Yale ERC060GIN48 Serie A908N02474C 20-12-11 PDF

Maintenance
AC MOTOR
CONTROLLERS/DISPLAY
PANEL
DESCRIPTION, CHECKS,
ADJUSTMENTS, AND
TROUBLESHOOTING
ERC20-32AGF (ERC040-065GH) [A908];
ERC/P16-20AAF (ERC030, 040AH) [B814/C814];
ERP20-30ALF (ERP040-060DH) [D216];
ERP20-32ALF (ERP040-065DH) [E216];
ERC35-55HG (ERC70-120HH) [B839/C839]
PART NO. 524183083 2200 YRM 1056

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
AC Motor Controllers/Display Panel Table of Contents
TABLE OF CONTENTS
Description .......................................................................................................................................................... 1
General ........................................................................................................................................................... 1
AC Motors ................................................................................................................................................... 1
Motor Controllers ........................................................................................................................................ 1
Master Controller ........................................................................................................................................ 1
Dash Display............................................................................................................................................... 1
Controller Area Network Bus (CANbus)...................................................................................................... 1
Master Controller Checks and Adjustments ........................................................................................................ 2
Function Settings................................................................................................................................................. 3
General ........................................................................................................................................................... 3
Function Numbers........................................................................................................................................... 3
Function Descriptions .......................................................................................................................................... 6
General ........................................................................................................................................................... 6
Function Number 1 BATTERY VOLTAGE ................................................................................................... 6
Function Number 2 EXTENDED SHIFT ..................................................................................................... 6
Function Number 3 ACCELERATION 1...................................................................................................... 6
Function Number 4 ACCELERATION 2...................................................................................................... 6
Function Number 5 TOP SPEED LIMIT...................................................................................................... 6
Function Number 6 REGEN BRAKING ...................................................................................................... 6
Function Number 7 AUTO DECELERATION .............................................................................................. 7
Function Number 8 BDI ADJUSTMENT ..................................................................................................... 7
Function Number 9 LIFT INTERRUPT ....................................................................................................... 7
Function Number 10 POWER STEERING TIME DELAY ........................................................................... 7
Function Number 11 SERVICE REMINDER .............................................................................................. 7
Function Number 12 CUSTOM ................................................................................................................... 7
Function Number 13 PUMP SPEED 1........................................................................................................ 7
Function Number 16 PUMP ACCELERATION ........................................................................................... 8
Troubleshooting ................................................................................................................................................... 8
General ........................................................................................................................................................... 8
Controller Status Light Emitting Diodes (LEDs) .............................................................................................. 9
Master Controller ........................................................................................................................................ 9
AC Motor Controllers .................................................................................................................................. 9
Status Codes................................................................................................................................................... 15
AC Motor Controllers Status Code Charts .......................................................................................................... 17
Troubleshooting When Dash and/or Lift Truck is not Operational ................................................................... 38
Typical Symptoms ....................................................................................................................................... 38
Truck Runs but Dash Display is not Operational, or Only Displays Status Code 55; an Additional
Delay Between Key ON and Line Contactor Closing May Occur................................................................ 38
Truck Does Not Run and Dash is Not Operational or Only Displays Status Code 55................................. 39
Hydraulics Operate Normally, Traction Does Not Operate Correctly, and Dash is Operational but no
Status Codes are Present........................................................................................................................... 40
Traction Operates Normally, Hydraulics do Not Operate Correctly, and Dash is Operational but no
Status Codes are Present........................................................................................................................... 40
AC Transistor Motor Controller Replacement ...................................................................................................... 40
General ........................................................................................................................................................... 40
General Maintenance Instructions .................................................................................................................. 46
Special Precautions .................................................................................................................................... 46
Fuses .............................................................................................................................................................. 47
Fan Test........................................................................................................................................................... 47
©2009 Yale Materials Handling Corp. i

Table of Contents AC Motor Controllers/Display Panel
TABLE OF CONTENTS (Continued)

Contactors....................................................................................................................................................... 47
Repair ......................................................................................................................................................... 47
Thermal Sensors............................................................................................................................................. 51
Motor Controller, Replace ............................................................................................................................... 51
Display Panel....................................................................................................................................................... 52
General ........................................................................................................................................................... 52
Premium Display Panel............................................................................................................................... 52
Standard Display Panel............................................................................................................................... 52
Display Functions and Features .......................................................................................................................... 53
Key-On Initialization ........................................................................................................................................ 53
Standard Display ............................................................................................................................................. 54
Premium Display ............................................................................................................................................. 54
Lift Truck Inspection Function.......................................................................................................................... 55
Access to Service Functions ........................................................................................................................... 55
Service Functions ........................................................................................................................................... 55
Service Functions ........................................................................................................................................... 56
Performance Modes ........................................................................................................................................ 58
Battery Discharge Indicator (BDI) ................................................................................................................... 58
Hourmeter ....................................................................................................................................................... 59
Dash Display Service Menu Navigation .............................................................................................................. 65
General ........................................................................................................................................................... 65
Moving Through Menu Selections................................................................................................................... 65
Editing and Adding Information ....................................................................................................................... 65
This section is for the following models:
ERC20-32AGF (ERC040-065GH) [A908];

ERC/P16-20AAF (ERC030, 040AH) [B814/C814];
ERP20-30ALF (ERP040-060DH) [D216];
ERP20-32ALF (ERP040-065DH) [E216];
ERC35-55HG (ERC70-120HH) [B839/C839]
ii
2200 YRM 1056 Description
Description
GENERAL Master Controller
The alternating current (AC) system consists of AC mo- The master controller is a general-purpose micro-con-
tors, motor controller(s), a master controller, and a dash troller for CANbus-based electric vehicles. It contains
display. The major difference between the AC system processing power, memory resources, analog and digi-
and the direct current (DC) system is the master con- tal input/output (I/O) to provide the required full-featured
troller performs many of the same functions that pre- functionality. The master controller is designed to man-
viously were performed in the motor controllers on the age the traction motor controller and pump motor con-
DC system. troller, interface to the operator controls, auxiliary func-
tions, and to control the vehicle dash display.
AC Motors
The master controller also manages the operating truck
The AC motors are three-phase AC induction motors. parameters, status codes, battery discharge indicator
They do not include motor brushes or commutators. An (BDI) function, hourmeters, password feature, and all
AC induction motor operates on three-phase AC power operator inputs. It also controls the contactor, cooling
provided directly by the motor controller. The motor’s fans, and strobe light relay.
speed is controlled by the motor controller and can be
changed by changing the frequency of the AC power Dash Display
provided to the motor. A speed sensor is built into the
rear motor bearing, which provides RPM and direction The new AC dash display is similar in appearance to
feedback to the motor controller. The motor controller the SEM dash display and includes the same features.
continuously monitors motor direction and speed. Us- In addition, the AC dash display provides expanded
ing this feedback, the AC motor control system can pro- service capabilities. The dash display has a pass-
vide much better vehicle top speed control than is avail- word-accessible service mode that allows a technician
able with DC SEM systems. to change control settings and view real-time RPMs,
current, temperature, and switch closure information.
The AC motors also have thermal sensors embedded Previously, a separate handset or computer was re-
in the motor windings that are continuously monitored quired for these operations. For a complete description
by the motor controllers. of the display panel, see the Display Panel section of
this manual.
Motor Controllers
Controller Area Network Bus (CANbus)
The motor controllers receive power from the truck’s
battery and convert it into three-phase AC power at the The motor controllers, master controller, and dash dis-
frequencies and currents necessary to drive the respec- play are connected together with a CANbus communi-
tive pump and/or traction motor. Each AC induction mo- cation system. A personal computer (PC) with the ap-
tor provides feedback of speed, rotation direction, and propriate Electric Truck AC Controller (ETACC) service
temperature directly to the motor controller. The two software and interface cable can easily communicate
motor controllers used to power the traction motor and with all system nodes by simply connecting to the CAN-
hydraulic pump motor are very similar. The primary mo- bus. A diagnostics connector, located under the dash
tor controller difference is in the power output rating. and next to the display, is configured specifically for this
purpose. See Figure 1 and section Troubleshooting
The motor controller logic board receives power from and Adjustments Using the AC Controls Program
the key switch. Power to the motors can be interrupted (ETACC) 2200 YRM 1058 for procedures to connect a
indirectly by the key switch. The motor controllers PC to lift truck.
get motor speed and temperature information directly
from the motors. The motor controllers do not get any
other input from the truck. The master controller relays
speed, acceleration, and direction commands to the
motor controllers.
1
Master Controller Checks and Adjustments 2200 YRM 1056
Legend for Figure 1

1. DIAGNOSTIC CONNECTOR
2. DASH DISPLAY
3. DASH WIRE HARNESS
Figure 1. Diagnostic Connector
Master Controller Checks and Adjustments

NOTE: All checks and adjustments to the master con- The following checks and adjustments may be made
troller can be done with a personal computer (PC) that using a PC or the dash display:
has the ETACC service software installed. See Trou- • Check the system status codes history.
bleshooting and Adjustments Using the AC Con- • Check the state of charge of the battery.
trols Program (ETACC) 2200 YRM 1058 for software • Check the hourmeter readings on the traction circuit
installation procedures. A diagnostics connector in the and hydraulic pump controllers.
wiring harness below the display panel can connect the • Monitor or adjust the register values for each function
PC to the CANbus system to communicate to the mas- as shown in Table 1, Table 2, and Table 3.
ter controller (see Figure 1). Many checks can also be
done at the display panel without being connected to a
PC.
2
2200 YRM 1056 Function Settings
Function Settings
GENERAL Table 1. Factory Parameters for ERP20-30ALF
(ERP040-060DH) (D216), ERP20-32ALF
The master controller has several functions (parame- (ERP040-065DH) (E216)
ters) that can be changed to configure different lift truck
models and voltages. The function settings are stored Factory
and used by the master controller to determine lift truck Factory
Function Setting
performance or other operation variables. Setting 72V
80V
NOTE: Table 1, Table 2, Table 3, and Table 4 show the 1-BATTERY VOLTAGE 72 80
default settings for each control function. The factory
2-EXTENDED SHIFT ENABLED ENABLED
settings are the recommended settings for new units.
These settings will give satisfactory performance for 3-ACCELERATION 1 40 40
most applications.
4-ACCELERATION 2 7 7
All functions can be adjusted within the permitted range 5-TOP SPEED LIMIT 94 100
to change the lift truck operation for a specific applica-
tion. Adjustment of a register to a number that is dif- 6-REGEN BRAKING 75 75
ferent than the factory setting is allowed, but follow the 7-AUTO
instructions carefully. Adjustments other than the fac- 70 70
DECELERATION
tory settings will cause the lift truck performance and
energy consumption to change. 8-BDI ADJUSTMENT 30 30
9-LIFT INTERRUPT ENABLED ENABLED
FUNCTION NUMBERS
10-PS TIME DELAY 20 20
WARNING 11-SERVICE
0 0
NEVER adjust any of the function registers without REMINDER
using the procedures and settings given in this sec- 12-CUSTOM 0 0
tion.
13-PUMP SPEED 1 25 25
NOTE: Functions 13, 14, and 15 do not apply to lift 14-PUMP SPEED 2 50 50
trucks that are equipped with the e-hydraulics option.
15-PUMP SPEED 3 95 95
The function numbers are code numbers for the differ-
ent parameters that can be set for the master controller. 16-PUMP
25 25
The PC or the dash display must be used to adjust the ACCELERATION
parameters for the master controller.
3
Function Settings 2200 YRM 1056
Table 2. Factory Setting for ERC020-032AGF (ERC40-65GH) (A908)
Factory Setting Factory Setting Factory Setting Factory Setting

