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.
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