Yale 524150797 Maintenance Manual
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Yale 524150797 Maintenance Manual

Yale 524150797 Maintenance Manual

Metric and inch (sae) fasteners
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Maintenance
METRIC AND INCH
(SAE) FASTENERS
PART NO. 524150797
8000 YRM 0231

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Summary of Contents for Yale 524150797

  • Page 1 Maintenance METRIC AND INCH (SAE) FASTENERS PART NO. 524150797 8000 YRM 0231...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General ..................................1 Threaded Fasteners ..............................1 Nomenclature, Threads ............................1 Strength Identification ............................2 Cotter (Split) Pins ..............................3 Fastener Torque Tables ............................8 Conversion Table ..............................10 This section is for the following models: ©2018 Yale Materials Handling Corp.

  • Page 5: General

    To make sure that you have the correct the description of a fastener. This length is shown in ® fastener, order fasteners and parts through the Yale inches for inch fasteners and in millimeters for metric Parts Depot. fasteners.

  • Page 6: Strength Identification

    General 8000 YRM 0231 Figure 1. Thread Design STRENGTH IDENTIFICATION The most common property classes for metric fasteners are 8.8 and 10.9. The property class is marked with a number on the head of the capscrew or CAUTION on a nut. Property classes less than 8.8 are often not marked.

  • Page 7: Cotter (Split) Pins

    8000 YRM 0231 General COTTER (SPLIT) PINS Unless otherwise specified, the legs of chain anchor cotter (split) pins are to be bent against the pin. See Cotter (split) pins are used in many applications on Figure 3. your forklift. They are typically used to retain parts such as pins and nuts.
  • Page 8 General 8000 YRM 0231 Table 1. Bolts and Screws...
  • Page 9 8000 YRM 0231 General Table 2. Studs and Nuts...
  • Page 10 General 8000 YRM 0231 Table 3. Torque Nuts...
  • Page 11 8000 YRM 0231 General Table 4. Torque Nuts With Nylon Insert...

  • Page 12: Fastener Torque Tables

    General 8000 YRM 0231 FASTENER TORQUE TABLES Table 5. Torque Values for Metric Fasteners* Property Class 5.8 Grade 8.8 Grade 10.9 Size and Pitch N•m lbf ft N•m lbf ft N•m lbf ft M3 × 0.5 M3.5 × 0.6 M4 × 0.62 0.97 0.5 0.7 1.1 0.99 1.55...
  • Page 13 8000 YRM 0231 General Table 6. Torque Values for Inch Fasteners* (Continued) Grade 2 Grade 5 Grade 8 Size and Pitch lbf ft N•m lbf ft N•m lbf ft N•m 1/2 1/2 13 UNC 20 37 41 50 56 57 85 77 115 80 90 110 120...

  • Page 14: Conversion Table

    General 8000 YRM 0231 CONVERSION TABLE Table 7. Conversion Table for Metric and English units Multiply To Get Multiply To Get Area inches 2 (in. 2) × 6.452 = centimeters 2 (cm 2) centimeters 2 (cm 2) × 0.155 = inches 2 (in. 2) feet 2 (ft 2) ×...
  • Page 15 8000 YRM 0231 General Table 8. Cotter Pin Dimensional Data Nominal Shank Diameter A Head Dia. B Length of Extended Recommended Hole Size Size A Prong C 1.00 mm 0.90 mm 0.70 mm 1.50 mm 1.52 mm 0.25 mm 0.91 mm 1.37 mm (0.031 in.) (0.035 in.)
  • Page 16 General 8000 YRM 0231 Table 9. Cotter Pin Dimensional Data Nominal Length Range Nominal Size - Part Numbers Length L 1.00 mm 1.60 mm 2.00 mm 2.50 mm 3.20 mm (0.031 in.) (0.047 in.) (0.062 in.) (0.094 in.) (0.125 in.) 6.35 mm 7.10 mm 5.50 mm...
  • Page 17 8000 YRM 0231 General Table 9. Cotter Pin Dimensional Data (Continued) Nominal Length Range Nominal Size - Part Numbers Length L 1.00 mm 1.60 mm 2.00 mm 2.50 mm 3.20 mm (0.031 in.) (0.047 in.) (0.062 in.) (0.094 in.) (0.125 in.) 101.6 mm 113.3 mm 98.8 mm...
  • Page 18 General 8000 YRM 0231 Table 10. Cotter Pin Dimensional Data (Continued) Nominal Length Range Nominal Size - Part Numbers Length L 4.00 mm 5.00 mm 6.30 mm 8.00 mm 9.52 mm (0.156 in.) (0.188 in.) (0.250 in.) (0.312 in.) (0.375 in.) 25.4 mm 26.9 mm 23.9 mm...
  • Page 19 8000 YRM 0231 General Table 11. Cotter Pin Dimensional Data Nominal Length L Length Range Nominal Size - Part Numbers 13.0 mm (0.500 in.) 16.00 mm (0.625 in.) 19.05 mm (0.750 in.) 20.5 mm (0.807 in.) 18.3 mm (0.720 in.) 25.4 mm (1.00 in.) 26.9 mm (1.060 in.) 23.9 mm (0.940 in.)
  • Page 20 NOTES...
  • Page 22 8000 YRM 0231 12/18 (8/16)(10/15)(3/15)(10/13)(12/04)
  • Page 23 Maintenance INDUSTRIAL BATTERY PART NO. 524158040 2240 YRM 0001...
  • Page 24 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.
  • Page 25 Knowing When Battery Is Fully Charged ......................15 Where to Charge Batteries ..........................15 Equipment Needed ............................15 Battery Connectors ............................. 16 Battery Care ................................16 Troubleshooting ..............................18 This section is for the following models: ©2018 Yale Materials Handling Corp.

  • Page 27: General

    2240 YRM 0001 General General This section describes how to select and do the batteries have a nameplate attached to the face of the maintenance for large batteries used in electric lift battery cover. This nameplate communicates specific trucks. This information is for service personnel that information about the battery including the name of the must do the maintenance on large lead-acid batteries.

  • Page 28: Lithium-Ion Batteries

    Specific Gravity 2240 YRM 0001 Legend for Figure 2. 1. VENT AND FILL 5. POSITIVE PLATE 6. EXPANSION MATS 2. POST 7. RETAINER 3. POST SEAL 8. SEPARATOR 4. PLATE 9. NEGATIVE PLATE PROTECTOR 10. BATTERY JAR (SHIELD) LITHIUM-ION BATTERIES A lithium-ion battery converts chemical energy into electrical energy.
  • Page 29 2240 YRM 0001 Chemical Reaction in a Cell The cell generates a voltage (potential difference) when two different types of metal are in the electrolyte. The two metals in a lead-acid cell are lead peroxide (PbO ) for positive plates, and sponge lead (Pb) for negative plates.

  • Page 30: Electrical Terms

    Electrical Terms 2240 YRM 0001 Figure 6. Charging Cell Electrical Terms Voltage: Is an electromotive force (EMF) (also called maintenance-free battery, the amount of free-standing "potential difference") caused by the difference in electrolyte above the plates is much higher, ensuring electric charge between two points.

  • Page 31: Battery Selection

    2240 YRM 0001 Battery Selection Figure 7. Electrical Terms Battery Selection NOTE: The capacity of the battery can be found on the lift truck's Nameplate. See the Frame section or Operating Manual for your lift truck for the location of the Nameplate.

  • Page 32: Battery Voltage

    Battery Voltage 2240 YRM 0001 Figure 9. Multicell Battery for Electric Lift Truck Battery Voltage NOTE: The voltage of the battery can be found on the To reach the necessary battery voltage, the cells are lift truck's Nameplate. See the Frame section or connected in series.

  • Page 33: Kilowatt-Hours

    2240 YRM 0001 Battery Maintenance discharging can be compared to a measurement of the battery capacity and ampere-hours. For example, a volts × amperes × hours = kilowatt-hours or kWh battery with a rating of 600 ampere-hours during a 1000 work period of 6 hours will generate 100 amperes per hour for 6 hours.

  • Page 34: Maintenance Records

    Battery Maintenance 2240 YRM 0001 Only trained persons are permitted to do Keep the battery compartment clean and dry. Use a maintenance on batteries and battery chargers. clean cloth to wash the battery with water. Dry with Make sure the regulations by government safety compressed air.
  • Page 35 2240 YRM 0001 Battery Maintenance Legend for Figure 10. 1. INSULATED SPREADER BAR 2. INSULATED STRAPS Figure 10. Change the Battery Figure 11. Battery Inspection Report...

  • Page 36: Adding Water To Battery

    Battery Maintenance 2240 YRM 0001 Figure 12. Daily Battery Report ADDING WATER TO BATTERY hole. The correct electrolyte level is shown in Figure 13. NOTE: Some batteries have sealed cells. These batteries do not need water added to the electrolyte. Some water is lost from the electrolyte of each cell during the charge and discharge cycle when the battery is in service.

  • Page 37: Hydrometer

    2240 YRM 0001 Battery Maintenance HYDROMETER electrolyte level is low, the percent of sulfuric acid in the electrolyte increases. When the electrolyte level NOTE: Some batteries have sealed cells. The specific decreases by 3 mm (1/8 in.), the specific gravity gravity of the electrolyte cannot be checked on these measurement can increase by 3 to 5 points.

  • Page 38: Charging Battery

    Battery Maintenance 2240 YRM 0001 CHARGING BATTERY NOTE: There can be one of two types of batteries. One type has removable cell caps. The other type has sealed cells. The sealed batteries require a different charger. The electrolyte level or specific gravity cannot be checked, and water cannot be added to the electrolyte of these sealed batteries.

  • Page 39: Types Of Battery Charges

    2240 YRM 0001 Battery Maintenance battery manufacturer. A fully charged battery will have shown in Figure 17. NEVER discharge a battery below a specific gravity of 1.265 to 1.310 at 25°C (77°F). See the limits shown in Figure 18. Discharging a battery Figure 15.

  • Page 40: Methods Of Charging

    Battery Maintenance 2240 YRM 0001 increases. The increasing voltage across the resistor causes an increasing voltage at the battery terminals. The charging is similar to the gradual charge. The resistor must be correctly set, or the charging rate will be wrong. The typical graphs for a modified constant voltage charger are shown in Figure 20.

  • Page 41: Troubleshooting Charger

    2240 YRM 0001 Battery Maintenance NOTE: Many users have battery chargers that can Remove a vent cap and look in the opening. If follow a program to automatically charge a battery you see bubbles in the electrolyte, the battery is according to recommendations of the battery either fully charged or in the final stage of manufacturer.

