I sure appreciate the ideas, after digging in to the fuse connections it appears the main DC fuse was damaged. Tested good across it and the bar in the sight glass appears fine, but the end had snapped off inside the laminated part. WTH? I'm ordering a new one today. We're getting the batteries tested to make sure they don't need to be replaced. If Y'all don't hear from me in a few days, it will mean we've resolved the problem
Thanks for the help!!

yes i agree with brewski
24v reading means they are not charged, might be why the battery lights are flashing.
The manual says to check the AC main power supply, which we know is working because it turns on, also says to check the DC fuse may be blown, and lastly it says the power circuit break down.

It does have a protection mode that if the DC fuse blows it will cause the red led to blink so check that fuse and it's connections.
when you start the charger it should try and charge for 5 mins, if the DC circuit is faulty (ie: blown fuse) it will start blinking.

If you are only seeing 24 volts your batteries are fully discharged. You should have above 25.6 volts to reset the BDI to full.

Busy day with other projects as well. Thanks for the updates. I was able to change mode with the horn, key method. I made sure the batteries are charged and in good condition. I get a 24 volt reading from battery connector at both points. Key switch circuit seems good and I cleaned the contacts at the connector. Not sure why I get the 3 beeps. Is there another point that may need attention?

3 beeps on lift means low battery

Well yes, it's traction since the lift is not variable.
I was going on the 3 beeps from the horn he spoke of.
He did mention the battery lights flashing though so Maybe he should check the charger. I do know from past dealings with these that the charger can affect the lift function too. He should check it and the sensor wires also.

Doesn't that only alter traction settings?
He has lift problems.

before you try to replace the controller you may want to verify the performance mode setting.
If you are familiar with how to change performance modes try to do this first when you start up the machine. Change it to a different mode.
Generally when you are changing modes the horn will sound off telling you what performance mode it is in 1 beep is mode 1, 2 beeps is mode 2, and 3 beeps is mode 3.

If you need assistance on how to do this proceedure here it is:
step 1- control handle in upright position
step2 - press horn button while turning on the keyswitch, release the horn button when the horn sounds.
step 3- toggle through the mode selection using the lift or lower buttons, the horn provides an audible indication as to what mode it is in as i mentioned above.
step 4- lower the handle to the operating position, the mode will stay until it is changed.
DO not turn off the key before lowering the handle, doing this will cancel the mode change.

try this and let us know what happens.

If you are sure the batteries are full charged and the problem still occurs you will need to replace the main controller.

Mrbob, I see you didn't get a response to your question last month. Did you get your problem resolved? I'm having the same problem with the zapi LED flashing and no lift, also my horn beeps 3 times when I depress the lift button. Everything seems good....

I have the same problem but the led on the zapi is flashing. Did you get yours working?

Kevin may have it right, I've seen this problem before, it's my experience that the key switch assy on this truck wear out quickly and become lose and sloppy with wear.

The battery charger comes with a red LED that will illuminate
or flash if a malfunction of the charger or battery
occurs.
One of the following may be the cause in the event of
charger failure and the red LED is blinking:


- AC mains failure
- DC fuse blown
- Power circuit break down
One of the following may be the cause in the event of battery failure and the red LED is ON:
- The total security time, 14 or 15 hours, has expired.
- The security time before the battery gassing voltage,
10 hours, has expired.
- The battery voltage is lower than 2.05V per cell after
one hour of charge.

Hope this helps understand why the battery charger light is flashing.
And what kevin_k said is also a possibility :o)

i,ve seen voltage loss across the keyswitch cause this 24v in>19v out due to bad contact in the switch.Battery guage will think battery is flat so will cut-out lift.check voltages at the plug into battery guage.