ZAPI™ CONTROLLERS

W20-25ZA [A495];
W25-30ZA 2 [B495];
W30-40ZA [B453];
W20-30ZR [B455];
W25-30-40ZC [B454]

PART NO. 1537482 2200 SRM 1064

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

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

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

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

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

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

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

WARNING
Indicates a 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 back-
ground. The CAUTION symbol and word are on yellow background.
ZAPI™ Controllers Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
ZAPI™ Transistor Motor Controller............................................................................................................. 2
Principles of Operation.................................................................................................................................. 2
Controller Safety ................................................................................................................................................ 3
Controller Adjustments ..................................................................................................................................... 3
Modes of Operation ............................................................................................................................................ 4
User-Selectable Operating Modes ................................................................................................................ 4
Programming...................................................................................................................................................... 5
Custom Performance Mode ........................................................................................................................... 5
Controller Parameters................................................................................................................................... 5
Setting Drive Modes.................................................................................................................................. 5
Tester Menu ................................................................................................................................................... 7
Set Option Menu............................................................................................................................................ 7
ZAPI™ Handset............................................................................................................................................. 8
Alarm Code Diagnostics .................................................................................................................................... 12
Alarm Code Diagnostic Procedure ................................................................................................................ 12
Troubleshooting.................................................................................................................................................. 14
Auxiliary Hydraulics (W30-40ZA, W20-30ZR, W25-30-40ZC) .................................................................... 39
Control Card Functional Test............................................................................................................................ 40
Traction Motor Test............................................................................................................................................ 42
ZAPI™ PC Interface .......................................................................................................................................... 44
Connecting PC to ZAPI™ Controller............................................................................................................ 44
File Menu ....................................................................................................................................................... 47
Open File.................................................................................................................................................... 47
TX From File ............................................................................................................................................. 48
Save File .................................................................................................................................................... 50
Print Settings ............................................................................................................................................ 52
Exit............................................................................................................................................................. 53
Connection Menu ........................................................................................................................................... 54
Function Menu............................................................................................................................................... 54
Parameter .................................................................................................................................................. 54
Memory Menu............................................................................................................................................ 59
Set Options ................................................................................................................................................ 60
Tester.......................................................................................................................................................... 62
Data Logger ............................................................................................................................................... 64
Alarm Logbook .......................................................................................................................................... 67
Alarms........................................................................................................................................................ 68
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) ............................................................. 69
Repair ................................................................................................................................................................. 70
Remove ........................................................................................................................................................... 70
Brass Stud Replacement ............................................................................................................................... 70
Remove....................................................................................................................................................... 70
Install ......................................................................................................................................................... 70
Install ............................................................................................................................................................. 70
Repair ............................................................................................................................................................. 70
Sideshift Setup With Auxiliary (W20/30ZR) ................................................................................................ 71

©2010 HYSTER COMPANY i

Table of Contents ZAPI™ Controllers

TABLE OF CONTENTS (Continued)

This section is for the following models:

W20-25ZA [A495];
W25-30ZA 2 [B495];
W30-40ZA [B453];
W20-30ZR [B455];
W25-30-40ZC [B454]

ii
2200 SRM 1064 General

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

Figure 1. Controller

1
Description 2200 SRM 1064

Description
ZAPI™ TRANSISTOR MOTOR NOTE: The dash indicator will display the code: EP
CONTROLLER 107 (or a higher number) for 1 to 2 seconds every
time the key switch is turned to the ON position. The
The ZAPI™ controller is a solid-state DC motor ZAPI handset similarly displays V1.07 (or higher).
controller utilizing SEM technology. It controls the This code represents the EEPROM software version
traction motor, brake, and hydraulic system. The and DOES NOT INDICATE A FAULT CODE.
controller receives inputs from the control handle by
serial communication, and direct inputs from the key Troubleshoot the fault using a ZAPI™ handset or a
switch and control handle arm position switch. The properly configured IBM compatible PC. On trucks
controller directly controls the traction motor, lift equipped with the optional dash display, the dash
pump motor, lift valve, proportional lowering valve, wiring harness plugs into the controller in place of
brake, and main contactor. Additional hydraulic the LED. The display also has a red LED, however,
functions, such as reach, sideshift, and tilt are con- it does not flash codes. If a fault occurs, the red LED
trolled through an auxiliary relay board mounted blinks, the wrench LCD is shown, and "AL" followed
to the front of the controller. Jumpers are used to by the fault number is displayed.
configure the basic controller and the controller with
auxiliary relay board for different truck models. PRINCIPLES OF OPERATION

The controller software provides self diagnostics The ZAPI™ transistor motor controller uses a so-
which are accessed by means of a ZAPI™ handset phisticated microprocessor to control the logic and
or a PC with specialized ZAPI™ software. The con- operation of the controller, eliminating the need for
troller software features a Test Menu for monitoring forward and reverse contactors. The SEM motor
controller inputs and outputs, a Diagnostic Menu for controller operates on the principle of controlling
viewing fault code information, and a Programming the motor field circuit and the motor armature
Menu for customizing the truck performance. The circuit independently. The controller has many
handset or PC connect to the controller through a programmable features, including maximum speed,
cable with a six pin connector which attaches to acceleration rate, release braking, and braking
the 10 pin "D" connector port on the bottom of the current limit. The SEM controller includes a full
controller. The connector is installed centered in the range of features, as well as diagnostic and setup
"D" port leaving two pins on each end of the "D" port capability.
vacant. The connector retainer clip will align and
NOTE: There are no user-serviceable parts in the
secure the connector in position.
ZAPI™ controller. No attempt should be made to
The self diagnostics monitor the traction motor, open, repair, or otherwise modify the controller.
brake coil, lowering valve coil, contactor coil, control Doing so may damage the controller and will void
handle serial communications, controller tempera- the warranty.
ture, 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.

2
2200 SRM 1064 Controller Adjustments

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

See Figure 2.

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

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

3
Modes of Operation 2200 SRM 1064

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

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

NOTE: You must use the handset or PC interface to

change this setting. Using the ZAPI™ handset or PC

4
2200 SRM 1064 Programming

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

CONTROLLER PARAMETERS Figure 3. ZAPI™ Handset

Parameters are controller settings that can be ad- 7. Press buttons 1 and 5 simultaneously.
justed to alter the performance characteristics of the
truck. 8. The screen will display CONFIG MENU.