  • Page 42: Battery Connectors

    Battery Maintenance 2240 YRM 0001 • Install a NO SMOKING sign in the service area BATTERY CARE Keep the charger in a clean, dry area with good • Keep batteries clean. Remove any spilled ventilation electrolyte. BATTERY CONNECTORS DO NOT overcharge the battery. This action will damage the battery.
  • Page 43 2240 YRM 0001 Battery Maintenance NOTE: INDICATOR INSERT (2). GREEN - FOR BATTERY WITH CELL CAPS. GRAY - FOR BATTERY WITH SEALED CELLS. NOTE: CONNECTOR BODY COLOR [ANDERSON SBE CONNECTOR ONLY (1)]. GRAY - 36-VOLT BATTERY. BLUE - 48-VOLT BATTERY. GREEN - 72-VOLT BATTERY. BLACK - 80-VOLT BATTERY. A.

  • Page 44: Troubleshooting

    Troubleshooting 2240 YRM 0001 Troubleshooting Table 2. BATTERY TROUBLESHOOTING GUIDE BATTERY INSPECTION PROCEDURES ↓ OBSERVE ALL SAFETY REQUIREMENTS CHECK ↓ INCORRECT ←———— BATTERY SIZE FOR CORRECT AMP HR. ————→ CORRECT RATING ON TRUCK CAPACITY PLATE AGAINST AMP HR. RATING LOCATED ON SIDE OF BATTERY OR STAMPED ON BATTERY POSITIVE TERMINAL.
  • Page 45 2240 YRM 0001 Troubleshooting Table 2. BATTERY TROUBLESHOOTING GUIDE (Continued) ↓ ↓ ↓ MORE THAN 100MA LESS THAN 100MA ↓ ↓ ———— BATTERY IS NOT LEAKING POSSIBLE SHORTED EXCESSIVELY OR CONDITION. WASHING OF SHORTED. WILL NOT BATTERY MAY BE LIKELY AFFECT SCR REQUIRED CIRCUIT OPERATION ↓...
  • Page 46 Troubleshooting 2240 YRM 0001 Table 2. BATTERY TROUBLESHOOTING GUIDE (Continued) DURING TESTING (POWER STEERING MOTOR RUNNING) MORE THAN .05 VOLTS LESS THAN .05 VOLTS ↓ ↓ —— —— LOCATE PROBLEM CELL OR CELLS. BATTERY IS IN GOOD CONDITION CHECK ELECTROLYTE ↓...
  • Page 48 2240 YRM 0001 10/18 (2/18)(8/16)(7/16)(1/16)(9/15)
  • Page 49 Maintenance AC MOTOR REPAIR MP20 [A249]; MPB045VG [A245] PART NO. 550036879 0620 YRM 1513...
  • Page 50 • 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 re- move parts.

  • Page 51: This Section Is For The Following Models

    Description ................................4 AC Motor Repair ............................... 4 Remove ................................4 Disassemble ................................. 4 Inspect .................................. 7 Assemble ................................7 Install ..................................7 Troubleshooting ................................ 8 This section is for the following models: (MP20) [A249]; (MPB045VG) [A245] ©2015 Yale Materials Handling Corp.

  • Page 53: General

    0620 YRM 1513 General General ACCESSING THE DRIVE UNIT This section contains repair and maintenance COMPARTMENT procedures for the AC traction motor. Additional information concerning the traction motor may be included in other sections when the information is The drive unit compartment is concealed behind a more closely related to other systems.
  • Page 54 General 0620 YRM 1513 To install the drive unit cover, place the bottom of the Remove the drive unit cover, starting at the top left drive unit cover onto the frame and position the lower edge of the cover and with both hands pull the cover edges partially into the lower retaining clips.

  • Page 55: Special Precautions

    0620 YRM 1513 Special Precautions Special Precautions DISCHARGING THE CAPACITORS WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnec- ted. To prevent electrical shock and personal in- jury, discharge the capacitor before inspecting or repairing any component.

  • Page 56: Description

    Description 0620 YRM 1513 Description The traction motor is a three-phase AC induction mo- nector links the encoder bearing wiring harness to the tor. DC battery current is converted into AC current in main wiring harness. A shaft extends out the top and the controller and then supplied to the traction motor.
  • Page 57 0620 YRM 1513 AC Motor Repair 1. ENCODER CONNECTOR (FEMALE 4 PRONG) 10. TEMP SENSOR CONNECTOR (FEMALE 2 2. ARMATURE PRONG) 3. SNAP RING 11. MOUNTING PLATE ASSEMBLY 4. SNAP RINGS (BRAKE ASSEMBLY) 12. SCREW 5. LOCKWASHER 13. GROMMET 6. ASSEMBLY SCREW 14.
  • Page 58 AC Motor Repair 0620 YRM 1513 Figure 5. Traction Motor Repair (A245)

  • Page 59: Inspect

    0620 YRM 1513 AC Motor Repair Legend for Figure 5 1. BRAKE ASSEMBLY 5. SPEED SENSOR 2. MOTOR 6. O-RING 3. SNAP RING 7. WOODRUFF KEY 4. ASSEMBLY SCREW 8. NUT INSPECT 5. Align the motor flanges and install the four as- sembly screws.

  • Page 60: Troubleshooting

    Troubleshooting 0620 YRM 1513 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Unusual noise from traction motor. Parking brake releasing/ Troubleshoot the parking brakes. damaged. Drive unit internal damage. Check that the drive unit rotates smoothly. Traction motor bearing damaged. Replace end head(s) and check stator and rotor for damage.
  • Page 61 0620 YRM 1513 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Traction motor does not operate. Battery lacks sufficient charge. Charge/change battery. Throttle position sensor or neutral Troubleshoot the throttle position switch broken or out of adjustment. sensor or neutral switch. Stator coil shorted to case.
  • Page 62 NOTES...
  • Page 64 0620 YRM 1513 3/15 (12/13)(4/12)
  • Page 65 Maintenance MASTER DRIVE UNIT MP20 [A249]; MPB045VG [A245] PART NO. 550036880 0630 YRM 1503...
  • Page 66 • 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 re- move parts.
  • Page 67 Remove ................................3 Install ..................................3 Master Drive Unit ..............................3 Remove ................................3 Steering Bearing .............................. 5 Install ..................................5 Troubleshooting ................................ 6 This section is for the following models: (MP20) [A249]; (MPB045VG) [A245] ©2015 Yale Materials Handling Corp.

  • Page 69: General

    0630 YRM 1503 General General The master drive unit (MDU) includes the drive motor, The MDU is vertically installed in the truck and allows brake assembly, drive unit, and drive tire and wheel an effective utilization of space. The compact, one- assembly.

  • Page 70: Safety Precautions

    Safety Precautions 0630 YRM 1503 Safety Precautions 3. Discharge the capacitors in the controllers by con- WARNING necting a 200-ohm, 2-watt resistor across the Put blocks under each side of the truck under the controller's B+ and B- terminals using insulated jumper wires.

  • Page 71: Drive Tire

    0630 YRM 1503 Drive Tire Drive Tire REMOVE 3. Loosen and remove the five lug nuts securing the drive tire and wheel assembly to the axle shaft. WARNING 4. Remove the drive tire and wheel assembly. Block each side of the truck under the drive unit INSTALL frame.
  • Page 72 Master Drive Unit 0630 YRM 1503 8. Tag and disconnect the wiring from the steering tiller to the lift truck. 9. Support the steering tiller and remove the four capscrews and washers securing the tiller to the master drive unit. See Figure 3. 1.

  • Page 73: Steering Bearing

    6. Install the traction motor: 1. From underneath the master drive unit mounting a. Apply a light coat of moly paste lubricant Yale ® casting, remove the eight capscrews retaining the part no. 580000793 to the traction motor steering bearing to the mounting casting.

  • Page 74: Troubleshooting

    Master Drive Unit 0630 YRM 1503 10. Install the steer components as removed. See the CAUTION section Steering Mechanism 1600YRM1504. To prevent damage to the brake assembly always 11. Lower the truck to the floor. follow the special procedure for brake adjustment when adjusting the brake.
  • Page 76 0630 YRM 1503 3/15 (12/13)(4/12)
  • Page 77 Maintenance STEERING MECHANISM MP20 [A249];MPB045VG [A245] PART NO. 550036881 1600 YRM 1504...
  • Page 78 • 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.
  • Page 79 Control Handle Head ..............................2 Control Handle ................................2 Remove .................................2 Install ..................................8 Gas Spring ................................9 Discharging the Gas Spring ..........................9 Remove .................................9 Install ...................................10 Troubleshooting ..............................10 This section is for the following models: (MP20) [A249]; (MPB045VG) [A245] ©2018 Yale Materials Handling Corp.

  • Page 81: General

    1600 YRM 1504 General General The control handle assembly is designed to perform MDU. Move the control handle left or right to turn the several functions. The standard control handle drive/steer tire and steer the truck. Controls mounted includes the speed/direction control and buttons for the in the handle are linked to the control panel by a wiring horn, traction reversing, and hydraulic functions.

  • Page 82: Control Handle Head

    Control Handle Head 1600 YRM 1504 Remove the 200-ohm, 2-watt resistor before reconnecting the battery. Control Handle Head Refer to the section Electrical System 2200YRM1508 for disassembly and assembly of the control handle for instructions on removing and installing the control head can be located in the same section.
  • Page 83 1600 YRM 1504 Control Handle Figure 2. Control Handle Assembly, Lift Truck Models MP20 (A249)
  • Page 84 Control Handle 1600 YRM 1504 Legend for Figure 2. 1. CONTROL HANDLE HEAD 9. CAPSCREW 2. CAPSCREW 10. PIVOT SHAFT 3. LOCKNUT 11. STRAP CLAMP 4. LOCKNUT 12. BUSHING 5. HOLE PLUG 13. SENSOR 6. GAS SPRING 14. BALL STUD 7.
  • Page 85 1600 YRM 1504 Control Handle Legend for Figure 3. 1. CONTROL 7. STRAP CLAMP HANDLE HEAD 8. BUSHING 2. CAPSCREW 9. PROX SENSOR 3. LOCKNUT 10. BALL STUD 4. HOLE PLUG 11. CONTROL HANDLE 5. GAS SPRING 6. PIVOT SHAFT 12.
  • Page 86 Control Handle 1600 YRM 1504 Figure 4. Delivery Handle (Optional)
  • Page 87 1600 YRM 1504 Control Handle Legend for Figure 4. 1. CONTROL HANDLE 6. PLUG 11. MOUNTING 16. CAPSCREW HEAD 7. BUSHING WELDMENT 17. CAPSCREW 2. CONTROL HANDLE 8. COVER 12. GROMMET 18. STRAP CLAMP 9. CAPSCREW 13. PIVOT SHAFT 19. SHIM 3.

