OFF. 12. LIFTING SWITCH = lifting function request from control handle card, proportional lift switch, ON/OFF.
13. LOWERING SWITCH = lowering function request from control handle card, proportional lowering switch, ON/OFF. 14. FORK LIFT SWITCH = lifting function request from control handle card, ON/OFF. 15. FORK LOW SWITCH = lowering function request from control handle card, ON/OFF. 16. R-SHIFT SWITCH = sideshift right switch, ON/OFF. 17. L-SHIFT SWITCH = sideshift left switch, ON/OFF. 18. BELLY SWITCH = traction reversing switch to the controller or traction reversing request from control handle card, ON/OFF. 19. SNAIL SWITCH = snail request from control handle card allows machine to drive with control handle up, turtle speed switch, ON/OFF. 20. HORN SWITCH = horn request from control handle card, ON/OFF. 21. SW4-SW9 = auxiliary function jumper. 22. BATTERY MODEL = battery-type of input switch, ON/OFF. ON = flooded battery (input closed), OFF = sealed battery (input open). 23. BATTERY CHARGE = battery charge indication, %.
SET OPTION MENU DRIVE MODES
ON
The truck has three performance modes, each with a fixed set of parameters. This function is enabled by setting DRIVE MODES = ON.
OFF
DRIVE MODES disabled. Custom Performance Mode is enabled, the adjustable parameters on Table 1 can be adjusted.
ZAPI™ HANDSET NOTE: The ZAPI handset will display the code: V1.07 (or a higher number) for 1 to 2 seconds every time the key switch is turned to the ON position. This code represents the EEPROM software version and DOES NOT INDICATE A FAULT CODE. The ZAPI™ handset must be connected to the controller before turning on the key. The handset must have an adapter harness to connect to the controller. The handset and adapter harness are available from your Yale dealer. Connect the handset to plug D. The handset can remain connected to the controller while running, and the parameters can be changed in real time. In this case, it is necessary to go in a standby condition (truck at rest) before switching OFF the controller in order to store the new values in the EEPROM. This section describes the ZAPI™ handset functions. Six buttons provide the capability of changing or reading the parameters.
1
Roll-Up
Push to scroll up.
2
Roll-Down
Push to scroll down.
3
Enter
Push to enter a submenu or to confirm a change.
4
Out
Push to exit a selected menu or to refuse a change.
5
Set-Up
Push to increase a parameter value.
6
Set-Down
Push to decrease a parameter value.
NOTE: After a modification, save the new values by pushing out, then enter to confirm. (Screen prompts will guide the user.) To navigate the menu options, numbers inside the triangles in the following map correspond to the same number 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.
Figure 4. ZAPI™ Handset Instructions
Alarm Code Diagnostics ALARM CODE DIAGNOSTIC PROCEDURE NOTE: The dash indicator will display the code: EP 107 (or a higher number) for 1 to 2 seconds every time the key switch is turned to the ON position. This code represents the EEPROM software version and DOES NOT INDICATE A FAULT CODE. When an alarm code(s) has been detected, the following procedure should be performed to properly read the codes and eliminate unnecessary procedures during troubleshooting.
CAUTION Always turn the key switch to the OFF position when connecting and disconnecting the handset or laptop cable into the truck controller. NOTE: If you are using a USB connection to your laptop, the cables and adaptors must be connected to both the laptop and the lift truck controller before the laptop is first started (booted) up.
1. Connect the Zapi™ Handset or laptop to the lift truck controller. Turn the handset or laptop on. Turn the lift truck key switch to the ON position and view the handset display. See Table 2. Table 2. Example Handset Software Versions
ZAPI CONSOLE V 3.07
NOTE: The handset will briefly display the handset software version for 1.5 seconds before changing to the second screen. Wait for the second screen to appear with the controller software version. 2. Write down the controller software version information and hourmeter reading that is displayed on the second screen of the handset. See Table 3.
Table 3. Example Controller Software Versions
MPB NA V 1.08 24 V - 180 A 000369 or SC P18 V 1.04 24 V - 180 A 00369 or COMBI - USA4 V 1.06 24 V - 180 A 000369
NOTE: The lower right hand numbers represent the hours since controller installation which may differ from total truck hours as shown on the digital dash indicator (DDI). 3. Go to "Alarm Menu." Press Enter. 4. Write down both lines of the alarm code. Then scroll to the next alarm code and record both lines again. Continue until the alarm codes repeat with identical information. Example: You will see five alarm codes as you scroll if five alarms have been generated, then they will repeat. The codes contain the actual alarm code (EVP NOT OK), controller hours at time of last occurrence (1350h), number or occurrences (#15), temperature at time of last occurrence (in Celsius (35C)). See Table 4. Table 4. Example Alarm Code
EVP NOT OK 1350h #15 35C
5. After all the alarm codes have been written down, then clear the log book by selecting "Clear the Log." The Zapi handset will ask "Are You Sure?" Press "Enter" then press "Out." NOTE: DO NOT disconnect or turn off the handset or laptop at this time. 6. Cycle the key switch to start the lift truck in the normal mode. Operate the lift truck until the alarm code reoccurs (faults out). Then, go back to the Alarm Code menu and write down the alarm codes which are now present. These alarms should be investigated first to isolate the most prominent malfunctions. NOTE: If the THERMAL PROTECTION alarm codes are generated, use the Tester Function = Temperature. If the controller sees 75°C (175°F) or below −10°C (14°F), it will reduce electrical current to the motors and regular performance of the lift truck will slow down. You can operate the truck with the Tester Function activated and monitor the controller’s internal temperature in real time. For additional heat dissipation, fold up several layers of aluminum foil and place it between the controller mounting base and the mounting plate to fill any air pockets in the mating surfaces which will impede conductivity and prevent the heat from flowing from the controller heat sink into the mounting plate of the controllers. The use of "conductivity paste’ is not recommended.