Function
36V 48V 72V 80V
1-BATTERY VOLTAGE 36 48 72 80
2-EXTENDED SHIFT ENABLED ENABLED ENABLED ENABLED
3-ACCELERATION 1 40 49 46 50
4-ACCELERATION 2 5 8 6 9
5-TOP SPEED LIMIT 85 92 91 98
6-REGEN BRAKING 60 60 60 70
7-AUTO DECELERATION 65 70 70 70
8-BDI ADJUSTMENT 30 30 30 30
9-LIFT INTERRUPT ENABLED ENABLED ENABLED ENABLED
10-PS TIME DELAY 20 20 20 20
11-SERVICE REMINDER 0 0 0 0
12-CUSTOM 0 0 0 0
13-PUMP SPEED 1 25 25 25 25
14-PUMP SPEED 2 50 50 50 50
15-PUMP SPEED 3 95 95 95 95
16-PUMP ACCELERATION 25 25 25 25
Table 3. Factory Setting for ERC/P16-20AAF (ERC030-040AH) (B814/C814)
Factory Setting
Function Factory Setting 36V Factory Setting 48V
48V (Europe)
1-BATTERY VOLTAGE 36 48 48
2-EXTENDED SHIFT ENABLED ENABLED ENABLED
3-ACCELERATION 1 48 66 62
5-TOP SPEED LIMIT 80 100 100
6-REGEN BRAKING 60 60 75
7-AUTO DECELERATION 65 70 70
8-BDI ADJUSTMENT 30 30 30
9-LIFT INTERRUPT ENABLED ENABLED ENABLED
10-PS TIME DELAY 20 20 20
11-SERVICE REMINDER 0 0 0
12-CUSTOM 0 0 0
13-PUMP SPEED 1 25 25 25
4
2200 YRM 1056 Function Settings
Table 3. Factory Setting for ERC/P16-20AAF (ERC030-040AH) (B814/C814) (Continued)
Factory Setting
Function Factory Setting 36V Factory Setting 48V
48V (Europe)
14-PUMP SPEED 2 50 50 50
15-PUMP SPEED 3 95 95 95
16-PUMP ACCELERATION 25 25 25
Table 4. Factory Parameters for ERC35-55HG (ERC70-120HH) (B839/C839)
Function Factory Setting 36V Factory Setting 48V Factory Setting 80V
1-BATTERY VOLTAGE 36V 48V 80V
2-EXTENDED SHIFT ENABLED ENABLED ENABLED
5-TOP SPEED LIMIT 85 100 100
6-REGEN BRAKING 65 65 65
7-AUTO DECELERATION 80 80 80
8-BDI ADJUSTMENT 30 30 30
9-LIFT INTERRUPT ENABLED ENABLED ENABLED
10-PS TIME DELAY 20 20 20
11-SERVICE REMINDER 0 0 0
12-CUSTOM 0 0 0
13-PUMP SPEED 1 25 25 25
14-PUMP SPEED 2 50 50 50
15-PUMP SPEED 3 95 95 95
16-PUMP ACCELERATION 25 25 25
5
Function Descriptions 2200 YRM 1056
Function Descriptions
GENERAL To increase the acceleration rate above the factory set-
ting, Function 2 will need to be set to disabled.
WARNING To reduce the acceleration rate below the factory set-
If any of the register values are changed, the op- ting, Function 2 may be enabled or disabled.
erators must be told that the lift truck will operate
differently. Any increase in performance will decrease the battery
shift life.
The following section contains descriptions for the dif-
ferent functions. The register setting for each function Function Number 4 ACCELERATION 2
is specific for each motor controller.
(Range 0-100)
Function Number 1 BATTERY VOLTAGE
Function 4 determines the truck acceleration rate when
(36, 48, 72, or 80) traction motor speed is above 1,500 rpm. The truck
will accelerate at this rate regardless of the load on the
Function 1 is used to inform the master controller what forks, provided that the motor and control can deliver
voltage battery is installed in the truck. The battery the required power.
choices are: 36, 48, 72, or 80.
To increase the acceleration rates above the factory
Function Number 2 EXTENDED SHIFT setting, Function 2 will need to be disabled.
(Enable or Disable) To reduce the acceleration rate below the factory set-
ting, Function 2 may be enabled or disabled.
Function 2 enables or disables a preset motor perfor-
mance program in the traction motor controller. Any increase in performance will decrease the battery
shift life.
When enabled, this function provides a balance be-
tween truck performance and battery shift life that will Function Number 5 TOP SPEED LIMIT
meet the requirements of most applications. Truck ac-
celeration and top speed will vary with the amount of (Range 1-100)
load on the forks.
Function 5 determines the top speed limit of the truck.
When disabled, truck acceleration and top speed are
determined by values set in Functions 3, 4, and 5. To increase the top speed above the factory setting,
Function 2 will need to be disabled.
If the motor and controller can deliver the power, then
the truck performance will not vary with the amount of To reduce the top speed below the factory setting,
load on the forks or the battery state of charge Function 2 may be enabled or disabled.
Grade climbing speed will also improve because the For speed limits slower than the normal truck speed,
motor controller will deliver maximum current. Any in- the top speed is the same regardless of the load on the
crease in performance will decrease the battery shift forks. Acceleration rates are also unaffected by lower-
life. ing the top speed.
Function Number 3 ACCELERATION 1 Any increase in performance will decrease the battery
shift life.
(Range 0-100)
Function Number 6 REGEN BRAKING
Function 3 determines the truck acceleration rate when
traction motor speed is below 1,500 rpm. The truck (Range 0-100)
will accelerate at this rate regardless of the load on the
Function 6 determines the maximum deceleration rate
forks, provided that the motor and control can deliver
when the accelerator pedal is fully depressed during
the required power.
regen braking.
6
2200 YRM 1056 Function Descriptions
NOTE: The deceleration rate is less when the pedal is Function Number 11 SERVICE REMINDER
not fully depressed.
(Set Next Hourmeter)
Function Number 7 AUTO DECELERATION
Function 11 can be used by the service technician to
(Range 0-100) show a Status Code 99 when the truck is due for ser-
vice.
Function 7 determines the maximum deceleration rate
when the accelerator pedal is released. The strength of To use this feature, set this function to the hourmeter
auto deceleration is a percentage of the regen braking reading that the service is to occur. When that hourme-
strength determined by Function 6. ter is reached, the dash display will display Status
Code 99 for 10 seconds each time the key is turned
A Function 7 setting of zero will turn off auto decel- ON. After 20 hours of operation, the truck will slow to
eration completely, and a setting of 100 will give auto half speed and the code will display continuously until
deceleration the same strength as regen braking. the service is performed. After servicing the truck,
Function 11 should be set to the next service hourme-
Function Number 8 BDI ADJUSTMENT ter reading to regain full performance.
(Range 0-100) NOTE: A setting of zero will disable this feature.
Function 8 allows for adjustment to improve the accu- Function Number 12 CUSTOM
racy of the Battery Discharge Indicator in the dash
display. Increasing the setting will cause the gage to (Range 0-100)
show empty at a higher specific gravity or battery volt-
age. Function 12 is not used except for special functions
required for special applications. Normally, this function
A setting of 30 is the recommended starting point for is set to zero.
flooded cell batteries, and a setting of 50 for mainte-
nance-free batteries. Further adjustments may be used A setting value of 1 will change auto deceleration to
to fine-tune the BDI accuracy. work even with a partial release of the accelerator
pedal. Normally, auto deceleration only works when
Function Number 9 LIFT INTERRUPT the accelerator pedal is fully released.
(Enable or Disable) A setting value of 2 will cause the maximum lift speed
and pump motor acceleration rate to change with the
Function 9 enables or disables the lift interrupt fea- performance mode selected. Normally, only traction
ture. The lift interrupt feature stops hoist operation speeds and acceleration rates change with the perfor-
when the BDI reads empty to protect the battery from mance mode selected.
excessive discharge and possible damage.
A setting value of 3 will combine the changes described
NOTE: Trucks are shipped from the factory with this fea- for setting values of 1 and 2.
ture enabled.
A setting value of 4 directs the master controller to out-
Function Number 10 POWER STEERING put forward and reverse signals that are compatible with
TIME DELAY wire guided trucks.
(Range 0-100) Function Number 13 PUMP SPEED 1

Function 10 sets the time delay for the power steering NOTE: This function does not apply for lift trucks that
contactor to open after the seat switch opens. The set- are equipped with the e-hydraulics option.
ting range is 1.5 to 65 seconds. Opening the key switch
will open the power steering contactor with no delay. (Range 0-100)
Function 13 determines the hydraulic pump motor low

speed. Low speed is used for tilt and some auxiliary
operations (sideshift).
7
Troubleshooting 2200 YRM 1056
Any increase in performance will decrease the battery (Range 0-100)

shift life.
Function 15 determines the hydraulic pump motor
Function Number 14 PUMP SPEED 2 high speed. High speed is used for maximum hoist
speed.
NOTE: This function does not apply for lift trucks that
are equipped with the e-hydraulics option. Any increase in performance will decrease the battery
shift life.
(Range 0-100)
Function Number 16 PUMP
Function 14 determines the hydraulic pump motor
ACCELERATION
medium speed. Medium speed is used for slow
hoist and some auxiliary operations. (Range 0-100)
Any increase in performance will decrease the battery Function 16 determines the hydraulic pump motor ac-
shift life. celeration rate. Higher numbers bring up motor speed
quicker.
Function Number 15 PUMP SPEED 3
Any increase in performance will decrease the battery
NOTE: This function does not apply for lift trucks that shift life.
are equipped with the e-hydraulics option.
Troubleshooting
GENERAL to the shank of the screwdriver to obtain readings.
An additional method would be to use a breakout
The AC motor and master controllers are sealed units kit, Yale P/N 580002086.
with no serviceable components. Troubleshooting is
usually limited to accessing status codes and follow- See Electrical Diagrams, AC Motor Control System
ing the diagnostic procedures listed in the Status Code 8000 YRM 1059 for ERP20-30ALF (ERP040-060DH)
Charts. (D216), ERC/P16-20AAF (ERC030-040AH) (B814/
C814), and ERC20-32AGF (ERC040-065GH) (A908)
Use standard testing procedures to verify inputs and or Diagrams, AC Motor Control System 8000 YRM
outputs when necessary. 1203 for ERC35-55HG (ERC070-120HH) (B839/C839)
or Electrical Diagrams, AC Motor Control System
CAUTION 8000 YRM 1225 ERP20-32ALF (ERP040-065DH)
(E216) for additional wiring details.
Never attempt to probe through the back of the con-
nector plugs of the motor controller. These plugs If the lift truck does not operate correctly, a status code
are special sealed plugs. Probing through the back is usually displayed on the display panel. If a status
of the plugs will destroy the seal and can cause a code is not displayed, see the section Troubleshooting
short circuit. If a circuit must be tested for voltage, When Dash and/or Lift Truck is not Operational.
check for voltage at an amp-type plug, a switch, or a
component. If a circuit is suspect, check the circuit Once the status code number is obtained, follow the
for continuity by disconnecting the P plug and test- procedures outlined in the Status Code Charts of this
ing continuity from the front (pin end) of the plug. manual to determine the problem.
Standard probes are too large to be inserted into the NOTE: Due to the interaction of the master controller
center of the female pins (sockets) of the special with all lift truck functions, almost any status code or
sealed plugs and can expand the pins. Expanded controller fault could be caused by an internal failure of
pins will not provide good connections once the the master controller. After all other status code proce-
plug is reconnected. The connectors are shaped to dures have been followed and no problem is found, the
allow the insertion of a small flat-blade screwdriver master controller should be replaced as the last option
into the connector. After inserting the screwdriver to correct the problem.
into the connector, attach probes with alligator clips
8
2200 YRM 1056 Troubleshooting
Tools and test equipment required are: clip leads, digital an access hole. On ERC35-55HG (ERC70-120HH)
multimeter (20,000 ohms per volt minimum), and basic (B839/C839) lift trucks, the master controller is lo-
hand tools. cated under the rear floor plate.
• The LED is located next to the wire harness connec-
Check resistance on RX1000 scale from frame to tor. See Figure 2.
power and controller terminals. Resistance of less than • The LED blinking rate is usually twice a second, when
20,000 ohms can cause misleading symptoms. Resis- the battery is connected and the key switch is in the
tance of less than 1000 ohms should be corrected first. OFF position.
• The LED blinking rate slows to once every two sec-
Before proceeding, visually check for loose wiring, mis-
onds when the battery is connected and the key
aligned linkage to the accelerator switch, signs of over-
switch is moved to the ON position.
heating of components, etc.
• If the above conditions are not present, the master
Prior to troubleshooting systems and components on controller may not be properly connected or may be
this lift truck, ensure the battery is the correct voltage faulty.
and is fully charged. Make sure the battery connec- • Due to the location of the master controller, a small
tor contacts are clean of corrosion and the battery po- inspection mirror may be needed to view the LED.
larity within the connector is correct. Inspect to en-
sure all fuses are correct and have not failed. Ensure
the key switch is in the ON position when making volt-
age checks or checking the operation of a component.
Make sure the floor (reset) switch and the operator pres-
ence switch has been properly closed.
Many faults noted by lift truck systems are the result