  • Page 88: Install

    Control Handle 1600 YRM 1504 INSTALL If previously removed, install the bushings into the control handle arm. Install the new gas spring into the control handle arm. Refer to Gas Spring in the section. NOTE: For lift truck models MP20 (A249) perform Step 3 to install prox sensor.

  • Page 89: Gas Spring

    1600 YRM 1504 Gas Spring 15. Adjust the prox sensor so the end of the sensor is 17. Install the drive unit compartment cover. no more than 4 mm (0.16 in.) from the support 18. Connect the battery and test the operation of the bracket.

  • Page 90: Install

    Troubleshooting 1600 YRM 1504 Remove the retention clip from the gas spring ball Make certain the control handle arm is secured in socket. Disconnect the gas spring from the ball the full upright position and position the new gas stud. spring into the control handle arm.
  • Page 92 1600 YRM 1504 12/18 (11/17)(7/16)(3/15)(12/13)(4/12)
  • Page 93 Maintenance BRAKES MP20 [A249]; MPB045VG [A245] PART NO. 550036882 1800 YRM 1505...
  • Page 94 • 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 re- move parts.
  • Page 95 Hold On Grade Test ............................. 3 Brake Coil Check ..............................4 Brake Assembly Repair ............................4 Remove ................................4 Install ..................................5 Troubleshooting ................................ 6 This section is for the following models: (MP20) [A249]; (MPB045VG) [A245] ©2015 Yale Materials Handling Corp.

  • Page 97: General

    1800 YRM 1505 General General 8000YRM1510 Periodic Maintenance WARNING 8000YRM1666 - How To Put A Lift Truck On DO NOT operate a lift truck that needs repairs. If a Blocks. repair is necessary, put a DO NOT OPERATE tag on the control handle. Remove the key from the WARNING key switch.

  • Page 98: Special Precautions

    Description 1800 YRM 1505 3. Lower the control handle arm to the operating or BRAKE OFF position. Refer to Figure 1. 4. Rotate direction/speed control (butterfly knobs) in the direction of travel. The friction brake is applied when the key switch is in the OFF position on ALL trucks.

  • Page 99: Brake Check

    1800 YRM 1505 Special Precautions Legend for Figure 2 1. CONTROLLER 2. POSITIVE CONNECTION 3. INSULATED JUMPER WIRES 4. 200-OHM, 2-WATT RESISTOR 5. NEGATIVE CONNECTION Figure 2. Discharging Controller Brake Check HOLD ON GRADE TEST the grade, the brake assembly must be repaired or re- placed.

  • Page 100: Brake Coil Check

    Brake Check 1800 YRM 1505 Brake Coil Check Check for correct brake coil resistance. The brake coil Table 1. Brake Coil Resistance can be checked with a ohmmeter. The coil resistance Model Number Resistance (±10%) should be the value shown in Table 1. MP20, MPB045VG 22.75 ohms Brake Assembly Repair...

  • Page 101: Install

    1800 YRM 1505 Brake Assembly Repair 4. Install the upper snap ring on the end of the motor WARNING shaft. Use caution when removing or installing snap 5. Replace the adapter and friction disk and tighten rings. These snap rings can come loose during re- the screws that hold the adapter to the brake.

  • Page 102: Troubleshooting

    Troubleshooting 1800 YRM 1505 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Brake does not release. Key switch is in the OFF position. Turn key switch to the ON position. Battery is not connected or prop- Connect or clean battery connec- erly charged.
  • Page 103 1800 YRM 1505 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Brake will not apply. Mechanical failure within the brake Replace the brake assembly. assembly. Brake linings worn beyond specifi- Replace the brake assembly. cation. See Brake Check in this section.
  • Page 104 NOTES...
  • Page 106 1800 YRM 1505 3/15 (12/13)(4/12)
  • Page 107 Maintenance HYDRAULIC SYSTEM MP20 [A249]; MPB045VG [A245] PART NO. 550036883 1900 YRM 1506...
  • Page 108 • 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 re- move parts.
  • Page 109 Relief Valve Pressure Check ..........................12 Relief Valve Adjust ............................. 13 Troubleshooting ..............................14 Lift Assemblies ..............................14 Hydraulic Cylinders .............................14 Hydraulic Pump ..............................15 This section is for the following models: (MP20) [A249]; (MPB045VG) [A245] ©2015 Yale Materials Handling Corp.

  • Page 111: General

    1900 YRM 1506 General General The hydraulic system provides the force required to The hydraulic pump and motor assemblies are lift the loads on all motorized lift trucks. mechanically joined together as a compact unit, combining the reservoir, pump, and motor together as The hydraulic system on the motorized lift truck a single assembly.

  • Page 112: Operation

    Special Precautions 1900 YRM 1506 Legend for Figure 1 1. CONTROLLER 2. POSITIVE CONNECTION 3. INSULATED JUMPER WIRES 4. 200-OHM, 2-WATT RESISTOR 5. NEGATIVE CONNECTION Figure 1. Discharging Controller Operation LIFTING A LOAD As oil is pushed out of the pump, it passes through a one-way check valve to the lift cylinder.
  • Page 113 1900 YRM 1506 Operation Once relief valve pressure is reached, hydraulic oil will continue to be diverted from the lift cylinder to the reservoir until the lift button is released or electrical power is interrupted. Figure 2. Hydraulic Schematic 1. LIFT CYLINDER 2.

  • Page 114: Lowering A Load

    Operation 1900 YRM 1506 LOWERING A LOAD 1. Flush the entire system when a failure is encoun- tered to make sure all paint, metal chips, welding A load is lowered by depressing the lower button. shot, and debris are removed. When the lower button is depressed, electric current 2.

  • Page 115: Hydraulic Unit

    1900 YRM 1506 Hydraulic Unit Hydraulic Unit REMOVE 3. Raise the drive wheel off the floor and put blocks under both sides of the drive unit frame. Refer to: • Periodic Maintenance 8000YRM1510 WARNING for lift truck model A249 Batteries are heavy and can cause personal in- •...

  • Page 116: Hydraulic Pump

    Hydraulic Pump 1900 YRM 1506 Hydraulic Pump REMOVE 5. Install the O-rings into the pump cavities. Apply grease to the return tubes. Insert tubes into pump 1. Remove the hydraulic unit from the lift truck. Re- cavities and O-rings. Grease the suction tube and fer to the Figure 4 or Figure 5 in this section.
  • Page 117 1900 YRM 1506 Hydraulic Pump Figure 4. Hydraulic Unit (A249)
  • Page 118 Hydraulic Pump 1900 YRM 1506 Legend for Figure 4 1. MOTOR 3. HYDRAULIC SUB UNIT 2. ELECTRO-POPPET VALVE 4. FILLER TANK 1. MOTOR 3. HYDRAULIC SUB UNIT 2. ELECTRO-POPPET VALVE 4. FILLER TANK Figure 5. Hydraulic Unit (A245)

  • Page 119: Hydraulic Pump Reservoir

    1900 YRM 1506 Hydraulic Pump Hydraulic Pump Reservoir REMOVE 6. Clean the reservoir and the suction screen. In- spect the screen for damage and replace if nec- The reservoir of the hydraulic pump unit can be re- essary. moved without removing the complete hydraulic unit. NOTE: The capscrews that hold the reservoir to the The motor will also come loose, with one set of subunit also hold the motor to the subunit.

  • Page 120: Hydraulic Cylinder

    Hydraulic Cylinder 1900 YRM 1506 Hydraulic Cylinder REMOVE 6. Open the battery tray so that the backside of the top center cover is showing. WARNING 7. Remove the capscrew securing the cover to the Put blocks under each fork. Position blocks on frame and lift the cover from its position.

  • Page 121: Install

    1900 YRM 1506 Hydraulic Cylinder 9. Install the new O-rings, rod seal, and wiper to the 8. Install the top center and main center covers as gland nut. removed. 10. Install the gland nut over the piston rod and into 9.

  • Page 122: Relief Valve Adjustment

    Relief Valve Adjustment 1900 YRM 1506 Relief Valve Adjustment RELIEF VALVE PRESSURE CHECK 5. Remove the drive unit compartment cover. Refer to AC Motor Repair 0620YRM1513, Accessing the Drive Unit Compartment. WARNING DO NOT make repairs or adjustments unless you 6.

  • Page 123: Relief Valve Adjust

    1900 YRM 1506 Relief Valve Adjustment 16. Remove the pressure gauge and tee. 7. Connect the battery and turn key to the ON posi- tion. 17. Reconnect the hydraulic hose to pump. 8. Recheck the relief pressure. See Relief Valve 18.

  • Page 124: Troubleshooting

    Troubleshooting 1900 YRM 1506 Troubleshooting LIFT ASSEMBLIES PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Forks fail to elevate. Faulty hydraulic equipment. See Pumps and Hydraulic Cylin- ders below. Deformed lifting components. Disassemble and replace dam- aged parts. Slow lifting speed and insufficient Faulty hydraulic equipment.

  • Page 125: Hydraulic Pump

    1900 YRM 1506 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Rod spontaneously retracts. Scores on inner surface of tube. Smooth surface with an oil stone. Score on tube. Replace cylinder tube. Score on piston ring. Replace piston ring. Foreign matter on packing ring. Replace packing.
  • Page 126 Troubleshooting 1900 YRM 1506 PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Pump produces noise. Cavitation caused by collapsed Drain and clean system. suction hose or clogged screen. Faulty oil suction. Add oil to specified level. Air suction through loose connec- Tighten all hose connections on tions on suction side.
  • Page 128 1900 YRM 1506 2/15 (12/13)(4/12)
  • Page 129 Maintenance ELECTRICAL SYSTEM MP20 [A249];MPB045VG [A245] PART NO. 550036885 2200 YRM 1508...
  • Page 130 • 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.
  • Page 131 Convenience Port ............................... 23 General ................................23 LED Status Display ............................24 Charging ................................24 Troubleshooting ..............................25 General ................................25 Error Modes ..............................26 A.C. Convenience Port Accessory (Optional) ..................... 28 Battery Pack Troubleshooting ......................... 28 ©2018 Yale Materials Handling Corp.
  • Page 132 Table of Contents TABLE OF CONTENTS (Continued) BDI Display ................................30 Remove ................................30 Install ...................................30 This section is for the following models: (MP20) [A249]; (MPB045VG) [A245]...