CAUTION If the battery has been disconnected and reconnected with the key switch in the ON position, a voltage spike can cause corruption of the Zapi controller EPROM. Remember to use the "Tester" function to check switch input from the control handle to the controller. This procedure will also alert you if the controller has been changed but the control handle card has not been reprogrammed. Zapi controller menu items: • ACCELERATOR = Volts Percent % = Shows Variable Voltage From Traction Thumbwheel (FWD or REV) • FORWARD AND BACKWARD SWITCH = "OFF to "ON" • LIFTING CONTROL = Volts Percent % = Lifting and Lowering = Proportional Switches (Control Handle Card Must be Calibrated) • LIFTING AND LOWERING SWITCH = "OFF" to "ON" • BELLY, HORN, SNAIL SWITCHES = "OFF" to "ON" • SW8 = Gray Button for Alt Functions = "OFF" to "ON" (Reach and Counterbalance) • ETC.
Troubleshooting Dash Display
Controller LED
Handset or PC
LCD display
Red LED
Red LED Fault Indicator
Located at base of motor controller.
Error codes stored under Main Menu Alarms
(Trucks equipped with optional dash display)
(Trucks without dash display)
Message displayed
on Handset or PC
CORRES PONDING SCHEMA TIC SHOWIN G CIRCUITS TO BE CHECKE D OR COMPON ENTS AFFECTE D
CONDITION TRUCK RESPONSE POSSIBLE CAUSES AND TEST PROCEDURES
LOGIC (Brief descriptio n of the reason behind truck exhibited malfunctio n.)
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. NOTE: The dash indicator will display the code: EP 107 (or a higher number) for 1 to 2 seconds every time the key switch is turned to the ON position. This code represents the EEPROM software version and DOES NOT INDICATE A FAULT CODE.
Dash Display
Controlle r LED
Handset or PC
No LEDs or LCDs illuminate d
LED OFF
Handset does not operate
CONDITION Dash display, controller LED, and truck inoperative with key switch in ON position. TRUCK RESPONSE Travel and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES
B+ and/or B− missing at controller. Confirm battery is connected and of proper voltage. Verify key switch is ON. Verify brake override circuit is connected in run position. Verify continuity between batteries negative (at battery) and −B power wire connection (at controller). If no continuity, check: Power wiring between battery and controller. Verify continuity between battery positive (at battery) and B-12 connection (at controller). If no continuity, check: Fuse 3 for open. Key switch continuity in ON position. Wiring battery + to main contactor to fuse 3 to key switch, to controller B-12 connection. Defective motor controller. Check for battery voltage between B-12 and B− power wire connection at controller. If correct battery voltage, replace controller. Refer to the section Electrical System 2200 YRM 1026 or Electrical System 2200 YRM 1007 for more information on troubleshooting electrical system circuits and components.
LOGIC Occurs when there is no power to the controller or the controller is defective.
Dash Display
Controlle r LED
Handset or PC
No LEDs or LCDs illuminate d
LED OFF
No error codes present
CONDITION Dash display and/or controller LED inoperative. TRUCK RESPONSE Travel and hydraulic functions normal. POSSIBLE CAUSES AND TEST PROCEDURES Open connection between dash display and controller. Verify harness connections at MDI and connector D on controller. Verify continuity of wires between MDI and controller. Defective dash display. Connect handset to controller and confirm communication to handset. If handset operates correctly, replace MDI. Defective LED. Disconnect LED and connect handset. If handset works, replace LED.
LOGIC Occurs when the MDI or LED receives no signal, or MDI or LED is damaged.
Dash Display
Controlle r LED
Handset or PC
No LEDs or LCDs illuminate d
LED OFF
NO COMMUNICATION
CONDITION
Dash display and/or controller LED inoperative. TRUCK RESPONSE Travel and hydraulic functions normal.
LOGIC Occurs when controller does not send a signal to the MDI or LED.
POSSIBLE CAUSES AND TEST PROCEDURES Defective controller. Connect handset to controller and confirm communication to handset. If handset will not communicate with controller, replace controller. Dash Display
Controlle r LED
Handset or PC
No Alarm
LED OFF - No Flashes
INCORRECT START
CONDITION Improper startup sequence by operator. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES
Check that all switches are in the neutral position. Throttle or hydraulic function selected at key ON. Steer handle in run position at key ON. Return steer handle to full upright position. Return throttle to neutral. Release all hydraulic function controls. If fault remains, attach handset and go to test menu. Check brake switch, it should be off. If steer handle is in vertical position and reading is not OFF, check brake switch for damage, interference, or shorts. Check accelerator Should be 0 volts at neutral. If not, repeat control card calibration. If this does not correct the problem, test the control card. Refer to Control Card Functional Test in this section. Check hydraulic inputs – Should be 0 volts. If not, recalibrate tiller card. Follow autolearn procedure listed in steering. If this does not clear fault, check buttons for damage or interference. Replace damaged or faulty buttons.
LOGIC Fault occurs when controller receives input that has not followed the proper operational sequence.
Dash Display
Controller LED
Handset or PC
AL01
1 Flash
VACC NOT OK
CONDITION
Connection/communicati on error between tiller card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled.
LOGIC Occurs when accelerator voltage from serial control card is higher than 1V (20%) before neutral switch is closed.
POSSIBLE CAUSES AND TEST PROCEDURES Control card throttle calibration is out of range. Install handset. Go to tester function of handset. If accelerator output is >1V (20%) and the enable switch is open, recalibrate control card. Control card throttle damaged or Cam Magnetic Holder not aligned with Alignment Window. Replace control card if needed. Dash Display
Controller LED
Handset or PC
AL01
1 Flash
PUMP VACC NOT OK
CONDITION Connection/communicati on error between control card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES
A
lift/lower switch is damaged or defective. Install handset. Go to tester function. Check lifting control and EVP voltage.” Check on/off switches and proportional switches for smooth, linear operation. Replace damaged switches. Control card lift/lower switch calibration is out of range. Install handset. Go to tester function. Check lifting control and EVP voltage. Output of proportional hydraulic controls should be less than 1V (20%) at neutral. Recalibrate control card. Replace control card if needed.
LOGIC Occurs if the output of one on the hydraulic controls is higher than 1V (20%) at start.
Dash Display
Controller LED
Handset or PC
AL01
1 Flash
FORW + BACK
CONDITION Connection/communicati on error between control card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES
Control card throttle device is damaged or defective. Install handset. Go to tester function. If forward switch and backward switch are both on at the same time, card may be damaged. Replace the control card if needed.
