Forklift,

Justin's summary of a 360 code is spot on. The code indicates a higher than normal current in the PS coil circuit. Normally this is the coil, but be aware of any corrosion or bad connections in the P1 connector of the fuse panel or the J pins at the back of the MIB. if your wiring and coil resistances all check out,a MIB is probably in order. If you have high resistance in your wiring due to the age of the truck, a new main harness may be advisable, however check all the fuse panel connections carefully first.

You may want to try erasing the MIB model code number and re- programmming it. The factory function default value for the power steering minimum current is 03 which represents 0.10 amps of current. The maximum current value for Power Steering contactor is 60 by default which is 2.04 amps.

You can check your current by placing the meter in series with the # 36 wire that goes to the J2-12 pin connection of the MIB and check you pull in current. If it is higher than 2.04 amps the code will generate indicating high resistance in the wiring or a possible bad field effect transistor (FET) in the MIB.

If you send me an e- mail at [email address removed] I can send you necessary schematics and manual pages for this truck.

Bruce Fraser
Yale Technical Services
[email address removed]

Justin??

Hey Justin
Any thoughts on this?

Ok Justin, took another run at it (no traction relay as I understand your description). If I understand right, I removed wires 10N and 35A from steering contactor. Looking for 605 ohms, I o ly had 67 initially, then the slowly increased. I then read (still disconnected) between 35A and chassis and 10N and chassis. Both read 8.4m ohms then slowly increased.
Where to now?:).
A schematic would be great. Please send to
steve at forkliftt. com

oops triple post

oops double post lol

Ah, if it was that close I would have considered it close enough that it should still work. I meant shorted (close to 0) or open (many hundreds of ohms to infinite) The last step is replacing parts. Did it have a Traction Relay? Look for wires melted to warm bus bars or heavy contactor lugs and cables. You could be picking up B+ there too on the wire back to the MIB.

If you need a schematic, email me.

Hey Justin
I made it to the jobsite last week and found the ps contactor coil had 57.7 ohms resistance. Just out of spec. I flew a new one in with some other parts I had coming and replaced the contactor last Thursday but still have the code. My customer had a repair at another location that took priority so I pulled up and hope to get back tomorrow to begin the remaining checks. I will absolutely keep you posted!!

Hey Forkliftt. Was curious if you got it sorted out.

Jplayer, go read my long post above. You're not realizing what he means. The code isn't on the SepEx box, it's on the MIB (main interface board). The code is a 60. The function is 3 (really 03) which gives you a display on the MIB of "0360". If everything was working correctly, the MIB would read "0300".

Curtis flash codes are two digit. So 3 blinks followed by 6 blinks isn't "thirty six" it's 3, 6. 3 would be the group of errors and 6 is the specific error for that group. Sometimes it helps if you know what the engineers who designed the stuff were thinking as far as how they grouped and designated things. I think these trucks use a 1244 but I could be mistaken. Remember, in these trucks, the SepEx is only for the traction motor and is secondary to the MIB.

Good luck all!
Justin

if by chance it is a curtis sepex controller , look on the controller and there should be an amber light flashing
if there is a traction code that light will be flashing a code if there is an issue with the controller itself. it will flash the digits of the code in sequence groups. ie: if the code is 36 then the light will flash 3 times, pause, then 6 times, then pause, then there will be a long pause and the code will either repeat itself or if there are multiple codes the next code will flash.

generally the light will be flashing slowly once every couple seconds on and off steady if operation on the controller is normal.
The sepex controller is genuine in itself as it is labeled as such
there should be a tag on top of the controller saying it is.

unlike its previous models like the pmc controller or the other earlier versions that were just a black box with a very small label. if the labels have come off and you cant tell then go to curtis instruments website and look in their controller section and determine which one it is by viewing them.

as for this code 360 i've checked in hysters equivilent of this truck and there is no such code, so eitiher you are reading it wrong, dont understand what you are looking for or yale is specific in their firmware coding system on that truck and you will have to have the yale service manual to determine what it is.
judging from the serial number IF this is a sepex controlled system it was one of thier first generation, i have my doubts though as they changed thier serial number layout when they went to the AC drives. My guess would be the curtis 12xx series control (the long black box with the rounded sides), and it has an amber light that flashes on the end near the control wiring connector. it pulses the error codes the same as i described above for the sepex.

is it flashing any codes? what are they?