  • Page 133: General

    2200 YRM 1508 General General WARNING DO NOT make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can create a dangerous operating condition. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately.

  • Page 134: Special Precautions

    Special Precautions 2200 YRM 1508 Special Precautions DISCHARGING THE CAPACITORS jumper wires. See Figure 2. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. WARNING The capacitor in the controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component.

  • Page 135: Electrical System Checks

    2200 YRM 1508 Electrical System Checks Electrical System Checks Discharge the capacitors. See Special Precautions in this section. WARNING Disconnect battery before opening NOTE: These checks require a volt-ohmmeter with a compartment cover or inspecting or repairing the meter movement. Most digital meters will not operate electrical system.
  • Page 136 Electrical System Checks 2200 YRM 1508 Table 1. Voltage Checks LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. NO FAULT IS DISPLAYED ON THE CONTROLLER. Possible Causes: 1. Battery not connected. 2. Control fuse is damaged. 3. Key switch or brake switch is damaged. 4.

  • Page 137: Repairs

    2200 YRM 1508 Repairs Repairs NOTE: Although the controller is factory programmed, any custom parameters must be uploaded or re- WARNING entered into the controller when replacing. See the DO NOT make repairs or adjustments unless you section User Interface. have been properly trained and authorized to do DO NOT replace the controller until you have so.

  • Page 138: Pump Contactor Coil, Check

    Repairs 2200 YRM 1508 PUMP CONTACTOR COIL, CHECK Disconnect coil wires. Test contactor coil using an ohmmeter to measure the resistance. The coil should read 55 ohms ±10%. Remove and replace contactor if resistance readings indicate a short circuit in both directions or if there is an open circuit in both directions.

  • Page 139: Remove

    2200 YRM 1508 Repairs Remove Refer to Figure 4 for the following procedures. Remove contactor as described in Pump Contactor, Replace. Remove screws (4) that fasten the top cover to the coil and frame. Remove cover, moving contact (2), and return spring.

  • Page 140: Fuses

    Fuses 2200 YRM 1508 Fuses WARNING The capacitor in the transistor controller can hold electrical charge after battery disconnected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses. Make certain the battery has been disconnected.

  • Page 141: Disconnect Switchbattery/Main Contactor And Coil

    2200 YRM 1508 Disconnect SwitchBattery/Main Contactor and Coil 1. BATTERY DISCONNECT SWITCH 2. NUT 3. WASHER 4. SCREW 1. BATTERY DISCONNECT SWITCH 5. FUSE 2. NUT 3. WASHER Figure 6. Electrical Components 4. FUSE Figure 7. Electrical Components ()A896, A890 Disconnect SwitchBattery /Main Contactor and Coil DISCONNECT SWITCH, CHECK Remove the two screws retaining the switch to...

  • Page 142: Horn

    Horn 2200 YRM 1508 Disconnect coil wires. Remove and replace contactor if resistance readings indicate a short circuit in both directions Test contactor coil using an ohmmeter to measure or if there is an open circuit in both directions. the resistance. The coil should read 30 ohms, Make sure coil wires are connected to the proper ±5%.

  • Page 143: Install

    2200 YRM 1508 Brake and Interlock Sensor Tighten the nuts retaining the sensor to the tiller bracket. Reconnect the sensor lead to the truck harness. CHECK Turn the key switch to the ON position. Move the tiller handle down and check that the brake releases when the handle is in the operating position.

  • Page 144: Steer Reduction Sensor

    Steer Reduction Sensor 2200 YRM 1508 Steer Reduction Sensor REMOVE INSTALL NOTE: Note routing of steer reduction sensor wiring Route steer reduction sensor around MDU and prior to removal to help during installation. AC Motor as noted during removal. Position lift truck on flat level surface. Turn key Connect sensor to main wiring harness connector switch to OFF position and disconnect battery.

  • Page 145: Height Limit

    2200 YRM 1508 Height Limit Height Limit Height limiting is controlled by the height limit switch in cause this current draw: The first is when the lift the controller. When the controller senses a high cylinder reaches maximum height, and the second is current draw from the hydraulic pump, it will shut down when the load exceeds the rated capacity.
  • Page 146 Control Handle 2200 YRM 1508 1. JUMPER TERMINALS (SV2) 4. LED DISPLAY SCREEN 2. HORN SWITCH (S1) 5. BELLY SWITCH (S) 3. THUMBWHEEL SWITCH (MAGNETIC HOLDER) 6. TURTLE SWITCH (S2) Figure 11. Control Handle Card Partially assemble the control handle head. Refer is 7.

  • Page 147: Calibrate

    2200 YRM 1508 Control Handle Calibrate Refer to Figure 11 for the following instructions. Verify that the key switch is in the OFF position. Move the jumper from P (park) to T (teach). See Figure 12. Ensure the leads from the Right Lift switch connects to the JP10 socket and the leads from the Right Lower switch connects to the JP12 socket.

  • Page 148: Assemble

    Control Handle 2200 YRM 1508 Move the jumper from T (teach) to P (park). See Figure 12. The LED screen will change to show a decimal beside the completed segments indicating they have been saved. See Figure 13, view E. 10.
  • Page 149 2200 YRM 1508 Control Handle 1. CAPSCREW 14. SUPPORT 2. WASHER 15. CONTROL HANDLE CARD 3. RH BUTTERFLY KNOB 16. SHAFT 4. BUSHING 17. LH BUTTERFLY KNOB 5. BELLY SWITCH COVER 18. SPRING 6. LOCKING LEVER 19. TILLER HEAD (UPPER HALF) 7.

  • Page 150: Charger And Convenience Port

    Charger and Convenience Port 2200 YRM 1508 Charger and Convenience Port REMOVE Position lift truck on level surface. Turn key switch to OFF position and disconnect the battery. Remove drive unit compartment cover. Refer to AC Motor Repair 0620YRM1513, Accessing the Drive Unit Compartment, Lift Trucks A419 and B419A245 and B245.

  • Page 151: Install

    2200 YRM 1508 ACCUSENSE Battery Charger Install two nuts holding charger onto control panel. See Figure 16. Install negative (black) electrical wire onto B(-) terminal of controller. See Figure 16. Install positive (red) wire onto fused B(+) terminal. Connect two electrical connectors to main wiring harness.
  • Page 152 ACCUSENSE Battery Charger 2200 YRM 1508 NOTE: Chargers can be identified by the MFR MOD the MFR MOD number read 1Q or 2Q, the equipment number on the charger label. If the first two digits of is a Gen IV Q-Series charger. Table 2.
  • Page 153 2200 YRM 1508 ACCUSENSE Battery Charger Table 3. LED Charge Modes MODE LED 1 LED 2 LED 3 LED 4 LED 5...

  • Page 154: Changing Mode Setting

    ACCUSENSE Battery Charger 2200 YRM 1508 Figure 20. Switch Position Mode Chart Changing Mode Setting mode. If the LEDs do not flash when initially connected to power, refer to Troubleshooting in this section. NOTE: Mode settings can be checked by connecting Modes are set by the sequence of the dip switches.

  • Page 155: Convenience Port

    2200 YRM 1508 ACCUSENSE Battery Charger CONVENIENCE PORT serial communication is lost or if the battery’s voltage is below charger’s minimum voltage for charging General threshold. Verify the connection from the 4 pin connector from convenience port to the 4 socket This charger is connected to a convenience port which connector from charger.

  • Page 156: Led Status Display

    ACCUSENSE Battery Charger 2200 YRM 1508 Legend for Figure 22. 1. RED: AC POWER / ERROR 1 2. RED: SHUTDOWN / ERROR 2 3. RED: BATTERY DETECTION / ERROR 3 4. YELLOW: FLASH WHEN TESTING / CONTINUOUS WHEN CHARGING / ERROR 4 5.

  • Page 157: Troubleshooting

    2200 YRM 1508 ACCUSENSE Battery Charger During this step, the yellow, CHARGING, LED to shutdown and will flash one or all three of the red will flash on and off every two seconds. The LEDs on the top of the charger. If this condition occurs, charger is checking for faults prior to the start of see Troubleshooting in this section.

  • Page 158: Error Modes

    ACCUSENSE Battery Charger 2200 YRM 1508 (1) Connect the charger plug to a 120 volt AC NO: Proceed to Step 5. power source using a 20 amp rated Is the Charging LED either flashing or illuminated extension cord. continuously when the charger is connected to a (2) How many times do all 5 LEDs flash upon 120 volt AC power source? connection?
  • Page 159 2200 YRM 1508 ACCUSENSE Battery Charger Table 5. LED Error Codes CONDITION LED 1 LED 2 LED 3 LED 4 LED 5 Battery Voltage High Flash Battery Pack Unbalanced Flash Excessive Charging Time Flash Flash Flash Battery Testing - 1 Flash Flash Battery Testing - 2...

  • Page 160: Convenience Port Accessory (Optional)

    ACCUSENSE Battery Charger 2200 YRM 1508 Severe Discharge Error: Based on 1.417V/cell, this After a charging cycle, the SG measurement for each error is produced when cell voltage falls below this cell should be 1.265 or greater. value (example: 17Vdc for 24V Battery Pack). A.C. From cell to cell within one battery: The SG Power should be connected to charger and charging measurements should not vary more than 0.020.
  • Page 161 2200 YRM 1508 ACCUSENSE Battery Charger Table 6. Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Dead battery Recharge or replace battery Failed (Open) fuse Replace Failed (Open) fuse Lift truck will not move Brake is applied Test the brake to ensure wiring to brake is good Drive motor not operating Repair or replace drive motor Sequencing fault...
  • Page 162 BDI Display 2200 YRM 1508 BDI Display REMOVE INSTALL NOTE: Access electrical connector and nuts through Install BDI display into front of control panel. See u-shaped cutout in top of control panel. Figure 23. Disconnect electrical connector from back of BDI Install two nuts onto back of BDI display.
  • Page 164 2200 YRM 1508 6/18 (11/16)(10/16)(8/16)(4/15)(12/14)
  • Page 165 Maintenance LIFTING MECHANISM MP20 [A249]; MPB045VG [A245] PART NO. 550036886 4000 YRM 1509...
  • Page 166 • 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 re- move parts.
  • Page 167 Install ..................................6 Rocker Arm and Pull Rods ............................7 Remove ................................7 Disassemble ................................. 9 Assemble ................................9 Install ..................................9 Troubleshooting ..............................10 This section is for the following models: (MP20) [A249]; (MPB045VG) [A245] ©2013 Yale Materials Handling Corp.