LOGIC Occurs if controller receives signal for forward and reverse directions simultaneously.
Dash Display
Controller LED
Handset or PC
AL01
1 Flash
SERIAL ERROR #1
CONDITION Connection/communicati on error between control card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Loose or damaged electrical connection between control card and controller. Verify connection at controller. Verify wire harness connection at base of steer handle. Verify connection at control card. Damaged or defective control card. Measure voltage at pin 5, connector C, on 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 connected means that the card may be
LOGIC No information or incorrect information has been sent from the control card to controller.
damaged. Test the control card. Refer to Control Card Functional Test in this section. Dash Display
Controller LED
Handset or PC
AL01
1 Flash
INPUT ERROR #1
CONDITION Connection/communicati on error between control card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Traction reversing switch is not connected. Install handset. Go to tester function. Check for operation of traction reversing switch. Verify that traction reversing switch cover is making contact with switch on control card. Possible damaged or defective control card. Replace the control card if needed.
LOGIC Traction Reversing Switch data signal is not present and hardware signal is present. Dash Display
Controller LED
Handset or PC
AL01
1 Flash
INPUT ERROR #2
CONDITION Connection/communicati on error between control card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Traction reversing switch is not connected. Install handset. Go to tester function. Check for operation of traction reversing switch. Verify that traction reversing switch cover is making contact with switch on control card. Damaged or defective cable. Check steer handle control cable for loose connections or broken wires. Damaged or defective control handle card. Replace control card if needed.
LOGIC Traction Reversing Switch hardware signal is not present and data signal is present.
Dash Displa y
Controlle r LED
Handset or PC
AL01
1 Flash
BATTERY CHARGING
CONDITION Controller waits in standby mode while a battery charger is connected. TRUCK RESPONSE Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES Connector E is loose at base of controller or defective. Inspect connector E. Check wire 100 between position E6 and E16 for continuity.
LOGIC Controller inputs indicate a battery charger is connected.
Dash Displa y
Controlle r 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
LOGIC Occurs when the controller detects a short in the main contactor circuit.
for shorts to chassis. See Traction Motor Test. Controller is damaged. Replace controller. Refer to the section Electrical System 2200 YRM 1026 or Electrical System 2200 YRM 1007 for more information on troubleshooting electrical system circuits and components. Dash Displa y
Controlle r LED
Handset or PC
AL4
4 Flashes
EVP NOT OK
CONDITION Lowering valve will not operate correctly. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Damaged or loose electrical connection to proportional lowering valve. Verify electrical connections between proportional valve coil and controller. Lowering coil damaged. Check lowering valve coil for correct resistance. Coil resistance should be approximately
LOGIC Occurs if electro-proportional valve is open before circuit is energized. Valve does not follow the supplied signal from controller.
17.8 ohms. Replace coil if damaged. Lowering valve cartridge is damaged. Replace lowering valve cartridge. Refer to the section Electrical System 2200 YRM 1026 or Electrical System 2200 YRM 1007 for more information on troubleshooting electrical system circuits and components. Dash Displa y
Controlle r LED
Handset or PC
AL5
5 Flashes
EB DRIVER KO
CONDITION Electric brake does not release or remains released at all times. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Damaged or loose electrical connection to brake. Verify electrical connection between electric brake and controller. Check brake coil for correct coil resistance. Disconnect brake.
LOGIC Occurs when brake driver circuit is shorted or open circuit.
Measure brake coil resistance in both directions. Coil resistance should be 14.3 ohms. Damaged fly-back diode at brake. Check coil resistance. Short circuit measured at brake connector may indicate a damaged diode. Cut one lead of diode and check with meter. If damaged, replace diode. Damaged controller. Activate the brake switch. Use voltmeter to measure voltage on wire 2C and 17 with brake connected in circuit. If both measurements are 24V and the alarm is displayed, then controller is damaged. Dash Displa y
Controlle r 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 LOGIC connections to traction motor. Verify electrical Occurs if while driving, the motor current does not exceed a preset minimum value. connections between traction motor and controller. raction motor armature resistance is too low. Check traction motor armature for shorts. Perform traction motor test. See Traction Motor Test in this section. Controller is damaged. Cycle key switch. Place steer handle in drive position and select throttle. If the truck starts to drive but then stops and presents code AL6, replace controller. Dash Display
Controller LED
Handset or PC
AL6
6 Flashes
HIGH FIELD CURR, BW HIGH FLD CURR, FW HIGH FLD CURR
CONDITION High field current values measured by controller. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Field wires are loose, damaged, or shorted. Verify connection of field wires to motor and controller. Motor field winding is shorted or too low. Check motor field for correct resistance and continuity. It should measure approximately 0.5 ohms. Perform traction motor test. See Traction Motor Test in this section. Failure of current sensor in controller.
Replace controller. ailure of field current driver in controller. Replace controller.
LOGIC Measured field current is too high.
Dash Display
Controller LED
Handset or PC
AL6
6 Flashes
NO FIELD CURR
CONDITION Low field current values measured by controller. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Cable connection to motor field is loose or damaged. Verify connection of field wires to motor and controller. Motor field winding is open or too high. Check motor field for correct resistance and continuity. It should measure approximately 0.5 ohms. Perform traction motor test. See Traction Motor Test in this section. 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 22.0 ohms (12.5 ohms for models MSW020/025E). Field current drivers in controller are damaged. Replace controller. Refer to the section Electrical System 2200 YRM 1026 or Electrical System 2200 YRM 1007 for more information on troubleshooting electrical system circuits and components.
LOGIC Measured field current is too low.
Dash Displa y
Controlle r LED
Handset or PC
AL6
6 Flashes
STBY I HIGH
CONDITION Controller detects motor current during standby mode. Standby mode occurs while the
truck is at rest with the contactor closed. TRUCK RESPONSE
LOGIC Occurs if controller detects motor currents during standby mode.
Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Damaged controller. Replace controller. Dash Displa y
Controlle r 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
LOGIC This alarm is generated when the controller temperature is outside −10 to 75°C (14 to 167°F).
to operating temperature. Controller temperature miscalibrated. Install handset. Go to tester function and check temperature. Controller and vehicle temperature should be same as room temperature at initial startup. If these temperatures differ, replace controller. Controller temperature sensor damaged. Replace controller. Controller damaged. Replace controller. Dash Displa y
Controlle r LED
Handset or PC
AL8
8 Flashes
POWER FAILURE #1
CONDITION Short circuit in device connected to controller. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES
Overcurrent detected in driven component. Check main harness for damaged or shorted connections to main contactor, brake, and electric valve coils. Check main contactor, brake, and proportional lowering solenoid for correct resistance values.
LOGIC Occurs when controller detects short circuit in component driven by controller.
Value should be within ±10% at room temperature. Main contactor = 22 ohms (12.5 ohms for models MSW020/025-E). Brake coil = 14.3 ohms Proportional lowering valve coil (EV1) = 17.8 ohms Lifting solenoid (EV2) = 22.2 ohms A/B directional valve coil (EV3, EV4) = 40.2 ohms Refer to the section Electrical System 2200 YRM 1026 or Electrical System 2200 YRM 1007 for more information on troubleshooting electrical system circuits and components. Dash Displa y
Controlle r LED
Handset or PC
AL10
LED ON (No Flashing)
EEPROM KO
CONDITION Fault in the memory area where parameters are stored. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Controller damaged. Clear fault log and recycle key switch OFF and ON. Operate lift truck to test. If fault reoccurs, replace controller.
LOGIC Occurs if controller discovers fault in the area of memory where parameters are stored.
Dash Displa y
Controlle r LED
Handset or PC
AL10
LED ON (No Flashing)
CAPACITOR CHARGE
CONDITION Main controller capacitors did not charge within 500 ms of key ON. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES
Loose or damaged wire connection. Inspect and confirm wire connections at contactor, pump motor, and traction motor. See Traction Motor Test in this section. Short circuit in harness. Disconnect main harness and check for shorts. Short circuit in component coil. Disconnect battery. Disconnect all drive motor, pump motor, solenoid, brake, and coil connections at the component end of the harness. Tape or secure the wire ends to prevent shorts. Discharge controller by placing 200Ω, 2W resistor across B+ and B− terminals. Reconnect battery and turn key ON. Use voltmeter to observe voltage across B+ and B−. If there is no voltage increase, replace controller. If there is a steady voltage increase to battery voltage, connect each accessory one at a time until the fault occurs to identify damaged component. If traction motor malfunction suspected, test for proper operation. Perform traction
LOGIC Occurs when an internal or external short or open prevents the main capacitors from charging at key ON.
motor test. See Traction Motor Test in this section. Damaged controller. Replace controller. Dash Display
Controller LED
Handset or PC
AL10
LED ON (No Flashing)
VMN NOT OK
CONDITION Measured voltage at traction motor inputs does not match battery voltage. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Loose or damaged cable connections to motor. Verify motor armature cables and connections. Ground between motor windings and chassis. Check for grounds between motor chassis and terminals. See Traction Motor Test in this section. Check for traction motor malfunction. Perform traction motor test. See Traction Motor Test in this section. 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.
Dash Display
Controller LED
Handset or PC
AL10
LED ON (No Flashing)
VFIELD NOT OK
CONDITION Voltage measured at field connections is not correct. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES
Cable connection to motor field is loose or damaged. Verify connection of field wires to motor and controller. Motor field winding is shorted to chassis. Check motor field for shorts to chassis. Measure motor field resistance. Motor field should be approximately 0.5Ω. Check for traction motor malfunction. Perform traction motor test. See Traction Motor Test in this section. Field current driver circuit has failed. Use a voltmeter to measure between F1 and B− and F2 and B− with battery connected and key ON. Voltage should measure 1/2 the voltage between B+ and B−. Replace controller. Field current drivers in controller are damaged. Replace controller Verify motor field cable connections.
LOGIC This fault occurs when the voltage measured at the field connections 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. Clear the fault log and recycle key switch OFF, then ON. Operate truck to test. If alarm returns, replace controller.
LOGIC Occurs if the watchdog hardware circuit is damaged. Dash Display
Controller LED
Handset or PC
AL10
LED ON (No Flashing)
Driver Shorted
CONDITION Voltage measured at field connections is not correct.
LOGIC
TRUCK RESPONSE Traction and hydraulic functions disabled.
This fault occurs when the voltage measured at the field connections is not the expected value.
POSSIBLE CAUSES AND TEST PROCEDURES Cable connection to motor field is loose or damaged. Verify connection of field wires to motor and controller. Main contactor coil shorted/open. Check contactor coil for correct resistance of 22.0 ohms (53.4 ohms for models MPB040-E). Motor field winding is shorted to chassis. Check motor field for shorts to chassis. Measure motor field resistance. Motor field should be approximately 0.5 ohms. Check for traction motor malfunction. Perform traction motor test. See Traction Motor Test in this section. Field current driver circuit has failed. Use a voltmeter to measure between F1 and B− and F2 and B− with battery connected and key ON. Voltage should measure 1/2 the voltage between B+ and B−. Replace controller. Field current drivers in controller are damaged. Replace controller. Verify motor field cable connections. Refer to the section Electrical System 2200 YRM 1026 or Electrical System 2200 YRM 1007 for more information on troubleshooting electrical system circuits and components. Dash Displa y
Controller LED
Handset or PC
AL66
Continuou s Flashing
BATTERY LOW
CONDITION Battery discharged and requires charging. TRUCK RESPONSE Hydraulic lift function disabled. POSSIBLE CAUSES AND TEST
PROCEDURES Battery voltage is low. Charge or replace battery. Controller voltage calibration is incorrect. Install handset. Go to test menu and select Battery Voltage. Compare tester voltage to voltage measured by an accurate digital voltmeter between B+ and B− terminals. Pull down tiller handle to engage contactor for this measurement. If these two voltages are more than 1.5 volts difference, replace controller.
LOGIC Controller measures low battery voltage over multiple checks during traction or hydraulic operation.