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

5
Programming 2200 SRM 1064

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, 9 = maximum
forks 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

6
2200 SRM 1064 Programming

TESTER MENU 14. FORK LIFT SWITCH = lifting function request

from control handle card, ON/OFF.
NOTE: The Tester function can be used to trou-
bleshoot multiple systems simultaneously while the 15. FORK LOW SWITCH = lowering function re-
truck is in operation. quest from control handle card, ON/OFF.

The most important input or output signals can be 16. R-SHIFT SWITCH = sideshift right switch,
measured in real time using the TESTER function ON/OFF.
of the handset. The handset acts as a multimeter to
read voltage, current, temperature, switch state, and 17. L-SHIFT SWITCH = sideshift left switch,
other functions. ON/OFF.

1. BATTERY VOLTAGE = battery voltage, nominal 18. BELLY SWITCH = traction reversing switch to
value = 24V. the controller or traction reversing request from
control handle card, ON/OFF.
2. MOTOR VOLTAGE = armature voltage ob-
tained, shown in volts. 19. SNAIL SWITCH = snail request from control
handle card allows machine to drive with control
3. MOTOR CURRENT = armature current during handle up, turtle speed switch, ON/OFF.
traction (positive value) or braking (negative
value) in amps. 20. HORN SWITCH = horn request from control
handle card, ON/OFF.
4. FIELD CURRENT = field current in the selected
traction direction in amps. 21. SW4-SW9 = auxiliary function jumper.

5. EVP VOLTAGE = proportional lowering valve 22. BATTERY MODEL = battery-type of input
coil voltage. switch, ON/OFF. ON = flooded battery (input
closed), OFF = sealed battery (input open).
6. TEMPERATURE = controller temperature, C.
23. BATTERY CHARGE = battery charge indication,
7. ACCELERATOR = directional control voltage re- %.
ceived from control handle.
SET OPTION MENU
8. LIFTING CONTROL = proportional lifting volt-
age received from control handle. DRIVE ON The truck has three
MODES performance modes, each
9. TILLER SWITCH = control handle switch input, with a fixed set of parameters.
ON/OFF. This function is enabled by
setting DRIVE MODES = ON.
10. FORWARD SWITCH = forward direction request
from control handle card, ON/OFF. OFF DRIVE MODES disabled.

11. BACKWARD SWITCH = backward direction re- Custom Performance Mode

quest from control handle card, ON/OFF. is enabled, the adjustable
parameters on Table 1 can be
12. LIFTING SWITCH = lifting function request adjusted.
from control handle card, proportional lift switch,
ON/OFF.

13. LOWERING SWITCH = lowering function re-

quest from control handle card, proportional
lowering switch, ON/OFF.

7
Programming 2200 SRM 1064

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

NOTE: The ZAPI handset will display the code: V1.07 2 Roll-Down Push to scroll down.
(or a higher number) for 1 to 2 seconds every time 3 Enter Push to enter a
the key switch is turned to the ON position. This submenu or to confirm
code represents the EEPROM software version and a change.
DOES NOT INDICATE A FAULT CODE.
4 Out Push to exit a selected
The ZAPI™ handset must be connected to the con- menu or to refuse a
troller before turning on the key. The handset must change.
have an adapter harness to connect to the controller.
The handset and adapter harness are available from 5 Set-Up Push to increase a
your Hyster dealer. Connect the handset to plug D. parameter value.
The handset can remain connected to the controller 6 Set-Down Push to decrease a
while running, and the parameters can be changed parameter value.
in real time. In this case, it is necessary to go in
a standby condition (truck at rest) before switching NOTE: After a modification, save the new values by
OFF the controller in order to store the new values pushing out, then enter to confirm. (Screen prompts
in the EEPROM. will guide the user.)
This section describes the ZAPI™ handset functions. To navigate the menu options, numbers inside the
Six buttons provide the capability of changing or triangles in the following map correspond to the same
reading the parameters. number on the handset keyboard buttons. The ori-
entation of the triangle indicates the way to the next
function. See Figure 3.

NOTE: Connect and disconnect the handset only with

the key switch in the OFF position.

For additional handset description, see Figure 4.

8
 NOTES

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9
Programming 2200 SRM 1064

10
2200 SRM 1064 Programming

Figure 4. ZAPI™ Handset Instructions

11
Alarm Code Diagnostics 2200 SRM 1064

Alarm Code Diagnostics

ALARM CODE DIAGNOSTIC PROCEDURE Table 3. Example Controller Software Versions

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 MPB NA V 1.08
represents the EEPROM software version and DOES 24 V - 180 A 000369
NOT INDICATE A FAULT CODE.
or
When an alarm code(s) has been detected, the follow- SC P18 V 1.04
ing procedure should be performed to properly read
the codes and eliminate unnecessary procedures dur- 24 V - 180 A 00369
ing troubleshooting. or
COMBI - USA4 V 1.06
CAUTION
Always turn the key switch to the OFF position 24 V - 180 A 000369
when connecting and disconnecting the hand-
set or laptop cable into the truck controller.
NOTE: The lower right hand numbers represent the
NOTE: If you are using a USB connection to your lap-
hours since controller installation which may differ
top, the cables and adaptors must be connected to
from total truck hours as shown on the digital dash
both the laptop and the lift truck controller before
indicator (DDI).
the laptop is first started (booted) up.
3. Go to "Alarm Menu." Press Enter.
1. Connect the Zapi™ Handset or laptop to the lift
truck controller. Turn the handset or laptop on. 4. Write down both lines of the alarm code. Then
Turn the lift truck key switch to the ON position scroll to the next alarm code and record both lines
and view the handset display. See Table 2. again. Continue until the alarm codes repeat
with identical information. Example: You will
Table 2. Example Handset Software Versions
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
ZAPI OK), controller hours at time of last occurrence
CONSOLE V 3.07 (1350h), number or occurrences (#15), tempera-
ture at time of last occurrence (in Celsius (35C)).
See Table 4.

