Yale ZAPI MPW045-E Guide

Maintenance
ZAPI™ CONTROLLERS
MPW045-E [B802];
MPW050-E [C802]
PART NO. 524188546 2200 YRM 1067

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.

ZAPI™ Controllers Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
ZAPI™ Transistor Motor Controller ................................................................................................................. 1
Principles of Operation.................................................................................................................................... 2
Controller Safety.................................................................................................................................................. 2
Controller Adjustments ........................................................................................................................................ 3
Modes of Operation............................................................................................................................................. 3
User-Selectable Operating Modes .................................................................................................................. 3
Programming ....................................................................................................................................................... 4
Custom Performance Mode ............................................................................................................................ 4
Controller Parameters ..................................................................................................................................... 4
Tester Menu .................................................................................................................................................... 5
Set Option Menu ............................................................................................................................................. 6
ZAPI™ Handset .............................................................................................................................................. 6
Troubleshooting ................................................................................................................................................... 10
Control Card Functional Test............................................................................................................................... 34
ZAPI™ PC Interface............................................................................................................................................ 36
Connecting PC to ZAPI™ Controller............................................................................................................... 36
File Menu ........................................................................................................................................................ 39
Open File .................................................................................................................................................... 39
TX From File ............................................................................................................................................... 40
Save File ..................................................................................................................................................... 42
Print Settings .............................................................................................................................................. 44
Exit.............................................................................................................................................................. 45
Connection Menu............................................................................................................................................ 46
Function Menu ................................................................................................................................................ 46
Parameter ................................................................................................................................................... 47
Memory Menu............................................................................................................................................. 51
Set Options ................................................................................................................................................. 52
Tester .......................................................................................................................................................... 54
Data Logger ................................................................................................................................................ 56
Alarm Logbook............................................................................................................................................ 59
Alarms......................................................................................................................................................... 60
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) .................................................................... 61
Repair.................................................................................................................................................................. 62
Remove........................................................................................................................................................... 62
Brass Stud Replacement ................................................................................................................................ 62
Remove....................................................................................................................................................... 62
Install .......................................................................................................................................................... 62
Install............................................................................................................................................................... 62
Repair.............................................................................................................................................................. 62
This section is for the following models:
MPW045-E [B802];
MPW050-E [C802]
©2010 Yale Materials Handling Corp. i

2200 YRM 1067 Description
General
This section describes the ZAPI™ transistor motor con-
troller. Procedures are outlined for controller safety, ad-
justments, troubleshooting, and repairs. See Figure 1.
Figure 1. Controller MPW045/050-E
Description
ZAPI™ TRANSISTOR MOTOR
CONTROLLER
The ZAPI™ controller is a solid-state DC motor con-
troller utilizing SEM technology. It controls the traction
motor, brake, and hydraulic system. The controller re-
ceives inputs from the control handle by serial commu-
nication, and direct inputs from the key switch and con-
trol handle arm position switch. The controller directly
controls the traction motor, lift pump motor, 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 soft-
ware features a Test Menu for monitoring controller in-
puts and outputs, a Diagnostic Menu for viewing fault
code information, and a Programming Menu for cus-
tomizing the truck performance. 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 in-
stalled 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.
1

Controller Safety 2200 YRM 1067
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 sophisti-
cated microprocessor to control the logic and operation
of the controller, eliminating the need for forward and
reverse contactors. The SEM motor controller operates
on the principle of controlling the motor field circuit and
the motor armature circuit independently. The controller
has many programmable features, including maximum
speed, acceleration rate, release braking, and braking
current limit. The SEM controller includes a full range
of features, as well as diagnostic and setup capability.
NOTE: There are no user-serviceable parts in the
ZAPI™ controller. No attempt should be made to open,
repair, or otherwise modify the controller. Doing so
may damage the controller and will void the warranty.
Controller Safety
WARNING
The ZAPI™ controllers can hold an electrical charge
for several minutes after the key switch has been
turned OFF. To prevent injury, discharge the con-
trollers by connecting a 200-ohm, 2-watt resistor
between the battery positive connector and battery
negative connector on the controller and hold there
for 5 seconds.
SeeFigure2.
1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
3. 200-OHM, 2-WATT RESISTOR
4. INSULATED JUMPER WIRES
Figure 2. Discharging Controller MPW045/050-E
2