Dash Displa y
Controller LED
Handset or PC
AL94
OFF
NONE
CONDITION Controller is installing hourmeter memory to MDI display if controller or MDI has been replaced. TRUCK RESPONSE Traction and hydraulic functions disabled for 1 minute. POSSIBLE CAUSES AND TEST PROCEDURES
No fault is occurring. Controller will send hourmeter data to MDI and truck will operate as soon as transfer is complete. Wait approximately 60 seconds.
LOGIC Synchronize hourmeter data between MDI and controller.
Dash Display
Controller LED
Handset or PC
AL99
Continuous Flash
BATTERY KO
CONDITION Improper battery connection or defective battery. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES Incorrect battery selected. Verify correct battery voltage for truck. Damaged or extremely discharged battery. Disconnect battery and check voltage at connector. Inspect battery for correct water level and damage. Repair or replace battery. Defective or damaged connection to battery. Inspect cable crimps and cables from battery to connector. Inspect cable crimps and cables from battery contactor to controller and contactor. Refer to the section Electrical System 2200 YRM 1026 or Electrical System 2200 YRM 1007 for more information on troubleshooting electrical system circuits and components.
LOGIC Battery voltage is much less than allowable.
AUXILIARY HYDRAULICS (MSW030/040-E, MRW020/030-E, MCW025/030/040-E) When experiencing a malfunction with the auxiliary operations of the lift truck, different components may be at fault. To accurately determine where the fault is occurring, you must test the circuits responsible for delivering the desired function. See Figure 5. For detailed auxiliary hydraulics troubleshooting, see Electrical System 2200 YRM 1026.
Figure 5. Auxiliary Hydraulic Logic
Control Card Functional Test
Refer to Figure 6 for the following procedures. 1. Follow all safety precautions as listed at the beginning of this section prior to performing any electrical checks. 2. Ensure Battery is fully charged. a. Verify continuity between battery negative (at battery) and −B terminal (at controller). 3. Check for loose connections or damaged wiring between control card and controller. a. Verify connection at the controller. b. Very wire harness connection at the base of the steer handle. 4. Connect ZAPI handset and go to tester function. Refer to ZAPI™ PC Interface in this section. NOTE: If ZAPI Handset can not be connected, consult LED OFF. See Troubleshooting in this section. 5. With ZAPI Handset connected, check the following: a. Look for battery voltage to be 25 ±0.5 volts. b. Check for accelerator output to be 95% or more at full throttle, and to be at 0% and 0V on neutral position. c. Check for lift switch, fork low switch, belly switch, and horn switch to alternate between on and off when switch is pressed and released. (Ensure belly switch is properly seated.) FF lift/lower switches doesn’t behave as expected, swap the On-Off switch with other On-Off switch available within tiller head to verify if problem follow the switch. d. Check lifting control to be more than 90%. of proportional hydraulic controls should be less than 10% at neutral. rtional lift/lower switches doesn’t behave as expected, swap the proportional switch with other proportional switch available within tiller head to verify if problem follow the switch. 6. If handset test are not passed, open tiller head and verify connection at control card: a. Power off the forklift and measure continuity between pin 2, on JP2, on the control card and B- at the controller. en or high resistance is measured, trace problem source and refer to Troubleshooting in this section. b. Power on the forklift and check for 7- segment LED to light on. D is not lit then check to have power on JP2, between pin 1 and pin 2. i. JP2 voltage reading shall be 14V or more, if not, then the tiller card is not receiving power from controller. Disconnect the connection at JP1 and verify the voltage between harness pins 1 and 2 is more than 14V. a. Check the wiring between the controller and the tiller card, as well as the controller output. b. Measure voltage at pin 5, on connector C, on the ZAPI controller. The voltage should be 12V with card disconnected and 3V to 9V with control card connected. If voltage is different, please refer to Troubleshooting, LED Off sections. c. Measure voltage at pin 7, on connector C, on ZAPI controller. It should have 22V or greater with card disconnected. If voltage is different, please refer to Troubleshooting, LED Off sections. d. Reconnect and measure voltage on JP2 again. ii. If voltage reading is achieved on JP2, and the 7 segment display is not lit, replace the tiller card. Refer to the section Electrical System 2200 YRM 1026 or Electrical System 2200 YRM 1007. umper on SV2 is not on Diagnose, Teach or Configuration mode. SV2 jumper can be either seated on parking position (P) or not present at all. 7 segment LED displays the proper control handle card setting: • The proper setting for these models is number 4. i. If not, proceed to reconfigure card through teach mode following auto-learning procedure listed in the Electrical System 2200 YRM 1026 or Electrical System 2200 YRM 1007 section. 7. If speed is other than desired, refer to in this section.
NOTE: ENSURE THAT THE CAM MAGNETIC HOLDER IS ALIGNED WITH THE ALIGNMENT WINDOW; OTHERWISE TRACTION FUNCTIONS WILL NOT OPERATE IN ONE OF THE DIRECTIONS. 1. JUMPER TERMINALS (SV2) 2. HORN SWITCH (S1) 3. THUMBWHEEL SWITCH (CAM MAGNETIC HOLDER) 4. LED DISPLAY SCREEN 5. BELLY SWITCH (S) 6. TURTLE SWITCH (S2) 7. ALIGNMENT WINDOW (CAM MAGNETIC HOLDER) Figure 6. Control Card
Traction Motor Test After troubleshooting the alarm codes per the troubleshooting section, some problems may be isolated to either the controller or the traction motor. There is no test that can be performed on the controller to determine if it is faulty. However, the traction motor can be eliminated as the problem by testing it to confirm proper operation. If the traction motor performs properly during the test, and all the other troubleshooting steps have been checked thoroughly, the controller is more likely to be functioning improperly. Use the following procedure to test the traction motor. 1. Position the lift truck drive end on blocks to securely suspend the drive tire off the floor. 2. Turn the key switch to the OFF position and disconnect the battery. Remove the drive unit compartment cover and discharge the capacitors in the controller. NOTE: Locate the brake override connector on the main wiring harness between the MDU and the controller. It is a normally unconnected wiring connector positioned near where the brake wiring harness and main wiring harness connect. 3. Disconnect the brake wiring harness connector from the main wiring harness and then connect the brake override connector into the brake wiring harness. With the key switch in the OFF position, connect the battery connector and listen for a "click" indicating that the brake has been released and the override function is working properly. Disconnect the battery and continue. See Figure 7.