NOTE: The handset will briefly display the handset Table 4. Example Alarm Code
software version for 1.5 seconds before changing to
the second screen. Wait for the second screen to ap-
pear with the controller software version. EVP NOT OK
2. Write down the controller software version infor- 1350h #15 35C
mation and hourmeter reading that is displayed
on the second screen of the handset. See Table 3.
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.

12
2200 SRM 1064 Alarm Code Diagnostics

6. Cycle the key switch to start the lift truck in

the normal mode. Operate the lift truck until CAUTION
the alarm code reoccurs (faults out). Then, go If the battery has been disconnected and recon-
back to the Alarm Code menu and write down nected with the key switch in the ON position, a
the alarm codes which are now present. These voltage spike can cause corruption of the Zapi
alarms should be investigated first to isolate the controller EPROM.
most prominent malfunctions.
Remember to use the "Tester" function to check
NOTE: If the THERMAL PROTECTION alarm codes switch input from the control handle to the con-
are generated, use the Tester Function = Temper- troller. This procedure will also alert you if the
ature. If the controller sees 75 C (175 F) or below controller has been changed but the control han-
10 C (14 F), it will reduce electrical current to the dle card has not been reprogrammed.
motors and regular performance of the lift truck will
slow down. Zapi controller menu items:
• ACCELERATOR = Volts Percent % = Shows
You can operate the truck with the Tester Func- Variable Voltage From Traction Thumbwheel
tion activated and monitor the controller’s inter- (FWD or REV)
nal temperature in real time. For additional heat • FORWARD AND BACKWARD SWITCH =
dissipation, fold up several layers of aluminum "OFF to "ON"
foil and place it between the controller mounting • LIFTING CONTROL = Volts Percent % =
base and the mounting plate to fill any air pock- Lifting and Lowering = Proportional Switches
ets in the mating surfaces which will impede con- (Control Handle Card Must be Calibrated)
ductivity and prevent the heat from flowing from • LIFTING AND LOWERING SWITCH = "OFF"
the controller heat sink into the mounting plate to "ON"
of the controllers. The use of "conductivity paste’ • BELLY, HORN, SNAIL SWITCHES = "OFF" to
is not recommended. "ON"
• SW8 = Gray Button for Alt Functions = "OFF"
to "ON" (Reach and Counterbalance)
• ETC.

13
Troubleshooting 2200 SRM 1064

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

CORRESPONDING SCHEMATIC SHOWING

CIRCUITS TO BE CHECKED OR COM-
PONENTS AFFECTED

CONDITION
TRUCK RESPONSE
POSSIBLE CAUSES AND TEST PROCEDURES LOGIC
(Brief description of the reason behind truck
exhibited malfunction.)

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

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.

14
2200 SRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

No LEDs or LCDs LED OFF Handset does not operate
illuminated
CONDITION
Dash display, controller LED, and truck inoperative
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 volt-
age.
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 con-
troller).
If no continuity, check: LOGIC
Power wiring between battery and controller.
Verify continuity between battery positive (at Occurs when there is no
battery) and B-12 connection (at controller). power to the controller or the controller is defective.
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 SRM
1026 or Electrical System 2200 SRM 1007 for
more information on troubleshooting electrical
system circuits and components.

15
Troubleshooting 2200 SRM 1064

Dash Display Controller LED Handset or PC

No LEDs or LCDs LED OFF No error codes present
illuminated
CONDITION
Dash display and/or controller LED inoperative.
TRUCK RESPONSE
Travel and hydraulic functions normal.
POSSIBLE CAUSES AND TEST PROCEDURES
• Open connection between dash display and con-
troller.
Verify harness connections at MDI and connector
D on controller.
Verify continuity of wires between MDI and con-
troller.
• Defective dash display.
Connect handset to controller and confirm com-
munication to handset. LOGIC
If handset operates correctly, replace MDI.
• Defective LED. Occurs when the MDI or
Disconnect LED and connect handset. If handset LED receives no signal, or MDI or LED is damaged.
works, replace LED.

Dash Display Controller LED Handset or PC

No LEDs or LCDs LED OFF NO COMMUNICATION
illuminated
CONDITION
Dash display and/or controller LED inoperative.
TRUCK RESPONSE
Travel and hydraulic functions normal.
POSSIBLE CAUSES AND TEST PROCEDURES
• Defective controller.
Connect handset to controller and confirm com-
munication to handset.
If handset will not communicate with controller,
replace controller.

LOGIC

Occurs when controller

does not send a signal to the MDI or LED.

16
2200 SRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

No Alarm LED OFF - No Flashes INCORRECT START
CONDITION
Improper startup sequence by operator.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• 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. Re-
turn 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 LOGIC
not, repeat control card calibration. If this does not
correct the problem, test the control card. Refer to Fault occurs when
Control Card Functional Test in this section. controller receives input that has not followed
• Check hydraulic inputs – Should be 0 volts. If not, the proper operational sequence.
recalibrate tiller card. Follow auto-learn procedure
listed in steering. If this does not clear fault, check
buttons for damage or interference. Replace dam-
aged or faulty buttons.

17
Troubleshooting 2200 SRM 1064

Dash Display Controller LED Handset or PC

AL01 1 Flash VACC NOT OK
CONDITION
Connection/communication error between tiller
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Control card throttle calibration is out of range.
Install handset. Go to tester function of handset.
If accelerator output is >1V (20%) and the enable
switch is open, recalibrate control card.
• Control card throttle damaged or Cam Magnetic
Holder not aligned with Alignment Window.
Replace control card if needed.

LOGIC

Occurs when accelerator

voltage from serial control card is higher than
1V (20%) before neutral switch is closed.

18
2200 SRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

AL01 1 Flash PUMP VACC NOT OK
CONDITION
Connection/communication error between control
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• A lift/lower switch is damaged or defective.
Install handset. Go to tester function. Check
lifting control and EVP voltage.” Check on/off
switches 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 lift-
ing control and EVP voltage. Output of propor-
tional hydraulic controls should be less than 1V
(20%) at neutral.
Recalibrate control card. LOGIC
• Replace control card if needed.
Occurs if the output of
one on the hydraulic controls is higher
than 1V (20%) at start.

