Hyster W40Z:
Doesn't lift of move

Batteries are fully charged but lift does not operate at all except for a horn on the red emergency button.

When the key is turned on a red light under the Zapi Controller flashes twice and when the control handle is lowered the light flashes continuously but nothing works.
  • Posted 25 Apr 2014 00:34
  • Discussion started by bad1129
  • New Jersey, United States
Showing items 1 - 4 of 4 results.
Thanks I got it working!
  • Posted 9 May 2014 03:08
  • Reply by bad1129
  • New Jersey, United States
Is the light flashing a repeating pattern, the trouble shooting suggests a continuous flashing indicates low battery voltage at the controller. Check the voltage at the controller. first with the handle up, then pull the handle down.
Battery voltage is low.

Controller voltage calibration is incorrect.
Compare the at Battery voltage to voltage
measured by an accurate digital voltmeter between
B+ and B terminal. Pull down tiller handle
to engage contactor for this measurement. If
these two voltages are more than 1 volt difference,
do the following:
Check for shorts to frame
Check at the connector
Check at the contactor
check if contactor engaged.
Defective or damaged connection to battery.
Inspect cable crimps and cables from battery to
connector.
Inspect cable crimps and cables from battery contactor
to controller and contactor.
Verify the voltage on the controller when the main
contactor closes.
If voltage is less than 21V, check the battery,
power connector, fuse, main contactor.
If is higher than 22V, most likely is the controller
Try draining the controller and repowering it
The ZAPI controllers can hold an electrical
charge for several minutes after the key
switch has been turned OFF. To prevent injury,
discharge the controllers by connecting
a 200-ohm, 2-watt resistor between the battery
positive connector and battery negative connector
on the controller and hold there for at least 5
seconds.
  • Posted 8 May 2014 17:24
  • Reply by Wajaxed
  • British Columbia, Canada
If it wasn't for human error and negligence, I would have nothing to do most days.
Stay safe

Ed
I don't recall a click when lowering the handle and the truck cannot be pushed so I would assume the brakes are on all the time,

I'm not familiar with the molex connector. Where is it located?
  • Posted 25 Apr 2014 23:51
  • Reply by bad1129
  • New Jersey, United States
do you hear the electronic brake coil click when you lower the handle? cna you push this truck or are the brakes on all the time?
this truck has a 2 wire molex connector jumper that can be plugged into the harness that allows the brakes to release as long as there is battery power (like for the transport driver to get a non running unit on the truck). but if left connected, the truck will not operate.
do you know of this wire connection? have you confirmed it is connected for normal operation?
  • Posted 25 Apr 2014 20:06
  • Reply by edward_t
  • South Carolina, United States
"it's not rocket surgery"

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