1. BRAKE WIRING HARNESS 2. MAIN WIRING HARNESS 3. BRAKE OVERRIDE CONNECTOR Figure 7. Brake Override Connector 4. Tag, identify, and then disconnect the field wires (F1 and F2) and motor leads (A1 and A2) from the traction motor. 5. Connect jumper wires as follows: a. Connect a jumper wire from B+ (battery positive) before it enters the controller to F2 terminal on the traction motor. b. Connect a jumper wire from F1 to A1 on the traction motor. NOTE: A remote starter switch is a jumper wire with an in-line momentary switch. c. Connect a remote starter switch from B− on the controller to A2 on the traction motor.
6. Connect the battery BUT LEAVE THE KEY SWITCH IN THE OFF POSITION. Press the remote start switch for 1/2 second then release. Note the direction of rotation of the drive tire and noise of the motor, bearings and gearbox. 7. Disconnect the battery then reconfigure the jumper wires as follows: a. Connect a jumper wire from B+ (battery positive) before it enters the controller to F2 terminal on the traction motor. b. Connect a jumper wire from F1 to A2 on the traction motor. NOTE: A remote starter switch is a jumper wire with an in-line momentary switch. c. Connect a remote starter switch from B− on the controller to A1 on the traction motor. 8. Connect the battery BUT LEAVE THE KEY SWITCH IN THE OFF POSITION. Press the remote start switch for 1/2 second then release. Note the direction of rotation of the drive tire (should be opposite of the first test) and noise of the motor, bearings and gearbox. 9. Disconnect the battery. 10. If the test proves the motor is not operating properly, repair the traction motor, bearings, or gearbox as necessary. If the test show the motor is operating properly: a. Remove the jumpers and reconnect the field wiring as removed. b. Clear the alarm log. c. Disconnect the brake override and reconnect the break wiring harness to the main wiring harness. d. Retest the lift truck. 11. If the alarm code NO TRACTION FWD OR REV or alarm code V FIELD NOT OK is generated, replace the controller. Calibrate the control handle card to the new controller.
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 access the controller. 3. Locate the communications port on the controller. (The port will have either a diagnostic LED, as in Figure 8, or a connector for the display, as in Figure 9.)
Figure 8. Diagnostic LED
Figure 9. Display Connection 4. Connect the interface cable to the controller and the PC. See Figure 10 and Figure 11.
Figure 10. Controller Connection
Figure 11. PC Connection 5. Locate the icon for the ZAPI™ software on the PC and double-click on it. See Figure 12.
Figure 12. ZAPI™ Icon
6. You should now see a screen as shown in Figure 13.
Figure 13. ZAPI™ Software Screen 7. Click on the START button first and then turn the key switch to ON. See Figure 14.
Figure 14. Start Button 8. If the connection was successful, you should now see the screen shown in Figure 15. If you get an error message, go back to Step 7 and try again.
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:
Connection Status:
If there is a current "live" error in the controller, the alarm code will appear here. CONNECTED
Indicates if the software is communicating with the PC.
Figure 15. ZAPI™ Software Version Screen
FILE MENU Open File When you select this function, you will be able to open a previously saved file that contains parameter settings for the controller. See Figure 16.
Figure 16. File - Open
Note that the previously saved file has the .csv extension, and observe how the file name was used. See the Save File section of this manual for proper file saving techniques. See Figure 17.
Figure 17. Look In:
TX From File This selection in the file menu is similar to the File Open selection. See Figure 18.
Figure 18. File - TX From File
Notice the CONNECTION STATUS while the file is downloaded into the controller. See Figure 19.
Figure 19. Connection Status
Save File The ZAPI™ PC software can save configurations for up to 500 controllers. When saving a configuration to the PC, the following steps should be followed to help track which file goes with each controller. See Figure 20.
Figure 20. File - Save
1. Try to use the actual truck serial number and put the word "settings" after it. (This is to keep the controller settings file separate from the tester function Save file.) See Figure 21.
Figure 21. Save: In 2. Once you select a file name and click on Save, you will see the screen shown in Figure 22.
Figure 22. Enter a Comment 3. Under the Enter a Comment box, you can either describe what is different with the settings or enter a customer name. Here is what a saved parameter file looks like: [Info] Chopper_Name=MPB NA V1.01 User_Comment=modified mode 4 to lower speed and coast more Save_Date=Thu Apr 04 15:58:15 2002 [Code;Name;Position;Menu;Value;Scaled Value] 0;ACCELER.DELAY;0;0;0;LEVEL=0 5;DECELER.DELAY;1;0;9;LEVEL=9 11;RELEASE BRAKING;2;0;0;LEVEL=9 12;INVERS.BRAKING;3;0;9;LEVEL=9 30;MAX SPEED FORW;4;0;9;LEVEL=9 31;MAX SPEED BACK;5;0;9;LEVEL=9 248;DRIVE MODES ;01;1;ON [End] [Validation] Code=FFDA [Stop]
Print Settings This selection allows you to print out your current parameter settings in the controller. See Figure 23.
Figure 23. File - Print
Exit This selection will exit the ZAPI™ PC console software. See Figure 24.
Figure 24. File - Exit
CONNECTION MENU There are two selections under this menu: 1. Start - Starts the connection between the controller and PC (operates the same as the main Start button on the right-hand side of the display screen). 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 25.
Figure 25. Connection Menu
FUNCTION MENU There are seven selections under this menu: 1. Parameter - Allows the performance and configuration of the controller to be adjusted. Refer to Parameter, in this section. 2. Tester - Allows the testing of various inputs and operations of the controller. Refer to Tester, in this section. 3. Alarm Logbook - Stores alarms that the controller detects. Refer to Alarm Logbook, in this section. 4. Program VACC - Not Used. 5. Motor Data - Not Used. 6. Ram Function - Only Factory Use. 7. EEPROM Function - Only Factory Use.
Parameter When you first activate this selection, the screen will look as indicated in Figure 26. In order to see the parameters 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.
