Yale D216 Erp20alf Erp25alf Erp30alf Erp040 060dh Lift Truck Service Repair Manual

Maintenance

TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS PROGRAM (ETACC) ERC20-32AGF (ERC040-065GH) [A908]; ERC/P16-20AAF (ERC030-040AH) [B814/C814]; ERC035-055HG (ERC70-120HH) [B839/C839]; ERP20-30ALF (ERP040-060DH) [D216/E216]; ERP1.60-1.80-2.00ATF (ERP030-040TH) [F807]; NDR030DA, NR035/040DA [A295]; NDR035EA, NR045EA [C861]; NDR030EA, NR035/040EA [D815]; MPE080-F [B890]; MPE060-F [B896]; MTR005-F [B902]; MTR007-F [B903]; MPC060-F [B904]; MPC080-F [B905]; MPE060-VG [A292]; MPE080-VG [A287]

PART NO. 524183085

2200 YRM 1058

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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.

Troubleshooting and Adjustments Using the AC Controls Program (ETACC)

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................

Computer Requirements .................................................................................................................................

Software, Install...............................................................................................................................................

Language Selection ........................................................................................................................................

Demo Mode.....................................................................................................................................................

Connect PC to Lift Truck .................................................................................................................................

Starting AC Controls Program.........................................................................................................................

Lift Truck Control Setup .......................................................................................................................................

Change Lift Truck Serial Number or Hourmeter ..............................................................................................

Setting Factory Default Values or Changing Lift Truck Parameters.................................................................

Create New Custom Lift Truck Configuration ..................................................................................................

Lift Truck Configuration Properties ..................................................................................................................

Import New Lift Truck Configuration From Disk...............................................................................................

Delete Custom Lift Truck Configuration or Password File ...............................................................................

Dash Display .......................................................................................................................................................

Custom Display Languages ............................................................................................................................

Download Display Language...........................................................................................................................

Clear Operator Log .........................................................................................................................................

Password Functions ............................................................................................................................................

Enable/Disable Password and Lift Truck Inspection Functions .......................................................................

Truck Inspection Checklist ..........................................................................................................................

Password ....................................................................................................................................................

Password Properties .......................................................................................................................................

Create New Password File ..............................................................................................................................

Download Passwords ......................................................................................................................................

Upload Passwords ..........................................................................................................................................

Reports Menu......................................................................................................................................................

Devices Report................................................................................................................................................

Custom Report ................................................................................................................................................

Password Report.............................................................................................................................................

Operator Report ..............................................................................................................................................

Current Settings Report ..................................................................................................................................

Status Code Report ........................................................................................................................................

Status Codes Log............................................................................................................................................

Troubleshooting ...................................................................................................................................................

Diagnostics......................................................................................................................................................

Help Menu ...........................................................................................................................................................

General ...........................................................................................................................................................

Contents..........................................................................................................................................................

Technical Support ...........................................................................................................................................

About Electric Truck AC Controls Program .....................................................................................................

©2011 Yale Materials Handling Corp.

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Table of Contents

Troubleshooting and Adjustments Using the AC Controls Program (ETACC)

TABLE OF CONTENTS (Continued) This section is for the following models: ERC20-32AGF (ERC040-065GH) [A908]; ERC/P16-20AAF (ERC030-040AH) [B814/C814]; ERC035-055HG (ERC70-120HH) [B839/C839]; ERP20-30ALF (ERP040-060DH) [D216/E216]; ERP1.60-1.80-2.00ATF (ERP030-040TH) [F807]; NDR030DA, NR035/040DA [A295]; NDR035EA, NR045EA [C861]; NDR030EA, NR035/040EA [D815]; MPE080-F [B890]; MPE060-F [B896]; MTR005-F [B902]; MTR007-F [B903]; MPC060-F [B904]; MPC080-F [B905]; MPE060-VG [A292]; MPE080-VG [A287]

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2200 YRM 1058

General

General The information contained in this manual gives the user a brief overview of the Electric Truck AC Controls Program. This manual also explains the common dropdown menu features for the user that are listed under the File menu, the Reports menu, the Tools menu, and the Help menu.

To run the setup program, follow these steps:

A personal computer (PC) can be used to set the traction motor and pump motor controller functions, read status codes, and perform numerous diagnostic and troubleshooting functions.

2. Click Start.

COMPUTER REQUIREMENTS The PC must have the following minimum configuration: 1. Microsoft Windows 2000™ or later operating system must be installed.

2. There must be an open Universal Serial Bus (USB) port available on the computer to connect to the lift truck.

3. There must be a compact disk read-only-memory (CD-ROM) drive installed on the computer.

4. Microsoft Internet Explorer™ Version 5.01 or later must be installed on the computer.

1. Place the CD in the CD-ROM drive. Installation will start automatically if the computer is set for automatic startup. If the computer is not set for automatic startup, go to Step 2.

3. Select Run and in the Open line enter D:\disk1\ setup.exe.

4. Click OK. The setup program will guide you through the rest of the steps to install the Electric Truck AC Controls Program Yale on the computer.

It is recommended that the program is installed to the default directories.

LANGUAGE SELECTION 1. When the program is first installed the language setup screen will appear. Click on the down arrow to see the languages to be selected. Select the desired language from the list. See Figure 1. The Electric Truck AC Controls Program Yale text will appear in the selected language.

5. The display screen resolution should be set to 800×600 pixels.

SOFTWARE, INSTALL NOTE: See instructions included with CD, Yale part number 524187015 (Initial Installation), and/or readme.txt file on the CD for additional instructions and possible password requirements.

NOTE: You must have Administrator rights to install this software on a PC. After installation, folders "EVS" and "Program Files/ETACC YALE/" and their sub-folders must have their security permissions set to allow full control.

NOTE: When installing the software on a PC with Microsoft Windows 2000 or a later Operating System, make sure that the computer is setup with Administrator rights on the computer.

NOTE: In the following examples, the D: drive represents the CD-ROM drive. The CD-ROM drive could be a different letter on the computer.

Figure 1. Language Selection

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General 2. After initial installation, if the selected language is to be changed, click File and select Settings from the drop down menu. A Settings pop-up box will appear on the screen. See Figure 2. Click the language tab and click on the down arrow. A drop down list of languages will appear. Select one of the following languages from the list: • English • German • French • Italian • Spanish

DEMO MODE 1. Select Settings from the File menu. A Settings pop-up box appears with a Communication, Language, General, and Window tab. See Figure 3.

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2200 YRM 1058 NOTE: In the Settings dialog box, on the Communication tab, if the Normal button is selected, the system is in the default status for operation and must be connected to an actual lift truck. See Figure 3.

If the Demo button is selected, the program is in the demonstration mode, and the program can be operated without being connected to an actual lift truck. See Figure 3.

2. Select the Communication tab and click the Demo selection.

2200 YRM 1058

General

Figure 2. Language Options

3

General

2200 YRM 1058

Figure 3. Settings Menu (Sheet 1 of 2)

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• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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