19
Troubleshooting 2200 SRM 1064

Dash Display Controller LED Handset or PC

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

LOGIC

Occurs if controller
receives signal for forward and reverse
directions simultaneously.

20
2200 SRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

AL01 1 Flash SERIAL ERROR #1
CONDITION
Connection/communication error between control
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Loose or damaged electrical connection between
control card and controller.
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 LOGIC
should be about 12V; with the card connected, it
should be about 5V. 0V or 12V with the card con- No information or
nected means that the card may be damaged. incorrect information has been sent from
Test the control card. Refer to Control Card the control card to controller.
Functional Test in this section.

21
Troubleshooting 2200 SRM 1064

Dash Display Controller LED Handset or PC

AL01 1 Flash INPUT ERROR #1
CONDITION
Connection/communication error between control
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Traction reversing switch is not connected.
Install handset. Go to tester function. Check for
operation of traction reversing switch.
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.

22
2200 SRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

AL01 1 Flash INPUT ERROR #2
CONDITION
Connection/communication error between control
card and traction controller.
TRUCK RESPONSE
Traction and hoist functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Traction reversing switch is not connected.
Install handset. Go to tester function. Check for
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 connec-
tions or broken wires.
• Damaged or defective control handle card. LOGIC
Replace control card if needed.
Traction Reversing
Switch hardware signal is not present
and data signal is present.

Dash Display Controller 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 defec-
tive.
Inspect connector E. Check wire 100 between po-
sition E6 and E16 for continuity.

LOGIC

Controller inputs
indicate a battery charger is connected.

23
Troubleshooting 2200 SRM 1064

Dash Display Controller LED Handset or PC

AL02 2 Flashes CONTACTOR CLOSED
CONDITION
Main contactor circuit is damaged.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Main contactor tips are welded closed.
Disconnect power leads at contactor. Use meter
to confirm open circuit across power terminals.
If short circuit is measured, replace contactor.
• Problem in motor field circuit.
Verify electrical connections between motor field
and controller.
Check motor field for shorts to chassis. See Trac-
tion Motor Test.
• Controller is damaged. LOGIC
Replace controller.
Refer to the section Electrical System 2200 SRM Occurs when the
1026 or Electrical System 2200 SRM 1007 for controller detects a short in the
more information on troubleshooting electrical main contactor circuit.
system circuits and components.

Dash Display Controller LED Handset or PC

AL4 4 Flashes EVP NOT OK
CONDITION
Lowering valve will not operate correctly.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Damaged or loose electrical connection to propor-
tional lowering valve.
Verify electrical connections between propor-
tional valve coil and controller.
• Lowering coil damaged.
Check lowering valve coil for correct resistance.
Coil resistance should be approximately 17.8
ohms.
Replace coil if damaged.
• Lowering valve cartridge is damaged. LOGIC
Replace lowering valve cartridge.
Refer to the section Electrical System 2200 SRM Occurs if electro-propor-
1026 or Electrical System 2200 SRM 1007 for tional valve is open before circuit is energized. Valve
more information on troubleshooting electrical does not follow the supplied signal from controller.
system circuits and components.

24
2200 SRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

AL5 5 Flashes EB DRIVER KO
CONDITION
Electric brake does not release or remains
released at all times.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Damaged or loose electrical connection to brake.
Verify electrical connection between electric
brake and controller.
• Check brake coil for correct coil resistance.
Disconnect brake. Measure brake coil resistance
in both directions. Coil resistance should be 14.3 LOGIC
ohms.
• Damaged fly-back diode at brake. Occurs when brake
Check coil resistance. Short circuit measured at driver circuit is shorted or open circuit.
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.

25
Troubleshooting 2200 SRM 1064

Dash Display Controller LED Handset or PC

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

Dash Display Controller LED Handset or PC

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

26
2200 SRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

AL6 6 Flashes NO FIELD CURR
CONDITION
Low field current values measured by controller.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Cable connection to motor field is loose or damaged.
Verify connection of field wires to motor and con-
troller.
• Motor field winding is open or too high.
Check motor field for correct resistance and
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. LOGIC
Verify electrical connection between controller
and contactor. Measured field current
Check contactor coil for correct resistance of 22.0 is too low.
ohms (12.5 ohms for models W20-25ZA).
• Field current drivers in controller are damaged.
Replace controller.
Refer to the section Electrical System 2200 SRM
1026 or Electrical System 2200 SRM 1007 for
more information on troubleshooting electrical
system circuits and components.

27
Troubleshooting 2200 SRM 1064

Dash Display Controller 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
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Damaged controller.
Replace controller.

LOGIC

Occurs if controller
detects motor currents during standby mode.

Dash Display Controller LED Handset or PC

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

28
2200 SRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

AL8 8 Flashes POWER FAILURE #1
CONDITION
Short circuit in device connected to controller.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Overcurrent detected in driven component.
Check main harness for damaged or shorted con-
nections to main contactor, brake, and electric
valve coils.
Check main contactor, brake, and proportional
lowering solenoid for correct resistance values.

Value should be within ±10% at room temperature. LOGIC

Main contactor = 22 ohms (12.5 ohms for models Occurs when controller
W20-25ZA). detects short circuit in component
Brake coil = 14.3 ohms driven by controller.
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 SRM
1026 or Electrical System 2200 SRM 1007 for
more information on troubleshooting electrical
system circuits and components.

29
Troubleshooting 2200 SRM 1064

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) EEPROM KO
CONDITION
Fault in the memory area where param-
eters are stored.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Controller damaged.
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.

30
2200 SRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

AL10 LED ON (No Flashing) CAPACITOR CHARGE
CONDITION
Main controller capacitors did not charge
within 500 ms of key ON.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Loose or damaged wire connection.
Inspect and confirm wire connections at contac-
tor, pump motor, and traction motor.
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 connec-
tions at the component end of the harness. Tape
or secure the wire ends to prevent shorts.
Discharge controller by placing 200 , 2W resis-
tor across B+ and B terminals. Reconnect bat-
LOGIC
tery and turn key ON. Use voltmeter to observe
voltage across B+ and B . If there is no voltage
Occurs when an internal
increase, replace controller. If there is a steady
or external short or open prevents the main
voltage increase to battery voltage, connect each
capacitors from charging at key ON.
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.

