Yale ZAPI MPW045-E Leitfaden

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]

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.

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

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.

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.

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).

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.

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