  • Page 169: General

    4000 YRM 1509 General General This section contains the description, repair, and For troubleshooting and repairs on the hydraulic adjustment procedures for the lifting mechanisms components, see Hydraulic System 1900YRM1506. installed on the MP20MP035-D, MP045VG lift truck. For troubleshooting and repairs on the electrical components see Electrical System 2200YRM1508.

  • Page 170: Install

    Caster Wheels 4000 YRM 1509 INSTALL 1. Install one of the bearings into the load wheel and install the spacer. 2. Install the other bearing into the load wheel. 3. Install the bushings into both ends of the load wheel. 4.

  • Page 171: Caster Wheels

    4000 YRM 1509 Caster Wheels Caster Wheels CASTER ADJUSTMENT • Periodic Maintenance 8000YRM1666 for lift truck model A245 WARNING 4. Loosen the wheel axle capscrews on either side In normal operation, the casters should continu- of the caster wheel until the adjuster can be ously contact the floor.

  • Page 172: Caster Replacement

    Caster Wheels 4000 YRM 1509 CASTER REPLACEMENT Drive the axle from the caster wheel and remove the wheel. See Figure 4. WARNING 3. Remove the dust caps, spacers, bearings, and Put blocks under both forks and on both sides of bushing from the caster wheel.

  • Page 173: Assemble

    4000 YRM 1509 Rear Link and Load Wheel Assembly Assemble 5. Align the caster wheel within the wheel frame and insert the axle. 1. Install the bearing in the top plate and install the retaining ring. 6. Install the adjusters into the wheel frame and lock in place with the axle capscrews.

  • Page 174: Disassemble

    Rear Link and Load Wheel Assembly 4000 YRM 1509 DISASSEMBLE 4. Connect the battery and press the lift button to raise the forks. 1. Remove the bushings from the rear link. See Fig- ure 1 and Figure 2. 5. Remove the blocks from under the forks and the drive tire.

  • Page 175: Rocker Arm And Pull Rods

    4000 YRM 1509 Rocker Arm and Pull Rods Rocker Arm and Pull Rods REMOVE the main frame, near the rocker arms. The blocks must be thick enough to just fit under the main frame. The main frame must not lower or tilt when WARNING the rocker arms or upper links are disconnected.
  • Page 176 Rocker Arm and Pull Rods 4000 YRM 1509 1. CAPSCREW 2. PIN Figure 7. Frame Separation CAUTION The rocker arm is heavy (11 kg). Support the rocker arm assembly during removal. 6. Remove the capscrews retaining the load wheel assemblies to the fork frame. Remove the load wheel assembly pivot pins from the fork frame.

  • Page 177: Disassemble

    4000 YRM 1509 Rocker Arm and Pull Rods 1. ROCKER ARM 2. BUSHING 3. REAR LINK ASSEMBLY Figure 11. Lift Linkage Disassembly ASSEMBLE 1. FORK 2. LIFT LINKAGE 1. Press new bushings into the rocker arm. Align the groove in bushings with the lube fitting for each Figure 9.

  • Page 178: Troubleshooting

    Troubleshooting 4000 YRM 1509 6. Align the load wheel assembly and pull rod with • Frame 0100YRM1665 the load wheel pivot pin hole in the fork frame. for lift truck model A245 7. Install the load wheel pivot pins and the cap- 10.
  • Page 179 4000 YRM 1509 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Slow lifting speed and insufficient Battery is discharged. Charge or replace battery. See the handling capacity. section Periodic Maintenance for your lift truck. Oil in the hydraulic reservoir is low. Fill reservoir to correct level.
  • Page 180 NOTES...
  • Page 182 Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011 4000 YRM 1509 12/13 (4/12)
  • Page 183 Maintenance CAPACITIES AND SPECIFICATIONS MP20 [A249]; MPB045VG [A245] PART NO. 550036888 8000 YRM 1511...
  • Page 184 • 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 re- move parts.
  • Page 185 Master Drive Unit ..............................3 Steering ................................3 Electrical ................................3 Lift Mechanism ..............................3 Covers .................................. 4 Operator Guard ..............................4 Battery Specifications ............................... 4 This section is for the following models: (MP20) [A249]; (MPB045VG) [A245] ©2016 Yale Materials Handling Corp.

  • Page 187: Hydraulic System

    ® Exxon Univis HVI 26 −15°C (5.0°F) −60°C (−76.0°F) Pour Point Maximum Field Personnel Note: The product listed above is the approved source that meets or exceeds Yale specifications. The use of products other than that listed above is unauthorized.

  • Page 188: Grease

    Moly-Fortified Dropping Pt. 310°C (590°F) 288°C (550°F) Field Personnel Note: The product listed above is the approved source that meets or exceeds Yale specifications. The use of products other than that listed above is unauthorized. Truck Weights Fork Length Fork Length...

  • Page 189: Torque Specifications

    8000 YRM 1511 Torque Specifications Torque Specifications Return Spring Mounting Stud (1) CASTER ASSEMBLY 35 N•m (26 lbf ft) Caster Mounting Capscrews (4 each) Return Spring to Support Bracket (1) 57 N•m (42 lbf ft) 35 N•m (26 lbf ft) Caster Axle Capscrews (2 each) Control Arm Pivot Pin to Support Bracket (1) 35 N•m (25 lbf ft)

  • Page 190: Covers

    Torque Specifications 8000 YRM 1511 Front Fork Frame Pivot Shaft to Fork (2) Center Top Cover Capscrew (1) 35 N•m (26 lbf ft) 35 N•m (26 lbf ft) Pull Rod Pivot Shaft to Rocker Assembly (2) Center Main Cover Mounting Nuts (3) 35 N•m (26 lbf ft) 35 N•m (26 lbf ft) Rear Fork Pivot Shaft to Fork (2)

  • Page 191: Battery Specifications

    8000 YRM 1511 Battery Specifications Table 1. Battery Specifications MP20 Ampere Kilowatt Compartment Compartment Recommended Voltage Hours Hours Weight (Max) Length (X) Width (Y) (Max) Height (Max) (Max) (Max) 704 mm 223 mm 627 mm 212 kg 5.28 (27.7 in.) (8.78 in.) (24.7 in.) (467 lb)
  • Page 192 NOTES...
  • Page 194 8000 YRM 1511 6/16 (3/16)(12/13)(4/12)
  • Page 195 Maintenance DIAGRAMS MP20 [A249]; MP045VG [A245] PART NO. 550036889 8000 YRM 1512...
  • Page 196 • 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.
  • Page 197 Table of Contents TABLE OF CONTENTS General Notes ................................1 Schematic/Wiring Diagrams ..........................2 This section is for the following models: (MP20) [A249]; (MP045VG) [A245] ©2018 Yale Materials Handling Corp.
  • Page 199 8000 YRM 1512 General Notes General Notes Chain lines indicate EE enclosure. All parts are shown in the normal position for the • following conditions: Broken lines are for option only. • • All unused terminals and connectors must be •...
  • Page 200 General Notes 8000 YRM 1512 SCHEMATIC/WIRING DIAGRAMS Figure 1. Schematic/Wiring Diagram Pallet Truck (Sheet 1 of 3)
  • Page 201 8000 YRM 1512 General Notes Figure 1. Schematic/Wiring Diagram Pallet Truck (Sheet 2 of 3)
  • Page 202 General Notes 8000 YRM 1512 Figure 1. Schematic/Wiring Diagram Pallet Truck (Sheet 3 of 3)
  • Page 203 8000 YRM 1512 General Notes Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 1 of 7)
  • Page 204 General Notes 8000 YRM 1512 Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 2 of 7)
  • Page 205 8000 YRM 1512 General Notes Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 3 of 7)
  • Page 206 General Notes 8000 YRM 1512 Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 4 of 7)
  • Page 207 8000 YRM 1512 General Notes Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 5 of 7)
  • Page 208 General Notes 8000 YRM 1512 Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 6 of 7)
  • Page 209 8000 YRM 1512 General Notes Figure 2. Schematic/Wiring Diagram Premium Walkie (Sheet 7 of 7)
  • Page 210 NOTES...
  • Page 212 8000 YRM 1512 3/18 (12/14)(1/14)(12/13)(7/13)(4/12)
  • Page 213 Maintenance FRAME MPB045VG [A245] PART NO. 550093874 0100 YRM 1665...
  • Page 214 • 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 re- move parts.
  • Page 215 Frame Separation and Assembly ..........................2 Frame Separation ..............................2 Frame Assembly ..............................2 Moveable Load Backrest ............................2 Removal ................................2 Disassembly ..............................4 Painting Instructions ..............................4 Label Replacement ..............................4 This section is for the following models: (MPB045VG) [A245] ©2016 Yale Materials Handling Corp.
  • Page 217 0100 YRM 1665 General General This section contains the description and repair system. The lift cylinder actuates to evenly lift the fork procedures for the frame weldments of the lift truck. frame and raise the load. The battery end of the fork This model has integral mounting brackets and holes frame weldment is lifted directly by the cylinder and factory drilled for the mounting of covers, the lift pump...
  • Page 218 Frame Separation and Assembly 0100 YRM 1665 Frame Separation and Assembly 2. Install both drive unit frame pivot pins to attach FRAME SEPARATION the rocker arms to the drive unit frame. See Rocker Arm and Pull Rods, Install in Lifting In some cases a fork frame or a drive unit frame may Mechanism 4000YRM1509.
  • Page 219 0100 YRM 1665 Frame Separation and Assembly 1. BRACKET WELDMENT 14. CAPSCREW 2. BUSHING 15. CAPSCREW 3. LOWER LINK 16. CAPSCREW 4. BOLT 17. NUT 5. NUT 18. KNOB 6. COVER 19. CAPSCREW 7. MOUNTING WELDMENT 20. COVER 8. UPPER LINK 21.
  • Page 220 Remove old rivets before installing a new nameplate 3. Carefully hold the label in the correct position ® cover. See your Yale lift truck dealer to make sure above the surface. Put the label in the correct po- the nameplate cover information is correct and com- sition on the surface.
  • Page 221 0100 YRM 1665 Label Replacement 1. WARRANTY LABEL 5. YALE LOGO LABEL 2. NAMEPLATE 6. PINCH WARNING LABEL 3. E - STOP LABEL 7. WARNING LABEL 4. BDI LABEL Figure 3. Labels and Decals...
  • Page 222 NOTES...
  • Page 224 0100 YRM 1665 7/16 (12/13)
  • Page 225 Maintenance PERIODIC MAINTENANCE MPB045VG [A245] PART NO. 550093875 8000 YRM 1666...
  • Page 226 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.
  • Page 227 Where to Charge Batteries ..........................17 Lithium-Ion Battery Care ..........................17 HOW TO CHANGE THE BATTERY ........................18 Changing Battery With Rollers ........................19 Remove ...............................19 Install ................................19 This section is for the following models: (MPB045VG) [A245] ©2019 Yale Materials Handling Corp.