of loose wiring connections and/or broken or shorted
wiring within the lift truck. Begin the troubleshooting
process by carefully inspecting the wiring involving 1. LED
the device or devices noted by the onboard diagnostic
system. Faults noted with components located on the Figure 2. Master Controller LED
reach attachment may be caused by broken or shorted
wires in the mast cable. Ensure the integrity of this AC Motor Controllers
cable before troubleshooting attachment-related faults.
NOTE: In Figure 3 through Figure 7 the terms Gen IV
and Gen V refer to Generation IV and Generation V
CONTROLLER STATUS LIGHT EMITTING
respectively. Controller and contactor panels labeled
DIODES (LEDS) Gen IV are used in early model lift trucks and controller
and contactor panels labeled Gen V are used in later
The AC traction motor controller, AC pump motor con-
model lift trucks.
troller (optional), and AC master controller each have a
separate LED to indicate its operating status. Each LED This section covers both the AC traction motor controller
is green in color and may be lit continuously or blinking. and AC pump motor controller. Remove the rear cover
See each description for the location of each LED. to view the motor controllers. See Figure 3, Figure 4,
Figure 5, Figure 6, and Figure 7.
Master Controller
• The LED is located next to the label on the plastic
• The master controller location varies with the truck cover of the controller. See Figure 3 or Figure 4 Fig-
model. On ERP20-30ALF (ERP040-060DH) (D216) ure 5 or Figure 6.
and ERP20-32ALF (ERP040-065DH) (E216), it is • The LED only turns on when the key switch is in the
located behind the battery and can be reached ON position.
by removing the plastic cover at the rear of the • The LED will show a steady continuous green color if
hood. On the ERC/P16-20AAF (ERC030, 040AH) there is no fault condition detected.
(B814/C814), it is located under the frame side plate • When a fault condition is detected that is not serious
on the right-hand side, and on the left-hand side for enough to shut down the truck, the LED blinking rate
the ERC20-32AGF (ERC040-065GH) (A908) line of is twice a second. A status code should appear on
trucks. A mirror can be used to view the LED through the dash display to reference the problem.
9
• When a fault condition is detected that has shut down • If the above conditions are not present, the AC mo-
the truck, the LED blinking rate will be at a very rapid tor controller may not be getting power from the key
rate (too fast to count). A status code should appear switch or may be faulty.
on the dash display to reference the problem.
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE 8. LINE CONTACTOR
SOLENOID 9. AC PUMP MOTOR CONTROLLER
3. FUSE 3 (15A) LIGHTS 10. POSITIVE TEMPERATURE COEFFICIENT
4. FUSE 4 (5A) KEY SWITCH RESISTOR (PTC)
5. POWER STEERING CONTACTOR 11. LED INDICATOR
6. FUSE 5 (40 A) POWER STEERING
Figure 3. AC Traction and AC Pump Motor Controllers (Gen V) (36v/48v or 72v/80v) for ERP20-30ALF
(ERP040-060DH) (D216) and ERC20-32AGF (ERC040-065GH) (A908), Later Models Only and for
ERC/P16-20AAF (ERC030-040AH) (B814) Lift Truck Models
10
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. LINE CONTACTOR

2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE 8. POSITIVE TEMPERATURE COEFFICIENT
SOLENOID RESISTOR (PTC)
3. FUSE 3 (15A) LIGHTS 9. AC TRACTION MOTOR CONTROLLER
4. FUSE 4 (5A) KEY SWITCH 10. FUSE (325A) PUMP
5. POWER STEERING CONTACTOR 11. CONTACTOR FOR DC PUMP MOTOR
6. FUSE 5 (40A) POWER STEERING 12. LED INDICATOR
Figure 4. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (Gen V) (36v/48v
or 72v/80v) for ERP20-30ALF (ERP040-060DH) (D216) and ERC20-32AGF (ERC040-065GH) (A908), Later
Models Only and for ERC/P16-20AAF (ERC030-040AH) (B814) Lift Truck Models
11
1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 6 (15A) LIGHTS 8. AC PUMP MOTOR CONTROLLER
3. FUSE 3 (5A) KEY SWITCH 9. LED INDICATOR
4. POWER STEERING CONTACTOR 10. POSITIVE TEMPERATURE COEFFICIENT
5. FUSE 4 (40A) POWER STEERING RESISTOR (PTC)
6. LINE CONTACTOR
Figure 5. AC Traction and AC Pump Motor Controllers (72v/80v) (Gen IV) for Early Model ERP20-30ALF
(ERP040-060DH) (D216) and ERC20-32AGF (ERC040-065GH) (A908) Lift Trucks
12
1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT

2. FUSE 5 (15A) LIGHTS RESISTOR (PTC)
3. FUSE 3 (5A) KEY SWITCH 8. AC TRACTION MOTOR CONTROLLER
4. POWER STEERING CONTACTOR 9. FUSE 2 (325A) PUMP
5. FUSE 4 (40A) POWER STEERING 10. CONTACTOR FOR DC PUMP MOTOR
6. LINE CONTACTOR 11. LED INDICATOR
Figure 6. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (72v/80v) (Gen IV) for
Early Model ERP20-30ALF (ERP040-060DH) (D216) and ERC20-32AGF (ERC040-065GH) (A908) Lift Trucks
13
1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT

2. FUSE 2 (15A) (SLOW BLOW) SEAT BRAKE RESISTOR (PTC)
SOLENOID 8. AC TRACTION MOTOR CONTROLLER
3. FUSE 3 (15A) LIGHTS 9. AC PUMP MOTOR CONTROLLER
4. FUSE 4 (5A) KEY SWITCH 10. FUSE 5 (40A) POWER STEERING
5. POWER STEERING CONTACTOR 11. LED INDICATOR
6. LINE TRACTION CONTACTOR 12. LINE PUMP CONTACTOR
Figure 7. AC Traction and Pump Motor Controllers for ERC35-55HG (ERC70-120HH) (B839/C839) Lift
Truck Models
14
STATUS CODES The master and motor controllers sense the following
types of malfunctions:
NOTE: Make sure the parameter values are correct for • Input voltages that are too high or too low
your lift truck to ensure the trouble is not just an incorrect • Input voltages in the wrong sequence or
setting. See Function Settings to set the correct param- • Correct input voltages that occur at the wrong time
eter values. If there is no status code display and the lift
truck does not operate correctly, there can be a fault in NOTE: A status code indication does not always mean
the master controller, the CANbus, or any device on the that there is a malfunction. A temporary operating con-
CANbus. See the section Troubleshooting When Dash dition can cause a status code display.
and/or Lift Truck is not Operational.
These code numbers are only codes to help identify a
The status codes are code numbers for malfunctions possible malfunction. A short description of the different
or lift truck operations that are not correct and that the status codes is shown in Table 5.
motor controller can sense. The master controller will
indicate this code number on the LCD screen of the The Status Code Charts in this section have a more
display panel. complete description of the status code, the circuit that
has generated the input for the status code, the symp-
tom, and the possible causes.
Table 5. List of Status Codes
Status Code Description Status Code Description

BLANK No input voltage to controller or 52 Traction or pump motor speed sensor
display panel. error.
1 No seat switch input. 53 Traction controller does not respond to
master controller.
2 The forward switch is closed before 54 Pump controller does not respond to
the key or seat switch closes. master controller.
3 The reverse switch is closed before 55 Dash display cannot communicate with
the key or seat switch closes. master controller.
4 Park brake applied while the key 56 Mini-lever module or joystick cannot
switch is in the ON position. communicate with master controller.
5 Start switch fails to close. 57 Valve driver module cannot
communicate with master controller.
6 Accelerator depressed, no direction 61 Current to cooling fans is too high
selected. during operation.
7 Acceleration voltage too high when 62 Current to reverse relay is too high
the key switch is first moved to the during operation.
ON position.
8 Acceleration input voltage too low 63 Current to DC pump contactor coil is
when the key switch is first moved to too high during operation.
the ON position.
9 Both the forward and reverse 64 Current to power steering contactor coil
directional switches are closed at the is too high during operation.
same time.
10 Armrest is up. 65 Current to the line contactor coil is too
high during operation.
11 The acceleration start switch closed 66 Short circuit sensed on power output to
before the key and/or the seat switch. traction motor.
15
Table 5. List of Status Codes (Continued)
Status Code Description Status Code Description

12 Mini-levers or joystick out of neutral 67 Short circuit sensed on power outage
when the key switch is moved to the to pump motor.
ON.
13 Brake pressure is out of range. 68 Current to seat brake controller too high
during operation.
15 Battery voltage is too low or master 69 Current to the pump line contactor coil
controller is adjusted to the wrong is too high during operation.
voltage.
16 Battery voltage is too high or master 70 Current to brake light relay is too high
controller is adjusted to the wrong during operation.
battery voltage.
21 Error in mini-lever module or joystick 76 Capacitor voltage is too high.
input.
22 Coil current to a valve coil is out of 90 Traction motor temperature too high.
range, too low.
23 Coil current to a valve coil is out of 91 Pump motor temperature too high.
range, too high.
41 Traction motor controller overheated. 95 Lift pump motor brushes are worn.
42 Pump motor controller overheated. 99 Maintenance Alert and Speed Limit.
43 Traction motor temperature sensor
out of range.
44 Pump motor temperature sensor out
of range.
51 Capacitor volts are too low before
line contactor closes.
16
2200 YRM 1056 AC Motor Controllers Status Code Charts
AC Motor Controllers Status Code Charts

Status Code Description Memory Recall Circuit
No seat switch input. No Traction
1
Symptom
Lift truck does not move.
Hydraulic functions are disabled.
Possible Causes and Test Procedures

• Seat switch malfunction.
Check to see that the seat switch operates properly.
Replace a failed switch.
• Check wiring to the seat switch and from the seat switch
to the master controller

The forward switch is closed before the No Traction
2 key or seat switch closes.
Symptom
Lift truck does not operate.

• A directional switch is closed when the key switch is
turned to the ON position. This violates the Static Re-
turn to Off (SRO) Startup Procedure, move the direc-
tional lever to the neutral position, and then select a
direction.
• A directional switch is failed closed or out of adjustment.
17
AC Motor Controllers Status Code Charts 2200 YRM 1056

The reverse switch is closed before key No Traction
3 or seat switch closes.
Symptom
Lift truck does not operate.

• A directional switch is closed when the key switch is
turned to the ON position. This violates the Static Re-
turn to Off (SRO) Startup Procedure, move the direc-
tional lever to the neutral position, and then select a
direction.
• A directional switch is failed closed or out of adjustment.

Park brake applied while the key switch No Traction
4 is in the ON position.
Symptom

• Park brake is applied.
Truck will not operate with park brake applied. Re-
lease the park break.
• Park brake switch is out of adjustment or is shorted.
18

Start switch fails to close. No Traction
5
Symptom

• Malfunction of start switch circuit.
Check for open circuit or loose connections in wiring
from key switch to start switch and from P16 to start
switch.
• Malfunction of start switch.
Check start switch for correct operation and output.

Accelerator depressed with no direction selected. No Traction
6
Symptom

• Accelerator pedal is depressed before closing a direc-
tion switch.
Status code will disappear when directional switch is
closed or when accelerator pedal is released.
• Malfunction of directional switch.
Check forward or reverse switch to make sure there
is continuity when direction is selected.
• Open circuit between directional switch and battery
positive or between directional switch and P4 or P5.
Check all wires and connections shown in trou-
bleshooting diagram.
19

Accelerator input voltage too high when key No Traction
7 is first moved to ON position.
Symptom

• Accelerator unit has a malfunction or is out of adjust-
ment. Maximum accelerator wiper voltage should be
11.00 volts with the pedal fully up.
• Open circuit between accelerator unit and P7.

Accelerator input voltage too low when key No Traction
8 is first moved to the ON position.
Symptom

• Minimum accelerator wiper voltage should be 10.70
volts with the pedal fully up.
• Accelerator unit has malfunction or is out of adjustment.
20

Both the forward and reverse directional switches No Traction
9 are closed at the same time.
Symptom

• Forward or reverse directional switch is failed closed or
out of adjustment (adjusted to be held closed).
Replace or adjust directional switches to make sure
they open when directional switch is returned to neu-
tral.
• Short circuit between battery positive and P4 and/or P5.
Disconnect wires from P4 and P5 and check wire for
short circuit to positive side of directional switch.