2200 YRM 1067 Modes of Operation
Controller Adjustments
The ZAPI™ transistor motor controller can store and
display Error Codes (Alarms). It is also possible to mod-
ify the controller Setup for individual preferences. Com-
munication with the controller is possible by four meth-
ods:
1. LED - An LED may be installed in trucks that do
not use a display. The LED can flash error codes
to the technician for diagnosis. The LED would be
installed on the bottom of the ZAPI™ controller. On
the MPW045/050-E, connector port D is used. 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.Perfor-
mance parameters that vary are acceleration, decel-
eration, regenerative (neutral) braking, and top travel
speed.
The three operator-selectable performance modes are
factory programmed per the following:
• Mode 1 - Economy mode (battery saver) - soft accel-
eration, reduced top speed with regenerative (neutral)
braking.
• Mode 2 - Performance with regenerative (neutral)
braking - medium acceleration, reduced top travel
speed with regenerative (neutral) braking.
• Mode 3 - Performance without regenerative (neutral)
braking - maximum acceleration, maximum top travel
speed with coast at throttle release.
The following procedure is used to access the user-se-
lectable operating modes:
1. The controller drive modes parameter must be ON.
This is the factory setting.
NOTE: You must use the handset or PC interface to
change this setting. Using the ZAPI™ handset or PC
connection, it is possible to set the drive mode parame-
ters to ON or OFF. In the ON mode, the user-selectable
rules are enabled. In the OFF mode, the lift truck will
only operate using the settings selected. The proce-
dure to alter or modify these settings is given in Pro-
gramming 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 proce-
dure is repeated.
9. Tur n ing t he key OFF before lowering the control
handle will cancel the mode change.
3

Programming 2200 YRM 1067
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:
1. Turn key switch OFF.
2. Remove drive unit compartment cover.
3. Connect adapter harness to handset.
NOTE: It may be necessary to remove the MDI harness
connector from the controller to install the adapter har-
ness.
NOTE: Connect and disconnect the handset only with
the key switch in the OFF position.
4. Connect adapter harness to controller.
5. Turn key switch ON.
6. The handset will turn ON. See Figure 3.
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. Pressbutton5or6tosetDriveModestoOFF.
12. Press button 4 to exit this menu.
13. The handset will prompt, "Are you sure?"
14. Press ENTER (button 3) to retain settings.
15. Press OUT (button 4) to discard settings.
16. Turn the key switc h OFF to save the drive modes
OFF parameter change.
17. Turn the key switc h ON to enter the MAIN MENU
and change the parameters outlined in Table 1.
4

2200 YRM 1067 Programming
Table 1. Parameters
Parameter Description Value and Affect
ACCELERATION DELAY Adjusts truck acceleration. 0 = short or rapid acceleration
9 = long or slow acceleration
DECELERATIONDELAY Adjusts truck deceleration according to
throttle position.
0 = short or rapid deceleration
9 = long or slow deceleration
RELEASE BRAKING Adjusts motor braking strength or
regenerative braking when throttle
is released. This determines coast
distance.
0 = soft braking
9 = strong braking
INVERSE BRAKING Adjusts plugging rate. 0 = long or soft plugging
9 = short or rapid plugging
MAX SPEED FORW Adjusts maximum speed in forward
direction, forks trailing.
0=minimum
9=maximum
MAX SPEED BACK Adjusts maximum speed in reverse
direction, forks leading.
0=minimum
9=maximum
TESTER MENU
The most important input or output signals can be mea-
sured in real time using the TESTER function of the
handset. The handset acts as a multimeter to read volt-
age, current, temperature, switch state, and other func-
tions.
1. BATTERY VOLTAGE = battery voltage, nominal
value = 24V, V.
2. MOTOR VOLTAGE = motor voltage obtained
VBATT - VMN, V.
3. MOTOR CURRENT = armature current during trac-
tion (positive value) or braking (negative value).
4. FIELD CURRENT = field current in the selected
traction direction.
5. TEMPERATURE = controller temperature, C.
6. ACCELERATOR = traction potentiometer value re-
ceived from control handle.
7. LIFTING CONTROL = lifting/lowering potentiome-
ter value received from control handle.
8. CONTROL HANDLE SWITCH = control handle
switch input, ON/OFF.
9. FORWARD SWITCH = forward direction request
from control handle card, ON/OFF.
10. BACKWARD SWITCH = backward direction re-
quest from control handle card, ON/OFF.
11. CUTBACK SWITCH 1 = speed reduction switch in-
put, ON/OFF (closed switch = OFF = no speed re-
duction).
12. LIFTING SWITCH = lifting function request from
control handle card, ON/OFF.
13. LOWERING SWITCH = lowering function request
from control handle card, ON/OFF.
14. FORK LIFT SWITCH = i - lift request from control
handle card, ON/OFF.
15. FORK LOW SWITCH = i - lift request from control
handle card, ON/OFF.
16. BELLY SWITCH = belly input switch to the controller
or belly request from control handle card, ON/OFF.
17. HARD & SOFT = snail request from control handle
card allows machine to drive with control handle up,
ON/OFF.
18. HORN SWITCH = horn request from control handle
card, ON/OFF.
19. LIFTING BLOCK = lifting block input switch,
ON/OFF(withLIFTINGBLOCKoptionpro-
grammed OFF).
5

