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General

This section describes how to select and do the
maintenance for large batteries used in electric lift
trucks. This information is for service personnel that
must do the maintenance on large lead-acid batteries.
Battery repair requires special training and equipment.
Do not try to repair a battery unless you have the
correct tools, equipment, and experience. Most battery
repairs are done by a special repair service. Some

batteries have a nameplate attached to the face of the
battery cover. This nameplate communicates specific
information about the battery including the name of the
battery manufacturer, battery type, serial number,
nominal voltage, capacity in amperes at the five-hour
rate, and service mass (with ballast if used to
compensate for lack of battery mass).

Battery Type

LEAD-ACID BATTERIES

A lead-acid battery converts chemical energy into
electrical energy. See Figure 1. Chemical changes
within the battery give the electrical energy. When the
chemical reaction has occurred so the battery will not
give its rated voltage and current, the battery is
discharged. A reverse chemical action must occur so
the battery can be used again. The batteries described
in this section can be charged again by an electric
voltage and current from an outside source so there is
a reverse chemical action. The lead-acid chemicals
store the electric energy until the electric energy is
needed to operate an electric device.

Figure 1. Lead-Acid Industrial Battery

A lead-acid battery is made from several lead-acid
batteries called cells. Each cell has positive and
negative plates with dielectric spacers between each

plate. All of the plates are within a solution of
electrolyte. See Figure 2.

2240 YRM 0001

General

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Summary of Contents for 524150797

Page 1: ...Maintenance METRIC AND INCH SAE FASTENERS PART NO 524150797 8000 YRM 0231 ...

Page 2: ...ications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using force to remove parts Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs or if the unit needs repairs Be sure to follow the WARNING and CAUTION notes in the instructions Gasoline Liquid Petroleum Gas LPG Compressed Natural Gas CNG ...

Page 3: ...g Corp 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 Table of Contents i ...

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Page 5: ...Le Systeme d Unites or the International System of units also called SI in all languages The SI System of measurement is described in ISO Standard 1000 1973 A conversion table of common measurements is shown in Table 7 NOMENCLATURE THREADS The thread design is specified by a series of numbers and letters for inch and metric fasteners See Figure 1 The diameter of the shank of the fastener is shown ...

Page 6: ...ber or the increase in the number of marks indicates increased bolt strength 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 on a nut Property classes less than 8 8 are often not marked Grades for inch bolts go from 2 to 8 Grade 2 fasteners normally do not have any marks The following tables show the m...

Page 7: ... Table 8 The legs of a cotter split pin are bent for the following reasons To retain the cotter split pin in the part To provide clearance between the cotter pin legs and other parts or members One or both cotter split pin legs must be bent to provide a minimum 90 angle between the legs See Figure 2 Figure 2 Minimum Angle Between Cotter Pin Legs Unless otherwise specified the legs of chain anchor ...

Page 8: ...Table 1 Bolts and Screws General 8000 YRM 0231 4 ...

Page 9: ...Table 2 Studs and Nuts 8000 YRM 0231 General 5 ...

Page 10: ...Table 3 Torque Nuts General 8000 YRM 0231 6 ...

Page 11: ...Table 4 Torque Nuts With Nylon Insert 8000 YRM 0231 General 7 ...

Page 12: ...550 1 660 2 040 2 240 1 100 1 140 1 230 1 510 1 660 M36 4 M36 3 M39 4 M39 3 1 200 1 280 1 560 1 640 885 945 1 150 1 210 1 930 2 040 2 490 2 630 1 430 1 510 1 840 1 940 2 620 2 780 3 390 3 570 1 940 2 050 2 500 2 640 M42 4 5 M42 3 M45 4 5 M45 3 M48 5 M48 3 1 930 2 070 2 410 2 580 2 900 3 160 1 430 1 530 1 780 1 910 2 140 2 330 3 080 3 320 3 850 4 120 4 630 5 040 2 280 2 450 2 840 3 040 3 420 3 720 ...

Page 13: ...435 480 455 500 615 680 1 1 8 UNC 14 UNF 185 210 255 285 485 540 655 735 680 765 925 1 040 1 1 8 1 1 8 7 UNC 12 UNF 265 300 360 405 595 670 805 905 965 1 080 1 310 1 470 1 1 4 1 1 4 7 UNC 12 UNF 375 415 510 565 840 930 1 140 1 260 1 360 1 500 1 850 2 050 1 3 8 1 3 8 6 UNC 12 UNF 490 560 665 760 1 100 1 250 1 490 1 700 1 780 2 040 2 420 2 760 1 1 2 1 1 2 6 UNC 12 UNF 650 735 885 995 1 460 1 650 1 9...

Page 14: ... Pressure pounds in 2 psi 6 895 kilopascal kPa kilopascals kPa 0 145 pounds in 2 psi pounds in 2 psi 0 007 megapascal MPa megapascals MPa 145 04 pounds in 2 psi Temperature Fahrenheit 32 0 56 Celsius C Celsius 1 8 32 Fahrenheit Torque pound inches lbf in 0 113 Newton meter N m Newton meter N m 8 851 pound inches lb f in pound feet lbf ft 1 356 Newton meter N m Newton meter N m 0 738 pound feet lb ...

Page 15: ...2 mm 0 123 in 3 76 mm 0 148 in 4 00 mm 0 156 in 3 80 mm 0 150 in 3 50 mm 0 138 in 6 50 mm 0 256 in 4 06 mm 0 16 in 1 78 mm 0 07 in 3 94 mm 0 155 in 4 55 mm 0 179 in 5 00 mm 0 188 in 4 60 mm 0 181 in 4 40 mm 0 172 in 8 00 mm 0 315 in 4 06 mm 0 16 in 2 03 mm 0 08 in 4 93 mm 0 194 in 5 33 mm 0 210 in 6 30 mm 0 250 in 5 90 mm 0 232 in 5 60 mm 0 220 in 10 3 mm 0 406 in 4 06 mm 0 16 in 2 03 mm 0 08 in 6...

Page 16: ... 000 in 26 9 mm 1 060 in 23 9 mm 0 940 in 0221874 0221879 0015202 0015213 0015223 31 75 mm 1 250 in 33 3 mm 1 310 in 29 2 mm 1 150 in 0015203 0015216 0015224 38 1 mm 1 500 in 40 9 mm 1 610 in 36 6 mm 1 440 in 0015204 0015217 0015225 44 45 mm 1 750 in 46 0 mm 1 810 in 42 9 mm 1 690 in 0015205 0015218 0015226 50 8 mm 2 000 in 52 3 mm 2 060 in 49 3 mm 1 940 in 0015206 0015219 0015227 57 15 mm 2 250 i...

Page 17: ...4 870 in 152 4 mm 6 000 in 153 9 mm 3 060 in 5 460 mm 138 7 in Table 10 Cotter Pin Dimensional Data Nominal Length L Length Range Nominal Size Part Numbers max min 4 00 mm 0 156 in 5 00 mm 0 188 in 6 30 mm 0 250 in 8 00 mm 0 312 in 9 52 mm 0 375 in 6 35 mm 0 250 in 7 10 mm 0 280 in 5 50 mm 0 217 in 9 525 mm 0 375 in 10 5 mm 0 413 in 8 80 mm 0 345 in 12 7 mm 0 500 in 13 5 mm 0 530 in 11 5 mm 0 453 ...

Page 18: ... in 52 3 mm 2 060 in 49 3 mm 1 940 in 0015237 0015246 0015255 0015265 0015271 57 15 mm 2 250 in 58 7 mm 2 310 in 55 1 mm 2 170 in 0015238 0015247 0015256 0221880 0221887 63 5 mm 2 500 in 65 0 mm 2 560 in 62 0 mm 2 440 in 0015240 0015248 0015257 0221881 0015273 69 85 mm 2 750 in 72 1 mm 2 840 in 68 3 mm 2 690 in 0015280 0015249 0015258 0221882 0015286 76 2 mm 3 000 in 81 3 mm 3 200 in 74 7 mm 2 940...

Page 19: ...mm 2 000 in 52 3 mm 2 060 in 49 3 mm 1 940 in 0221890 57 15 mm 2 250 in 58 7 mm 2 310 in 55 1 mm 2 170 in 0221891 63 5 mm 2 500 in 65 0 mm 2 560 in 62 0 mm 2 440 in 0221892 69 85 mm 2 750 in 72 1 mm 2 840 in 68 3 mm 2 690 in 0221893 0221895 76 2 mm 3 000 in 81 3 mm 3 200 in 74 7 mm 2 940 in 0015291 0221896 88 9 mm 3 500 in 91 4 mm 3 600 in 87 4 mm 3 440 in 0015292 0221897 101 6 mm 4 000 in 113 3 m...

Page 20: ...NOTES 16 ...

Page 21: ......

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: ...ications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using force to remove parts Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs or if the unit needs repairs Be sure to follow the WARNING and CAUTION notes in the instructions Gasoline Liquid Petroleum Gas LPG Compressed Natural Gas CNG ...

Page 25: ...lowatt Hours 7 Battery Maintenance 7 Safety Procedures 7 Maintenance Records 8 New Battery 8 Cleaning Battery 8 Adding Water to Battery 10 Hydrometer 11 Battery Temperature 11 Charging Battery 12 Types of Battery Charges 13 Methods of Charging 14 Troubleshooting Charger 15 Knowing When Battery Is Fully Charged 15 Where to Charge Batteries 15 Equipment Needed 15 Battery Connectors 16 Battery Care 1...

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Page 27: ...ck of battery mass Battery Type LEAD ACID BATTERIES A lead acid battery converts chemical energy into electrical energy See Figure 1 Chemical changes within the battery give the electrical energy When the chemical reaction has occurred so the battery will not give its rated voltage and current the battery is discharged A reverse chemical action must occur so the battery can be used again The batte...

Page 28: ... negative is considered an anode A cathode is the electrode or terminal in which current leaves the cell or battery while the anode is the electrode or terminal in which current enters the cell or battery Lithium ion batteries are maintenance free and do not require equalization charges or specific gravity corrections Specific Gravity The strength of the electrolyte is measured in points of specif...