Armrest is up No E-Hydraulics
10
Symptom

• Put the armrest in the down position and ensure that it
is latched properly.
• Armrest switch malfunction.
Replace a failed switch.
• Check wiring to the armrest switch from the mini-lever
module or joystick.
21

The accelerator start switch closed before No Traction
11 the key and/or the seat switch.
Symptom

• The accelerator pedal was depressed when the key
was turned to the ON position. This violates the Static
Return to Off (SRO) Startup Procedure. To correct this
action, release the accelerator pedal and resume nor-
mal operation.
• The accelerator pedal was depressed when the opera-
tor sat down. This violates the SRO Startup Procedure.
To correct this action, release the accelerator pedal and
resume normal operation.
• The accelerator start switch is out of adjustment or has
a short.
22

Mini-levers or joystick out of neutral when the No E-Hydraulics
12 key is moved to the ON position.
Symptom

• One (or more) hydraulic functions are commanded
while the key is turned to the ON position.
Status code will disappear when all hydraulic com-
mands are returned to neutral.
• Malfunction of joystick, if equipped.
Power-On truck.
Display the diagnostic menu on the dash display
panel.
•Is the joystick input = 128?
•Yes: Go to next step.
•NO: Replace joystick. See Electro-Hydraulic
Control Valve 2000 SRM 1224.
• Malfunction of mini-lever, if equipped.

Stroke each lever to full stroke and allow lever to
snap back to center.
Power-On truck.
Display the diagnostics menu on the dash display
panel.
•Is each mini-lever input = 128?
•YES: Go to next step
•NO: Replace the lever. See Electro-Hydraulic
Operate each lever to full stroke forward and slowly

release (1-2 seconds from full stroke). Read input
when fully released.
•Is each mini-lever input = 128?
•YES: Go to next step.
•NO: Replace lever. See Electro-Hydraulic Con-
trol Valve 2000 SRM 1224.
Operate each lever to full stroke back and slowly

release (1-2 seconds from full stroke). Read input
when fully released.
• Is each mini-lever input = 128?
• YES: Problem resolved.
• NO: Replace lever. See Electro-Hydraulic Con-
23

Brake Pressure is out of range No Traction
13
Symptom
Top speed reduced to half

• Failed sensor
Check wiring for damage. Replace sensor.

Battery voltage is too low or truck is adjusted No Traction
15 to the wrong battery voltage.
Symptom

• Discharged battery.
Check battery for correct open circuit voltage. Cor-
rect voltages are listed on right. Charge battery if
required.
• Battery is damaged.
Check each battery cell for correct voltage (greater
than 1.85 volts each cell). Replace or repair battery.
• Incorrect master controller adjustment.
Check the battery volts setting in the master con-
troller for the correct battery volts.
• Check the battery volts on the main power cables at the
motor controllers.
24

Battery voltage is too high or master controller No Traction
16 is adjusted to the wrong battery voltage.
Symptom

• Incorrect master controller adjustment.
Check the battery volts setting in the master con-
troller for the correct battery volts.
• Battery overcharged or incorrect battery used.
Check battery for correct open circuit voltage. Cor-
rect voltages are listed on right. If voltage is too high,
check battery charger for correct output voltage.

Error in the mini-lever module or joystick input. No E-Hydraulics
21
Symptom

• Malfunction of joystick, if equipped.
Power-On truck.
Display the diagnostics menu on the dash.
•Is the joystick input = 128?
•NO: Replace joystick. See Electro-Hydraulic
• Malfunction of mini-lever, if equipped.
Power-On truck.
Display the diagnostics menu on the dash display
panel.
•Is the mini-lever input = 128?
•NO: Replace lever. See Electro-Hydraulic Con-
• Check "No. of functions Setting" in the "E-Hyd Setup
Menu"
25

A valve coil current is out of range, too low. No E-Hydraulics
22
Symptom

• Wiring from the valve driver module to the valve coil is
open.
• Valve coil malfunction.
Check the resistance of the valve coil. The approxi-
mate coil resistance at room temperature should be
8 ohms.

A valve coil current is out of range, too high. No E-Hydraulics
23
Symptom

• Wiring from the valve driver module to the valve coil is
shorted.
• Valve coil malfunction.
Check the resistance of the valve coil. The approxi-
mate coil resistance at room temperature should be
8 ohms.
26

Traction motor controller overheated. Yes Traction
41
Symptom
Truck acceleration is reduced or truck may
stop completely.

• Excessive pushing or stalling of traction motor.
• Check operation of cooling fans.
See Fan Test.
• Check for proper application of thermal grease between
motor controller and heat sink.

Pump motor controller overheated. Yes Traction
42
Symptom
Truck acceleration and travel speed is reduced and
pump motor may stop completely.

• Excessive operation or stalling of the pump motor.
• Check operation of the cooling fans.
See Fan Test.
• Check for proper application of thermal grease between
motor controller and heat sink.
27

Traction motor temperature sensor out of range. No Traction
43
Symptom
Status code is displayed for 10 seconds after startup. Truck still operates, but traction
motor overtemperature protection is inoperative.

• Wiring from motor temperature sensor to the motor controller is open or has shorted.
• Motor temperature sensor is faulty.
Replace the motor, or operate without the temperature sensor.

Pump motor temperature sensor out of range. No Pump
44
Symptom
Status code is displayed for 10 seconds after startup. Truck still operates, but pump motor
overtemperature protection is inoperative.

• Wiring from motor temperature sensor to the motor controller is open or has shorted.
• Motor temperature sensor is faulty.
Replace the motor, or operate without the temperature sensor.

Capacitor volts are too low before line No Traction
51 contactor closes.
Symptom
Lift truck does not move and line contactor does not close.

• A Positive Temperature Coefficient (PTC) is discon-
nected or malfunctioning, preventing the capacitors to
charge when the battery is plugged in.
• An accessory or component other than the motor con-
trollers is connected to load side of line contactor. This
will cause the PTC to get hot and not charge the capac-
itors.
• Repeated charging/discharging the capacitors during
troubleshooting may cause a Status Code 51. If the
PTC is hot, allow it to cool.
• Status code will occur if the line contactor does not
close properly and truck operation is attempted.
• Status code will occur if battery voltage drops below
50% nominal voltage.
28

Traction or pump motor speed sensor error. No Traction
52
Symptom
Traction or pump motor operates very slowly and jerky.

• Disconnected or broken sensor wires between motor and motor controller.
• Malfunction of motor encoder bearing.

Traction controller does not respond to No Traction
53 master controller.
Symptom

• Malfunction of motor controller.
Check key switch input to motor controller.
See Controller Status Light Emitting Diodes (LEDs).
• CANbus communication between motor controller and master controller is not working.
Check for loose or broken wires.
• Open connection between motor controller pin 13 (ground) and pin 12 and/or pin 20. See the Electrical Dia-
grams manual for your lift truck model. Pins 12 and 20 are truck I.D. pins.
• A code may appear when the master controller does not detect the key turning OFF, but the pump controller does
detect the key turning OFF. This is caused when there is a voltage on the key switch circuit that is greater that 3
volts and less than 10 volts with the key turned OFF.

Pump controller does not respond to No Pump
Symptom
Hydraulic pump motor does not operate.

• Malfunction of motor controller.
Check key switch input to motor controller.
See Controller Status Light Emitting Diodes (LEDs).
• CANbus communication between motor controller and master controller is not working
• This status code may appear on trucks with contactor controlled DC pump motors. The master controller senses
the presence of a contactor by a voltage on pin 40. If there is no voltage on pin 40, the master controller assumes
an AC pump motor controller is present, but not able to communicate.
Check for voltage at the pump contactor coil.
Check wiring from pump contactor coil to master controller, pin 40.
• A code may appear when the master controller does not detect the key turning OFF, but the pump controller does
detect the key turning OFF. This is caused when there is a voltage on the key switch circuit that is greater that 3
volts and less than 10 volts with the key turned OFF.
29

Dash display cannot communicate with Yes Traction
Symptom
Varies due to problem.

• If truck operates and code is displayed on dash, the CANbus communication is not working between the dash
and the master controller. See the section Troubleshooting When Dash and/or Lift Truck is not Operational.
• If truck does not operate and code is displayed on dash, see the section Troubleshooting When Dash and/or Lift
Truck is not Operational.

Mini-lever module or joystick cannot communicate No E-Hydraulics
56 with the master controller.
Symptom

• Check input to the mini-lever module (or joystick).
Voltage should be in the range 9-16V.
• Check LED status of the valve driver module.
Green LED should be on.
• CANbus communication between mini-lever module and master controller is not working

Valve driver module cannot communicate No E-Hydraulics
57 with master controller.
Symptom

• Check LED status of the valve driver module.
Green LED should be on.
• CANbus communication between mini-lever module and master controller is not working
30

Current to cooling fans is too high during operation. No Traction
61
Symptom
Lift truck does not move. If fault occurred during truck
operation, status code will not display until the key
switch is cycled to OFF and then to ON again.

• A fan or wiring to fan may have a short.
• Trucks using a fan power supply may have a short in
the power supply.
• If the status code is displayed while fans or power sup-
ply are disconnected, fault is probably in the master
controller.

Current to reverse relay is too high No Traction
62 during operation.
Symptom

• Reverse relay coil or wiring may have a short.
Check the coil resistance with the wires discon-
nected. The approximate resistance is 576 ohms.
• If status code is displayed while relay coil wires are
disconnected, the fault is probably in master controller.
31

Current to DC pump contactor coil is too No Traction
63 high during operation.
Symptom

• DC pump contactor coil or wiring to coil may have a
short.
Check the coil resistance with wires disconnected.
Approximate coil resistance, at room temperature,
should be:
36/48 volt trucks 31 ohms
• If status code is displayed while contactor coil wires are

Current to power steering contactor coil is No Traction
64 too high during operation.
Symptom

• Power steering contactor coil or wiring to coil may have
a short.
should be:
32

Current to the line contactor coil is too No Traction
65 high during operation.
Symptom

• Line contactor coil or wire to coil has a short.
should be:

Short circuit sensed on power output No Traction
66 to traction motor.
Symptom

• Short circuit in motor or heavy power wires going to
motor.
• If status code is displayed with motor power wires dis-
connected, the short circuit is internal.
Replace motor controller.
33

Short circuit sensed on power output No Pump
67 to pump motor.
Symptom
Hydraulic pump motor does not operate.

• Short circuit in motor or heavy power wires going to
motor
• If status code is displayed with motor power wires dis-
connected, short circuit is internal.
Replace motor controller.
Status Code Description Memory Recall

No
Current to seat brake controller too high
Symptom
Lift truck does not move, and seat brake does not release.
If fault occurs during truck operation, status code does
not display until the key switch is turned to the OFF
position and then turned to the ON position.

• Seat brake controller or wire to controller has a short
• If status code is displayed with the wires disconnected,
the fault is probably in the master controller
34

Current to the pump line contactor coil is No Traction
69 too high during operation.
Symptom

• Pump line contactor coil or wire to coil has a short.
should be:

Current to brake light relay is too high No Traction
Symptom

• Brake light relay coil or wiring may have a short.
Check the coil resistance with the wires discon-
nected. The approximate resistance is 160 ohms.
• If status code is displayed while relay coil wires are

Capacitor voltage too high. No Traction
76
Symptom
Lift truck does not work.

• Regen setting too high.
Combination of a fully charged battery and a high regen setting may cause status code.
35

Traction motor temperature too high. Yes Traction
90
Symptom
Truck acceleration is reduced, or truck may stop completely.

• Excessive pushing or stalling of traction motor.
• Operation may continue at slower duty cycle.
Allow traction motor to cool to regain full performance.
• Comparing the motor temperature through the display panel with a known motor temperature, such as room
temperature, can check the motor temperature sensor.
• A shorted or open temperature sensor will generate a status code 43.

Pump motor temperature is too high. Yes Pump
91
Symptom
Truck acceleration and travel speed reduced. Pump motor may stop completely.

• Excessive operation or stalling of pump motor.
• Operation may continue at slower duty cycle.
Allow pump motor to cool off to regain full performance.
• Comparing the motor temperature through the display panel with a known motor temperature, such as room
temperature, can check the motor temperature sensor.
• A shorted or open temperature sensor will generate a status code 43.
36

DC lift pump motor brushes are worn. Yes Pump
95
Symptom
Status code warning only.