Programming 2200 YRM 1067
20. BATTERY MODEL = battery-type of input switch,
ON/OFF. ON = flooded battery (input closed), OFF
= sealed battery (input open).
21. BATTERY CHARGE = battery charge indication, %.
SET OPTION MENU
ON The truck has three performance
modes, each with a fixed set
of parameters. This function
is enabled by setting DRIVE
MODES = ON.
DRIVE
MODES
OFF DRIVE MODES disabled.
ZAPI™ HANDSET
The ZAPI™ handset must be connected to the con-
troller 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 B. The hand-
set can remain connected to the controller while run-
ning, 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 or-
der 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.
1Roll-Up Push to scroll up.
2Roll-Down Push to scroll down.
3Enter Push to enter a submenu
or to confirm a change.
4Out Push to exit a selected
menu or to refuse a
change.
5Set-Up Push to increase a
parameter value.
6Set-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 trian-
gles in the following map correspond to the same num-
ber on the handset keyboard buttons. The orientation of
the triangle indicates the way to the next function. See
Figure 3.
NOTE: Connect and disconnect the handset only with
the key switch in the OFF position.
For additional handset description, see Figure 4.
6

NOTES
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7

Programming 2200 YRM 1067
8

2200 YRM 1067 Programming
Figure 4. ZAPI™ Handset Instructions
9

Troubleshooting 2200 YRM 1067
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
CORRESPONDING SCHEMATIC SHOWING
CIRCUITS TO BE CHECKED OR AFFECTED
COMPONENT(S)
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 controller.
In most instances, it will be necessary to use a handset or a PC to further define the possible causes and test
procedures.
10

2200 YRM 1067 Troubleshooting
Dash Display Controller LED Handset or PC - 12V
No LEDs or LCDs
illuminated
LED OFF Handset does not operate
CONDITION
Dash display, controller LED, and truck inoperative.
TRUCK RESPONSE
Travel and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
•B+ and/or B missing at controller.
Confirm battery is connected and of proper voltage.
Verify key switch is ON.
Verify brake override circuit is connected in run po-
sition.
Verify continuity between batteries negative (at bat-
tery) and B power wire connection (at controller).
If no continuity, check:
Power wiring between battery and controller.
Verify continuity between battery positive (at bat-
tery) and B-1 and B-12 connection (at controller).
If no continuity, check:
Fuse 2 for open.
Key switch continuity in ON position.
Wiring battery + to main contactor to fuse 2 to key
switch, to controller A-6 connection.
•Defective battery charger.
Disconnect wires 2D and 12 from leads to battery
charger.
Use test lead to connect 2D and 12.
If truck operates, check charger fuses, repair or re-
place battery charger.
•Defective motor controller.
Check for battery voltage between A-6 and B
power wire connection at controller.
If correct battery voltage, replace controller.
Refer to the section Electrical System 2200 YRM
1007 for more information on troubleshooting electrical
system circuits and components.
LOGIC
Occurs when there is no
power to the controller or the controller is defective.
11