Page 29: ...n the sulfuric acid is removed from the electrolyte the specific gravity of the electrolyte decreases See Figure 5 The potential difference of a discharged cell is approximately 1 75 volts When a direct current is applied to a discharged cell the lead sulfate is changed into lead and sulfuric acid The lead goes to the positive plate and stays as lead and to the negative plate and stays as lead per...

Page 30: ...teries use a calcium alloy of lead instead of an antimony alloy which reduces the amount of electrolysis In a maintenance free battery the amount of free standing electrolyte above the plates is much higher ensuring enough electrolytes to keep the plates covered during extended periods of use Therefore there is no need to add water to a maintenance free battery during the course of its life Floode...

Page 31: ...lly equal to the number of batteries needed For example for three work periods you need three batteries The capacity of the battery you need is found as follows The size of the lift truck and the attachments The type of work Heavy duty operation or normal operation for one 8 hour work period Lift trucks are available in various voltage ranges See Figure 8 The small walkie lift trucks are normally ...

Page 32: ...s The minimum weight of the battery is shown on the nameplate If the battery is not the minimum weight the capacity of the lift truck is reduced If the battery used in the lift truck is less than the size of the battery compartment blocks and spacers must be installed to hold the battery in position See the Frame or Periodic Maintenance service manual or Operating Manual for your lift truck model ...

Page 33: ...n Equalization Charge once a month SAFETY PROCEDURES 1 Wear a rubber apron gloves boots and goggles or a face shield when doing maintenance on batteries 2 Batteries generate hydrogen gas when they are being charged Keep open fire away from batteries Do not check the electrolyte level with a match or a lighter Do not smoke and do not create sparks 3 Lift batteries correctly with a crane or equipmen...

Page 34: ... of the cells is at the correct level Charge the battery for 6 hours or until the specific gravity is correct Make sure the battery is correctly installed in the lift truck Use a spreader bar with slings designed for the battery to lift and move the battery See Figure 10 Always complete the Battery Inspection Report and the Daily Battery Report See Figure 11 and Figure 12 CLEANING BATTERY WARNING ...

Page 35: ...Figure 10 Change the Battery Legend for Figure 10 1 INSULATED SPREADER BAR 2 INSULATED STRAPS Figure 11 Battery Inspection Report 2240 YRM 0001 Battery Maintenance 9 ...

Page 36: ... MAINTENANCE See the instructions from the manufacturer of your battery for the operating level of the electrolyte Always use distilled water If you add distilled water wait 5 minutes before measuring the specific gravity with a hydrometer DO NOT add water to a cell before or during the charging cycle water must be added after the charging cycle If water is added before the charging cycle the elec...

Page 37: ... you are using does not have a temperature correction you will have to use a thermometer Special battery thermometers are available that will indicate the correction factor directly and add or subtract the correct number of points See Figure 16 NEVER charge a battery at a rate that will raise the electrolyte temperature above 49 C 120 F NEVER let a battery stay discharged for long periods A temper...

Page 38: ...es only in the special area for charging batteries When charging the batteries keep the vent caps clean The battery charger area must have ventilation so that explosive fumes are removed Open the hood over the battery or remove the cover if the battery has a cover Disconnect the battery when doing cleaning and maintenance If the lift truck has been operated with a low battery check the contactors ...

Page 39: ...of the battery after an equalizing charge there can be a damaged cell Consult your battery dealer NOTE Many customers have battery chargers that can follow a program to automatically charge a battery according to recommendations of the battery manufacturer Use the recommendations of the battery manufacturer for charging the battery When performing a monthly equalization charge it is recommended to...

Page 40: ...is controlled by a resistor When the charging current decreases the voltage across the resistor 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: ...rcuit Make sure the charger voltage is the correct voltage for the battery 1 During charging the voltage increases slowly When the battery is fully charged the voltage level is constant 2 Remove a vent cap and look in the opening If you see bubbles in the electrolyte the battery is either fully charged or in the final stage of charging 3 The specific gravity reading is constant and within the limi...

Page 42: ...OR POWER CABLES TO LIFT TRUCK 3 BRACKET 4 CONNECT AND DISCONNECT HANDLES Figure 22 SB Battery Connector BATTERY CARE 1 Keep batteries clean Remove any spilled electrolyte 2 DO NOT overcharge the battery This action will damage the battery 3 DO NOT discharge the battery to less than the recommendation A deep discharge will shorten the battery life 4 Charge batteries in an area with good ventilation...

Page 43: ... OR CONTACT IN HOUSING 5 SLOT FOR LOCK PIN 6 CONTACT FOR CONNECTOR OF 12 VOLT BATTERY TAP 7 KEY RED 2 AND BLACK 4 CONNECTORS ALIGN ON KEY 8 LOCK PINS FOR 12 VOLT CONNECTOR MUST INSTALL FROM FRONT OF CONNECTOR THROUGH RED AND BLACK CONNECTORS 9 12 VOLT WIRE TO TRUCK TRUCK HALF OR TO BATTERY BATTERY HALF 10 INDICATOR INSERT FOR BATTERY VOLTAGE AND BATTERY TYPE ROTATE FOR CORRECT VOLTAGE IN WINDOW 12...

Page 44: ...LUG BATTERY AND CHECK BATTERY VOLTAGE 2 1 VOLTS PER CELL ELECTROLYTE LEVEL IF ELECTROLYTE IS DARK REPLACE BATTERY AND CONTACT BATTERY VENDOR CORRECT VOLTAGE LOW VOLTAGE IF WASHING IS REQUIRED REMOVE BATTERY FROM TRUCK AND WASH WITH A NEUTRALIZING AGENT BAKING SODA AND WATER VENT CAPS MUST BE IN PLACE IF ELECTROLYTE LEVEL IS LOW ADD DISTILLED WATER ONLY RECHARGE REPLACE OR RECHARGE BATTERY CORRECT ...

Page 45: ...ING THAT VOLTAGE BY 2 WILL HELP INDICATE WHAT CELL IS SHORTED REPLACE BATTERY AND CONTACT BATTERY VENDOR BATTERY IS IN GOOD CONDITION INCORRECT ADD 1 400 ELECTROLYTE TO RAISE OR DISTILLED WATER TO LOWER RECHARGE FOR 1 1 2 HOURS TO MIX CORRECTED INCORRECT 4 BATTERY LOAD TEST BATTERY IS IN GOOD CONDITION REPLACE BATTERY AND CONTACT VENDOR PLACE AMP SHUNT METER IN SERIES WITH EITHER THE POS OR NEG BA...

Page 46: ...LL POWER CABLES AND DIRECTIONAL CONTACTORS FOR POSSIBLE CARBON BUILD UP IN DRIVE MOTOR POWER CABLES ARE GOOD TRUCK SIDE WIRING TEST TO CHECK FOR SHORTED CONDITION IN TRUCK WIRING SIDE PLACE VOLT OHMMETER ON RX 1 SCALE CONNECTING POS NEG METER LEADS ACROSS TRUCK SIDE BATTERY RECEPTACLE SW OFF READING SHOULD BE LESS THAN 30 0HMS LESS THAN 30 0HMS MORE THAN 30 0HMS CHECK FOR SHORTED CONDITIONS IN TRU...

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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: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using for...

Page 51: ...ompartment 1 Accessing the Drive Unit Compartment 2 Special Precautions 3 Discharging the Capacitors 3 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 Table of Contents i ...

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Page 53: ...YRM1508 ACCESSING THE DRIVE UNIT COMPARTMENT The drive unit compartment is concealed behind a molded cover which fits securely around the drive unit and steer support to the frame To remove the drive unit cover first remove the two nuts securing the cover to the frame Starting at the top left edge of the cover and with both hands pull the cover away from the frame until the cover kicks out from th...

Page 54: ...ove the drive unit cover starting at the top left edge of the cover and with both hands pull the cover away from the frame until the cover kicks out from the retaining clips Repeat this for the right side of the cover Work around the edge of the cover until free from the truck See Figure 2 To install the drive unit cover place the bottom of the drive unit cover onto the frame and position the lowe...

Page 55: ... the capacitor and never put power to the controller with any power wire dis connected Never short any controller terminal or motor terminal to battery Make sure to use proper procedures when servicing the controller 1 Turn the key switch to the OFF position and dis connect the battery 2 Remove the drive unit compartment cover to ac cess the controller See GeneralGeneralGeneral 3 Discharge the cap...

Page 56: ...t from the lift truck Refer to Steering Mechanism 1600YRM1504 CAUTION Remove the brake only as directed Changes to adjustment screws may render the brake unusa ble The brake is factory set and cannot be adjus ted if altered NOTE The brake may be removed at this point However it is not necessary to remove the brake if the motor will not be disassembled 3 Remove the brake from the top of the tractio...

Page 57: ... ASSEMBLY 5 LOCKWASHER 6 ASSEMBLY SCREW 7 STATOR 8 NUTS 9 LOCKWASHER 10 TEMP SENSOR CONNECTOR FEMALE 2 PRONG 11 MOUNTING PLATE ASSEMBLY 12 SCREW 13 GROMMET 14 FLANGE BRAKE END 15 FLANGE HOUSING 16 BEARING AND WIRING Figure 4 Traction Motor Repair 0620 YRM 1513 AC Motor Repair 5 ...

Page 58: ...Figure 5 Traction Motor Repair A245 AC Motor Repair 0620 YRM 1513 6 ...

Page 59: ...nd install into the drive unit Slowly lower the ar mature through the stator while turning to align the spines of the shaft with the drive unit 4 Position the flange brake end onto the armature shaft and stator as removed Be careful not to damage the encoder bearing wiring harness dur ing installation 5 Align the motor flanges and install the four as sembly screws 6 Install the brake to the top of...

Page 60: ...mme ter Resistance should be 530 ohms at 25 C 77 F Inspect and repair temperature sensor wire The temperature sensor wire can be repaired but the temperature sensor must be replaced if faulty Main wiring harness damaged Test temperature sensor circuit through main wiring harness from connection at controller Temperature sensor malfunction Measure resistance with ohmme ter If wiring is ok resistanc...