• Pump motor brushes are worn too short.
• Motor brush wear sensor wires to motor controller may
have a short to battery positive.

Maintenance Alert and Speed Limit. No Traction
99
Symptom
Status code is displayed and, after 20 hours, truck speed is reduced to 50% of normal top speed.

• Maintenance reminder indicating it is time to service truck. It was set by a technician through the dash display or
with a PC.
• The technician must perform desired maintenance and reset reminder to next hourmeter reading that mainte-
nance should occur.
37
TROUBLESHOOTING WHEN DASH • If status code 55 is displayed, proceed to

AND/OR LIFT TRUCK IS NOT Step 2.
OPERATIONAL • If status code 55 is not displayed, check for
battery power between the display connec-
Typical Symptoms tor pins 1 and 2. Power should be detected
between the display connector pins 1 and 2,
There are four typical symptoms that may occur when regardless of the key position. If power is de-
the dash and/or lift truck is not operational: tected between the display connector pins 1
and 2, proceed to Step 3.
• The truck runs but the dash display is not operational,
or only displays status code 55. An additional delay 2. Check the CANbus as follows:
between the key ON and the line contactor closing
may occur. a. Status code 55 indicates that the display cannot
• The lift truck does not run and the dash is not opera- communicate over the CANbus.
tional, or only displays status code 55. • Connect a PC with ETACC installed, and pro-
• The hydraulics operate normally, the traction does not ceed to “Report – Devices” to determine if the
operate correctly, and the dash is operational but no software article number in the dash software
status codes are present. and master controller can be read.
• The traction operates normally, the hydraulics do not • If ETACC can read both the dash software
operate correctly, and the dash is operational but no article number and master controller article
status codes are present. number, proceed to Step 3.
• If ETACC can only read the article number in
Truck Runs but Dash Display is not the master controller, and not the article num-
Operational, or Only Displays Status Code ber in the dash software, check the wiring and
55; an Additional Delay Between Key ON connector between the dash and the diag-
and Line Contactor Closing May Occur nostic connector. If the wiring and connector
are good, proceed to Step 3.
Possible reasons include: • If ETACC can only read the article number in
• There is no power to the display. the dash software, and not the article number
• There is no CANbus connection. in the master controller, check the wiring and
• A software fault has occurred in the display software. connector between the diagnostic connector
• An internal hardware fault has occurred in the display. and the master controller.
Troubleshoot as follows: 3. Check the software as follows:
• Check the power to the display. See Step 1.
• Check the CANbus. See Step 2. a. On lift trucks equipped with premium displays,
• Check the software. See Step 3. use ETACC to download a standard display lan-
• Check the hardware. See Step 4. guage. If the software appears to download the
standard display language, but the display does
1. Check the power to the display as follows: not function, proceed to Step 4.
a. When the key switch is turned ON, does the b. On lift trucks equipped with standard displays,
display back light illuminate? proceed to Step 4.
• If YES, the display has power. Proceed to 4. Check the hardware as follows:
Step 3.
• If NO, turn the key OFF and proceed to a. Replace the display with a new or known good
Step b. display. Does the display function now?
b. With the key switch OFF, press the "*" key • If YES, the hardware was causing the fault.
twice. An external light source may be needed • If NO, recheck by performing Step 1 through
to read the display as the display back light may Step 4.
not illuminate.
38
Truck Does Not Run and Dash is Not ohms. This resistance is the result of the 120
Operational or Only Displays Status Code ohm termination resistors at the traction control
55 and in the dash display. If the resistance is not
within specification, check the traction control
Possible reasons include: termination resistor and dash display termina-
• The display is bad and the software was not given tion resistor.
enough time to boot up.
• The key switch has no power. b. If the dash and traction control are determined
• There is no CANbus signal to or from the controllers not to be the problem, check the harness by
due to a faulty control. disconnecting all controls and checking the re-
• There is no CANbus signal to or from the controllers sistance between pins A and B, A and C, and B
due to a faulty harness. and C. Also check the resistance between the
truck frame and pins A, B, and C. If the resis-
Troubleshoot as follows: tance is not greater than 100K ohms, correct
• Make sure that the software has had time to boot up the fault in the harness.
without the dash, and make sure that the truck is not
running. See Step 1. c. If the resistance is greater than 100K ohms,
• Check for power from the key switch. See Step 2. connect the termination resistor at the traction
• Check to see that the CANbus is physically intact. control by connecting the 23 pin connector. On
See Step 3. early model lift trucks, it may be necessary
• Check the CANbus signal to and from the controllers. to connect the external termination resistor lo-
See Step 4. cated next to the 23 pin connector and check
that the resistance between A and B is 110 to
1. Make sure that the software has had time to boot 130 ohms.
up without the dash, and make sure that the truck
is not running by turning the key ON and waiting 30 d. If the resistance in Step c is correct, connect
seconds with the operator in the seat and the park the dash display and check that the resistance
brake released. If the truck runs, see the section between A and B is 55 to 65 ohms.
Truck Runs but Dash Display is not Operational, or e. Connect each additional control and check that
Only Displays Status Code 55; an Additional Delay the resistance between A and B remains be-
Between Key ON and Line Contactor Closing May tween 55 to 65 ohms.
Occur.
4. Check the CANbus signal to and from the con-
2. Check for power from the key switch by turning the trollers by using ETACC to determine if the software
key switch ON and checking the LED on the master article number can be read for all of the devices.
controller.
a. If all of the devices are being read, use ETACC
a. If the LED blinks two times per second, check to determine if all of the switches and sensor
the key switch circuit. outputs are correct.
b. If the LED blinks once every two seconds, the b. If no devices are being read, disconnect the de-
key switch has power. Proceed to Step 4. vices one at a time to determine if one particu-
c. If the LED does not illuminate, check the battery lar device is disabling the CANbus.
supply circuit to the master controller. If the NOTE: The key switch must be turned ON to read the
supply is good, replace the master controller. traction and pump control.
3. Check to see that the CANbus is physically intact c. If only some devices are being read, check the
by measuring the following resistances at the diag- power to the devices that are not being read.
nostic connector: If available, reload the software to the devices
a. With the battery disconnected and the control that have power and are not being read. Re-
capacitors discharged, the resistance between place the devices as necessary.
pins A and B should be between 55 and 65
39
AC Transistor Motor Controller Replacement 2200 YRM 1056
Hydraulics Operate Normally, Traction • ERP20-32ALF (ERP040-065DH) [E216] Only - It the

Does Not Operate Correctly, and Dash lift truck does not have a light harness, locate the main
is Operational but no Status Codes are accessory harness connector and install a 20,000 to
25,000 ohm 1/2 watt or larger resistor between pins 2
Present (wire 10R) and 5 (wire 84C), and make sure that there
Possible reasons include: is no voltage when the brake pedal is released.
• The master controller is not detecting input from the
accelerator sensor. Traction Operates Normally, Hydraulics
• ERP20-32ALF (ERP040-065DH) [E216] Only - A do Not Operate Correctly, and Dash is
brake pressure sensor is faulty. Operational but no Status Codes are
Present
Troubleshoot as follows:
• Using the dash display or ETACC, check the throt- Possible reasons include:
tle potentiometer voltage as the accelerator is de- • There is no switch input from the hand levers.
pressed. • The master controller has incorrectly defined the lift
• ERP20-32ALF (ERP040-065DH) [E216] Only - If the truck due to a corrupt register in the traction control.
lift truck is equipped with brake lights, check that the
brake lights are OFF when the brake pedal is re- Troubleshoot as follows:
leased. If the brake lights remain ON after the brake • Using the dash display or ETACC, check that the
pedal is released, the master controller will not com- switch inputs as the hydraulic levers are actuated.
mand the traction controller to move. • If the lift truck has contactor hydraulics, connect the
• ERP20-32ALF (ERP040-065DH) [E216] Only - If pump AC controller connector to the traction control.
the lift truck is not equipped with brake lights but Turn the key switch ON then OFF, then reconnect
is equipped with a light wire harness, install relay the traction controller connector. Update the master
580035738 and suppression module 580034404, if controller software when the problem has been cor-
required. Use an ohmmeter across the NO to COM rected.
contacts to make sure that the relay releases when
the brake pedal is released.
AC Transistor Motor Controller Replacement

GENERAL The assembly of the AC traction motor controller with
optional AC pump motor controller is shown in Figure 8,
NOTE: In Figure 8 through Figure 12, the terms Gen Figure 9, and Figure 10. The assembly of the AC Trac-
IV and Gen V refer to Generation IV and Generation tion Motor controller with contactor for DC Lift Pump
V respectively. Controller and contactor panels labeled Motor is shown in Figure 11 and Figure 12. There are
Gen IV are used in early model lift trucks and controller NO internal parts of these motor controllers that can be
and contactor panels labeled Gen V are used in later repaired. Each of these motor controllers must be re-
model lift trucks. placed if an internal malfunction occurs.
40
2200 YRM 1056 AC Transistor Motor Controller Replacement
1. FUSE 1 (15A) 7. AC TRACTION MOTOR CONTROLLER

2. FUSE 2 (15A) (SLOW) 8. LINE CONTACTOR
3. FUSE 3 (15A) 9. AC PUMP MOTOR CONTROLLER
4. FUSE 4 (5A) 10. POSITIVE TEMPERATURE COEFFICIENT
5. POWER STEERING CONTACTOR RESISTOR (PTC)
6. FUSE 4 (POWER STEERING) (40A) 11. LED INDICATOR
Figure 8. AC Traction and AC Pump Motor Controllers (Gen V) (36v/48v or 72v/80v) for ERP20-30ALF
(ERP040-060DH) (D216) and ERC20-32AGF (ERC040-065GH) (A908), Later Models Only and for
ERC/P16-20AAF (ERC030-040AH) (B814) Lift Truck Models
41

3. FUSE 3 (5A) 9. LED INDICATOR
4. POWER STEERING CONTACTOR 10. POSITIVE TEMPERATURE COEFFICIENT
5. FUSE 4 (POWER STEERING) (40A) RESISTOR (PTC)
6. LINE CONTACTOR
Figure 9. AC Traction and AC Pump Motor Controllers (72v/80v) (Gen IV) for Early Model ERP20-30ALF
(ERP040-060DH) (D216) and ERC20-32AGF (ERC040-065GH) (A908) Lift Trucks
42

2. FUSE 2 (15A) (SLOW) RESISTOR (PTC)
5. POWER STEERING CONTACTOR 10. POWER STEERING FUSE (40A)
6. LINE TRACTION CONTACTOR 11. LED INDICATOR
12. LINE PUMP CONTACTOR
Figure 10. AC Traction and AC Pump Motor Controllers for ERC35-55HG (ERC70-120HH) (B839/C839)
Lift Truck Models
43

2. FUSE 2 (15A) (SLOW) RESISTOR (PTC)
4. FUSE 4 (5A) 10. FUSE (PUMP) (325A)
5. POWER STEERING CONTACTOR 11. CONTACTOR FOR DC PUMP MOTOR
6. FUSE 4 (POWER STEERING) (40A) 12. LED INDICATOR
7. LINE CONTACTOR
Figure 11. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (Gen V) (36v/48v
or 72v/80v) for ERP20-30ALF (ERP040-060DH) (D216) and ERC20-32AGF (ERC040-065GH) (A908), Later
Models Only and for ERC/P16-20AAF (ERC030-040AH) (B814) Lift Truck Models
44

2. FUSE 5 (15A) RESISTOR (PTC)
4. POWER STEERING CONTACTOR 9. FUSE 2 (PUMP) (325A)
5. FUSE 4 (POWER STEERING) (40A) 10. CONTACTOR FOR DC PUMP MOTOR
6. LINE CONTACTOR 11. LED INDICATOR
Figure 12. AC Traction Motor Controller and Contactor Control for DC Lift Pump Motor (72v/80v) (Gen IV)
for Early Model ERP20-30ALF (ERP040-060DH) (D216) and ERC20-32AGF (ERC040-065GH) (A908)
45
GENERAL MAINTENANCE of silicone (heat transfer) grease, Yale P/N 504223239,

