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 user-
selectable 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 0 = short or rapid acceleration 0

acceleration. 9 = long or slow acceleration

DECELERATION DELAY Adjusts truck 0 = short or rapid deceleration 5

deceleration according to 9 = long or slow deceleration
throttle position.
 RELEASE BRAKING Adjusts motor braking 0 = soft braking 7
strength or regenerative 9 = strong braking
braking when throttle is
released. This
determines coast
distance.

INVERSE BRAKING Adjusts plugging rate. 0 = long or soft plugging 9

9 = short or rapid plugging

CUTBACK SPEED Speed control for trucks 0 = slow 9

in optional mode. 9 = fast
(not used)

MAX SPEED FORW Adjusts maximum speed 0 = minimum 4

in forward direction, forks 9 = maximum
trailing.

MAX SPEED BACK Adjusts maximum speed 0 = minimum 4

in reverse direction, forks 9 = maximum
leading.

LIFT MAX TIME Adjusts the maximum 0 = minimum or approximately 9

time for lifting forks. 5 seconds
9 = maximum or approximately
65 seconds

AUXILIARY TIME Adjusts the maximum 0 = minimum or approximately 5

time for auxiliary 1.5 seconds
hydraulic functions. 9 = maximum or approximately
6 seconds

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 Controlle Handset or PC

Display r LED

No LEDs LED OFF Handset does not operate

or LCDs
illuminate
d

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 LOGIC
proper voltage.
Verify key switch is
Occurs when there is no power to the controller or the controller is defective.
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.
 Dash Controlle Handset or PC
Display r LED

No LEDs LED OFF No error codes present

or LCDs
illuminate
d

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 LOGIC
communication to
handset. Occurs when the MDI or LED receives no signal, or MDI or LED is damaged.
If handset operates
correctly, replace MDI.
Defective LED.
Disconnect LED and
connect handset. If
handset works,
replace LED.

Dash Controlle Handset or PC

Display r LED

No LEDs LED OFF NO COMMUNICATION

or LCDs
illuminate
d

CONDITION
 Dash display and/or
controller LED
inoperative.
LOGIC
TRUCK RESPONSE

Travel and hydraulic Occurs when controller does not send a signal to the MDI or LED.
functions normal.

POSSIBLE CAUSES
AND TEST
PROCEDURES

Defective controller.
Connect handset to
controller and confirm
communication to
handset.
If handset will not
communicate with
controller, replace
controller.

Dash Controlle Handset or PC

Display r LED

No Alarm LED OFF INCORRECT START

- No
Flashes

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 LOGIC
function selected at
key ON. Steer handle
Fault occurs when controller receives input that has not followed the proper
in run position at key
operational sequence.
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 auto-
learn procedure listed
in steering. If this does
not clear fault, check
buttons for damage or
interference. Replace
damaged or faulty
buttons.

Dash Controller Handset or PC

Display LED

AL01 1 Flash VACC NOT OK

CONDITION
 Connection/communicati
on error between tiller
card and traction
controller. LOGIC
TRUCK RESPONSE
Occurs when accelerator voltage from serial control card is higher than 1V
Traction and hoist (20%) before neutral switch is closed.
functions disabled.

POSSIBLE CAUSES
AND TEST
PROCEDURES

Control card throttle

calibration is out of
range.
Install handset. Go to
tester function of
handset. If accelerator
output is >1V (20%) and
the enable switch is
open, recalibrate control
card.
Control card throttle
damaged or Cam
Magnetic Holder not
aligned with Alignment
Window.
Replace control card if
needed.

Dash Controller Handset or PC

Display LED

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 LOGIC
lifting control and EVP
voltage.” Check on/off
Occurs if the output of one on the hydraulic controls is higher than 1V (20%)
switches and
at start.
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.

Dash Controller Handset or PC

Display LED

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 LOGIC
switch and backward
switch are both on at the
Occurs if controller receives signal for forward and reverse directions
same time, card may be
simultaneously.
damaged.
Replace the control card
if needed.

Dash Controller Handset or PC

Display LED

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, LOGIC
connector C, on the
controller. With control No information or incorrect information has been sent from the control card to
card disconnected, this controller.
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
 damaged.
Test the control card.
Refer to Control Card
Functional Test in this
section.

Dash Controller Handset or PC

Display LED

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 Controller Handset or PC

Display LED
 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 LOGIC
operation of traction
reversing switch. Traction Reversing Switch hardware signal is not present and data signal is
Verify that traction present.
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.

Dash Controlle Handset or PC

Displa r LED
y

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 LOGIC
Connector E is loose at
base of controller or Controller inputs indicate a battery charger is connected.
defective.
Inspect connector
E. Check wire 100
between position E6
and E16 for
continuity.