  • Page 229: Introduction

    This section contains the instructions for periodic Schedule. Service Manuals are available from your maintenance and inspection and a Maintenance Yale® lift truck dealer to help users who do their own Schedule. repairs. The Maintenance Schedule has time intervals for Your Yale®...

  • Page 230: Drive Unit Compartment Covers

    Introduction 8000 YRM 1666 A. LH SIDE C. FORKS TRAILING B. RH SIDE D. FORKS LEADING Figure 1. Truck Orientation DRIVE UNIT COMPARTMENT COVERS To install drive unit cover, place the bottom of the drive unit cover onto the frame and position the lower edges The drive unit compartment is concealed behind a partially into the lower retaining clips.

  • Page 231: How To Move A Disabled Truck

    8000 YRM 1666 Introduction 1. DRIVE UNIT COMPARTMENT COVER 3. RETAINING CLIPS 2. ALIGNMENT PIN 4. FRAME Figure 2. Drive Unit Compartment Cover HOW TO MOVE A DISABLED TRUCK Make sure no one except the driver is near the lift trucks during towing.

  • Page 232: How To Tow The Lift Truck

    Introduction 8000 YRM 1666 How to Tow the Lift Truck section of this manual. Use NOTE: The Brake Release Adapter MUST be the control handle to steer the lift truck while it is being removed after repairs are completed BEFORE towed.

  • Page 233: How To Raise The Load Wheels

    8000 YRM 1666 Special Precautions Use a special low clearance hydraulic jack, crane, Raise the lift truck only enough to suspend the or another lift truck to raise the drive tire. Make drive tire. Install additional blocks under the frame sure that the jack, crane, or other lift truck has the near the drive tire.

  • Page 234: Maintenance Schedule

    Maintenance Schedule 8000 YRM 1666 CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire disconnected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller.
  • Page 235 8000 YRM 1666 Maintenance Schedule Figure 5. Maintenance Points Table 1. Maintenance Schedule (See )Figure 5 Item Item 8 Hr/ 2000 Procedure or Specification Hr/ 2 Hr/ 1 Quantity mont year Battery Check Level See Specifications Brake Check Operation Hold on 10% Grade Directional/Speed Check Operation Control...

  • Page 236: Maintenance Procedures Every 8 Hours Or Daily

    Maintenance Procedures Every 8 Hours or Daily 8000 YRM 1666 Table 1. Maintenance Schedule (See )Figure 5 (Continued) Item Item 8 Hr/ 2000 Procedure or Specification Hr/ 2 Hr/ 1 Quantity mont year Lift, Lower Operation Check Operation Safety Labels and Replace if See Parts Manual Operating Manual...

  • Page 237: Safety Labels

    8000 YRM 1666 Maintenance Procedures Every 8 Hours or Daily Safety Labels the battery area. Keep the top of the battery clean, dry, and free of corrosion. Make sure the battery is charged and has the correct WARNING voltage and ampere hour rating for the lift truck. See If labels that have warnings or instructions are the nameplate.

  • Page 238: Drive Tire, Load Wheels, Casters, And Frame

    Maintenance Procedures Every 8 Hours or Daily 8000 YRM 1666 CAUTION Protect the hydraulic system from dirt and contaminants when servicing hydraulic system. Never operate the pump without the proper amount of oil in the hydraulic system. The operation of the hydraulic pump with low oil levels will damage the pump.
  • Page 239 8000 YRM 1666 Maintenance Procedures Every 8 Hours or Daily WARNING normal operation, casters should continuously contact the floor. As the drive tire wears, the frame will move closer to the floor and the casters will carry more of the load. If the casters are not periodically adjusted, they will bear too much of the lift truck's weight and reduce the load on the drive tire necessary to maintain...

  • Page 240: Checks With Key Switch Turned On

    Maintenance Procedures Every 8 Hours or Daily 8000 YRM 1666 CHECKS WITH KEY SWITCH TURNED ON Never operate the pump without the proper amount of oil in the hydraulic system. Operating Operation the hydraulic pump with low oil levels will damage the pump.

  • Page 241: Maintenance Procedures Every 350 Hours Or Every 2 Months

    8000 YRM 1666 Maintenance Procedures Every 350 Hours or Every 2 Months Check the operation of the lift and lower release the traction reverse button. The lift truck functions. Push the lift button and then the lower should not resume movement in the direction of button.

  • Page 242: Hydraulic System

    Contact your Yale dealer for information on optional The hydraulic oil is hot at normal operating packages. temperatures. Be careful when draining the oil.

  • Page 243: Maintenance Procedures Every 2000 Hours Or Yearly

    8000 YRM 1666 Maintenance Procedures Every 2000 Hours or Yearly tire for embedded rocks, glass, wire, pieces of metal, prevent damage to the axle seal. Make sure the wheel holes, cuts, and other damage. Remove any object bolts are tight. When installing the tire and wheel, snug that will cause damage.

  • Page 244: Battery Maintenance

    Battery Maintenance 8000 YRM 1666 Battery Maintenance HOW TO CHARGE THE BATTERY Table 2. Specific Gravity Corrections Specific Electrolyte Correction Correct WARNING Gravity Temperatur Points Value DO NOT put tools on the battery. Reading If the lift truckwas operatedwith a lowbattery, 1.210 31°C (88°F) +0.003...

  • Page 245: Lithium-Ion Battery

    8000 YRM 1666 Battery Maintenance Always use a hydrometer to check the battery if the Knowing When Battery Is Fully Charged battery is charged at regular intervals. Frequent charging of a battery that has a 2/3 or more charge WARNING can decrease the life of the battery.

  • Page 246: How To Change The Battery

    Battery Maintenance 8000 YRM 1666 HOW TO CHANGE THE BATTERY WARNING Make sure the capacity of the crane and spreader bar is greater than the weight of the battery. The weight of the battery is normally shown on the battery case. The spreader bar must NOT be made of metal or it must have insulated straps.

  • Page 247: Changing Battery With Rollers

    8000 YRM 1666 Battery Maintenance Connect the battery. Test the operation of the Attach the hook of the battery puller to the lifting motorized hand truck before returning the truck to hole of the battery. DO NOT touch battery cell service.
  • Page 248 NOTES...
  • Page 250 8000 YRM 1666 3/19 (2/19)(10/15)(6/15)(3/15)(12/13)
  • Page 251 Maintenance CONTROLLER DIAGNOSTICS MPB045VG [A245] PART NO. 550095689 9000 YRM 1671...
  • Page 252 • 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 re- move parts.
  • Page 253 Table of Contents TABLE OF CONTENTS SECTION 9030 - ELECTRICAL SYSTEM Group 03 - General Maintenance and Diagnostic Data..............9030-03-1 Group 20 - Diagnostic Trouble Codes....................9030-20-1 This section is for the following models: (MPB045VG) [A245] ©2015 Yale Materials Handling Corp.
  • Page 254 5. Most of the cross-reference data in the manual will be electronically linked for rapid and easy access. Use the links wherever the cursor highlights an item as a linkable option. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins...
  • Page 255 Mode (1 through 3) -Max Decel....................9030-03-10 Mode (1 through 3) -Neutral Braking.................... 9030-03-10 Mode (1 through 3) -Max Braking....................9030-03-10 Max Speed TM2........................... 9030-03-10 Max Accel TM2..........................9030-03-10 Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-1...
  • Page 256 DTC 30232 - Software ......................... 9030-20-58 DTC 30247 - Parameter........................9030-20-59 DTC 30248 - Low Temp........................9030-20-61 DTC 60050 - EmerRevr........................9030-20-63 DTC 60210 - EmerRevr........................9030-20-63 Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-2...

  • Page 257: General Troubleshooting

    Refer to 8000 YRM 1512 for wiring diagrams and ad- wiring involving the device or devices noted by the on- ditional circuit information. board diagnostic system. . Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-1...

  • Page 258: Discharging The Capacitors

    DO NOT short across the motor controller termi- nals with a screwdriver or jumper wire. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-2...

  • Page 259: Pc Service Tool

    Digital Multimeter (DMM) Digital multimeters provide several measurement functions in one tool. A DMM should be capable of ac- curately measuring voltage, amperage, and resist- Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-3...

  • Page 260: Basic Electrical Troubleshooting

    Measure voltage between measure voltage between TS04 and B(-). terminal before FU1 and B(-). Is voltage same as battery voltage? NOTE: Key in ON position. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-4...

  • Page 261: Amperage Checks

    The voltage of the meter bat- damaged, or corroded connections. tery and the amount of current flow in the circuit are Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-5...

  • Page 262: Lift And Lower Switch Check

    4. Measure resistance of tiller card switch JP15, pin NO- Replace faulty switch. 1 and pin 2. Is resistance 1.4K ohms ± 0.14K ohms Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-6...

  • Page 263: Multiplexing

    5 volts when added together. If both CAN HI and CAN LO have consistent 2.5 volt, there is no communication on the CANbus. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-7...

  • Page 264: Troubleshooting The Tiller Control Card Termination Resistor

    1000 RPM, upon steering the motor will de- sequent status code and description. Two seconds celerate to 750 RPM. will lapse between display screens before displaying the code sequencing. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-8...

  • Page 265: Traction Steering Decel Ramp

    Max Speed above which the “HS” parameters will be to neutral at high vehicle speeds. used. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-9...

  • Page 266: Fine Tuning-Ls (Low Speed)

    Larger values represent slower response. RPM = V * 936 Desired Example: RPM = 2.5MPH * 936 = 2340 rpm Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-10...

  • Page 267: Neutral Braking Tm2

    The BDI (battery discharge indicator) algo- C. OPERATIONAL REGION C rithm continuously calculates the battery state-of- charge whenever KSI is on. Figure 9030-03-3. Operational Regions Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-11...

  • Page 268: Battery-Bdi Empty Volts

    Undervoltage = Either Min Voltage controller voltage interval counter. (16.8V) or User Undervoltage × Nominal Voltage, whichever is higher. The User Undervoltage parame- Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-12...

