Description
ZAPI™ TRANSISTOR MOTOR
CONTROLLER
The ZAPI™ controller is a solid-state DC motor
controller utilizing SEM technology. It controls the
traction motor, brake, and hydraulic system. The
controller receives inputs from the control handle
by serial communication, and direct inputs from
the key switch and control handle arm position
switch. The controller directly controls the traction
motor, lift pump motor, lift valve, proportional low-
ering 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 con-
troller 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 con-
troller software features a Test Menu for monitor-
ing controller inputs and outputs, a Diagnostic
Menu for viewing fault code information, and a Pro-
gramming Menu for customizing the truck perform-
ance. The handset or PC connect to the controller
through a cable with a six pin connector which at-
taches to the 10 pin "D" connector port on the bot-
tom of the controller. The connector is installed cen-
tered 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, con-
trol handle serial communications, controller tem-
perature, and internal logic functions. The control-
lers on standard trucks come equipped with a red
LED fault indicator located at the bottom of the
controller. In the event of a fault, the LED flashes a
numeric code.
NOTE:
The dash indicator will display the code: EP
107 (or a higher number) for 1 to 2 seconds every
time the key switch is turned to the ON position.
The ZAPI handset similarly displays V1.07 (or
higher). This code represents the EEPROM soft-
ware 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 so-
phisticated 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 cir-
cuit independently. The controller has many pro-
grammable features, including maximum speed, ac-
celeration rate, release braking, and braking cur-
rent limit. The SEM controller includes a full range
of features, as well as diagnostic and setup capabil-
ity.
NOTE:
There are no user-serviceable parts in the
ZAPI™ controller. No attempt should be made to
open, repair, or otherwise modify the controller. Do-
ing so may damage the controller and will void the
warranty.
Description
2200 SRM 1064
2