31
Troubleshooting 2200 SRM 1064

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 sec-
tion.
• Check for traction motor malfunction.
Perform traction motor test. See Traction Motor
Test in this section.
• Damaged controller. LOGIC
Voltage at –T terminal on controller should be the
same as the +B terminal. Occurs when controller
Replace controller. observes differences between battery voltage
and voltage supplied to the traction motor.

32
2200 SRM 1064 Troubleshooting

Dash Display Controller LED Handset or PC

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

33
Troubleshooting 2200 SRM 1064

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.

34
2200 SRM 1064 Troubleshooting

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
This fault occurs when
Traction and hydraulic functions disabled.
the voltage measured at the field connections
POSSIBLE CAUSES AND TEST PROCEDURES is not the expected value.
• Cable connection to motor field is loose or damaged.
Verify connection of field wires to motor and con-
troller.
• Main contactor coil shorted/open.
Check contactor coil for correct resistance of 22.0
ohms (53.4 ohms for models W40Z).
• 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 be-
tween B+ and B .
Replace controller.
• Field current drivers in controller are damaged.
Replace controller. Verify motor field cable con-
nections.
Refer to the section Electrical System 2200 SRM
1026 or Electrical System 2200 SRM 1007 for
more information on troubleshooting electrical
system circuits and components.

35
Troubleshooting 2200 SRM 1064

Dash Display Controller LED Handset or PC

AL66 Continuous Flashing BATTERY LOW
CONDITION
Battery discharged and requires charging.
TRUCK RESPONSE
Hydraulic lift function disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Battery voltage is low.
Charge or replace battery.
• Controller voltage calibration is incorrect.
Install handset. Go to test menu and select
Battery Voltage. Compare tester voltage to volt-
age measured by an accurate digital voltmeter
between B+ and B terminals. Pull down tiller
handle to engage contactor for this measure-
ment. 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.

36
2200 SRM 1064 Troubleshooting

Dash Display 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.

37
Troubleshooting 2200 SRM 1064

Dash Display Controller LED Handset or PC

AL99 Continuous Flash BATTERY KO
CONDITION
Improper battery connection or defective battery.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Incorrect battery selected.
Verify correct battery voltage for truck.
• Damaged or extremely discharged battery.
Disconnect battery and check voltage at connec-
tor. Inspect battery for correct water level and
damage. Repair or replace battery.
• Defective or damaged connection to battery.
Inspect cable crimps and cables from battery to
connector.
Inspect cable crimps and cables from battery con- LOGIC
tactor to controller and contactor.
Refer to the section Electrical System 2200 SRM Battery voltage is much
1026 or Electrical System 2200 SRM 1007 for less than allowable.
more information on troubleshooting electrical
system circuits and components.

38
2200 SRM 1064 Troubleshooting

AUXILIARY HYDRAULICS (W30-40ZA,

W20-30ZR, W25-30-40ZC)
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 SRM 1026 .

Figure 5. Auxiliary Hydraulic Logic

39
Control Card Functional Test 2200 SRM 1064

Control Card Functional Test

Refer to Figure 6 for the following procedures. (2) If Proportional lift/lower switches
doesn’t behave as expected, swap the
1. Follow all safety precautions as listed at the be- proportional switch with other propor-
ginning of this section prior to performing any tional switch available within tiller
electrical checks. head to verify if problem follow the
switch.
2. Ensure Battery is fully charged.
6. If handset test are not passed, open tiller head
a. Verify continuity between battery negative
and verify connection at control card:
(at battery) and B terminal (at controller).
a. Power off the forklift and measure continuity
3. Check for loose connections or damaged wiring
between pin 2, on JP2, on the control card
between control card and controller.
and B- at the controller.
a. Verify connection at the controller.
(1) If an open or high resistance is mea-
b. Very wire harness connection at the base of sured, trace problem source and refer to
the steer handle. Troubleshooting in this section.

4. Connect ZAPI handset and go to tester function. b. Power on the forklift and check for 7- seg-
Refer to ZAPI™ PC Interface in this section. ment LED to light on.

NOTE: If ZAPI Handset can not be connected, consult (1) If the LED is not lit then check to have
LED OFF. See Troubleshooting in this section. power on JP2, between pin 1 and pin 2.
i. JP2 voltage reading shall be
5. With ZAPI Handset connected, check the follow- 14V or more, if not, then the tiller
ing: card is not receiving power from
controller. Disconnect the connec-
a. Look for battery voltage to be 25 ±0.5 volts. tion at JP1 and verify the voltage
between harness pins 1 and 2 is
b. Check for accelerator output to be 95% or
more than 14V.
more at full throttle, and to be at 0% and 0V
a. Check the wiring between the
on neutral position.
controller and the tiller card,
c. Check for lift switch, fork low switch, belly as well as the controller output.
switch, and horn switch to alternate be- b. Measure voltage at pin 5, on
tween on and off when switch is pressed and connector C, on the ZAPI con-
released. (Ensure belly switch is properly troller. The voltage should be
seated.) 12V with card disconnected
and 3V to 9V with control card
(1) If ON-OFF lift/lower switches doesn’t connected. If voltage is dif-
behave as expected, swap the On-Off ferent, please refer to Trou-
switch with other On-Off switch avail- bleshooting, LED Off sections.
able within tiller head to verify if prob- c. Measure voltage at pin 7, on
lem follow the switch. connector C, on ZAPI con-
troller. It should have 22V
d. Check lifting control to be more than 90%. or greater with card discon-
nected. If voltage is different,
(1) Output of proportional hydraulic con-
please refer to Troubleshoot-
trols should be less than 10% at neutral.
ing, LED Off sections.