  • Page 269: Status Codes And Descriptions

    The Traction Controller has detected that the Main Contactor is stuck closed or has welded tips. The Traction Controller has detected that the Main Contactor is not closed or stuck open. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-13...
  • Page 270 The Tiller Control Card has detected a Belly Switch Mismatch fault. The Tiller Control Card has detected a Belly Switch release fault. The Tiller Control Card has detected a Tiller Arm release fault. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-03-14...
  • Page 271 1. Replace faulty controller or tiller card. Make sure to indicate the Diagnostic Trouble Code on the warranty claim to include an accurate problem description leading to controller replacement. END POSSIBLE CAUSES END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-1...

  • Page 272: Dtc 30001 Liftcoil

    3. Measure voltage between pump coil terminal TS12 and B(+) while operating tiller card lift switch. Is voltage 24 ± 2.5 Vdc? YES: Disconnect battery and proceed to Cause B. NO: Proceed to Cause C. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-2...
  • Page 273 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-3...
  • Page 274 Diagnostic Trouble Codes ELECTRICAL SYSTEM DTC 30001 (Cont) LiftCoil DIAGRAMS Lift Coil and Pump Contactor END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-4...

  • Page 275: Dtc 30003 Lwrcoil

    3. Measure voltage between CRS05, socket 2 and B(+) while operating tiller card lower switch. Is voltage 24 ± 2.5 Vdc? YES: Disconnect battery and proceed to Cause B. NO: Proceed to Cause C. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-5...
  • Page 276 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-6...
  • Page 277 ELECTRICAL SYSTEM Diagnostic Trouble Codes DTC 30003 (Cont) LwrCoil DIAGRAMS Lower Coil and Pump Motor END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-7...

  • Page 278: Dtc 30033 Main Cont

    CPS001, socket 6. Is resistance <1 ohm? YES: Proceed to Cause B. NO: Inspect ground control circuit 075 for open or source of excessive resistance. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-8...
  • Page 279 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-9...
  • Page 280 Diagnostic Trouble Codes ELECTRICAL SYSTEM DTC 30033 (Cont) Main Cont DIAGRAMS Battery Disconnect / Main Contactor and Contactor Coil END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-10...

  • Page 281: Dtc 30035 Brake

    Is voltage same as key switch input? YES: Disconnect battery and proceed to Cause B. NO: Inspect circuit 239 for open or short. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-11...
  • Page 282 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-12...
  • Page 283 ELECTRICAL SYSTEM Diagnostic Trouble Codes DTC 30035 (Cont) Brake DTC 30035 BRAKE DIAGRAMS Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-13...
  • Page 284 Diagnostic Trouble Codes ELECTRICAL SYSTEM DTC 30035 (Cont) Brake Brake Coil END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-14...

  • Page 285: Dtc 30037 Alrmcoil

    Is resistance <1 ohm? YES: Connect traction controller connector CPS01 and proceed to Cause B. NO: Inspect ground control circuit 045 for open or short. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-15...
  • Page 286 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-16...
  • Page 287 ELECTRICAL SYSTEM Diagnostic Trouble Codes DTC 30037 (Cont) AlrmCoil DIAGRAMS Horn / Alarm END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-17...

  • Page 288: Dtc 30039 Audible Alarm (Opt)

    YES: Connect traction controller connector CPS01 and proceed to Cause B. NO: Inspect ground control circuit 728 for open, short, or source of excessive resistance. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-18...
  • Page 289 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-19...

  • Page 290: Dtc 30060 - Mtr Curr

    1. Measure continuity between the traction motor terminals U and V. Is continuity present? YES: Proceed to Step 2. NO: Repair or replace faulty traction motor. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-20...
  • Page 291 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES DIAGRAMS Traction Motor END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-21...

  • Page 292: Dtc 30062 Encoder

    YES: Reconnect the encoder connector CPS003, battery, and proceed to Cause B. NO: Inspect signal circuit 577 for open or source of excessive resistance. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-22...
  • Page 293 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-23...
  • Page 294 Diagnostic Trouble Codes ELECTRICAL SYSTEM DTC 30062 (Cont) Encoder DTC 30062 ENCODER DIAGRAMS Traction Motor END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-24...

  • Page 295: Dtc 30067 - Maincont (Stuck Closed)

    Is continuity present? YES: Reconnect battery and all connectors. Proceed to Cause B. NO: Inspect ground control circuit 075 for open or short. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-25...
  • Page 296 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-26...
  • Page 297 ELECTRICAL SYSTEM Diagnostic Trouble Codes DTC 30067 (Cont) MainCont (Stuck Closed) DIAGRAMS Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-27...
  • Page 298 Diagnostic Trouble Codes ELECTRICAL SYSTEM DTC 30067 (Cont) MainCont (Stuck Closed) Main Contactor END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-28...

  • Page 299: Dtc 30068 - Maincont (Stuck Open)

    Is continuity present? YES: Reconnect battery and all connectors. Proceed to Cause B. NO: Inspect ground control circuit 075 for open or short. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-29...
  • Page 300 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-30...
  • Page 301 ELECTRICAL SYSTEM Diagnostic Trouble Codes DTC 30068 (Cont) MainCont (Stuck Open) DIAGRAMS Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-31...
  • Page 302 Diagnostic Trouble Codes ELECTRICAL SYSTEM DTC 30068 (Cont) MainCont (Stuck Open) Main Contactor END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-32...

  • Page 303: Dtc 30069 Precharge

    YES: Verify battery state of charge and recheck condition. If actual voltage does not agree with PC service tool diagnostics, proceed to Cause B. NO: Proceed to Cause A. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-33...
  • Page 304 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-34...
  • Page 305 ELECTRICAL SYSTEM Diagnostic Trouble Codes DTC 30069 (Cont) Precharge END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-35...

  • Page 306: Dtc 30080 Overheat

    3. Measure resistance between CPS02, socket 2 and B(-). is resistance ≤ 1 ohm? YES: Proceed to Cause B. NO: Inspect circuit 101 for open or shorts. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-36...
  • Page 307 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES DTC 30080 OVERHEAT DIAGRAMS Traction Motor END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-37...

  • Page 308: Dtc 30086 Lowbatt

    YES: Disconnect battery and discharge the capacitor. Connect battery and re-key the vehicle prior to perform- ing Cause A. NO: Problem may be intermittent. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-38...
  • Page 309 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-39...
  • Page 310 Diagnostic Trouble Codes ELECTRICAL SYSTEM DTC 30086 (Cont) LowBatt END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-40...

  • Page 311: Dtc 30087 Overvolt

    Is voltage above 26 Vdc? YES: Ensure battery is rated at 24V and is properly connected to the truck. NO: Proceed to Cause B. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-41...
  • Page 312 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-42...
  • Page 313 ELECTRICAL SYSTEM Diagnostic Trouble Codes DTC 30087 (Cont) OverVolt END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-43...
  • Page 314 3. With encoder connector and battery display connector removed, measure voltage between CRS07, socket 5 and B(-). Is voltage 12 ± 1.5 Vdc? YES: Proceed to Step 4. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-44...
  • Page 315 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude and accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-45...
  • Page 316 Diagnostic Trouble Codes ELECTRICAL SYSTEM DTC 30090 (Cont) 12 Vdc / 5 Vdc Supply Output END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-46...

  • Page 317: Dtc 30106 Cancomm

    If voltage is above 5 volts, the CAN HI circuit is shorted to power. 2. Measure voltage between the tiller card connector CJ2, socket 1 and B(-). Is CAN LO voltage approximately 2.5 Vdc? Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-47...
  • Page 318 1. Replace faulty handle. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-48...
  • Page 319 ELECTRICAL SYSTEM Diagnostic Trouble Codes DTC 30106 (Cont) CANcomm DTC 30106 CANCOMM DIAGRAMS Control Card END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-49...

  • Page 320: Dtc 30201 - Start Up

    Refer to Electrical System YRM manual for tiller arm operational range information. Is fault caused by tiller arm operation? YES: Clear fault. NO: Proceed to Cause A. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-50...
  • Page 321 CRP10. Measure resistance between CRP06/pin 6, CRP10/pin 2, CPS01/socket 9. Is resistance ≤ 1 ohm? YES: Proceed to Cause D. NO: Inspect circuit 601 for open, shorts or source of excessive resistance. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-51...
  • Page 322 1. Replace faulty handle. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-52...
  • Page 323 ELECTRICAL SYSTEM Diagnostic Trouble Codes (Cont) Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-53...
  • Page 324 Diagnostic Trouble Codes ELECTRICAL SYSTEM (Cont) END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-54...

  • Page 325: Dtc 30227 Stalled

    NO: Proceed to Step 4. 4. Re-key the vehicle. Is the code still present? YES: Proceed to Cause A. NO: Problem may be intermittent. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-55...
  • Page 326 YES: Proceed to Step 3. NO: Repair or replace faulty motor. 3. Measure continuity between the motor terminals W and V. Is continuity present? Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-56...
  • Page 327 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES DTC 30227 STALLED DIAGRAMS Traction Motor END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-57...

  • Page 328: Dtc 30232 Software

    1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-58...

  • Page 329: Dtc 30247 Parameter

    YES: Clear error fault code from history. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description of service provided. NO: Proceed to Cause B. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-59...
  • Page 330 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-60...

  • Page 331: Dtc 30248 Low Temp

    -30°C (-22°F) or higher. Did system record and code reset? YES: Instruct operator on thermal management. NO: Proceed to Cause A. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-61...
  • Page 332 1. If no faults are found, replace controller. Make sure to indicate the DTC code(s) on the warranty claim to in- clude an accurate problem description leading to controller replacement. END POSSIBLE CAUSES END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-62...

  • Page 333: Dtc 60050 - Emerrevr

    Was fault due to interlock or tiller arm operation? YES: Clear fault. NO: Proceed to Cause B. Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-63...
  • Page 334 1. If no faults are found, replace tiller control card. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement. END POSSIBLE CAUSES Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-64...
  • Page 335 ELECTRICAL SYSTEM Diagnostic Trouble Codes (Cont) DIAGRAMS Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-65...
  • Page 336 Diagnostic Trouble Codes ELECTRICAL SYSTEM (Cont) Emergency Reverse END FAULT Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030-20-66...
  • Page 338 Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011 9000 YRM 1671 9/15 (1/15)(12/14)(10/14)(4/14)(1/14)
  • Page 339 Maintenance LITHIUM-ION BATTERY MPW45HD [A245];MP16, MP18, MP20, MP22 (MPB045VH) [B245] PART NO. 550136713 2240 YRM 1890...
  • Page 340 • 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.
  • Page 341 Knowing When Battery Is Fully Charged ......................16 Where to Charge Batteries ..........................16 Battery Care ................................16 Shipping and Handling ............................17 This section is for the following models: (MPW45HD) [A245]; MP16, MP18, MP20, MP22 (MPB045VH) [B245] ©2019 Yale Materials Handling Corp.