Page 61: ...ing and case Resistance should be at 50 000 ohms or above Replace stator or traction motor assembly if necessary Stator wires broken open circuit Check resistance between motor terminals Resistance should read less than 1 ohm between each ter minal Replace stator or traction motor assembly if necessary Electric brake assembly not releas ing damaged Troubleshoot the electric brake as sembly Drive u...

Page 62: ...NOTES 10 ...

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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: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using for...

Page 67: ...BLE OF CONTENTS General 1 Safety Precautions 2 Drive Tire 3 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 Table of Contents i ...

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Page 69: ...MDU and traction motor is metric Use the correct tools to avoid damage The MDU is vertically installed in the truck and allows an effective utilization of space The compact one piece housing is made of high duty nodular iron thus having a high rigidity and optimum guiding precision This allows a fully integrated bearing of the helical spur gear stage with a very high running smoothness i e no driv...

Page 70: ... Personal Computer WARNING To avoid controller damage always disconnect the battery Discharge the capacitor and never put power to the controller with any power wire dis connected Never short any controller terminal or motor terminal to battery Make sure to use proper procedure when servicing the controller 1 Block the lift truck so that the drive wheel is off the floor See Periodic Maintenance 80...

Page 71: ...plete MDU Read the entire procedure first and perform only the steps necessary to make the required repairs WARNING Cleaning solvents can be flammable toxic and can cause skin irritation Wear protective gear when handling solvents and always follow the recommendations of the manufacturer WARNING Put blocks under each side of the truck under the MDU frame Position blocks on both sides of the load w...

Page 72: ... and washers securing the tiller to the master drive unit See Figure 3 1 TILLER MOUNTING BOLTS 2 TILLER MOUNT 3 TILLER ASSEMBLY Figure 3 Tiller Mounting 10 Remove the tiller from the lift truck 11 Remove the traction motor and brake as a single assembly a Remove the four screws and lockwashers re taining the drive motor See Figure 4 b Attach a sling and an over head hoist to the drive motor c Lift...

Page 73: ...g cast ing 1 CAPSCREWS Figure 5 Steering Bearing 2 Align the eight mounting holes in the bearing with the holes in the casting 3 Install the eight capscrews to retain the bearing to the casting Torque the mounting capscrews to 23 N m 17 lbf ft 4 Use a jack to position the drive unit 5 Align the drive unit with the screw holes in the steering bearing and install the capscrews attach ing the drive u...

Page 74: ...of the truck 14 Install the drive unit compartment cover and re turn truck to service Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Lift truck will not move Motor not operating Check wiring or repair motor Check battery battery connection and truck fuses Damaged gears or bearings Replace drive unit MDU makes noise Dry or damaged bearings Replace drive unit Worn or damaged gears Replac...

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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: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using for...

Page 79: ...General 1 Special Precautions 1 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 Table of Contents i ...

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Page 81: ...iver to discharge the traction motor controller WARNING To avoid personal injury and prevent electrical shock perform the following steps before performing any troubleshooting or adjustments and connecting or disconnecting a handset or PC CAUTION To avoid controller damage always disconnect the battery Discharge the capacitor and never put power to the controller with any power wire disconnected N...

Page 82: ...nd 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 Refer to the Special Precautions section of this manual 1 Move the lift truck to a safe level area and block the wheels to prevent movement 2 Turn the key switch to the OFF position and disconnect the battery 3 Remo...

Page 83: ...Figure 2 Control Handle Assembly Lift Truck Models MP20 A249 1600 YRM 1504 Control Handle 3 ...

Page 84: ...HANDLE HEAD 2 CAPSCREW 3 LOCKNUT 4 LOCKNUT 5 HOLE PLUG 6 GAS SPRING 7 SCREW 8 CAPSCREW 9 CAPSCREW 10 PIVOT SHAFT 11 STRAP CLAMP 12 BUSHING 13 SENSOR 14 BALL STUD 15 CONTROL HANDLE ARM 16 RETAINING NUT Control Handle 1600 YRM 1504 4 ...

Page 85: ... Models MPB045VG A245 Legend for Figure 3 1 CONTROL HANDLE HEAD 2 CAPSCREW 3 LOCKNUT 4 HOLE PLUG 5 GAS SPRING 6 PIVOT SHAFT 7 STRAP CLAMP 8 BUSHING 9 PROX SENSOR 10 BALL STUD 11 CONTROL HANDLE ARM 12 RETAINING NUT 1600 YRM 1504 Control Handle 5 ...

Page 86: ...Figure 4 Delivery Handle Optional Control Handle 1600 YRM 1504 6 ...

Page 87: ... A245 the removal procedures for the prox sensor will depend on which prox sensor arrangement your lift truck has If prox sensor is mounted with Bellville washers and prox sensor cable is marked with yellow heat shrink perform Step 11 through Step 13 If prox sensor arrangement does not include these parts go to Step 14 for removal procedures 11 Remove button tie wrap from side of mounting weldment...

Page 88: ...sor and make a loop of 125 mm 5 0 in See Figure 6 7 Lightly pull on control handle arm wire harness until it is taunt 8 Install button tie wrap around control handle arm wire harness and yellow heat shrink on prox sensor cable Fasten button tie wrap and prox sensor cable and control handle arm wire harness to side of mounting weldment See Figure 4 and Figure 5 9 Tighten retaining nuts to 24 N m 21...

Page 89: ...rocedures before removing the gas spring DISCHARGING THE GAS SPRING WARNING Goggles and a face shield must be worn for personal protection as metal chips and hydraulic lubricant may be ejected from the drill operation due to the high internal pressure CAUTION The control handle return spring is charged with pressurized gas and contains a hydraulic oil lubricant NOTE This process is a destructive o...

Page 90: ...w threads before installing the nut 4 Align the lower end of the gas spring into position using a screwdriver and hold in position Install the capscrew and locknut securing the rod end of the gas spring to the steer swivel Tighten to 35 N m 26 lbf ft 5 Install the plastic plugs to the access holes on the control handle shaft as removed 6 Test for proper operation Install covers as removed Troubles...

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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: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using for...

Page 95: ...ENTS General 1 Description 1 Special Precautions 2 Brake Check 3 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 Table of Contents i ...

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Page 97: ...peed direction control to the NEU TRAL position Controlled plugging is reversing the speed direction control while traveling causing the unit to slow to a stop Return the speed direction control to the NEU TRAL position to remain stopped If the speed direc tion control is not returned to the NEUTRAL position the lift truck will accelerate in the opposite direction Controlled plugging should stop t...

Page 98: ...he capacitors in the controller by con necting a 200 ohm 2 watt resistor across the con troller s B and B terminals with insulated jumper wires DO NOT use a screwdriver to discharge the traction motor controller To avoid personal injury and prevent electrical shock perform the following steps before per forming any troubleshooting or adjustments and connecting or disconnecting a handset or PC CAUT...

Page 99: ... lift truck at the base of a 10 percent grade 1 0 m rise in 10 0 m 3 ft rise in 30 ft grade with the forks facing uphill Standing to the side of the lift truck slowly drive the lift truck up the grade and bring the lift truck to a stop using the di rectional controls plugging Move the control handle to the BRAKE ON position to apply the parking brake See Figure 3 If the brake fails to hold the lif...

Page 100: ...he truck to a safe level area Turn the key switch to the OFF position and disconnect the battery Block the wheels to prevent unexpected movement See Periodic Maintenance 8000YRM1510 for lift truck model A249 Periodic Maintenance 8000YRM1666 for lift truck model A245 2 Remove the drive unit compartment cover Refer to AC Motor Repair 0620YRM1513 3 Disconnect the brake wiring connector from the main ...

Page 101: ... groove inside the brake hub Slide the brake hub down onto the traction motor shaft and Woodruff key 4 Install the upper snap ring on the end of the motor shaft 5 Replace the adapter and friction disk and tighten the screws that hold the adapter to the brake Tor que to 11 N m 8 lbf ft 6 Replace the brake and install the lockwashers and capscrews that hold the brake to the motor 7 Tighten the capsc...

Page 102: ...lace the brake assembly Brake coil has shorted to frame or between the windings Measure coil resistance Refer to Brake Check in this section If re sistance is below specification re place the brake assembly Check coil for short to frame using an ohmmeter If shorted to frame re place the brake assembly Incorrect or no voltage supplied to brake Measure voltage to brake using a voltmeter If voltage i...

Page 103: ...OR ACTION Brake will not apply Mechanical failure within the brake assembly Replace the brake assembly Brake linings worn beyond specifi cation See Brake Check in this section Replace the brake assembly 1800 YRM 1505 Troubleshooting 7 ...

Page 104: ...NOTES 8 ...

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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: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using for...

Page 109: ... 5 Remove 5 Install 5 Hydraulic Pump 6 Remove 6 Install 6 Hydraulic Pump Reservoir 9 Remove 9 Install 9 Hydraulic Cylinder 10 Remove 10 Repacking 10 Install 11 Relief Valve Adjustment 12 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 Table of Conten...

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Page 111: ...component Wear safety glasses Make certain the battery has been disconnected DO NOT use a screwdriver to discharge the trac tion motor controller WARNING To avoid personal injury and prevent electrical shock perform the following steps before per forming any troubleshooting or adjustments and connecting or disconnecting a handset or PC CAUTION To avoid controller damage always disconnect the batte...

Page 112: ...and Figure 3 If the breather is clogged or blocked the abil ity of the system to lift a load will be greatly reduced As oil is pushed out of the pump it passes through a one way check valve to the lift cylinder The check valve prevents oil from flowing back to the pump when lifting ceases holding the lift cylinder in the raised position until lowered The piston will begin to lift the load when flu...

Page 113: ...iverted 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 HYDRAULIC POWER UNIT 3 CAPSCREW 4 FITTING 5 HOSE 6 FITTING Figure 3 Hydraulic System 1900 YRM 1506 Operation 3 ...

