Yale D216 ERP20-30 ALF Service Manual – PDF DOWNLOAD

Yale D216 ERP20-30 ALF Service Manual – PDF DOWNLOAD

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Yale D216 ERP20-30 ALF Service Manual – PDF DOWNLOAD

DESCRIPTION:

Yale D216 ERP20-30 ALF Service Manual – PDF DOWNLOAD

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]

• 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.

TABLE OF CONTENTS:

Yale D216 ERP20-30 ALF Service Manual – PDF DOWNLOAD

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 14 PUMP SPEED 2 8
Function Number 15 PUMP SPEED 3 8
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

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