40
2200 SRM 1064 Control Card Functional Test

d. Reconnect and measure volt- (3) Ensure 7 segment LED displays the
age on JP2 again. proper control handle card setting:
ii. If voltage reading is achieved • The proper setting for these models is
on JP2, and the 7 segment display number 4.
is not lit, replace the tiller card. Re- i. If not, proceed to reconfigure
fer to the section Electrical Sys- card through teach mode following
tem 2200 SRM 1026 or Electrical auto-learning procedure listed in
System 2200 SRM 1007. the Electrical System 2200 SRM
1026 or Electrical System 2200
(2) Ensure jumper on SV2 is not on Di- SRM 1007 section.
agnose, Teach or Configuration mode.
SV2 jumper can be either seated on 7. If speed is other than desired, refer to in this sec-
parking position (P) or not present at tion.
all.

NOTE: ENSURE THAT THE CAM MAGNETIC HOLDER IS ALIGNED WITH THE ALIGNMENT WINDOW; OTHER-
WISE 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

41
Traction Motor Test 2200 SRM 1064

Traction Motor Test

After troubleshooting the alarm codes per the trou-
bleshooting 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 mo-
tor can be eliminated as the problem by testing it to
confirm proper operation. If the traction motor per-
forms properly during the test, and all the other trou-
bleshooting steps have been checked thoroughly, the
controller is more likely to be functioning improperly.
Use the following procedure to test the traction mo-
tor.

1. Position the lift truck drive end on blocks to se-

curely suspend the drive tire off the floor.

2. Turn the key switch to the OFF position and dis-

connect the battery. Remove the drive unit com-
partment cover and discharge the capacitors in
the controller.

NOTE: Locate the brake override connector on the

main wiring harness between the MDU and the con-
troller. It is a normally unconnected wiring connector
positioned near where the brake wiring harness and
main wiring harness connect. 1. BRAKE WIRING HARNESS
2. MAIN WIRING HARNESS
3. Disconnect the brake wiring harness connec- 3. BRAKE OVERRIDE CONNECTOR
tor from the main wiring harness and then
connect the brake override connector into the Figure 7. Brake Override Connector
brake wiring harness. With the key switch in 4. Tag, identify, and then disconnect the field wires
the OFF position, connect the battery connector (F1 and F2) and motor leads (A1 and A2) from
and listen for a "click" indicating that the brake the traction motor.
has been released and the override function is
working properly. Disconnect the battery and 5. Connect jumper wires as follows:
continue. See Figure 7.
a. Connect a jumper wire from B+ (battery pos-
itive) before it enters the controller to F2 ter-
minal on the traction motor.

b. Connect a jumper wire from F1 to A1 on the

traction motor.

42
2200 SRM 1064 Traction Motor Test

NOTE: A remote starter switch is a jumper wire with remote start switch for 1/2 second then release.
an in-line momentary switch. Note the direction of rotation of the drive tire
(should be opposite of the first test) and noise of
c. Connect a remote starter switch from B on the motor, bearings and gearbox.
the controller to A2 on the traction motor.
9. Disconnect the battery.
6. Connect the battery BUT LEAVE THE KEY
SWITCH IN THE OFF POSITION. Press the 10. If the test proves the motor is not operating prop-
remote start switch for 1/2 second then release. erly, repair the traction motor, bearings, or gear-
Note the direction of rotation of the drive tire box as necessary. If the test show the motor is
and noise of the motor, bearings and gearbox. operating properly:

7. Disconnect the battery then reconfigure the a. Remove the jumpers and reconnect the field
jumper wires as follows: wiring as removed.

a. Connect a jumper wire from B+ (battery pos- b. Clear the alarm log.
itive) before it enters the controller to F2 ter-
minal on the traction motor. c. Disconnect the brake override and reconnect
the break wiring harness to the main wiring
b. Connect a jumper wire from F1 to A2 on the harness.
traction motor.
d. Retest the lift truck.
NOTE: A remote starter switch is a jumper wire with
an in-line momentary switch. 11. If the alarm code NO TRACTION FWD OR REV
or alarm code V FIELD NOT OK is generated, re-
c. Connect a remote starter switch from B on place the controller. Calibrate the control handle
the controller to A1 on the traction motor. card to the new controller.

8. Connect the battery BUT LEAVE THE KEY

SWITCH IN THE OFF POSITION. Press the

43
ZAPI™ PC Interface 2200 SRM 1064

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

1. Turn the key switch to the OFF position.

2. Remove the drive unit compartment cover to ac-

cess the controller.

3. Locate the communications port on the con-

troller. (The port will have either a diagnostic Figure 10. Controller Connection
LED, as in Figure 8, or a connector for the dis-
play, as in Figure 9.)

Figure 11. PC Connection

Figure 8. Diagnostic LED
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 Fig-

ure 13.
Figure 9. Display Connection

4. Connect the interface cable to the controller and

the PC. See Figure 10 and Figure 11.

44
2200 SRM 1064 ZAPI™ PC Interface

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

45
ZAPI™ PC Interface 2200 SRM 1064

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

46
2200 SRM 1064 ZAPI™ PC Interface

FILE MENU
Open File
When you select this function, you will be able to
open a previously saved file that contains parame-
ter settings for the controller. See Figure 16.

Figure 16. File - Open

47
ZAPI™ PC Interface 2200 SRM 1064

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

48
2200 SRM 1064 ZAPI™ PC Interface

Notice the CONNECTION STATUS while the file is

downloaded into the controller. See Figure 19.

Figure 19. Connection Status

49
ZAPI™ PC Interface 2200 SRM 1064

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

help track which file goes with each controller. See
The ZAPI™ PC software can save configurations for Figure 20.
up to 500 controllers. When saving a configuration

Figure 20. File - Save

1. Try to use the actual truck serial number and put controller settings file separate from the tester
the word "settings" after it. (This is to keep the function Save file.) See Figure 21.

Figure 21. Save: In

50
2200 SRM 1064 ZAPI™ PC Interface

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 0;ACCELER.DELAY;0;0;0;LEVEL=0

describe what is different with the settings or en- 5;DECELER.DELAY;1;0;9;LEVEL=9
ter a customer name. 11;RELEASE BRAKING;2;0;0;LEVEL=9
12;INVERS.BRAKING;3;0;9;LEVEL=9
Here is what a saved parameter file looks like: 30;MAX SPEED FORW;4;0;9;LEVEL=9
[Info] 31;MAX SPEED BACK;5;0;9;LEVEL=9
Chopper_Name=MPB NA V1.01 248;DRIVE MODES ;01;1;ON
User_Comment=modified mode 4 to lower [End]
speed and coast more
Save_Date=Thu Apr 04 15:58:15 2002 [Validation]
Code=FFDA
[Code;Name;Position;Menu;Value;Scaled [Stop]
Value]

51
ZAPI™ PC Interface 2200 SRM 1064

Print Settings
This selection allows you to print out your current
parameter settings in the controller. See Figure 23.

