Zapi FC2086 Status Codes
Controller Adjustments
The ZAPI™ transistor motor controller can store and display Error Codes (Alarms). It is also possible
to modify the controller Setup for individual preferences. Communication with the controller is possible by four methods:
1. LED - An LED may be installed in trucks that do not use a dash display. The LED flashes error codes to the technician
for diagnosis. The LED would be installed on the bottom of the ZAPI™ controller. The LED is installed in the connector port
2. Dash Display - Some trucks are equipped with an optional dash display or MDI. Error codes are shown on the LCD
when the wrench symbol and red light are lit. The format is AL XX where XX is the error code.
3. ZAPI Handset - A diagnostic handset is available thru your Hyster or Yale dealer. The handset makes it possible to
diagnose faults and modify controller settings.
4. Personal Computer - The controller can also be connected to a 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 list of diagnostic codes are explained in this section.
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.
Dash Display
Controller LED
Handset or PC
CONDITION
No LEDs or LCDs
illuminated
LED OFF
Handset does not
operate Dash display, controller LED, and truck inoperative
TRUCK RESPONSE
Travel and hydraulic functions disabled.
POSSIBLE CAUSES AND TEST PROCEDURE
• 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
position.
Verify continuity between batteries negative (at
battery) and B power wire connection (at controller).
If no continuity, check:
Power wiring between battery and controller.
Check for +24V at D-4, A-3, and A-6.
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 charge
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 replace 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.
Dash Display
Controller LED
Handset or PC
CONDITION
No LEDs or LCDs
illuminated
LED OFF
No error codes present
Dash display and/or controller LED inoperative.
TRUCK RESPONSE
Travel and hydraulic functions normal.
POSSIBLE CAUSES AND TEST PROCEDURE
• Open connection between dash display and controller.
Verify harness connections at MDI and connector
B on controller.
Verify continuity of wires between MDI and controller.
• Defective dash display.
Connect handset to controller and confirm communication
to handset.
If handset operates correctly, replace MDI.
FOR REFERENCE ONLY 5/4/10 Rev A
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