  • Page 343: General

    2240 YRM 1890 General General This section describes how to select and perform This Nameplate communicates specific information maintenance on batteries used in electric lift trucks. about the battery including the name of the battery Battery diagnosis and replacement requires special manufacturer, battery type, serial number, nominal training and equipment.

  • Page 344: Battery Voltage

    Battery Voltage 2240 YRM 1890 positive and negative at a quick and constant rate, the voltage is called Alternating Current. Figure 1. Electrical Terms Battery Voltage If you have more than one lift truck in operation, NOTE: The voltage of the battery can be found on the •...

  • Page 345: Wake-Up Circuit

    2240 YRM 1890 Charging and Troubleshooting management system), that will shut down the battery terminals, which then powers the electrical system. under following scenarios: The battery system will remain active until another sleep mode timeout occurs. • Under/Over temperature The wake-up circuit does not require special operation; Under/Over Charge •...
  • Page 346 Charging and Troubleshooting 2240 YRM 1890 There are also physical differences between Gen III For more information about these chargers, refer to and Gen IV chargers. Gen III charger wire harness the following Service Manuals: connections are on the right side of the charger face •...

  • Page 347: Changing Mode Setting

    2240 YRM 1890 Charging and Troubleshooting Figure 5. Switch Position Mode Chart Changing Mode Setting Modes are set by the sequence of the dip switches. Tampering with the Charging Mode Label voids NOTE: Mode settings can be checked by connecting warranty.

  • Page 348: Convenience Port

    Charging and Troubleshooting 2240 YRM 1890 Table 2. LED Charge Mode Indicator MODE SETTING LED 1 LED 2 LED 3 LED 4 LED 5 Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing...
  • Page 349 2240 YRM 1890 Charging and Troubleshooting Figure 6. Battery Charger Diagram (GPT)

  • Page 350: Led Status Display

    Charging and Troubleshooting 2240 YRM 1890 LED Status Display The charger has five colored LEDs located on the top of the charger. The LEDs are used to indicate the status of the charger during operation. The order of the LEDs may vary with models, but are labeled to identify their function.

  • Page 351: Charger Troubleshooting

    2240 YRM 1890 Charging and Troubleshooting CHARGER TROUBLESHOOTING CAUTION General The charger comes factory set to the battery NOTE: The charger runs a pre-qualifying test (yellow installed at the factory and must be changed if charging light flashing) at the beginning of the charge using different batteries.
  • Page 352 Charging and Troubleshooting 2240 YRM 1890 (2) NO: Change the charger mode to the proper YES: Proceed to Step 6. setting for the battery type being used. See NO: If no other LEDs are flashing, replace Changing Mode Setting . After changing the charger.

  • Page 353: Error Modes

    2240 YRM 1890 Charging and Troubleshooting Table 4. Charge Errors (Continued) Condition LED 1 LED 2 LED 3 LED 4 LED 5 Batt Is 100% Flashing Flashing Discharged Batt Beyond Over Flashing Flashing Discharged Batt Emergency Under Flashing Flashing Flashing - Voltage Batt Temperature Flashing...
  • Page 354 Charging and Troubleshooting 2240 YRM 1890 Battery Over Voltage: Charger’s Output DC Cable Remove all loads from battery, including charger and connection is possibly connected to a battery pack allow time for battery pack to ‘spring’ back to above with voltage higher than the output rating of the 1Vdc/cell.

  • Page 355: A.c. Convenience Port Accessory

    2240 YRM 1890 Charging and Troubleshooting Excessive Charge Time Error: Occurs when B- input through pin 3 is what the battery use as a charging took too long AND the battery voltage was signal to indicate that battery shall provide all available not allowed to increase above 2.17V/cell.

  • Page 356: Wake-Up Relay

    Charging and Troubleshooting 2240 YRM 1890 Wake-up Relay diagnose and repair, check pack external temperature, if over temp conditions exists, allow The wake-up relay is provided constant 24 volt input. to cool for 1 hour. If below the minimum When the key switch is closed, ground is supplied to temperature, move battery into a warmer area for the relay, activating the coil, closing the relay contacts.

  • Page 357: Battery Ratings

    2240 YRM 1890 Battery Ratings Over Current / Shorts: The pack is designed to NOTE: Only if ALL conditions above have been self-protect and shutdown if current exceeds performed and verified should the battery be serviced allowable rate. Batteries can be recovered by and/or replaced.

  • Page 358: Cleaning Battery

    Battery Maintenance 2240 YRM 1890 If the Lithium-Ion battery is dropped or heavily Knowing When Battery Is Fully Charged impacted, the battery should be quarantined and monitored for 24 hours in case of a fire. WARNING CLEANING BATTERY Always connect the positive cable to the positive terminal and connect the negative cable to the negative terminal.

  • Page 359: Shipping And Handling

    2240 YRM 1890 Battery Maintenance Use a battery charger that is correct for the Shipping container must provide documentation/ battery. A battery charger that is set for an indications that a Li-Ion battery is enclosed, a ampere-hour rate that is too high will cause a high statement of hazards, procedure if damaged, and internal heat and damage the battery.
  • Page 360 NOTES...
  • Page 362 2240 YRM 1890 3/19 (11/16)(10/16)(3/16)(10/15)(9/15)
  • Page 363 Maintenance ® ACCUSENSE GEN IV CHARGER (DETACHABLE BATTERY LEADS) MPB045VG, W45ZHD [A245]; MPB040E [B827]; MSW025-030-F [B895] PART NO. 550149026 2200 YRM 2030...
  • Page 364 • 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 re- move parts.
  • Page 365 Charger Troubleshooting ............................9 Error Code Description .............................9 Diagnostics and Troubleshooting ........................11 Output Connector Circuit ........................... 12 Vehicle Lockout Control Option ......................... 13 This section is for the following models: (MPB045VG, W45ZHD) [A245]; (MPB040E) [B827]; (MSW025-030-F) [B895] ©2017 Yale Materials Handling Corp.

  • Page 367: General

    2200 YRM 2030 General General This section describes the operation and the battery manufacturer, battery type, serial number, nominal voltage, capacity in amperes at the five-hour ® troubleshooting of the AccuSense Q-Series Charger. rate, and service mass (with ballast if used to Charger diagnosis and service requires special compensate for lack of battery mass).

  • Page 368: Accusense ® Q-Series Charger

    2200 YRM 2030 ® AccuSense Q-Series Charger ® AccuSense Q-Series Charger CHARGER MODE/BATTERY TYPE The battery charger has 7 mode settings. The proper mode setting is determined by the type batteries be- SELECTION ing used in the battery pack. Note that batteries must be uniform in brand and model.

  • Page 369: Mode Setting Check

    2200 YRM 2030 ® AccuSense Q-Series Charger Figure 5. Switch Position Mode Chart Mode Setting Check Modes are set by the sequence of the mode switches. Tampering with the Charging Mode Label voids war- NOTE: Mode settings can be checked by connecting ranty.

  • Page 370: Convenience Port

    2200 YRM 2030 ® AccuSense Q-Series Charger CONVENIENCE PORT This charger is connected to a convenience port which is located in the dash board of the truck. The convenience port has an LED status lights that display in the same manner as the charger. The con- venience port will be connected to the charger via two connectors.

  • Page 371: Multi-Stage Charging

    2200 YRM 2030 ® AccuSense Q-Series Charger Figure 7. Battery Charger Diagram MULTI-STAGE CHARGING 3. ABSORPTION Charge Stage (Constant-Volt- age): Charger charges at a constant voltage level to There are multiple charging stages for the Q-Series provide adequate time for the battery plates to ®...
  • Page 372 2200 YRM 2030 ® AccuSense Q-Series Charger Variations in this charge stage are highly de- Power-On LED or flashing the LCD Backlight, pendent on the battery Charge MODE selec- continually throughout the ENTIRE charge cy- ted. Flooded Lead Acid batteries are typically cle.

  • Page 373: Led Display, Multi-Stage Charge

    2200 YRM 2030 ® AccuSense Q-Series Charger LED Display, Multi-Stage Charge The LEDs and Menu Switch operate as follows: Table 3. LED Charging Status INDICATOR COLOR FUNCTION Power ON Illuminates continuously when AC power is present. If flashing, refer to Troubleshooting procedures.

  • Page 374: Cell, Battery, And Battery Pack Voltage

    Cell, Battery, and Battery Pack Voltage 2200 YRM 2030 Cell, Battery, and Battery Pack Voltage VOLTAGES A 24 Vdc battery pack, consisting of four 6 Vdc batter- ies, has a minimum voltage of 21 Vdc under a load (12 cells X 1.75 Vdc / cell = 21 Vdc). Battery packs are composed of batteries, and each battery is composed of cells.

  • Page 375: Troubleshooting

    2200 YRM 2030 Troubleshooting Troubleshooting CHARGER TROUBLESHOOTING • The convenience port also flashes from the center LED to the outer LED in a back and forth pattern if communication between the Error Code Description charger and convenience port is lost or if the battery’s voltage is below charger’s minimum The number of Error Codes available exceeds a count voltage for charging threshold.
  • Page 376 Troubleshooting 2200 YRM 2030 Table 4. Charge Errors (Continued) Condition LED 1 LED 2 LED 3 LED 4 LED 5 Flashing Excessive Safety Time Error Mode Selected Not Valid - Flashing Empty Flashing Flashing Product Not Operational Lockout (Inhibit) Enable Flashing Defective Lockout (Inhibit) Disable...

  • Page 377: Diagnostics And Troubleshooting

    2200 YRM 2030 Troubleshooting Batt Temperature Sensor Open / Shorted: If a Bat- Excessive Charge Time Error: Occurs when charg- tery Temperature Sensor Cable was installed at start ing took too long AND the battery voltage was not al- of charging, but then later found to be open or short lowed to increase above 2.17V/cell.

  • Page 378: Output Connector Circuit

    Troubleshooting 2200 YRM 2030 and not able to break down and recombine back onto the battery plates; stratification of the acid into layers where a denser acid layer is carrying most of the am- perage; an overcharged cell due to other cells being unbalanced and at a much lower state of charge.

  • Page 379: Vehicle Lockout Control Option

    2200 YRM 2030 Troubleshooting Vehicle Lockout Control Option Refer to Step 1 to locate two circuit pins that connect the lockout (Inhibit) circuit. The main output connector from which the battery output lead originates may have four or six contacts installed.
  • Page 380 NOTES...
  • Page 382 2200 YRM 2030 6/17 (11/16)(10/16)

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