yeah jim_k
its strange
i looked all through the hyster service side and there is no access to any operator manuals directly
they make you go through a request and download process before you can get a copy of one related to a particular model.
You would think they would give a service tech access to ALL the material directly.....
DOH!

i do have a question though , is it the zapi thats beeping? or the charger?

Swoop has described the BDI and code display unit clearly, but from what has been stated I would agree that the battery needs thoroughly testing as in my experience the capacity can be reduced dramatically after a couple of years use and especially if a lot of opportunist charging has taken place, also the battery sending circuit on these trucks can give some problems and one of the weak spots can be the key switch assy which in my opinion is weak on these trucks in that they don't conduct the full voltage when worn also the line contractors can Be prone to voltage drop. So the main cables from the battery need checking for voltage drop back to the power unit to see where the voltage drop is occurring.

Regards Titus

had this once, it was a broken drive motor field cable. other time it was the tiller card like the friends above mentioned.

The 3 beeps are mentioned in operators manual. It is used to tell operator batteries need to be charged. Usually drive and lift still work. I would check batteries and cables first. These are really simple pallet jacks. I have had the handset for years and hardly use it.

yes this unit has a zapi controller on it

like justinm says
check the display unit, see if its showing a code.
I'll assume it doesnt have a display that shows codes so like justinm said, look on the controller and see what the flash sequence is on the LED on the controller.

Also like jim said, check the batteries, dead batteries can cause problems and is the first thing you should check in any case.

On a display capable of showing codes it will have several lights for the battery indicator, also will have a small window showing hour meter, in THIS window when you turn on the truck it will flash a short display of the model version like 'EP 107' or something like this. The actual error or alarm will look like 'AL094' or something like this.


From what i can see in the troubleshooting guide there is no mention about any 'beeps' so you will have to see if the LED is blinking in any sort of flash code.

It's a high possibility you're going to need a zapi handset to know whats going on with this truck.

Three beeps when trying to use hydraulics indicate dead batteries

dos the truck roll or are the brakes on and locked? This truck has a place to plug in some wires in the harness that will release the brakes, but it prevents correct traction controller operation. I see them sometimes use the brake override to load the truck, but forget to remove the wires when delivered.

If it's a Zapi it should have an LED plugged into one of the ports on the motor controller. What pattern does it flash after the contactor opens back up?
It will flash followed by a short pause or a long pause
Example: Code 13 = O----O-O-O----(start code again)O----O-O-O----(infinity or till you shut off the key lol)

Oops sorry. This controller should only flash a single digit (7 flashes = a 7), flash endlessly, or stay on continuously. If it doesn't light up, you either you lost power or the jack thinks it's working correctly. It looks like a little light bulb sticking out of a plug.

I agree most of the troubles we have had are tiller card or lift/lower buttons

I think i would check the mux card in tiller head and associated wiring.