Troubleshooting 2200 YRM 1067
Dash Display Controller LED Handset or PC - 24V
No LEDs or LCDs
illuminated
LED OFF Handset does not operate
CONDITION
Dash display, controller LED, and truck inoperative.
TRUCK RESPONSE
Travel and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
•B+ and/or B missing at controller.
Confirm battery is connected and of proper voltage.
Verify key switch is ON.
Verify brake override circuit is connected in run po-
sition.
Verify continuity between batteries negative (at bat-
tery) and B power wire connection (at controller).
If no continuity, check:
Power wiring between battery and controller.
Verify continuity between battery positive (at bat-
tery) and B-1 and B-12 connection (at controller).
If no continuity, check:
Fuse 2 for open.
Key switch continuity in ON position.
Wiring battery + to main contactor to fuse 2 to key
switch, to controller A-6 connection.
•Defective battery charger.
Disconnect wires 2D and 12 from leads to battery
charger.
Use test lead to connect 2D and 12.
If truck operates, check charger fuses, repair or re-
place battery charger.
•Defective motor controller.
Check for battery voltage between A-6 and B
power wire connection at controller.
If correct battery voltage, replace controller.
Refer to the section Electrical System 2200 YRM
1007 for more information on troubleshooting electrical
system circuits and components.
LOGIC
Occurs when there is no
power to the controller or the controller is defective.
12

2200 YRM 1067 Troubleshooting
Dash Display Controller LED Handset or PC
No LEDs or LCDs
illuminated
LED OFF No error codes present
CONDITION
Dash display and/or controller LED inoperative.
TRUCK RESPONSE
Travel and hydraulic functions normal.
POSSIBLE CAUSES AND TEST PROCEDURES
•Open connection between dash display and controller.
Verify harness connections at MDI and connector
D on controller.
Verify continuity of wires between MDI and con-
troller.
•Defectivedashdisplay.
Connect handset to controller and confirm commu-
nication to handset.
If handset operates correctly, replace MDI.
•Defective LED.
Disconnect LED and connect handset. If handset
works, replace LED.
LOGIC
Occurs when the MDI or
LED receives no signal, or MDI or LED are damaged.
Dash Display Controller LED Handset or PC
No LEDs or LCDs
illuminated
LED OFF NO COMMUNICATION
CONDITION
Dash display and/or controller LED inoperative.
TRUCK RESPONSE
Travel and hydraulic functions normal.
POSSIBLE CAUSES AND TEST PROCEDURES
•Defective controller.
Connect handset to controller and confirm commu-
nication to handset.
If handset will not communicate with controller, re-
place controller.
LOGIC
Occurs when controller
does not send a signal to the MDI or LED.
13

Troubleshooting 2200 YRM 1067
Dash Display Controller LED Handset or PC
No Alarm LED OFF - No Flashes INCORRECT START
CONDITION
Improper startup sequence by operator.
TRUCK RESPONSE
Traction and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
•Throttle or hydraulic function selected at key ON. Steer
handle in run position at key ON.
Return steer handle to full upright position. Return
throttle to neutral. Release all hydraulic function
controls.
If fault remains, attach handset and go to test menu.
•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 volt-
age is other than 0 volts at neutral, check the function-
ality of the control card. Refer to Control Card Func-
tional Test in this section.
•Check hydraulic inputs – Should be 0 volts. If not, re-
calibrate tiller card. Follow auto-learn procedure listed
in steering. If this does not clear fault, check but-
tons for damage or interference. Replace damaged
or faulty buttons.
LOGIC
Fault occurs when
controller receives input that has not followed
the proper operational sequence.
14

2200 YRM 1067 Troubleshooting
Dash Display Controller LED Handset or PC
AL01 1Flash 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.
•If card cannot be recalibrated, check the functionality
of the control card. Refer to Control Card Functional
Test in this section.
LOGIC
Occurs when accelerator
voltage from serial control card is higher than 1V
(20%) before neutral switch is closed.
15

Troubleshooting 2200 YRM 1067
Dash Display Controller LED Handset or PC
AL01 1Flash PUMP VACC NOT OK
CONDITION
Connection/communication error between control
cardandtractioncontroller.
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 lift-
ing control and EVP voltage. Check on/off switches
and proportional switches for smooth, linear opera-
tion. 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.
•Check the functionality of the control card. Refer to
Control Card Functional Test in this section. LOGIC
Occurs if the output of
one on the hydraulic controls is higher
than 1V (20%) at start.
16