Figure 26. Parameter
You will now see a screen like Figure 27, while the data are being downloaded.
Figure 27. Downloading Screen
Now that the parameters have downloaded, you should see a screen as indicated in Figure 28.
Figure 28. Drive Mode Please note that the current drive mode the lift truck was in will be displayed. (There are three modes that cannot be adjusted.) In order to make any changes to the parameters, you must turn on Mode 4, which is covered in Set Options, in this section. Adjustments can be made by first highlighting the parameter 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.
There are six parameters that can be adjusted to affect the performance of the lift truck. See Figure 29.
Figure 29. Adjustable Parameters 1. ACCELER. DELAY - Amount of ramp-up to full speed. • Level 0 - Large acceleration curve, up to full speed. • Level 9 - Short acceleration curve, up to full speed. 2. DECELER. DELAY - Amount of ramp-down to a lower speed. • Level 0 - Large deceleration curve, to a lower speed (coasting). • Level 9 - Short deceleration curve, to a lower speed (aggressive). 3. RELEASE BRAKING - Amount of braking when the accelerator is released. • Level 0 - Minimum braking (coasting). • Level 9 - Maximum braking (aggressive).
4. INVERSE BRAKING - Amount of braking when the lift truck is "plugged." • Level 0 - Minimum braking. • Level 9 - Maximum braking. 5. MAX SPEED FORW - Maximum speed of the lift truck in the handle direction. • Level 0 - Minimum speed. • Level 9 - Maximum speed. 6. MAX SPEED BACK - Maximum speed of the lift truck in the forks direction. • Level 0 - Minimum speed. • Level 9 - Maximum speed.
Notice that the ACCELER. DELAY function has been adjusted. The parameter settings are "live," which means as they are being adjusted. The lift truck will react to the setting. Once the lift truck is performing as wanted, the Store button is pressed to save the settings into the controller. See Figure 30.
Figure 30. Store Button NOTE: If the Store button is not pressed before turning off the lift truck, then all changed parameters will be lost.
Memory Menu If you wish to start all over with your adjustments prior to pressing the Store button, then you can select the Memory menu to see the screen in Figure 31.
Figure 31. Memory Menu This menu has three selections: 1. Receive - Same as Receive menu and Receive button. 2. Store - Same as Store button. 3. Restore - Will revert the parameter settings to what they were before adjustments were made. Note this will not work if the settings were stored before using this function.
Set Options This selection will allow Mode 4 to be activated, so that the performance parameters can be adjusted for a custom configuration. See Figure 32.
Figure 32. Set Options
Highlight Drive Modes and then click on the scroll bar to the right and select OFF. See Figure 33.
Figure 33. Turn Off Drive Modes Do the following steps once this has been done: 1. Press the Store button to save the change into the controller. 2. Press the Close button to go to the main screen of the ZAPI™ PC software. 3. Press the Stop button to disconnect the communication 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).
Tester This selection allows the technician to monitor up to four items at a time to help troubleshoot problems. See Figure 34.
Figure 34. Tester The Tester function also features a data-logging capability to further assist the technician and the factory with problems. The PC software can test the following (four selections at a time). See Figure 35. 1. Battery Voltage - voltage across the battery. 2. Motor Voltage - voltage across the traction motor. 3. Motor Current - current through the traction motor. 4. Field Current - current through the fields in the traction motor. 5. Temperature - current temperature of the controller. 6. Accelerator - voltage and percent of "throw" from the traction thumbwheel. 7. Lifting Control 8. Tiller Switch - position of tiller handle. 9. Forward Switch - directional input. 10. Backward Switch - directional input. 11. Lifting Switch - refers to switch on right side of tiller head. 12. Lowering Switch - refers to switch on right side of tiller head. 13. Fork Lift Switch - refers to switch on left side of tiller head. 14. Fork Lower Switch - refers to switch on left side of tiller head. 15. Belly Switch 16. Snail Switch 17. Horn Switch 18. Cutback Switch 19. Lifting Block 20. Battery Model 21. Battery Charge - remaining charge on the battery.
Figure 35. Test Name
Data Logger
Figure 36. Data Logger In addition to "live testing" of the controller, the ZAPI™ PC software also includes a data-logging capability. See Figure 36. There are four buttons associated with this, as listed below. 1. Advanced - Allows the user to select sample rates 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. The Advanced button allows the user to initiate a series of samples to be taken for the 4 items you have selected in the tester menu. Users can select the desired time intervals between samples (time steps) and the number of samples to be taken (samples). Time steps are in increments equal to 0.1 seconds. Therefore a selection of 20 time steps and 50 samples would result in a sample being taken every two seconds until 50 samples have been recorded. See Figure 37.
Figure 37. Tester Advanced
Figure 38. Logging Process As the data logger is running, the screen will look like what is shown in Figure 38. During the logging process, you will still be able to see the values changing in the display menu. Once the data logger is done, you can save the log using the Save Rec. button. See Figure 39.
Figure 39. Save As Once the log file has been saved, the user can either analyze the data him/herself or e-mail the file to the factory for analysis. The raw data file looks like this (see Figure 40): [Info] Chopper_Name=CS P20 V1.00 Save_Date=Thu Apr 04 13:32:24 2002 TIME;MOTOR CURRENT;ACCELERATOR;BATTERY CHARGE ;FIELD CURRENT;
0;0;0.00
0;80;0.0;
10;0;0.00
0;80;0.0;
20;0;0.00
0;80;0.0;
30;0;0.00
0;80;0.0;
40;0;0.00
0;80;0.0;
50;0;0.00
0;80;7.2;
60;3;0.00
0;80;7.2;
70;3;0.27
10;80;7.2;
80;3;0.27
10;80;12.7;
90;8;0.53
16;80;12.7;
Figure 40. Test Data
Alarm Logbook The ZAPI™ controller can record up to five unique alarms and store them in a logbook that the PC can access. See Figure 41.
Figure 41. Alarm Logbook
The display screen (Figure 42) will display any current "live" alarms. Note the display ACTUAL ALARM that indicates a current "live" alarm condition.