Figure 23. File - Print

52
2200 SRM 1064 ZAPI™ PC Interface

Exit
This selection will exit the ZAPI™ PC console soft-
ware. See Figure 24.

Figure 24. File - Exit

53
ZAPI™ PC Interface 2200 SRM 1064

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

troller and PC (operates the same as the main
There are two selections under this menu: Stop button on the right-hand side of the display
1. Start - Starts the connection between the con- screen).
troller and PC (operates the same as the main See Figure 25.
Start button on the right-hand side of the display
screen).

Figure 25. Connection Menu

FUNCTION MENU 6. Ram Function - Only Factory Use.

7. EEPROM Function - Only Factory Use.
There are seven selections under this menu:
1. Parameter - Allows the performance and config- Parameter
uration of the controller to be adjusted. Refer to
Parameter, in this section. When you first activate this selection, the screen will
2. Tester - Allows the testing of various inputs and look as indicated in Figure 26. In order to see the
operations of the controller. Refer to Tester, in parameters of the controller, you have to download
this section. them to the PC. This can be done by 1 of 2 ways.
3. Alarm Logbook - Stores alarms that the con- 1. Receive menu - This will only download the cur-
troller detects. Refer to Alarm Logbook, in this rent selected tab.
section. 2. Receive - This will download all parameters and
4. Program VACC - Not Used. configurations to the PC so you can adjust them.
5. Motor Data - Not Used.

54
2200 SRM 1064 ZAPI™ PC Interface

Figure 26. Parameter

You will now see a screen like Figure 27, while the
data are being downloaded.

Figure 27. Downloading Screen

55
ZAPI™ PC Interface 2200 SRM 1064

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

56
2200 SRM 1064 ZAPI™ PC Interface

There are six parameters that can be adjusted to af-

fect the performance of the lift truck. See Figure 29.

Figure 29. Adjustable Parameters

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

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

57
ZAPI™ PC Interface 2200 SRM 1064

Notice that the ACCELER. DELAY function has been react to the setting. Once the lift truck is performing
adjusted. The parameter settings are "live," which as wanted, the Store button is pressed to save the
means as they are being adjusted. The lift truck will settings into the controller. See Figure 30.

Figure 30. Store Button

NOTE: If the Store button is not pressed before turn-

ing off the lift truck, then all changed parameters will
be lost.

58
2200 SRM 1064 ZAPI™ PC Interface

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: 3. Restore - Will revert the parameter settings to
1. Receive - Same as Receive menu and Receive what they were before adjustments were made.
button. Note this will not work if the settings were stored
2. Store - Same as Store button. before using this function.

59
ZAPI™ PC Interface 2200 SRM 1064

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

60
2200 SRM 1064 ZAPI™ PC Interface

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: 4. Turn the key switch on the lift truck to OFF; then
1. Press the Store button to save the change into do the reconnect procedure.
the controller. 5. Now the parameters in the Function Menu can
2. Press the Close button to go to the main screen be adjusted to a custom configuration (Mode 4).
of the ZAPI™ PC software.
3. Press the Stop button to disconnect the commu-
nication between the PC and the controller.

61
ZAPI™ PC Interface 2200 SRM 1064

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 ca- 8. Tiller Switch - position of tiller handle.
pability to further assist the technician and the fac- 9. Forward Switch - directional input.
tory with problems. 10. Backward Switch - directional input.
11. Lifting Switch - refers to switch on right side of
The PC software can test the following (four selec- tiller head.
tions at a time). See Figure 35. 12. Lowering Switch - refers to switch on right side
1. Battery Voltage - voltage across the battery. of tiller head.
2. Motor Voltage - voltage across the traction mo- 13. Fork Lift Switch - refers to switch on left side
tor. of tiller head.
3. Motor Current - current through the traction 14. Fork Lower Switch - refers to switch on left
motor. side of tiller head.
4. Field Current - current through the fields in the 15. Belly Switch
traction motor. 16. Snail Switch
5. Temperature - current temperature of the con- 17. Horn Switch
troller. 18. Cutback Switch
6. Accelerator - voltage and percent of "throw" 19. Lifting Block
from the traction thumbwheel. 20. Battery Model
7. Lifting Control

62
2200 SRM 1064 ZAPI™ PC Interface

21. Battery Charge - remaining charge on the bat-

tery.

Figure 35. Test Name

63
ZAPI™ PC Interface 2200 SRM 1064

Data Logger

Figure 36. Data Logger

In addition to "live testing" of the controller, the selected in the tester menu. Users can select the
ZAPI™ PC software also includes a data-logging desired time intervals between samples (time steps)
capability. See Figure 36. There are four buttons and the number of samples to be taken (samples).
associated with this, as listed below. Time steps are in increments equal to 0.1 seconds.
1. Advanced - Allows the user to select sample Therefore a selection of 20 time steps and 50 sam-
rates and length of recording. ples would result in a sample being taken every two
2. Start Rec. - Starts the data logger. seconds until 50 samples have been recorded. See
3. Stop Rec. - Stops the data logger. Figure 37.
4. Save Rec. - Saves the log to a file.

The Advanced button allows the user to initiate a se-

ries of samples to be taken for the 4 items you have

Figure 37. Tester Advanced

64
2200 SRM 1064 ZAPI™ PC Interface

Figure 38. Logging Process

As the data logger is running, the screen will look Once the data logger is done, you can save the log
like what is shown in Figure 38. During the logging using the Save Rec. button. See Figure 39.
process, you will still be able to see the values chang-
ing in the display menu.