Page 114: ...ystem CLEAN Adhere to the following precautionary steps to ensure that the hydraulic system remains clean 1 Flush the entire system when a failure is encoun tered to make sure all paint metal chips welding shot and debris are removed 2 Filter each change of oil to prevent the introduc tion of contaminants into the system 3 Provide continuous protection from airborne con tamination by keeping the b...

Page 115: ...rance Refer to Periodic Maintenance 8000YRM1510 for lift truck model A249 Periodic Maintenance 8000YRM1666 for lift truck model A245 3 Raise the drive wheel off the floor and put blocks under both sides of the drive unit frame Refer to Periodic Maintenance 8000YRM1510 for lift truck model A249 Periodic Maintenance 8000YRM1666 for lift truck model A245 4 Discharge the capacitor See Special Precau t...

Page 116: ...nd O rings Grease the suction tube and insert into locking device with hole Install and tighten the spring retaining screw to secure the suction tube 6 Remove the retainer and replace the O ring Lightly grease the O ring before installation 7 Align the reservoir so the hose connections will be in the same position as they were prior to re moval Install the four capscrews to retain the res ervoir 8...

Page 117: ...Figure 4 Hydraulic Unit A249 1900 YRM 1506 Hydraulic Pump 7 ...

Page 118: ...d for Figure 4 1 MOTOR 2 ELECTRO POPPET VALVE 3 HYDRAULIC SUB UNIT 4 FILLER TANK 1 MOTOR 2 ELECTRO POPPET VALVE 3 HYDRAULIC SUB UNIT 4 FILLER TANK Figure 5 Hydraulic Unit A245 Hydraulic Pump 1900 YRM 1506 8 ...

Page 119: ...servoir and the suction screen In spect the screen for damage and replace if nec essary NOTE The capscrews that hold the reservoir to the subunit also hold the motor to the subunit When the capscrews are removed the motor will be resting on the subunit When reinserting the capscrews ensure that the motor is located correctly and the coupler is seated properly INSTALL 1 Lubricate a new O ring using...

Page 120: ...uring the main center cover to the frame and remove the cover 9 Remove the retainer from the lift cylinder rod 10 Manually compress the lift cylinder while holding the lower switch 11 Disconnect and plug the hydraulic line from the lift cylinder 12 Remove the lift cylinder from the lift truck REPACKING CAUTION Lubricate the seals packing and O rings with clean hydraulic oil before assembling CAUTI...

Page 121: ... will leak from the breather during operation If too much oil has been added drain the excess or use a suction device to remove some of the oil 7 Run the pump for 5 seconds and energize the lowering valve at the same time so that oil gets through the pump body and valve at 0 0 psi Op erate the forks up and down three or four times to remove air from the system Operate the lift truck until the hydr...

Page 122: ...r ating temperature 43 to 49 C 110 to 120 F 2 Lower the forks completely to relieve pressure from hydraulic circuit 3 Turn key switch to the OFF position and discon nect the battery 4 Block load wheels to prevent lift truck from mov ing 5 Remove the drive unit compartment cover Refer to AC Motor Repair 0620YRM1513 Accessing the Drive Unit Compartment 6 Discharge the capacitor See Special Precau ti...

Page 123: ... if adjustment is necessary 1 Verify the key switch is in the OFF position and the battery is disconnected 2 Remove the hydraulic reservoir See Hydraulic Pump Reservoir 3 Loosen the locking nut on the relief valve See Figure 8 4 Adjust the relief valve screw in small increments Turn the adjustment screw clockwise to increase pressure Turn the adjustment screw counter clockwise to decrease pressure...

Page 124: ... components Disassemble repair or replace Bent hydraulic cylinder piston rod See Hydraulic Cylinders below HYDRAULIC CYLINDERS PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Oil leaks from cylinder gland around piston rod An oil ring appears on the piston rod Foreign matter on packing Replace packing Score on piston rod Remove any foreign matter Smooth rod surface with an oil stone If oil still leaks ...

Page 125: ...ar ring Replace wear ring included in packing kit HYDRAULIC PUMP PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Pump not delivering oil Pump does not draw oil Check pump piping and valves for leaks Low oil level in reservoir Check fluid level Clogged screen at pump inlet Change oil and clean screen Pump pressure fails to rise Improperly adjusted relief valve Increase to specified pressure us ing a pre...

Page 126: ...ther clogged Clean or replace breather Cavitation caused by high oil vis cosity Change to recommended oil and operate pump in recommended temperature ranges Abnormal temperature rise of hy draulic oil Overwork Adjust workload to fall within pump s operating range Improper viscosity or contaminated oil Drain and replace oil with recom mended oil Pump case or drive gear broken Incorrect pressure set...

Page 127: ......

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: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using for...

Page 131: ...ct Switch 9 Main Contactor Coil Check 9 Horn 10 Remove 10 Install 10 Brake and Interlock Sensor 10 Remove 10 Install 11 Check 11 Steer Reduction Sensor 12 Remove 12 Install 12 Height Limit 12 Control Handle 13 Disassemble 13 Control Handle Card 13 Configure 13 Calibrate 15 Assemble 16 Charger and Convenience Port 18 Remove 18 Install 19 ACCUSENSE Battery Charger 19 Charger Mode Battery Type Select...

Page 132: ...TABLE OF CONTENTS Continued BDI Display 30 Remove 30 Install 30 This section is for the following models MP20 A249 MPB045VG A245 Table of Contents ii ...

Page 133: ...ERATE tag on the control handle Remove the key from the key switch This manual describes the electrical system used on the motorized hand lift truck Procedures are outlined for the maintenance adjustment and repair that may be required when servicing this lift truck See Figure 1 1 BATTERY DISCONNECT SWITCH AND MAIN CONTACTOR 2 DISPLAY 3 FUSE 4 KEY SWITCH 5 CONTROLLER 6 BRAKE 7 TRACTION MOTOR 8 HYD...

Page 134: ...e 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 1 Move the truck to a safe level area Turn the key switch to the OFF position and disconnect the battery 2 Remove the drive unit compartment cover to access the driv...

Page 135: ...and disconnect the battery 3 Discharge the capacitors See Special Precautions in this section NOTE These checks require a volt ohmmeter with a meter movement Most digital meters will not operate correctly for some of these checks Specific checks require additional equipment NOTE The correct meter polarity is necessary for the checks The voltage checks are made between the point indicated in Table ...

Page 136: ...battery voltage at control fuse Connect battery or check wiring between battery and fuse 1 1 Check for battery voltage at control fuse terminal of key switch 1 1 1 Battery voltage at key switch Check for damaged key switch Check connector 1 1 2 No voltage at key switch Wire to key switch or connections is damaged 1 3 Key switch closed Brake switch closed Check for battery voltage at B terminal of ...

Page 137: ... wheel is raised to prevent movement and possible injury Raise the drive wheel See the section How to Put a Lift Truck on Blocks The blocks must prevent the lift truck from falling and causing personal injury or property damage Periodic Maintenance 8000YRM1510 for lift truck model A249 Periodic Maintenance 8000YRM1666 for lift truck model A245 NOTE Although the controller is factory programmed any...

Page 138: ...is disconnected and capacitor in controller is discharged For the correct procedure to discharge the controller refer to Special Precautions Make an identification of the wires and cables and disconnect them from the contactor assembly Remove mounting screws and replace contactor assembly Install wires and cables as removed CONTACTOR TIPS REPLACE CAUTION All contactor tips must be replaced at the ...

Page 139: ...ap from frame 6 Remove coil from frame Install 1 Install new coil on frame and install end cap 2 Install moving contact 2 and return spring 3 Install capscrews washers and nuts that make up the fixed contactor tips 1 to the top cover NOTE Check that the moving contactor and springs move freely without binding 4 Install cover to coil and frame using screws 4 5 Install contactor assemblies on the li...

Page 140: ...motor The fuses are located on the contactor panel Remove and replace as required See Figure 5 and Figure 6 The motorized hand trucks use a single 4 amp FU2 fuse for the control circuit and 175 amp FU1 fuses for both the drive motor and the hydraulic pump motor The fuses are located on the contactor panel Remove and replace as required If it cannot be determined visually that a fuse has failed che...

Page 141: ...o the OFF position and disconnect the battery 2 Remove the drive unit compartment cover See AC Motor Repair 0620YRM1513 Accessing the Drive Unit Compartment 3 Tag and remove all cables and wires attached to the switch 4 Remove the two screws retaining the switch to the lift truck frame See Figure 7Figure 6 5 Remove the switch INSTALLDISCONNECT SWITCH 1 Install the switch into the opening on the li...

Page 142: ...he contactor bracket See Figure 3 5 Remove the horn from the lift truck INSTALL 1 Position the horn on the two studs on the contactor bracket 2 Install the lock nuts on the studs 3 Install all wires removed from the horn 4 Install the drive unit compartment cover 5 Turn the key switch to the ON position and connect the battery 6 Operate the horn to confirm proper operation Brake and Interlock Sens...

Page 143: ...Reconnect the sensor lead to the truck harness CHECK 1 Turn the key switch to the ON position 2 Move the tiller handle down and check that the brake releases when the handle is in the operating position See Figure 9 1 BRAKE ON 2 BRAKE OFF 3 BRAKE ON Figure 9 Brake Operation 3 Continue moving the handle down and check that the brake engages when the handle is fully lowered 4 Adjust the sensor if ne...

Page 144: ...ector See Figure 10 5 Remove sensor from lift truck 1 LOCKNUT 2 STEER REDUCTION SENSOR 3 MOUNTING BRACKET 4 MAIN WIRING HARNESS CONNECTOR 5 PUMP CONTACTOR 6 BUTTON HEAD CLAMP Figure 10 Steer Reduction Sensor INSTALL 1 Route steer reduction sensor around MDU and AC Motor as noted during removal 2 Connect sensor to main wiring harness connector located under pump contactor See Figure 10 3 Slide sens...

Page 145: ... 3 The handle is comprised of two molded plastic halves and is held together by capscrews Remove the screws 4 Disengage the hooks under the auto reverse switch Slide the upper half off of the lower half using a gentle rocking motion while lifting and pulling the upper half away from lower half 5 Unplug the handle wiring harness from the control handle card 6 Place upper half of the handle upside d...