INSTRUCTIONS between the controller and the heat sink to not allow
air gaps between the two.
The motor controllers, like other electronic devices,
have temperature limits. These devices can be dam- Controller wire plugs and other exposed transistor con-
aged if they get too hot. Normal maintenance will help troller parts should be kept free of dirt and paint that
prevent high-temperature conditions. Always make might change the effective resistance between points.
sure motor controllers are installed using heat sink
compound and that all heat sink surfaces are clean. CAUTION
DO NOT block cooling airflow.
DO NOT operate the traction system at high speed
or rapidly change direction of operation with the
Special Precautions
wheels raised. Motor controller damage can occur.
WARNING DO NOT subject the controller to any high voltage (hipot

To avoid injury and prevent electrical shock, per- or megger) testing.
form the following steps before troubleshooting, Use a lead acid battery with the voltage and ampere
adjustments, or repair: hour rating specified for the lift truck. Follow normal bat-
• Turn the key switch to the OFF position and dis- tery maintenance procedures, recharging at 80 percent
connect the battery connector. discharge, with monthly equalizing charges.
• Discharge the capacitors in the controllers by
pushing and holding the horn button down until Parts of these assemblies not covered in this manual
the horn stops making a sound. cannot be repaired and must be replaced if they mal-
function. The contactors are serviceable.
CAUTION
To help prevent controller damage: WARNING
• ALWAYS disconnect the battery when servicing Some checks in this section must be done with the
the controllers. battery connected and power applied to the con-
• ALWAYS discharge the capacitors before per- troller. When making these checks, make sure the
forming any service. drive wheels are raised from the floor. See proce-
• NEVER make a short circuit at any motor con- dures given in the Periodic Maintenance Manual or
troller terminal to battery (+), battery ( ), or the the Operating Manual for your lift truck.
frame.
• Remove the motor controllers before performing Make sure you disconnect the battery and sepa-
any authorized welding procedures. rate the connector before you remove any power
cables from the power terminals of the motor con-
Never add any electrical component to the lift truck troller. The capacitor stores electrical energy and
without approval from your dealer for your lift truck. can cause injury, if a person discharges a capacitor,
Other electrical components can prevent operation to parts of the body. AFTER the battery is discon-
and/or damage the motor controller. nected and the key switch is in the OFF position,
make sure you also discharge the capacitors.
NEVER USE STEAM TO CLEAN ELECTRONIC COM-
PONENTS. Discharge the capacitors in the controllers by push-
ing and holding the horn button down until the horn
In dusty areas, blow low-pressure air over the controller stops making a sound.
to remove dust. In oily or greasy areas, a mild solution
of detergent or denatured alcohol can be used to wash NOTE: The bolts and screws connected to the elec-
off the controller; and then, low-pressure air should be tronic components are normally metric sizes.
used to completely dry the controller.
Make sure that you use the correct fastener for the part
For the controller to be most effective, it must be that has been disassembled or removed.
mounted against the finned aluminum heat sink. Dur-
ing installation of the controller, apply a sufficient layer
46
FUSES
The fuses are found on the contactor panels. See Fig-
ure 8, Figure 9, Figure 10, Figure 11, and Figure 12.
The condition of the fuses can normally be checked by
looking at them. Some fuses do not change in appear-
ance and must be checked with an ohmmeter.
FAN TEST
To determine if the fans are operating correctly, go to
the Access to Service Functions section of this YRM.
Using the procedures in that section, go to Diagnostics
Menu and select No Run Diagnostics. From there, go
to Fan On, which is the last menu item. As soon as Fan
On is selected, the fans should start running. 1. CONTACTOR 4. MOVABLE
2. POWER CONTACTS
On 36/48 volt trucks, the fans operate at battery volt- TERMINALS 5. SPRING
age. If battery voltage is present at the fan terminal strip 3. FIXED CONTACTS 6. PLUNGER
and the fan(s) doesn’t run, replace the fan(s). If battery
voltage is not present at the fan terminal strip, look for Figure 13. Pump Motor Contactor
problems in the positive circuit from the key switch or
the negative circuit to pin 15 on the master controller. Repair
On 72/80 volt trucks, the fans operate with a fan power Tag, identify, and disconnect the wires and cables from
supply. If the power supply voltage (48 volts) is present the contactor assembly. Remove the mounting screws
and the fan(s) doesn’t run, then replace the fan(s). If and remove the contactor assembly. See Figure 14.
there is battery voltage to the fan power supply and Contactor Contacts. The contacts in a contactor are
there is no output voltage, then replace the fan power made of special silver alloy. The contacts will look
supply. If battery voltage is not present at the power black and rough from normal operation. This condition
supply, look for problems in the positive circuit from the does not cause problems with the operation of the lift
key switch or the negative circuit to pin 15 on the master truck. Cleaning is not necessary. DO NOT USE A
controller. FILE ON THE CONTACTS. DO NOT LUBRICATE THE
CONTACTS.
CONTACTORS
There can be three contactors on these lift trucks. All CAUTION
lift trucks have a power steering contactor and a line ALWAYS replace all of the contacts in a contactor
contactor. See Figure 13 and Figure 14. Lift truck mod- at the same time. Replace the contacts when the
els ERC35-55HG (ERC70-120HH) (B839/C839) have thickness of any area of a contact is less than 30
a separate line contactor for the pump motor controller. percent of the thickness of a new contact or if there
Lift trucks that do not have a pump motor controller also is any transfer of contact material.
have a contactor to energize the lift pump motor. See
Figure 13. Coil. Check the coil with an ohmmeter for an open cir-
cuit or a short circuit. Coil resistance is very low. Ap-
proximate coil resistance, at room temperature, can be
determined by looking at Status Codes 63, 64, 65, and
69. Replace the coil if it is damaged. Make sure the coil
wires are connected again to the correct terminals.
47
Legend for Figure 14

1. TOP COVER
2. FIXED CONTACT SETS
3. MOVABLE CONTACTS
4. SCREW
5. RETURN SPRING
6. INSULATOR
7. COIL ASSEMBLY
NOTE: Some wire numbers found in Table 6, Table 7,

and Table 8 may or may not be followed by a letter,
depending on the lift truck model.
Figure 14. Replacement Parts of Power Steering

Contactor
Table 6. 42-Pin Connections/Descriptions for Master Controller
Pin No. Wire Number Function

1
2 7 SEAT SWITCH
3 10 KEY SWITCH
4 8 REVERSE SWITCH
5 6 FORWARD SWITCH
6 32 +12 V
7 13 ANALOG GROUND
8 72 CANbus GROUND
9 51 PUMP HIGH SPEED
48
Table 6. 42-Pin Connections/Descriptions for Master Controller (Continued)
Pin No. Wire Number Function

10 84D BRAKE LIGHT RELAY COIL
11* 24A PUMP LINE CONTACTOR
12 6 FORWARD SIGNAL
13 24 LINE CONTACTOR
14 3 BATTERY POSITIVE
15 65 FAN
16 15 ACC START SWITCH
17 107 PUMP MOTOR BRUSH WEAR
18 108 PUMP MOTOR BRUSH WEAR
19 44 PARK BRAKE
20
21
22 74 CANbus HIGH
23 73 CANbus LOW
24
25
26
27
28 13 BATTERY NEGATIVE
29 46 SEAT BRAKE
30
31 45 BRAKE FLUID LEVEL
32 100 DC PUMP MOTOR TEMPERATURE
33 53 PUMP LOW SPEED
34
35
36 29 ACCELERATOR PEDAL POSITION
37 359 BRAKE FLUID PRESSURE
38 52 PUMP MEDIUM SPEED
39
40 54 DC PUMP CONTACTOR
41 8 REVERSE SIGNAL
42 60 POWER STEERING CONTACTOR
*ERC35-55HG (ERC70-120HH) (B839/C839) LIFT TRUCK MODELS ONLY
49
Table 7. Pin Connections/Descriptions for 72/80 (Gen IV) Volt Motor Controllers
Wire Number
Pin No. Traction Pump Function
1 10 10 KEY SWITCH
2
3 33 33 SENSOR VOLTAGE SUPPLY
4 13 13 BATTERY NEGATIVE
5 104 110 SENSOR BEARING SIGNAL
7 102 100 MOTOR TEMPERATURE
8
9 CONTROLLER ID PIN
10 74 74 CANbus HIGH
11 73 73 CANbus LOW
12 74 CANbus TERMINATION RESISTANCE
13 72 72 CANbus GROUND
Table 8. Pin Connections/Descriptions for 36/48 and 72v/80v (Gen V) Volt Motor Controllers
Wire Number
Pin No. Traction Pump Function
1 10 10 KEY SWITCH
2
3 33 33 SENSOR VOLTAGE SUPPLY
4 13 13 BATTERY NEGATIVE
7 72 72 CANbus GROUND
12 CONTROLLER ID PIN
13 13 CONTROLLER ID PIN GROUND
14 73 73 CANbus LOW
15 73 CANbus LOW
16 102 100 MOTOR TEMPERATURE
17 13 13 MOTOR TEMPERATURE GROUND
20 CONTROLLER ID PIN
22 74 74 CANbus HIGH
23 74 CANbus HIGH
50
THERMAL SENSORS
CAUTION
The thermal sensors for AC motors are embedded in DO NOT remove the small screws that fasten the
the motor windings and are continuously monitored by cover of the motor controller.
the motor controllers. They are part of the motor and
cannot be replaced or repaired. Make sure there is no dirt between the plate of the
motor controller and the mount surface of the lift
MOTOR CONTROLLER, REPLACE truck heat sink.
Make sure the battery is disconnected and the capacitor 3. Put an even coat of the silicone compound (Yale
is discharged. Discharge the capacitor by holding down P/N 504223239) or equivalent on the plate of the
the horn button until the horn stops making a sound. motor controller. Make sure there are no air spaces
Put a DO NOT CONNECT tag on the battery connec- between the plate and mount surface of the lift truck
tor. Replace the motor controller as described in the heat sink. The plate of the motor controller must
following procedure. make full contact with the heat sink. Install the
mount screws that fasten the motor controller to the
1. Make an identification for correct connection of the heat sink.
power cables on the power terminals of the motor
controller. Disconnect the power cables and the 4. Install the power cables at the power terminals of
connector plug for the control wires. the motor controller as identified during removal.
Install the connector plug for the control wires on
2. Remove the eight (traction) or six (pump) mounting the connector of the motor controller.
screws that fasten the plate of the motor controller
to the lift truck heat sink. Carefully remove the mo- 5. Remove the DO NOT CONNECT tag from battery
tor controller. connector and reconnect the battery.
51
Display Panel 2200 YRM 1056
Display Panel
GENERAL • Allows access to the User Check List function.
There are two dash display options, Standard and Pre- Standard Display Panel
mium.Both displays look identical. See Figure 15.
• Allows preassigned service passwords to control ac-
Premium Display Panel cess to the service functions available through the
display.
• Allows preassigned user passwords to control driver • Provides the same comprehensive set of service
access to the vehicle. functions using the mode keys and LCD as the Pre-
• Provides four driving modes that are accessed mium Display.
through the keypad.
• Allows preassigned service passwords to control ac- Standard and Premium display panels are interchange-
cess to the service functions available through the able on the vehicle. Therefore, the display system can
display. be easily upgraded or downgraded by changing the dis-
• Provides a comprehensive set of service functions, play panel.
which are accessed through the mode keys and liquid
crystal display (LCD).
Figure 15. Standard and Premium Display Panel
52
2200 YRM 1056 Display Functions and Features
Display Functions and Features

KEY-ON INITIALIZATION The indicator lights turn off sequentially, except for the
seat belt light, which will remain lighted for approxi-
Upon turning the key to the ON position, the display se- mately 10 seconds.
quentially lights the indicators, from left to right, located
along the top of the display. See Figure 16.
NOTE: The seat belt light will stay on whether the seat
belt is fastened or not fastened.
1. HOURMETER INDICATOR 8. LCD SCREEN

2. WRENCH INDICATOR 9. STAR PUSH BUTTON
3. BATTERY INDICATOR 10. PUSH BUTTON #1
4. BATTERY DISCHARGE INDICATOR (BDI) 11. PUSH BUTTON #2
5. BRAKE FLUID LEVEL 12. PUSH BUTTON #3
6. PARKING BRAKE 13. PUSH BUTTON #4
7. FASTEN SEAT BELT 14. PUSH BUTTON #5
Figure 16. Dash Display
53
Display Functions and Features 2200 YRM 1056
STANDARD DISPLAY Controls Program (ETACC) 2200 YRM 1058, Enable/