Figure 42. Actual Alarm The PC software will provide the alarm name and the number of times it has occurred, the temperature of the controller when the alarm occurred, and the hourmeter reading (internal to the controller) of when the alarm occurred. The user can check for new alarms by pressing the Update key or clear out the alarm log by pressing the Clear key. The following list consists of possible alarms.
Alarms 1. EVP NOT OK 2. BRAKE DRIVER KO 3. VFIELD NOT OK 4. PUMP VACC NOT OK 5. SERIAL ERROR #1 6. WATCHDOG 7. EEPROM KO 8. FORW + BACK 9. VMN NOT OK 10. CONTACTOR CLOSED 11. I=0 EVER 12. STBY I HIGH 13. HIGH FIELD CURRENT 14. NO FIELD CURRENT 15. CAPACITOR CHARGE 16. LOW BATTERY 17. THERMAL PROTECTION
18. CHARGING BATTERY 19. POWER FAILURE #1 20. DRIVER SHORTED 21. CONTACTOR DRIVER 22. VACC NOT OK 23. INCORRECT START 24. INPUT ERROR #2 25. INPUT ERROR #1
PROGRAMMING TILT AND SIDESHIFT ON THE ZAPI CONTROLLER (LAPTOP) 1. Connect the laptop to the ZAPI Controller: a. If equipped with sideshift, make sure controller connector "E" on the main wiring harness has a jumper wire installed between E3 to E13. b. Turn the key switch to the OFF position. SHUT DOWN the laptop. Make certain the laptop was powered off as opposed to restarted or in standby mode. c. Connect the laptop to the controller using the appropriate cables and connectors. d. Turn the key switch to the ON position and then POWER ON the laptop. e. Launch the ZAPI Laptop Software program from the desktop icon or the start menu. 2. ON the drop down menu, click on "Configuration," "COM Port." a. Select the COM port "ComPort2." b. Select the Baud Rate "1200 bps." c. Click "OK" then "Start" in the console window. d. Verify the connection status reads "CONNECTED."
CAUTION This procedure will access High Level Programming of the ZAPI controller. 3. On the drop down menu, click on "Configuration," "Enter Password." a. Enter the password ZAPI (in all capital letters). The password can only be entered if the Com Configuration was properly connected in the previous steps. b. Click "OK."
4. On the drop down menu, click on "Function," "EEPROM Function." a. Delete the value in the address box and enter F000. b. Click "Start Write." c. Verify that the new console window states "WRITE EEPROM CELL." d. Delete the value in the address box and enter F000. e. Click "Start Write" again. f. Verify that the new console states "READ EEPROM CELL." g. Click "Stop Write." h. Delete the value in the "Value" box and enter 55AA. i. Click "Start Write" again. j. Verify the values in the ADDRESS box and the VALUE box. k. Click the "Close" button. 5. On the drop down menu, click on "Function," "Parameters." a. Select the "Parameter Change" tab. b. Click "Receive." c. Click the "Set Options" tab. d. Select the parameter name "AUX INPUT #1." e. Change the parameter value to PRESENT using the drop box in the upper right corner of the console.
f. Click the "Store" button in the lower left of the window to save. Verify the value has changed in the "Parameter Value" column. 6. Verify all settings and click the "Close" button in the lower right of the window to return to the Main Menu.
Repair REMOVE 1. Park lift truck in a safe, level area. 2. Block drive wheel to prevent lift truck from moving. 3. Connect handset or PC and download parameters, if possible. 4. Turn key to OFF. 5. Disconnect battery. 6. Remove cover.
WARNING The capacitors in the controller remain charged for several minutes after operation. To prevent personal injury and/or damage to equipment, the controller should be discharged. To discharge the controller, connect a 200-ohm, 2- to 3-watt resistor between the battery positive and negative terminals on the controller for at least 5 seconds. Refer to Figure 1 in the General section of this manual. 7. Discharge controller. 8. Identify and tag all power cables and wires connected to controller for later installation. 9. Remove all power cables and wires connected to controller. 10. Loosen both capscrews retaining controller to plate. 11. Remove controller.
BRASS STUD REPLACEMENT Remove 1. Remove M8 nut, lockwasher, flat washer, brass washer, power fuse, and brass washer from brass stud. 2. Remove brass stud from controller.
Install The stud must be installed in the correct orientation with regard to the relief groove. 1. Install brass stud onto controller and tighten to 10 to 11 N•m (92 to 97 lbf in). 2. Install brass washer, power fuse, brass washer, flat washer, lockwasher, and M8 nut to brass stud. Tighten M8 nut to 10 to 11 N•m (92 to 97 lbf in).
INSTALL 1. Align controller to plate and capscrews. Tighten capscrews. 2. Connect all power cables and wires connected to controller. 3. Connect battery. 4. Connect handset or PC. 5. Turn key to ON. 6. Upload parameters. 7. Remove blocks from drive wheel. 8. Test lift truck in a safe, level area away from other personnel and equipment. 9. Install cover.
REPAIR 1. Check and replace fuses as necessary. 2. Check and repair wiring (see troubleshooting guide). 3. Check the battery pack. 4. Check the motors and motor connections. 5. Replace controllers when necessary by following the remove and install procedures listed above.
SIDESHIFT SETUP WITH AUXILIARY (MRW020/030-E) To enable the sideshift function on the MRW020/030-E stacker trucks with auxiliary board, follow the following procedure: 1. Jumper must be installed in connector E - positions 3 and 13. 2. Connect ZAPI™ handset. 3. When main menu appears, press ENTER. 4. Scroll to ALARMS. 5. Press buttons 5 and 6 at the same time. 6. Scroll to READ EEPROM" Press ENTER. 7. Using ROLL and SET keys, change address to F000 1234. 8. Press ENTER. Press OUT until the main menu appears. 9. Press buttons 1 and 5 at the same time. 10. Scroll to the SET OPTION menu. Press ENTER. 11. Scroll to AUX INPUT #1. Set to PRESENT. 12. Press OUT. Handset will ask, ARE YOU SURE?. Press ENTER. 13. Press OUT until the main menu appears. 14. Turn key OFF and ON to retain settings. 15. Confirm operation of sideshift function.
Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011