Page 146: ...that the battery is connected and turn the key switch to the ON position 3 The LED will display the program setting for approximately five seconds See Figure 11 The proper control handle card setting for this model is 7 If the correct number is displayed on the LED the control handle card is configured correctly 4 To begin configuring the card turn the key switch to the OFF position 5 Move the jum...

Page 147: ...splay the program setting for approximately five seconds Calibrate Refer to Figure 11 for the following instructions 1 Verify that the key switch is in the OFF position 2 Move the jumper from P park to T teach See Figure 12 a 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 See Figure 11 b Ensure the leads...

Page 148: ...w a decimal beside the completed segments indicating they have been saved See Figure 13 view E 10 Use diagnostic from handset to verify the Throttle output 95 and above for both directions 11 Recycle the key switch OFF and ON and test all truck functions for proper operation ASSEMBLE 1 Install control handle card in the upper half of control handle See Figure 14 NOTE When inserting knobs make sure...

Page 149: ...ILLER HEAD LOWER HALF 10 CAPSCREW 11 SPRING 12 PUSH BUTTON REAR COVER 13 SCREW 14 SUPPORT 15 CONTROL HANDLE CARD 16 SHAFT 17 LH BUTTERFLY KNOB 18 SPRING 19 TILLER HEAD UPPER HALF 20 LABEL 21 PUSH BUTTON ASSEMBLY 22 LABEL 23 SPRING 24 HORN BUTTON 25 SPRING Figure 14 Control Handle 2200 YRM 1508 Control Handle 17 ...

Page 150: ...wer cord use care not to damage convenience port power cord or LED connector as you feed them through the front of the control panel 5 Remove convenience port from front of control panel See Figure 15 1 CHARGER CONVENIENCE PORT 2 LOCKNUT 3 CONTROL PANEL 4 POWER CORD 5 CONNECTOR 6 ANTI ROTATION PIN 7 POSITIVE RED CONNECTION FUSED B Figure 15 Charger Convenience Port 6 Disconnect two electrical conn...

Page 151: ...proper mode settings Damage to the batteries or charger may occur if the mode setting is not correct for the type of batteries being used If the battery manufacturer of the battery you are using is not listed contact Service Engineering through the Contact Management System NOTE Mode settings can be checked by connecting the battery charger to a 120V AC power source and watching the LED display Th...

Page 152: ...cal differences between Gen III and Gen IV chargers Gen III charger wire harness connections are on the right side of the charger face only Gen IV charger wire harness connections are on both sides of the charger face See Figure 17 and Figure 18 Figure 17 Gen III Charger Figure 18 Gen IV Charger For the Gen IV chargers refer to Accusense Gen IV Charger 2200YRM2030 For other charger models use this...

Page 153: ...Charge Modes MODE LED 1 LED 2 LED 3 LED 4 LED 5 1 OFF OFF OFF OFF ON 2 OFF OFF OFF ON OFF 4 OFF OFF ON OFF OFF 5 OFF OFF ON OFF ON 15 OFF ON ON ON ON 16 ON OFF OFF OFF OFF 2200 YRM 1508 ACCUSENSE Battery Charger 21 ...

Page 154: ...y on the charger will flash to indicate the selected battery mode Consult Table 3 to determine the selected mode If the LEDs do not flash when initially connected to power refer to Troubleshooting in this section Modes are set by the sequence of the dip switches Tampering with the Charging Mode Label voids warranty See Figure 20 for dip switch settings ACCUSENSE Battery Charger 2200 YRM 1508 22 ...

Page 155: ... if serial communication is lost or if the battery s voltage is below charger s minimum voltage for charging threshold Verify the connection from the 4 pin connector from convenience port to the 4 socket connector from charger If flashing code continues disconnect the positive red B wire reconnect and try to charge system again If this does not work use an alternate charger to increase battery vol...

Page 156: ...down SDN RED Flashes if abnormal shutdown has occurred See Table 5 to identify the fault Detection Error DET RED Illuminates continuously when battery is not connected to charger or battery voltage is less than 21V If flashing see Table 5 to identify the fault Charging CHG YELLOW Charge status indicator flashes during charging cycle Charged CHD GREEN Illuminates continuously at the same time as th...

Page 157: ...been without charging for more than 30 days If an equalization cycle is not desired disconnect and reconnect AC power to reset the charge counter to 1 and skip the Equalization Stage NOTE If the charger noted an abnormal charge condition during the charging the charger will attempt to shutdown and will flash one or all three of the red LEDs on the top of the charger If this condition occurs see Tr...

Page 158: ...he Detection LED illuminated continuously when the charger is connected to a 120 volt AC power source a YES Battery is not connected to charger or battery voltage is less than 2V Check connections If connections are clean and tight troubleshoot the battery pack See Battery Pack Troubleshooting b NO Proceed to Step 5 5 Is the Charging LED either flashing or illuminated continuously when the charger...

Page 159: ...placement of the batteries Refer to the Equipment s Operators manual for instructions on servicing the battery pack Excessive Charging Time Occurs when charging took too long Possible causes include use of a battery load that is draining energy from the battery while the charger is trying to charge that same battery aged or unbalanced battery cell conditions etc Battery Testing This error is only ...

Page 160: ... gravity SG level for each battery cell after a charging cycle After a charging cycle the SG measurement for each cell should be 1 265 or greater From cell to cell within one battery The SG measurements should not vary more than 0 020 If variance is greater than 0 020 it is recommended that the battery be replaced with the same type of battery as the other three batteries in that pack From battery...

Page 161: ...e the forks Dead battery Recharge or replace battery Failed Open fuse Replace Failed Open fuse Lift pump motor wiring loose or disconnected Reconnect or tighten loose wiring connections Lift pump motor not operating Repair or replace lift pump motor Operator controls do not work Dead battery Recharge or replace battery Failed Open fuse Replace Failed Open fuse Control handle wiring loose or discon...

Page 162: ...rm this repair 2 Remove two nuts from back of BDI display See Figure 23 3 Remove BDI display from front of control panel See Figure 23 1 BDI DISPLAY 2 ELECTRICAL CONNECTOR 3 NUT 4 CONTROL PANEL 5 CONTROL PANEL CUTOUT Figure 23 BDI Display INSTALL 1 Install BDI display into front of control panel See Figure 23 2 Install two nuts onto back of BDI display See Figure 23 3 Install electrical connector ...

Page 163: ......

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: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using for...

Page 167: ... Caster Adjustment 3 Caster Replacement 4 Disassemble 4 Assemble 5 Rear Link and Load Wheel Assembly 5 Remove 5 Disassemble 6 Assemble 6 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 Lifting Mechanism Table of Contents i ...

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Page 169: ... forward in the direction of the drive motor The movement of the pull rods cause the rear links and load wheels to pivot down lifting the rear of the fork frame This helps lift the fork frame and keep the forks parallel with the ground NOTE The lift linkage is not adjustable Load Wheel REMOVE 1 Move the lift truck to a safe and level area 2 Use the lift button to raise the lift truck to its maxi m...

Page 170: ...the ON position Press the lift button to raise the front forks 7 Remove the blocks from the lift truck and press the lower button to lower the forks 8 Test operation of the lift truck before returning the truck to service 1 BUSHING 2 LEVER 3 BUSHING 4 BALL BEARING 5 ROLLER 6 SPACER 7 LOAD WHEEL 8 CAPSCREW Figure 1 Single Load Wheel Assembly 1 BUSHING 2 LEVER 3 WASHER 4 ROCKER PLATE 5 BUSHING 6 CAP...

Page 171: ...or the proper caster checking and adjust ment procedures NOTE The casters include an eccentric mounting of the caster wheels to facilitate adjustment 1 Park the lift truck on a smooth and level surface with the control handle centered and with no load on the forks Lower the forks completely 2 Turn the key switch to the OFF position and dis connect the battery DO NOT remove the bat tery 3 Place the...

Page 172: ...xle adjuster into the caster frame and the caster wheel Install the adjuster and axle capscrew Tighten the capscrew to 35 N m 25 lbf ft 4 To reinstall the caster align the caster with the holes in the frame and install the four screws Tighten the nuts to 56 to 58 N m 41 to 43 lbf ft 5 Repeat procedure to replace the second caster if necessary Disassemble 1 Remove the caster wheel from the frame Re...

Page 173: ...area 2 Use the lift button to raise the lift truck to its maxi mum height 3 Put blocks under both forks and on both side front and back of the drive tire to prevent move ment of the lift truck See the section Periodic Maintenance 8000YRM1510 for lift truck model A249 Periodic Maintenance 8000YRM1666 for lift truck model A245 4 Press the lower button to relieve pressure from the hydraulic system 5 ...

Page 174: ...e retaining pin into the rear link casting and through the hole in the pull rod pivot pin 2 Align the rear link with the fork frame and install the rear link pivot pin Install the retaining cap screw into the fork frame 3 Lubricate all linkage pivot pins with multipurpose grease See the Recommended Schedule of Maintenance in the section Periodic Maintenance 8000YRM1510 for lift truck model A249 Pe...

Page 175: ...n to raise the forks to maximum height 3 When performing service that will require the rocker arms or the upper links to be removed put a solid wood or metal block under each side of 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 the rocker arms or upper links are disconnected Put blocks under both for...

Page 176: ...k frame Remove the rocker arm pivot pins 8 Remove the lift linkage assembly from the fork frame See Figure 9 9 Remove the capscrews retaining the pull rod pins to the rocker arm assembly See Figure 10 10 Remove the pull rod pins and separate the pull rods from the rocker arm assembly 11 Remove the retaining pins from the load wheel assembly and remove the pull rod pins Separate the pull rods from ...

Page 177: ... pressed flush with the pull rod end INSTALL 1 Insert the front of the pull rod into the rocker arm assembly and install the pull rod pivot pins 2 Install the capscrews to retain the pull rod pivot pins CAUTION The rocker arm is heavy 11 kg Support the rocker arm assembly during installation 3 Align the rocker arm assembly with the pull rods attached with pivot pins holes in the fork frame 4 Insta...