Dash Controlle Handset or PC

Displa r LED
y

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 LOGIC
circuit.
Verify electrical Occurs when the controller detects a short in the main contactor circuit.
connections
between motor field
and controller.
Check motor field
 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 Controlle Handset or PC

Displa r LED
y

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 LOGIC
valve coil for correct
resistance. Coil Occurs if electro-proportional valve is open before circuit is energized. Valve does
resistance should not follow the supplied signal from controller.
be approximately
 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 Controlle Handset or PC

Displa r LED
y

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
LOGIC
electric brake and
controller.
Check brake coil for Occurs when brake driver circuit is shorted or open circuit.
correct coil
resistance.
Disconnect brake.
 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 Controlle Handset or PC

Displa r LED
y

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. LOGIC
ailure of field current driver in controller.
Replace controller. 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. LOGIC
Main contactor circuit damaged or disconnected.
Verify electrical connection between controller Measured field current is too low.
and contactor.
Check contactor coil for correct resistance of
22.0 ohms (12.5 ohms for models MSW020/025-
E).
Field current drivers in controller are damaged.
Replace controller.
Refer to the section Electrical System 2200
YRM 1026 or Electrical System 2200 YRM
1007 for more information on troubleshooting
electrical system circuits and components.

Dash Controlle Handset or PC

Displa r LED
y

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.
LOGIC
TRUCK
RESPONSE
Occurs if controller detects motor currents during standby mode.
Traction and
hydraulic functions
disabled.

POSSIBLE
CAUSES AND
TEST
PROCEDURES

Damaged controller.
Replace controller.

Dash Controlle Handset or PC

Displa r LED
y

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). LOGIC

POSSIBLE This alarm is generated when the controller temperature is outside −10 to 75°C
CAUSES AND (14 to 167°F).
TEST
PROCEDURES

Controller temperature
is too hot/cold.
Move truck to
cooler or warmer
location and allow
controller to return
 to operating
temperature.
Controller temperature
miscalibrated.
Install handset. Go
to tester function
and check
temperature.
Controller and
vehicle 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 Controlle Handset or PC

Displa r LED
y

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 LOGIC
damaged or
shorted
Occurs when controller detects short circuit in component driven by controller.
connections to main
contactor, brake,
and electric valve
coils.
Check main
contactor, brake,
and proportional
lowering solenoid
for correct
resistance values.

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 Controlle Handset or PC

Displa r LED
y

AL10 LED ON EEPROM KO

(No
Flashing)
 CONDITION

Fault in the memory

area where
parameters are
stored.

TRUCK
RESPONSE

Traction and
hydraulic functions
disabled.

POSSIBLE
CAUSES AND
TEST
PROCEDURES LOGIC
Controller damaged.
Occurs if controller discovers fault in the area of memory where parameters are
Clear fault log and
stored.
recycle key switch
OFF and ON.
Operate lift truck to
test. If fault
reoccurs, replace
controller.

Dash Controlle Handset or PC

Displa r LED
y

AL10 LED ON CAPACITOR CHARGE

(No
Flashing)

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 LOGIC
contactor, pump
motor, and traction
Occurs when an internal or external short or open prevents the main capacitors
motor.
from charging at key ON.
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
 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.
LOGIC
Damaged controller.
Voltage at –T terminal on controller should be
the same as the +B terminal. Occurs when controller observes differences between
Replace controller. 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. LOGIC
Verify connection of field wires to motor and
controller. This fault occurs when the voltage measured at the
Motor field winding is shorted to chassis. field connections is not the expected value.
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.

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
LOGIC
Voltage measured at field connections is not
correct.
 TRUCK RESPONSE This fault occurs when the voltage measured at the
field connections is not the expected value.
Traction and hydraulic functions disabled.

POSSIBLE CAUSES AND TEST PROCEDURES

Cable connection to motor field is loose or damaged.

Verify connection of field wires to motor and
controller.
Main contactor coil shorted/open.
Check contactor coil for correct resistance of 22.0
ohms (53.4 ohms for models MPB040-E).
Motor field winding is shorted to chassis.
Check motor field for shorts to chassis.
Measure motor field resistance. Motor field should
be approximately 0.5 ohms.
Check for traction motor malfunction.
Perform traction motor test. See Traction Motor
Test in this section.
Field current driver circuit has failed.
Use a voltmeter to measure between F1 and B−
and F2 and B− with battery connected and key
ON. Voltage should measure 1/2 the voltage
between B+ and B−.
Replace controller.
Field current drivers in controller are damaged.
Replace controller. Verify motor field cable
connections.
Refer to the section Electrical System 2200
YRM 1026 or Electrical System 2200 YRM 1007
for more information on troubleshooting electrical
system circuits and components.

Dash Controller Handset or PC

Displa LED
y

AL66 Continuou BATTERY LOW

s Flashing

CONDITION

Battery discharged
and requires
charging.

TRUCK
RESPONSE

Hydraulic lift function

disabled.

POSSIBLE
CAUSES AND
TEST
 PROCEDURES

Battery voltage is low.

Charge or replace
LOGIC
battery.
Controller voltage
calibration is Controller measures low battery voltage over multiple checks during traction or
incorrect. hydraulic operation.
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.

Dash Controller Handset or PC

Displa LED
y

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 LOGIC
operate as soon as
transfer is complete.
Synchronize hourmeter data between MDI and controller.
Wait approximately
60 seconds.

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
LOGIC
contactor to controller and contactor.
Refer to the section Electrical System 2200
YRM 1026 or Electrical System 2200 YRM 1007 Battery voltage is much less than allowable.
for more information on troubleshooting electrical
system circuits and components.

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: 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 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