Disable Password and Lift Truck Inspection Functions.
Following the sequence given above, and as the seat
belt light becomes illuminated, the LCD displays the BDI
as a bar. See Figure 17. As the battery is discharged,
the bar becomes shorter.
Figure 19. Password Prompt Screen
If the password is not entered within 5 to 8 seconds,

a reminder screen is shown on the LCD display. See
Figure 20.
Figure 17. Battery Discharge Indicator
When the key is turned to the OFF position, the Hour-

glass indicator becomes illuminated, and the following
hourmeter information is flashed on the LCD screen:
Traction Hours for 3-4 seconds, followed by Pump
Hours for 3-4 seconds, after which the display turns off
and appears black. See Figure 18.
Figure 20. Password Reminder Screen
Until a password is entered that matches a password

stored in the vehicle master controller, the lift and trac-
tion systems are inoperative. Passwords may be en-
tered in the master controller using either the dash dis-
play (see Dash Display Service Menu Navigation) or by
using the ETACC PC service software. See the sec-
tion Troubleshooting and Adjustments Using the AC
Controls Program (ETACC) 2200 YRM 1058.
A few seconds after the correct password has been en-

tered, the BDI and performance mode are displayed
and the vehicle can be operated. See Figure 21.
Figure 18. Traction/Pump Hours
PREMIUM DISPLAY
Following the sequence given above, and as the seat
belt light becomes illuminated, the LCD displays the
prompt for the operator to enter a password if this func-
tion has been enabled. See Figure 19. If the pass-
word function is disabled, the display will bypass the
password prompt. To enable the password function,
see Troubleshooting and Adjustments Using the AC Figure 21. Display Screen (Premium Display)
54
LIFT TRUCK INSPECTION FUNCTION The display will prompt the service technician for a five-
digit password. See Figure 23. The default setting for
If this function is turned on, the operator is prompted to the password is 55555. When a correct password is
answer a checklist of questions. The operator indicates entered, the Service Features menu is displayed as fol-
a 1 for pass or a 4 for fail. If the operator indicates lows:
the vehicle passes the inspection, the display will show • Setup Menu
the previous information and the operator can drive the • Password Menu (Operator passwords are only avail-
vehicle. If the operator indicates that the vehicle fails the able with Premium Display)
inspection, Service Required will appear on the display • Diagnostic Menu
screen, and the vehicle will only operate in Mode 1 until • View Hourmeter
the required action is taken. See Figure 22.
Figure 23. Password Request

Figure 22. Inspection Failure Screen
The technician can scroll through the menu using the
The inspection feature can be enabled with or without
up [1] or down [2] arrows and select the desired function
the password function enabled, depending upon the
by pressing the [4] button. Each menu selection has a
user’s preference. The inspection checklist feature, as
list of submenu functions. The submenus are viewed
with the password feature, may be set up using either
and items selected by scrolling through the menu in the
the dash display or using a PC. For the PC instructions,
same manner as described above.
go to the section Troubleshooting and Adjustments
Using the AC Controls Program (ETACC) 2200 YRM To exit a selected function and return to the previous
1058. The checklist must be enabled or disabled by a function, press the [3] button. Pressing the [3] button
service technician. multiple times will return the technician to the operator’s
driving mode.
The following is the list of checks:
• Check for leaks.
SERVICE FUNCTIONS
• Check service brake.
• Check park brake. The following submenu functions are accessible from
• Check horn, lights, and reverse alarm. the Main Menu of Service Functions, described above.
• Check gauges and warning lights. This includes the following three vehicle setup values
• Check tire condition and pressure. and 16 control function settings. The 16 control function
• Check hydraulic oil level. settings are discussed further in Function Descriptions.
• Setup Menu
ACCESS TO SERVICE FUNCTIONS Serial Number
Set Traction Hours
All service functions are accessible from either Stan-
Set Pump Hours
dard or Premium displays. The following functions are
Control Function Settings
the same with either display version, except as noted in
1. Battery voltage
the following sections.
2. Extended Shift
Once the vehicle is turned ON with the key switch and 3. Acceleration 1
the initialization process has been completed, a service 4. Acceleration 2
technician can gain access to the service functions by 5. Top speed limit
pressing the star button ( ) twice. 6. Regen braking
7. Auto deceleration
NOTE: It is suggested that the factory set password, 8. BDI adjustment
55555, be changed prior to the lift truck being placed 9. Lift interrupt
into service. 10. PS time delay
55
11. Service reminder The following submenu functions are accessible from
12. Custom the Main Menu of Service Functions, described above.
13. Pump speed 1 This includes the following three vehicle setup values
14. Pump speed 2 and 16 control function settings. The 16 control function
15. Pump speed 3 settings are discussed further in Function Descriptions.
16. Pump acceleration • Setup Menu
• Password Menu Serial Number
Enter Password Set Traction Hours
Truck Inspection Set Pump Hours
Add Password Control Function Settings
Delete Password 1. Battery voltage
Edit Password 2. Extended Shift
3. Acceleration 1
NOTE: All indications in the diagnostic menu are 4. Acceleration 2
shown as On, Off, or a value (i.e., Throttle Pot Volt). 5. Top speed limit
On is indicated by a 1. Off is indicated by a 0. 6. Regen braking
7. Auto deceleration
• Diagnostic Menu
8. BDI adjustment
No Run Diagnostics
9. Lift interrupt
Direction switch
10. PS time delay
Accelerator start
11. Service reminder
Throttle pot volt
12. Custom
Seat switch
13. PUMP SPEED 1 (NOT USED WITH E-HYD)
Park brake
Pump switch #1
Pump switch #2
16. Pump acceleration
Pump switch #3
• E-HYD SETUP
Steering brush #1
LIFT SPEED
Steering brush #2
Setting 0 to 100: This function determines the
DC pump brush #1
top speed of the pump motor when lift is used
DC pump brush #2
by the operator. Factory default is 100
DC pump motor temp
TILT SPEED
Fan on
Setting 0 to 25: This function determines the top
Run Diagnostics
speed of the pump motor when tilt is used by the
Traction motor speed
operator. Factory default is 25.
Traction motor amps
AUX 1 SPEED
Traction motor temp
Setting 0 to 30 (standard flow) or 0 to 50 (high
AC pump motor speed
flow option), see Figure 25 , Figure 26, Fig-
AC pump motor amps
ure 27. This function determines the top speed
AC pump motor temp
of the pump motor when 1 is used by the oper-
• View Hourmeter
ator. Factory default is 25.
Traction Hourmeter
AUX 2 SPEED
Pump Hourmeter
Setting 0 to 30 (standard flow) or 0 to 50 (high
Secure Hourmeter
flow option), see Figure 25 , Figure 26, Fig-
ure 27. This function determines the top speed
SERVICE FUNCTIONS
of the pump motor when auxiliary 2 is used by
NOTE: The following service functions apply only to the operator. Factory default is 25.
ERP20-32ALF (ERP040-065DH) (E216), ERC/P16- AUX 3 SPEED
20AAF (ERC030-040AH) (C814), and ERC35-55HG Setting 0 to 30 (standard flow) or 0 to 50 (high
(ERC070-120HH) (C839). In addition these functions flow option), see Figure 25 , Figure 26, Fig-
also apply to ERC20-32AGF (ERC040-065GH) (A908) ure 27. This function determines the top speed
lift trucks produced after January 1, 2006. of the pump motor when auxiliary 3 is used by
the operator. Factory default is 25.
56
NO OF FUNCTIONS EDIT PASSWORD

Setting 3 or 4: For hydraulic valves with a single • NO RUN DIAGNOSTICS
auxiliary function, the number of auxiliary func- DIRECTION SWITCH
tions is set to 3. For hydraulic valves with double ACCELERATOR LOCK
auxiliary functions, the number of auxiliary func- THROTTLE POT VOLT
tions is set to 4. SEAT SWITCH
CLAMP INSTALLED? PARK BRAKE
Setting Yes or No: If a clamp attachment is in- PUMP SWITCH #1
stalled, then the setting is yes. If the number of PUMP SWITCH #2
functions is 3, then the clamp is assumed to be PUMP SWITCH #3
aux 1 position. If the number of functions is 4, DC PUMP BRUSH #1
then the clamp is assumed to be aux 2. DC PUMP BRUSH #2
HI FLOW AUX INSTLD? DC PUMP MOTOR
Setting Yes or No: If the E-hydraulic valve has FAN ON
the optional High Flow Auxiliary block installed, • RUN DIAGNOSTICS
then set this to Yes. If it is a standard flow auxil- TRACTION MOTOR SPEED
iary block, then the setting is No. See Figure 25 TRACTION MOTOR AMPS
and Figure 26. TRACTION MOTOR TEMP
• E-HYD CALIBRATION TRACTION CNTRL TEMP
CALIBRATE LIFT AC PUMP MOTOR SPEED
CALIBRATE TILT FW AC PUMP MOTOR AMPS
CALIBRATE TILE BK AC PUMP MOTOR TEMP
CALIBRATE AUX1 DIR A AC PUMP CNTRL TEMP
CALIBRATE AUX1 DIR B • E-HYD DIAGNOSTICS
CALIBRATE AUX2 DIR A LIFT/LOWER INPUT
CALIBRATE AUX2 DIR B The four inputs are displayed on a scale from 0
Calibration procedure is as follows: to 255. The value ranges from 0 when the lever
1. The operator must be on the seat, and the is moved to the full back position to 255 when
armrest down and latched in order to calibrate the lever is moved to the full forward position.
the valve. The value 128 must be displayed when the lever
2. Press the or keys to select the function for is in the neutral position.
which calibration is desired. Press the key TILT INPUT
to start calibration of that function. AUX1 INPUT
3. The master controller will run the pump at a AUX2 INPUT
slow speed and will command cracking current CLAMP INTERLOCK
to that function. Use the or keys to in- When the clamp interlock switch on the mini-
crease or decrease the cracking current until lever module is pressed, 1 will be displayed on
there is creep in the function. A number from the Dash Display.
0 to 15 will be displayed on the Dash Display DUAL FUNCTION SW
which corresponds to a cracking current off set If the truck is equipped with a third auxiliary func-
value. objective is to find the value of cracking tion then the dual function switch will indicate
current that produces the slowest creep speed. whether it is pressed (1) or released (0).
Press the key to save. LIFT COIL CURRENT
4. Once the calibration is saved, the pump will The coil currents, as measured by the Valve
stop and the Dash Display will return to the Driver, is displayed in mA/10. The maximum
calibration menu. Repeat the above procedure value 255 corresponds with 2550 mA (or 2.55
to calibrate the next function. amps).
5. No calibration is required for the lowering func- TILT COIL CURRENT
tion. AUX1 COIL CURRENT
• PASSWORD MENU AUX2 COIL CURRENT
ENTER PASSWORD • VIEW HOURMETER
TRUCK INSPECTION TRACTION HOURMETER
ADD PASSWORD PUMP HOURMETER
DELETE PASSWORD SECURE HOURMETER
57
PERFORMANCE MODES • Flooded cell, standard amp-hour batteries