Page 178: ...attery See the section Periodic Maintenance 8000YRM1510 for lift truck model A249 Periodic Maintenance 8000YRM1666 for lift truck model A245 11 Test the operation of the lift truck before returning the truck to service Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Forks fail to elevate Battery is discharged Charge or replace battery See the section Periodic Maintenance for your lift t...

Page 179: ...stem 1900YRM1506 Deformed lifting components Disassemble and replace dam aged parts Load exceeds lifting capacity Select loads within capacity rating Forks fail to lower Battery is discharged Charge or replace battery See the section Periodic Maintenance for your lift truck Deformed forks Disassemble repair or replace Deformed lifting components Disassemble repair or replace Bent lift cylinder pis...

Page 180: ...NOTES 12 ...

Page 181: ......

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: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using for...

Page 185: ...ase 2 Truck Weights 2 Tires 2 Torque Specifications 3 Caster Assembly 3 Caster Assembly Dynamic 3 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 Table of Contents i ...

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Page 187: ...tes 32 C 90 F Oil Temperature Footnotes 1 0 35 MPa 51 psi 21 C 70 F Oil Temperature 2 10 Amps 1 270 Battery Specific Gravity 3 0 6 to 0 0 MPa 87 to 0 psi 32 C 90 F Oil Temperature Full Flow Hydraulic Oils Operating Condition Standard CS Freezer Truck Temperature Range 0 to 84 C 32 to 120 F 18 to 84 C 0 to 120 F For All Hydraulically Actuated Equipment Specification ISO VG 46 Antiwear HCE 140 Exxon...

Page 188: ...ted above is the approved source that meets or exceeds Yale specifications The use of products other than that listed above is unauthorized Truck Weights Unit Fork Length 900 mm 35 4 in Weight Fork Length 1000 mm 39 4 in Weight Fork Length 1150 mm 45 2 in Weight MP20 MP035 D and MP045VG 518 kg 1142 lb 523 kg 1153 lb 530 kg 1168 lb Tires Unit Size Item Torque MP20 230 mm 84 mm Wheel Lug Nut 120 N m...

Page 189: ...et 2 27 N m 20 lbf ft Butterfly Throttle Control to Handle 2 1 N m 9 lbf in Return Spring Mounting Stud 1 35 N m 26 lbf ft Return Spring to Support Bracket 1 35 N m 26 lbf ft Control Arm Pivot Pin to Support Bracket 1 35 N m 26 lbf ft ELECTRICAL Battery Post Nut 8 5 1 5 N m 6 0 1 0 lbf ft Brake Assembly to Traction Motor Capscrews 3 10 N m 89 lbf in Traction Motor Power Wire Nuts 3 8 N m 71 lbf in...

Page 190: ...26 lbf ft Battery Retainer Capscrew 1 35 N m 26 lbf ft Center Top Cover Capscrew 1 35 N m 26 lbf ft Center Main Cover Mounting Nuts 3 35 N m 26 lbf ft Main Cover Mounting Nuts 2 35 N m 26 lbf ft OPERATOR GUARD Guard Assembly to Frame Capscrews 6 25 6 N m 19 lbf ft Wire Retention Clamp to Guard Assembly Cap screw 1 52 N m 38 lbf ft Battery Specifications Battery Compartment is shown in Figure 1 Fig...

Page 191: ...x Weight Max 24 220 5 28 704 mm 27 7 in 223 mm 8 78 in 627 mm 24 7 in 212 kg 467 lb Table 2 Battery Specifications MPB045VG Voltage Ampere Hours Max Kilowatt Hours Max Compartment Length X Compartment Width Y Max Recommended Height Max Weight Max 24 110 4 58 704 mm 27 7 in 153 mm 6 02 in 655 mm 25 8 in OPEN 8000 YRM 1511 Battery Specifications 5 ...

Page 192: ...NOTES 6 ...

Page 193: ......

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: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using for...

Page 197: ... 2018 Yale Materials Handling Corp TABLE OF CONTENTS General Notes 1 Schematic Wiring Diagrams 2 This section is for the following models MP20 A249 MP045VG A245 Table of Contents i ...

Page 198: ......

Page 199: ...t With battery disconnected Reverse is travel in the direction of the forks Chain lines indicate EE enclosure Broken lines are for option only All unused terminals and connectors must be secure to a main wire harness branch All connectors are drawn from front view and are enlarged for clarity 8000 YRM 1512 General Notes 1 ...

Page 200: ...SCHEMATIC WIRING DIAGRAMS Figure 1 Schematic Wiring Diagram Pallet Truck Sheet 1 of 3 General Notes 8000 YRM 1512 2 ...

Page 201: ...Figure 1 Schematic Wiring Diagram Pallet Truck Sheet 2 of 3 8000 YRM 1512 General Notes 3 ...

Page 202: ...Figure 1 Schematic Wiring Diagram Pallet Truck Sheet 3 of 3 General Notes 8000 YRM 1512 4 ...

Page 203: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 1 of 7 8000 YRM 1512 General Notes 5 ...

Page 204: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 2 of 7 General Notes 8000 YRM 1512 6 ...

Page 205: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 3 of 7 8000 YRM 1512 General Notes 7 ...

Page 206: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 4 of 7 General Notes 8000 YRM 1512 8 ...

Page 207: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 5 of 7 8000 YRM 1512 General Notes 9 ...

Page 208: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 6 of 7 General Notes 8000 YRM 1512 10 ...

Page 209: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 7 of 7 8000 YRM 1512 General Notes 11 ...

Page 210: ...NOTES 12 ...

Page 211: ......

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: ...odic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using for...

Page 215: ...ENTS General 1 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 Table of Contents i ...

Page 216: ......

Page 217: ...rk frame weldment is linked to the main frame weldment by the lift links of the lifting mechanism system The lift cylinder actuates to evenly lift the fork frame and raise the load The battery end of the fork frame weldment is lifted directly by the cylinder and pivots on the lift links to the main frame weldment The fork tips are lifted simultaneously by push rods connecting the lift links to the...

Page 218: ...one of the frames away from the other FRAME ASSEMBLY 1 Align both frames so the pins may be installed to assemble the frames to each other 2 Install both drive unit frame pivot pins to attach the rocker arms to the drive unit frame See Rocker Arm and Pull Rods Install in Lifting Mechanism 4000YRM1509 3 Install the retainer pin to attach the hydraulic cyl inder to the fork frame See Hydraulic Cylin...

Page 219: ... UPPER LINK 9 LOAD BACKREST 10 BUSHING 11 BOLT 12 PLATE WELDMENT 13 SPACER 14 CAPSCREW 15 CAPSCREW 16 CAPSCREW 17 NUT 18 KNOB 19 CAPSCREW 20 COVER 21 CLIP 22 PLATE 23 NUT 24 WASHER 25 CAPSCREW 26 NUT Figure 2 Moveable Load Backrest Assembly 0100 YRM 1665 Frame Separation and Assembly 3 ...

Page 220: ...ces where the paint is completely removed using primer Apply the primer before applying the color paint 3 Protect all surfaces that will not be painted DO NOT paint cylinder rods cables labels plates or controls 4 Paint all the surfaces the original color using Yale paint Follow the directions on the con tainer Label Replacement WARNING Replace damaged Warning or Caution labels im mediately If lab...

Page 221: ...1 WARRANTY LABEL 2 NAMEPLATE 3 E STOP LABEL 4 BDI LABEL 5 YALE LOGO LABEL 6 PINCH WARNING LABEL 7 WARNING LABEL Figure 3 Labels and Decals 0100 YRM 1665 Label Replacement 5 ...

Page 222: ...NOTES 6 ...

Page 223: ......

Page 224: ...0100 YRM 1665 7 16 12 13 ...

Page 225: ...Maintenance PERIODIC MAINTENANCE MPB045VG A245 PART NO 550093875 8000 YRM 1666 ...

Page 226: ...ications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using force to remove parts Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs or if the unit needs repairs Be sure to follow the WARNING and CAUTION notes in the instructions Gasoline Liquid Petroleum Gas LPG Compressed Natural Gas CNG ...

Page 227: ...S WITH KEY SWITCH TURNED ON 12 Operation 12 Maintenance Procedures Every 350 Hours or Every 2 Months 13 Battery 13 HYDRAULIC SYSTEM 14 Hydraulic Oil 14 CASTER LUBRICATION 14 DRIVE TIRE CHECK 14 Maintenance Procedures Every 2000 Hours or Yearly 15 HYDRAULIC SYSTEM 15 Oil Change 15 Battery Maintenance 16 HOW TO CHARGE THE BATTERY 16 Equalizing Charge 16 Normal Charge 16 Lithium Ion Battery 17 Chargi...

Page 228: ......

Page 229: ...ir is necessary attach a DO NOT OPERATE tag to the control handle Report the need for repairs to your supervisor immediately Some users have service personnel and facilities to perform the procedures listed in the Maintenance Schedule Service Manuals are available from your Yale lift truck dealer to help users who do their own repairs Your Yale lift truck dealer has the trained personnel and equip...

Page 230: ...or the right side of the cover Work around the edge of the cover umtil free from the truck See Figure 2 To install drive unit cover place the bottom of the drive unit cover onto the frame and position the lower edges partially into the lower retaining clips Align holes in the in the cover with alignmnet pins attached to farme Push the top of the cover partially into the upper retaining clips Do no...

Page 231: ...weight of the disabled truck at the center of the forks and be careful not to damage the underside of it Tilt the mast back and travel slowly Make sure no one except the driver is near the lift trucks during towing Both the tow truck and the disabled truck can cause a personal injury during towing To avoid personal injury use extra care when moving a lift truck during the following conditions Brak...

Page 232: ...ed BEFORE returning the truck to service 3 Steer the lift truck with the control handle while it is being towed Use one hand and walk to one side of the lift truck DO NOT walk or stand between the towing vehicle and the lift truck 4 Tow the lift truck slowly 5 If counterbalanced style lift truck configured with the drive wheels nearest to the forks is used to tow the disabled lift truck The lift t...