I can provide the manual
Please inform the beginning of the series
or put the serial number
I have manuals mib
this machine uses a controller curtis sepex
and a mib

Justin,
Bless you:)!!I can't wait till Monday to take another run at it!

Oh and if all that tests good the MIB itself might be shorted internally. If that's the case, contact Flight Systems in PA, and send it in for a "test and advise".

Good luck again! :D

Hey everyone. :D

I think I see the confusion. First off, AC doesn't designate an AC truck. It's just the model code. Just a coincidence. It's actually a mid 90's machine.

Secondly, the code 0360 is on the MIB (main interface board). The actual code 03-60.

03 designates the function that's in use. In this case 03 basically means neutral, or that the key is on and someone is standing on both pedals, no functions requested.

60 is your actual fault code. In this case it's saying that the PS (power steering contactor) coil and/or the TR (traction relay, it's a smaller relay) coil, or their respective circuits, is shorted. Only the coils not the tips. TR is an option, not all trucks have it. If your PS coil only has 2 push on connectors (B+ and -) and 2 open spades, it does not have a TR relay.

The PS contactor is on the contactor panel. It is hooked up to fuse # 3 (FU3 - 100 amp) via a short jumper cable. Its wires to the coil are 10 and 10A (B+). The other is 36 (- to pin J2-12 on the MIB).

The TR relay is a small relay by the PS relay on the contactor panel. Its wires are 10N (B+) and 36A (- to - on the PS coil) Both 10N and 36A run to the PS coil.

Ok, so disconnect the battery, disconnect all the small wires from the PS contactor. Measure the resistance of the PS contactor from + to -. It should read about 52 ohms (+/- 4 ohms so anywhere between 48 to 56 ohms is acceptable). If close to 0 ohms, the coil is shorted and replace it.

Measure the resistance between wires 36A and 10N (TR relay still wired) It should read about 605 ohms (+/- 35 ohms). If close to 0 (or far less than the acceptable amount) remove wires 36A and 10N from the TR coil. Measure the coil. It should read as above. If you read close to 0 replace it. If good measure the wires again. It should be infinite (OL) resistance. If you read any continuity under 500 ohms I'd say, look for shorts. Test 10N and 36A for shorts to frame. If you find shorts in that short harness, repair it.

Still all good? Disconnect J1 and J2 from the MIB (it's usually easier to pull the MIB from the frame to get to the harness). Check resistance between wires 36 and 10,10A at the PS contactor (still disconnected there, too). You should read infinite resistance. If you get continuity, look for shorts between the 36 and any power wire or the frame. Repair shorts if found.

Good luck! Any questions reply here or email me (in my profile)
Justin

Hey Roger,
It's not AC, but it's also not a GE system. I believe it is Curtis but I will check.

By the serial # it looks to be a non ac unit. What make is the control panel? I am thinking ge ev100.If it is the ev100 than I would check the line contactor and fuses.

Bumping it to the top. Looking for any help.

Electro drive. Will do. Need some help here! I went to the Yale dealer yesterday and we determined I had a 0360. Meaning=0360 ps or traction relay high current (stuck, coil shorted, wire to frame) 
I went to the jobsite. Checked for no continuity across power steering pump tips, also for continuity through ps pull in coil. I'm not sure what the traction relay is, but I did the same checks on the FR contactors and also a big "truck power contactor" (I think). All checked OK. Any help is appreciated!!

for placing the serial number
I can help
contact me by email or skype
my skype: hyster.brasil

HI Mate

I have a manual for an AC NR Yale, but my error code list goes up to 348. If you manage to get hold of the info is it possible to forward the info to me also?

Regards