Figure 39. Save As

65
ZAPI™ PC Interface 2200 SRM 1064

Once the log file has been saved, the user can either 0;0;0.00 0;80;0.0;
analyze the data him/herself or e-mail the file to the
factory for analysis. 10;0;0.00 0;80;0.0;
20;0;0.00 0;80;0.0;
The raw data file looks like this (see Figure 40):
[Info] 30;0;0.00 0;80;0.0;
Chopper_Name=CS P20 V1.00 40;0;0.00 0;80;0.0;
Save_Date=Thu Apr 04 13:32:24 2002
TIME;MOTOR CURRENT;ACCELERATOR;BAT- 50;0;0.00 0;80;7.2;
TERY CHARGE ;FIELD CURRENT; 60;3;0.00 0;80;7.2;
70;3;0.27 10;80;7.2;
80;3;0.27 10;80;12.7;
90;8;0.53 16;80;12.7;

Figure 40. Test Data

66
2200 SRM 1064 ZAPI™ PC Interface

Alarm Logbook
The ZAPI™ controller can record up to five unique
alarms and store them in a logbook that the PC can
access. See Figure 41.

Figure 41. Alarm Logbook

67
ZAPI™ PC Interface 2200 SRM 1064

The display screen (Figure 42) will display any ALARM that indicates a current "live" alarm condi-
current "live" alarms. Note the display ACTUAL tion.

Figure 42. Actual Alarm

The PC software will provide the alarm name and 7. EEPROM KO

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

68
2200 SRM 1064 ZAPI™ PC Interface

PROGRAMMING TILT AND SIDESHIFT ON 4. On the drop down menu, click on "Function,"
THE ZAPI CONTROLLER (LAPTOP) "EEPROM Function."

1. Connect the laptop to the ZAPI Controller: a. Delete the value in the address box and enter
F000.
a. If equipped with sideshift, make sure con-
troller connector "E" on the main wiring har- b. Click "Start Write."
ness has a jumper wire installed between E3
c. Verify that the new console window states
to E13.
"WRITE EEPROM CELL."
b. Turn the key switch to the OFF position.
d. Delete the value in the address box and enter
SHUT DOWN the laptop. Make certain
F000.
the laptop was powered off as opposed to
restarted or in standby mode. e. Click "Start Write" again.
c. Connect the laptop to the controller using the f. Verify that the new console states "READ
appropriate cables and connectors. EEPROM CELL."
d. Turn the key switch to the ON position and g. Click "Stop Write."
then POWER ON the laptop.
h. Delete the value in the "Value" box and enter
e. Launch the ZAPI Laptop Software program 55AA.
from the desktop icon or the start menu.
i. Click "Start Write" again.
2. ON the drop down menu, click on "Configura-
tion," "COM Port." j. Verify the values in the ADDRESS box and
the VALUE box.
a. Select the COM port "ComPort2."
k. Click the "Close" button.
b. Select the Baud Rate "1200 bps."
5. On the drop down menu, click on "Function," "Pa-
c. Click "OK" then "Start" in the console win- rameters."
dow.
a. Select the "Parameter Change" tab.
d. Verify the connection status reads "CON-
NECTED." b. Click "Receive."

c. Click the "Set Options" tab.

CAUTION
This procedure will access High Level Pro- d. Select the parameter name "AUX INPUT
gramming of the ZAPI controller. #1."

3. On the drop down menu, click on "Configura- e. Change the parameter value to PRESENT
tion," "Enter Password." using the drop box in the upper right corner
of the console.
a. Enter the password ZAPI (in all capital let-
ters). The password can only be entered if the f. Click the "Store" button in the lower left of
Com Configuration was properly connected the window to save. Verify the value has
in the previous steps. changed in the "Parameter Value" column.

b. Click "OK." 6. Verify all settings and click the "Close" button in
the lower right of the window to return to the
Main Menu.

69
Repair 2200 SRM 1064

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

6. Remove cover. INSTALL

1. Align controller to plate and capscrews. Tighten
WARNING capscrews.
The capacitors in the controller remain
charged for several minutes after operation. 2. Connect all power cables and wires connected to
To prevent personal injury and/or damage controller.
to equipment, the controller should be dis-
3. Connect battery.
charged. To discharge the controller, connect
a 200-ohm, 2- to 3-watt resistor between the 4. Connect handset or PC.
battery positive and negative terminals on
the controller for at least 5 seconds. Refer to 5. Turn key to ON.
Figure 1 in the General section of this manual.
6. Upload parameters.
7. Discharge controller.
7. Remove blocks from drive wheel.
8. Identify and tag all power cables and wires con-
nected to controller for later installation. 8. Test lift truck in a safe, level area away from
other personnel and equipment.
9. Remove all power cables and wires connected to
controller. 9. Install cover.

10. Loosen both capscrews retaining controller to REPAIR

plate.
1. Check and replace fuses as necessary.
11. Remove controller.
2. Check and repair wiring (see troubleshooting
BRASS STUD REPLACEMENT guide).

3. Check the battery pack.

Remove
4. Check the motors and motor connections.
1. Remove M8 nut, lockwasher, flat washer, brass
washer, power fuse, and brass washer from brass 5. Replace controllers when necessary by following
stud. the remove and install procedures listed above.
2. Remove brass stud from controller.

70
2200 SRM 1064 Repair

SIDESHIFT SETUP WITH AUXILIARY 8. Press ENTER. Press OUT until the main menu
(W20/30ZR) appears.

To enable the sideshift function on the W20/30ZR 9. Press buttons 1 and 5 at the same time.
stacker trucks with auxiliary board, follow the fol-
10. Scroll to the SET OPTION menu. Press ENTER.
lowing procedure:
11. Scroll to AUX INPUT #1. Set to PRESENT.
1. Jumper must be installed in connector E - posi-
tions 3 and 13. 12. Press OUT. Handset will ask, ARE YOU SURE?.
Press ENTER.
2. Connect ZAPI™ handset.
13. Press OUT until the main menu appears.
3. When main menu appears, press ENTER.
14. Turn key OFF and ON to retain settings.
4. Scroll to ALARMS.
15. Confirm operation of sideshift function.
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.

71
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 TECHNICAL PUBLICATIONS

2200 SRM 1064 WIP (9/08)(4/08)(11/07)(3/04)(7/03)(5/03)(4/03)(2/03) Printed in U.S.A.