Page 233: ... and web sling under the forks to raise the load wheels Another lift truck can also be used to raise the forks Make sure that the crane and sling or other lift truck has a capacity of at least 2 3 the total weight of the lift truck as shown on the capacity plate 3 Raise the forks only enough to suspend the wheels Install blocks under the forks at the rear of the wheels to support the lift truck Sp...

Page 234: ...3 INSULATED JUMPER WIRES 4 200 OHM 2 WATT RESISTOR 5 NEGATIVE CONNECTION Figure 4 Discharging Capacitors Maintenance Schedule The Maintenance Schedule is divided into three time intervals which call for particular maintenance procedures to be performed The intervals are 1 Day or 8 Hours 2 Months or 350 Hours and 1 Year or 2000 Hours for normal operation whichever comes first Normal operation is co...

Page 235: ...ld on 10 Grade4 3 Directional Speed Control X Check Operation 4 Gauges Horn and Fuses X Check Operation 5 Hydraulic Oil Full Mark X6 C Maximum 0 75 liter 0 79 qt Minimum 0 6 liter 0 63 qt Standard 0 to 48 C 32 to 120 F 1 Cold Storage Freezer 18 to 48 C 0 to 120 F 2 Sub Zero 40 to 48 C 40 to 120 F 6 Oil Leaks X Check for Leaks X Check C Change L Lubricate NOTE Never use steam to clean electrical pa...

Page 236: ...ith 2 4 Molybdenum Disulfate for normal operations X Check C Change L Lubricate NOTE Never use steam to clean electrical parts Maintenance Procedures Every 8 Hours or Daily WARNING DO NOT operate a lift truck that needs repairs If a repair is necessary attach a DO NOT OPERATE tag to the control handle and disconnect the battery Inspect the lift truck every 8 hours or daily before use Put the lift ...

Page 237: ...tery clean and painted Leakage and corrosion from the battery can cause a malfunction in the electric controls of the lift truck Use a water and sodium bicarbonate solution soda to clean the battery and 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 voltage and ampere hour rating for the lift truck See the nameplate...

Page 238: ...t the tire for embedded rocks glass wire pieces of metal holes cuts and other damage See Figure 6 Remove any object that will cause damage Check for loose or missing nuts and broken studs Remove any wire strapping or other material that is wrapped around the axle to prevent damage to the axle seal 1 REMOVE EMBEDDED OBJECTS 2 CHECK FOR CUTS SPLITS AND OTHER DAMAGE Figure 6 Tire Check Inspect the fr...

Page 239: ...s completely 2 Turn the key switch to the OFF position and disconnect the battery DO NOT remove the battery 3 Place the lift truck on blocks on both side of the drive frame See 4 Loosen the wheel axle capscrews on either side of the caster wheel until the adjuster can be pulled away from the caster assembly clear of the adjustment pin See Figure 7 1 ADJUSTMENT PIN 2 ADJUSTER 3 AXLE CAPSCREW Figure...

Page 240: ... hydraulic system Operating the hydraulic pump with low oil levels will damage the pump 1 Raise the forks slowly without a load Check for smooth operation and mechanical interference Mechanical interference is caused by damaged or worn linkage or shafts or by incorrect adjustment of the tension rods 2 Check for damaged or worn linkage bushings or shafts 3 Check for missing or loose shaft pins 4 Ch...

Page 241: ...y must fit the battery compartment so the battery restraint panels will operate correctly Use spacers to prevent the battery from moving more than 13 0 mm 0 5 in in any direction NOTE Battery water levels can be maintained without removing the battery from the truck Check for loose or broken electrical connections and damaged wires or cables Examine the battery case for damage and leakage See the ...

Page 242: ...en the oil is at normal operating temperature and forks are in the lowered position Remove drive unit cover Remove breather cap from hydraulic pump and reservoir Add hydraulic oil if necessary through the breather filler pipe until oil is at Full mark on reservoir Install breather cap and tighten DO NOT OVERFILL CASTER LUBRICATION CAUTION Use only the recommended lubricants for your application Re...

Page 243: ...be changed after the initial 350 hour break in period and then every 2000 hours thereafter Lower the forks turn the key switch to the OFF position and disconnect the battery Remove drive unit compartment cover Remove the screws securing retaining brackets to the bottom of the lift pump Slightly twist the reservoir from the hydraulic pump andmotor assembly to remove Recover the reservoir O ring Emp...

Page 244: ...ity Reading Electrolyte Temperatur e Correction Points Correct Value 1 210 31 C 88 F 0 003 1 213 1 210 27 C 81 F 0 001 1 211 1 210 25 C 77 F 0 000 1 210 1 210 18 C 64 F 0 004 1 206 0 001 for each 1 7 C 35 F from the 25 C 77 F Base Value Degrees C x 1 8 32 Degrees F Equalizing Charge NOTE Many customers have battery chargers that can follow a program to automatically charge a battery according to r...

Page 245: ...ary to make a periodic check that the charger is operating correctly Refer to Step 2 Knowing When Battery Is Fully Charged WARNING Always connect the positive cable to the positive terminal and connect the negative cable to the negative terminal Any other connection will cause injury and damage NEVER connect the battery charger plug to the plug of the lift truck You can damage the traction control...

Page 246: ...The replacement battery must fit the battery compartment Make sure the battery cables have clearance to move during lifting and lowering of the forks Make sure that the replacement battery is the correct voltage and weight as shown on the capacity plate See Figure 9 1 Turn the key switch to the OFF position Disconnect the battery Use a spreader bar and lifting device to remove the battery 1 CRANE ...

Page 247: ... the battery stand and puller with the battery compartment and battery 4 Adjust the legs of the battery stand so top of rollers are the same height as the bottom of the battery Make sure the battery stand is level WARNING To prevent personal injury and equipment damage DO NOT permit hook to touch battery cell terminals 5 Attach the hook of the battery puller to the lifting hole of the battery DO N...

Page 248: ...NOTES 20 ...

Page 249: ......

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: ...K ON BLOCKS in the Operating Manual or the Periodic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other...

Page 253: ...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 CONTROLLER DIAGNOSTICS Table of Contents i ...

Page 254: ...ntenance Diagnostic Data The General Maintenance and Diagnostic Data group includes general troubleshooting dis charging the capacitors basic electrical trou bleshooting multiplexing User Iterface and status codes and descriptions 20 Diagnostic Trouble Codes The Diagnostic Trouble Codes group includes all troubleshooting procedures for status codes reported by a given Node or system For a listing ...

Page 255: ...terface Setup and Troubleshooting 9030 03 8 Parameters 9030 03 8 Status Code Indication 9030 03 8 Speed Steering Reduction 9030 03 8 Traction Steering Decel Ramp 9030 03 9 Response Full Accel Rate HS 9030 03 9 Response Full Accel Rate LS 9030 03 9 Response Low Accel Rate 9030 03 9 Response Neutral Decel Rate HS 9030 03 9 Response Neutral Decel Rate LS 9030 03 9 Fine Tuning Partial Decel Rate 9030 ...

Page 256: ...nd Descriptions 9030 03 12 Status Codes 9030 03 13 Status Code Descriptions 9030 03 13 Group 20 Diagnostic Trouble Codes DTC 30001 LiftCoil 9030 20 2 DTC 30003 LwrCoil 9030 20 5 DTC 30033 Main Cont 9030 20 8 DTC 30035 Brake 9030 20 11 DTC 30037 AlrmCoil 9030 20 15 DTC 30039 Audible Alarm Opt 9030 20 18 DTC 30060 Mtr Curr 9030 20 20 DTC 30061 Mtr Open 9030 20 20 DTC 30062 Encoder 9030 20 22 DTC 300...

Page 257: ...e lift truck Begin the troubleshooting process by carefully inspecting the wiring involving the device or devices noted by the on board diagnostic system The controllers are sealed units with no serviceable components Troubleshooting is usually limited to ac cessing status codes and following the diagnostic pro cedure provided for each status code Use standard testing procedures to verify inputs a...

Page 258: ...the battery has been disconnected DO NOT short across the motor controller termi nals with a screwdriver or jumper wire CAUTION To avoid controller damage always disconnect the battery discharge the internal or external ca pacitors and never put power to the controller while any power wires are disconnected Never short any controller terminal or motor terminal to the battery Make sure to use prope...

Page 259: ...ting across a suspected open in the circuit Jumper wires can be used for located opens shorts and performing voltage drops If a cir cuit operates correctly with the jumper wire in place and is faulty when the jumper wire is removed a fault can be found in the bypassed location Jumper wires can also be used to eliminate sections of the circuit to diagnose either power or grounds Us ing the jumper w...

Page 260: ...ce is operating In a circuit with a single load device the device will drop the total voltage of the circuit If the device drops less than battery voltage it can be as sumed that the circuits are using the remaining volt age as a source of excessive resistance or a poor connection exists assuming the battery state of charge is correct 1 Verify battery connectors for loose terminals and appropriate...

Page 261: ...e damage of the meter and the electrical system Resistance Checks The ohmmeter is used to measure a circuit or device s resistance in ohms Ohmmeters use low internal volt age and current which flow through an isolated circuit or device being tested The voltage of the meter bat tery and the amount of current flow in the circuit are used to calculate the circuit s resistance It is neces sary to disc...

Page 262: ...Measure resistance of tiller card switch JP15 pin 1 and pin 2 Is resistance 1 4K ohms 0 14K ohms YES Suspect faulty tiller card NO Replace faulty switch Lift Function Fault If the lift function is inoperative and no code has been displayed perform the following troubleshooting pro cedures 1 Open tiller head assembly and inspect tiller card Are lower switches connected to tiller card con nectors JP...

Page 263: ...ing the CANbus NOTE Refer to the latest Diagram YRM for the most current circuit information When the CANbus is active and modules are commu nicating CAN HI and CAN LO voltage will be approxi mately 5 volts when added together If both CAN HI and CAN LO have consistent 2 5 volt there is no communication on the CANbus If CAN HI is shorted to B or CAN LO is shorted to battery voltage network communic...