• Flooded cell, high amp-hour capacity batteries
NOTE: Performance modes are not available on the • Valve regulated (absorbed glass mat) maintenance-
Standard Dash display, and the factory configuration is free batteries (VRLA)
equivalent to Mode 4.
When equipped with the Premium Dash display, the fol-

lowing four operator-selectable performance modes are
available. These modes are preconfigured from the fac-
tory as described below. Mode 4 provides the highest
performance and Modes 1-3 are percentages of Mode
4. A service technician, using the dash display or con-
necting with the PC software, can revise the control set-
tings and configure the top speed and acceleration of
the vehicle. The relationship between Modes 1 through
4 remains constant and cannot be altered.
With the premium display, the operator can change

modes by pressing the numbered keys on the dash Figure 24. Battery Discharge Indication in Dash
display. Any number can be selected at any time to Display LCD Window
change the performance mode. The change does not
take effect until the operator releases the accelerator The lift interrupt feature is controlled by the vehicle mas-
pedal. If the password is enabled, the operator will be ter controller and prevents the lift function when the bat-
limited by the performance level set in the password tery is 80 percent discharged. Although lift interrupt
function. prevents lifting, low speed functions, such as tilt and
sideshift, remain operational to allow the operator to
Mode 4 is the highest level of performance available to
more easily remove the forks from the load and return
the operator, regardless of the performance setup in
to the battery charging area.
the control. For instance, if the control is configured
to limit top speed less than maximum, then Mode 4 top When lift interrupt is initiated, it will remain in effect until
speed is equal to the top speed set in the control. Three the battery is disconnected and a recharged battery is
lower performance modes are available to the operator reconnected to the vehicle. When a battery is replaced
by using the buttons on the display. These lower perfor- or recharged, the new state of charge must be at least
mance settings are percentages of the highest perfor- 25 percent greater than the previous state of charge.
mance available in Mode 4 as described below: This prevents the BDI from being activated by a battery
• Mode 4 - This is the highest performance mode. that has recovered slightly during an idle period.
Other modes are a lower percentage of Mode 4.
• Mode 3 - Top speed is the same as Mode 4. Acceler- A BDI adjustment feature is provided through the con-
ation is 80 percent of Mode 4. trol setup function, which is accessible using either the
• Mode 2 - Top speed is 80 percent of Mode 4. Accel- dash display or the PC service software. The adjust-
eration is 70 percent of Mode 4. ment scale is 0-100, with a value of 30 for the factory
• Mode 1 - Top speed is 60 percent of Mode 4. Accel- setting. The setting of 30 is the starting point for flooded
eration is 60 percent of Mode 4. cell-type batteries of all voltages and amp-hour capaci-
ties. The adjustment can then be used to fine-tune the
BATTERY DISCHARGE INDICATOR (BDI) BDI lift interrupt feature. For example, if it is desired to
have the lift interrupt to occur at a higher battery specific
The AC control system includes a Battery Discharge In- gravity, then the value would be increased. The value
dicator (BDI) that provides indication of the battery state is decreased if a lower specific gravity is desired for the
of charge. See Figure 24. The BDI feature is displayed lift interrupt point.
to the operator on the dash display with a 20-segment
bar. For information on how the BDI system works, see If a maintenance-free battery is installed, the BDI ad-
the Operating Manual for your lift truck. justment should be increased to a value of about 50
as a starting point. Fine-tuning can be done from that
The BDI provides full functionality when used with a full value.
range of batteries including:
58
HOURMETER 3. Secure hours - based on traction hours. The secure

hours cannot be reset.
There are three different hourmeter functions.
1. Pump hours - accumulates time only when the The hourmeter data is stored in the master controller
pump motor is operating. during every 6 minutes of operation. If there is a loss of
2. Traction hours - accumulates time when the seat power, data is not lost.
switch is closed and the key switch is in the ON
position.
59
Figure 25. Electro-Hydraulic Control Valve Schematic (Standard Flow) for Lift Truck Models ERP20-32ALF
(ERP040-065DH) (E216), ERC/P16-20AAF (ERC030-040AH), (C814), ERC020-032AGF (ERC040-065GH)
(A908)
60

1. AUXILIARY 2 VALVE (SP5) 15. STEERING RELIEF VALVE
2. AUXILIARY 1 VALVE (SP4) 16. HYDRAULIC TANK
3. TILT CYLINDERS 17. HYDRAULIC FILTER
4. LIFT CYLINDER 18. HYDRAULIC PUMP
5. SECONDARY LOWERING CONTROL INTEGRAL 19. PRIMARY RELIEF VALVE (RV1)
WITH LIFT CYLINDERS 20. SECONDARY RELIEF VALVE (RV2)
6. PRIMARY LOWERING CONTROL (MOUNTED 21. TILT SOLENOID VALVE (SP3)
ON MAST) 22. LIFT SOLENOID VALVE (SP1)
7. STEERING CYLINDER 23. PRIORITY COMPENSATOR VALVE (EC1)
8. STEERING WHEEL 24. LOWERING COMPENSATOR VALVE (EC2)
9. STEERING CHECK PORT 25. TILT COUNTERBALANCE VALVE (CB1)
10. STEERING CONTROL UNIT 26. CHECK VALVE LIFT CIRCUIT (CV1)
11. HAND PUMP 27. FLOW REGULATOR VALVE (FR1)
12. STEERING VALVE 28. LOWER SOLENOID VALVE WITH MANUAL
13. MAIN CONTROL VALVE OVERRIDE (SP2)
14. STEERING PUMP 29. GAUGE PORT
61
Figure 26. Electro-Hydraulic Control Valve Schematic (High Flow) for Lift Truck Models ERP20-32ALF
(ERP040-065DH) (E216), ERC/P16-20AAF (ERC030-040AH), (C814), ERC020-032AGF (ERC040-065GH)
(A908)
62

1. PILOT-OPERATED SPOOL VALVE (PE1) 16. HYDRAULIC TANK
2. PILOT-OPERATED SPOOL VALVE (PE2) 17. HYDRAULIC FILTER
3. TILT CYLINDERS 18. HYDRAULIC PUMP
4. LIFT CYLINDER 19. PRIMARY RELIEF VALVE (RV1)
5. SECONDARY LOWERING CONTROL INTEGRAL 20. SECONDARY RELIEF VALVE (RV2)
WITH LIFT CYLINDERS 21. TILT SOLENOID VALVE (SP3)
6. PRIMARY LOWERING CONTROL (MOUNTED 22. LIFT SOLENOID VALVE (SP1)
ON MAST) 23. PRIORITY COMPENSATOR VALVE (EC1)
7. STEERING CYLINDER 24. LOWERING COMPENSATOR VALVE (EC2)
8. STEERING WHEEL 25. PILOT-OPERATED SOLENOID VALVE (EHPR1
9. STEERING CHECK PORT THROUGH 4)
10. STEERING CONTROL UNIT 26. TILT COUNTERBALANCE VALVE (CB1)
11. HAND PUMP 27. FLOW REGULATOR VALVE (FR1)
12. STEERING VALVE 28. LOWER SOLENOID VALVE WITH MANUAL
13. MAIN CONTROL VALVE OVERRIDE (SP2)
14. STEERING PUMP 29. CHECK VALVE LIFT CIRCUIT (CV1)
15. STEERING RELIEF VALVE 30. GAUGE PORT
63
1. PILOT OPERATED SPOOL VALVE (PE1) 16. HYDRAULIC TANK

2. PILOT OPERATED SPOOL VALVE (PE2) 17. HYDRAULIC FILTER
3. TILT CYLINDERS 18. HYDRAULIC PUMP
4. LIFT CYLINDERS 19. PRIMARY RELIEF VALVE (RV1)
5. SECONDARY LOWERING CONTROL INTEGRAL 20. SECONDARY RELIEF VALVE (RV2)
WITH LIFT CYLINDERS 21. PROPORTIONAL SOLENOID VALVE (LIFT) (SP1)
6. PRIMARY LOWERING CONTROL MOUNTED 22. PROPORTIONAL SOLENOID VALVE
ON THE MAST (LOWERING) (SP2)
7. STEERING CYLINDER 23. PRIORITY COMPENSATOR VALVE (EC1)
8. STEERING WHEEL 24. LOWERING COMPENSATOR VALVE (EC2)
9. STEERING CHECKPORT 25. PILOT OPERATED SOLENOID VALVE (EHPR 1
10. STEERING CONTROL UNIT THROUGH 6)
11. HAND PUMP 26. TILT COUNTER BALANCED VALVE (CB1)
12. STEERING VALVE 27. FLOW REGULATOR VALVE (FR1)
13. MAIN CONTROL VALVE 28. MANUAL LOWERING VALVE (NV1)
14. STEERING PUMP 29. LIFT CIRCUIT CHECK VALVE (CU1)
15. STEERING RELIEF VALVE 30. GAUGE PORT
Figure 27. Electro-Hydraulic Control Valve Schematic for Lift Truck Models (ERC70-120HH) (C839)
64
2200 YRM 1056 Dash Display Service Menu Navigation
Dash Display Service Menu Navigation

GENERAL 2. To move into a submenu of a main menu item, press
the → (right arrow) key on the dash display numeric
To enter the service mode, turn the key to the ON posi- key pad. To move into a sub submenu, as with the
tion and press the (enter) key twice. Enter Password Diagnostics menu, press the → (right arrow) key
prompt will appear on the display. See Figure 28. All lift again.
trucks will have 55555 as the default service password
at the time of delivery. This password can be changed 3. To move up or down within the submenu or the sub
by a service technician. Go to Editing and Adding Infor- submenu, press the ↑ (up arrow) or ↓ (down arrow)
mation. keys.
4. To move out of the sub submenu and return to the

submenu, press the ← (left arrow) key.
5. To move out of the submenu and return to the Main

Menu, press the ← (left arrow) key.
6. To exit the service mode, press the ← (left arrow)

key.
Figure 28. Password Prompt EDITING AND ADDING INFORMATION

The ↑ (up arrow) and the ↓ (down arrow) keys allow you NOTE: The setup and password menus can be used to
to move up and down within a menu. The ← (left arrow) edit or add information to the truck software. When an
key and the → (right arrow) key allow you to move from item in these menus is selected, the current value will
menu to menu. The (enter) key allows you to enter be displayed. The characters available to be selected
or save a parameter. The 5 (five) key is only used if from the display are 0 through 9, A through Z, blank,
it is part of the password required to enter the service and dash. Each line in the display can have no more
mode. See Figure 29. than 20 characters including blanks.
1. If a change is to be made, press the → (right arrow)

key and the cursor will blink on one of the charac-
ters. The ← (left arrow) key and → (right arrow) key
are used to move from character to character in the
item being changed.
2. When a character that is to be changed is blink-

Figure 29. Dash Display Keys ing, use the ↑ (up arrow) and ↓ (down arrow) keys
to scroll up or down until the desired character is
MOVING THROUGH MENU SELECTIONS found. Use the ← (left arrow) or → (right arrow)
keys to move to the next character to be changed.
1. When the service technician’s password has been
This is repeated until all changes in the item have
correctly entered, the first menu item, which is the
been made.
Setup menu, is displayed on the dash display LCD
screen. To view the next menu item, press the 3. When all changes have been made, press the (en-
↓ (down arrow) key on the dash display numeric ter) key to store the value. Press the ↑ (up arrow)
key pad. Repeat this until the desired menu item key or the ↓ (down arrow) key to access the next
has been reached. To return to a previous menu item to be changed. Repeat this procedure for each
item, press the ↑ (up arrow) key. When the last item that is to be changed.
menu item is reached and the ↓ (down arrow) key
is pressed again, the first menu item will return to 4. When all changes have been made, press the ←
the display. (left arrow) key to exit the menu.
65
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
66
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
2200 YRM 1056 3/09 (4/08)(6/07)(11/06)(3/06)(1/06)(7/05)(3/05)(5/04)(3/04)(1/04)(12/03) Printed in U.S.A.

Yale ERC060GIN48 Serie A908N02474C 20-12-11 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Yale ERC060GIN48 Serie A908N02474C 20-12-11 PDF

Uploaded by

Copyright:

Available Formats

Maintenance

PART NO. 524183083 2200 YRM 1056

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2009 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

ERC20-32AGF (ERC040-065GH) [A908];

Legend for Figure 1

Figure 1. Diagnostic Connector

Master Controller Checks and Adjustments

Table 2. Factory Setting for ERC020-032AGF (ERC40-65GH) (A908)

Factory Setting Factory Setting Factory Setting Factory Setting

Table 3. Factory Setting for ERC/P16-20AAF (ERC030-040AH) (B814/C814)

Table 3. Factory Setting for ERC/P16-20AAF (ERC030-040AH) (B814/C814) (Continued)

Table 4. Factory Parameters for ERC35-55HG (ERC70-120HH) (B839/C839)

(Range 0-100) Function Number 13 PUMP SPEED 1

Function 13 determines the hydraulic pump motor low

Any increase in performance will decrease the battery (Range 0-100)

Many faults noted by lift truck systems are the result

1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. LINE CONTACTOR

1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. AC TRACTION MOTOR CONTROLLER

1. FUSE 7 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT

1. FUSE 1 (15A) AUXILIARY TERMINAL STRIP 7. POSITIVE TEMPERATURE COEFFICIENT

Table 5. List of Status Codes

Status Code Description Status Code Description

Table 5. List of Status Codes (Continued)

Status Code Description Status Code Description

AC Motor Controllers Status Code Charts

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

• Malfunction of mini-lever, if equipped.

Operate each lever to full stroke forward and slowly

Operate each lever to full stroke back and slowly

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures

Status Code Description Memory Recall Circuit

Possible Causes and Test Procedures