Page 264: ...ction Controller connectors cables and components 1 Measure resistance between the Traction Control ler connector CPS01 pin 21 and pin 34 Is resistance 120 12 ohms YES Reconnect the Traction Controller connec tors cables components and proceed to Trouble shooting the CANbus NO Replace Traction Controller User Interface USER INTERFACE SETUP AND TROUBLESHOOTING The dash display has a LCD screen for ...

Page 265: ...parameter sets the rate in seconds at which the speed command increases when a small amount of throttle is applied This rate is typically adjusted to af fect low speed maneuverability Response Neutral Decel Rate HS This parameter sets the rate in seconds that is used to slow down the vehicle when the throttle is released to neutral at high vehicle speeds Response Neutral Decel Rate LS This paramet...

Page 266: ... rpm at full throttle RPM VDesired 936 Example RPM 2 5MPH 936 2340 rpm Mode 1 through 3 Max Accel This parameter sets the rate in seconds at which the motor speed command increases when throttle is ap plied Larger values represent slower response Mode 1 through 3 Walk Accel This parameter sets the rate in seconds at which the motor speed command increases when throttle is ap plied when truck is no...

Page 267: ...ick Lift command It shall be enough to lift up the load from the ground so that load wheels can move freely Full Lift Interval This optional parameter sets the period of time for which the truck will lift once traction is commanded while Quick Lift mode Lift Run Time This parameter sets the maximum allowable time to have the motor pump running upon lift command BDI Warning Lift Lock Enable This pa...

Page 268: ...age bridge disabled motor current set to 0 User Undervoltage Undervoltage Either Min Voltage controller voltage 16 8V or User Undervoltage Nominal Voltage whichever is higher The User Undervoltage parame ter can be used to adjust the undervoltage threshold which is the voltage at which the controller will cut back drive current to prevent damage to the electrical system The undervoltage threshold ...

Page 269: ...atus Codes NODE STATUS DESCRIPTION XX 099 Internal Fault 30 001 The Traction Controller has detected a fault in the Lift Coil circuit 30 003 The Traction Controller has detected a fault in the Lower Coil circuit 30 033 The Traction Controller has detected a fault in the Main Contactor Coil circuit 30 035 The Traction Controller had detected a fault in the Brake Coil circuit 30 037 The Traction Con...

Page 270: ...has detected that the traction motor has stalled 30 231 The Traction Controller has set the maintenance reminder 30 232 The Traction Controller has detected software update request 30 247 The Traction Controller has detected parameter update request 30 248 The Traction Controller has detected temperatures below controller operating range The Traction Controller and Tiller Control Card can detect a...

Page 271: ... faults detected observed YES Repair replace connector or wiring associated with faults found Refer to the appropriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Cause A NO Problem may be intermittent CAUSE A INTERNAL FAULT PROCEDURE OR ACTION 1 Replace faulty controller or tiller card Make sure to indicate the Diagnostic Trouble Code o...

Page 272: ... YES Proceed to Cause A NO Problem may be intermittent CAUSE A LIFT COIL WIRING FAULT PROCEDURE OR ACTION NOTE Disconnect pump coil terminals TS11 and TS12 located on left side of traction controller Turn key to ON position 1 Measure voltage between pump coil terminal TS11 and B Is voltage 24 2 5 Vdc YES Disconnect battery and proceed to Step 2 NO Inspect circuit 239 for open or short 2 Disconnect...

Page 273: ...ft coil CAUSE C FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertine...

Page 274: ... LiftCoil DIAGRAMS Lift Coil and Pump Contactor END FAULT Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 4 ...

Page 275: ...t YES Proceed to Cause A NO Problem may be intermittent CAUSE A LOWER COIL WIRING FAULT PROCEDURE OR ACTION NOTE Disconnect lower coil connector CRS05 located within hydraulic pump motor and turn key to ON position 1 Measure voltage between lower coil connector CRS05 socket 1 and B Is voltage 24 2 5 Vdc YES Disconnect battery and proceed to Step 2 NO Inspect circuit 239 for open or short 2 Disconn...

Page 276: ...er coil CAUSE C FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertine...

Page 277: ...nt LwrCoil DIAGRAMS Lower Coil and Pump Motor END FAULT ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 7 ...

Page 278: ...2 2 Re key the vehicle Is the code still present YES Proceed to Cause A NO Problem may be intermittent CAUSE A MAIN CONTACTOR COIL WIRING FAULT PROCEDURE OR ACTION NOTE Key in ON position 1 Disconnect the main contactor coil s positive socket terminal TS007 and measure voltage between socket ter minal TS007 and B Is voltage 24 2 5 Vdc YES Proceed to Step 2 NO Inspect circuit W239 B for open or sho...

Page 279: ...y main contactor coil CAUSE C FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and...

Page 280: ...AGRAMS Battery Disconnect Main Contactor and Contactor Coil END FAULT Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 10 ...

Page 281: ...lace connector or wiring associated with faults found Refer to the appropriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Cause A NO Fault may be intermittent CAUSE A WIRING FAULT PROCEDURE OR ACTION NOTE Perform Step 1 with key in ON position 1 Disconnect CPS01 and measure voltage between CPS01 socket 1 and B Note voltage reading recon...

Page 282: ...USE C FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulleti...

Page 283: ...C 30035 Cont Brake DTC 30035 BRAKE DIAGRAMS ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 13 ...

Page 284: ...DTC 30035 Cont Brake Brake Coil END FAULT Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 14 ...

Page 285: ...propriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Cause A NO Problem may be intermittent CAUSE A ALARM WIRING FAULT PROCEDURE OR ACTION NOTE Perform Step 1 with key in ON position 1 Disconnect alarm connector TS09 and measure voltage between socket 1 and B Is voltage 24 2 5 Vdc YES Disconnect battery and proceed to Step 2 NO Inspect ...

Page 286: ...to Cause C CAUSE C FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pert...

Page 287: ...037 Cont AlrmCoil DIAGRAMS Horn Alarm END FAULT ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 17 ...

Page 288: ... System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Cause A NO Problem may be intermittent CAUSE A ALARM WIRING FAULT PROCEDURE OR ACTION NOTE Perform Step 1 with key in ON position 1 Disconnect optional alarm connector CPS13 and measure voltage between socket 1 and B Is voltage 24 2 5 Vdc YES Disconnect battery and proceed to Step 2 NO Inspect circuit 01...

Page 289: ... alarm NO Proceed to Cause C CAUSE C FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for pos...

Page 290: ...eed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Cause A NO Problem may be intermittent CAUSE A TRACTION MOTOR CABLE FAULT PROCEDURE OR ACTION 1 Inspect controller phase cable terminals for proper torque and connections Are phase cables properly secured YES Proceed to Step 2 NO Repair and properly torque cables 2 Disconnect the traction motor cables from the traction con...

Page 291: ...or replace faulty traction motor CAUSE C FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section i...

Page 292: ...tion motor encoder connector CPS03 and measure voltage between socket 1 and B Is voltage 5 0 5 Vdc YES Proceed to Step 2 NO Inspect circuit 250 for open or short 2 Measure voltage between the encoder connector CPS03 socket 1 and socket 4 Is voltage 5 0 5 Vdc YES Disconnect battery and proceed to Step 3 NO Inspect ground circuit 102 for open or short 3 Disconnect the Combination controller connecto...

Page 293: ...oes voltage signal relate to traction motor movement YES Proceed to Cause C NO Replace faulty encoder CAUSE C FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 ELECTRICAL SYSTEM Diagnostic Trouble Codes...

Page 294: ...ncoder DTC 30062 ENCODER DIAGRAMS Traction Motor END FAULT Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 24 ...

Page 295: ...Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Cause A NO Problem may be intermittent CAUSE A MAIN CONTACTOR COIL WIRING FAULT PROCEDURE OR ACTION NOTE Key in ON position 1 Disconnect the main contactor coil s positive socket terminal TS07 and measure voltage between the terminal and B Is voltage 24 2 5 Vdc YES Disconnect battery and procee...

Page 296: ...Proceed to Cause C CAUSE C FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and ch...

Page 297: ...C 30067 Cont MainCont Stuck Closed DIAGRAMS ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 27 ...

Page 298: ...Cont MainCont Stuck Closed Main Contactor END FAULT Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 28 ...

Page 299: ...ropriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Cause A NO Problem may be intermittent CAUSE A MAIN CONTACTOR COIL WIRING FAULT PROCEDURE OR ACTION NOTE Key in ON position 1 Disconnect the main contactor coil s positive socket terminal TS07 and measure voltage between the terminal and B Is voltage 24 2 5 Vdc YES Disconnect battery a...

Page 300: ...tage between controller B and controller B terminal Oper ate turtle switch while measuring voltage Is voltage present between B and B terminals YES Proceed to Cause D NO Replace faulty main contactor CAUSE D FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 descriptio...

Page 301: ...TC 30068 Cont MainCont Stuck Open DIAGRAMS ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 31 ...

Page 302: ... Cont MainCont Stuck Open Main Contactor END FAULT Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 32 ...

Page 303: ...tep 2 2 Re key the vehicle Is the code still present YES Disconnect battery and discharge the capacitor Connect battery and re key the vehicle prior to perform ing Step 3 NO Problem may be intermittent NOTE The capacitor bank will charge only when the main contactor is closed If the truck is static tiller arm up no inputs commanded the capacitor voltage is going to be 0 Vdc and KSI Key Switch Inpu...

Page 304: ... to the Basic Electrical Troubleshootingsection and perform Voltage Checks CAUSE B FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 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 Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual s...

Page 305: ...DTC 30069 Cont Precharge END FAULT ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 35 ...

Page 306: ...r to cool for approximately 15 minutes System will recover once tem perature is below 115 C 239 F for the traction motor and 85 C 185 F for the traction controller Is the code still present YES Proceed to Cause A NO Fault may be intermittent Review truck usage weight load and rated capacities CAUSE A WIRING FAULT PROCEDURE OR ACTION 1 Perform Voltage Checks as indicated in the Basic Electrical Tro...

Page 307: ...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 ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 37 ...

Page 308: ...trical tests PROCEDURE OR ACTION 1 Conduct a visual inspection of all connectors wiring associated with the fault code Are any faults detected observed YES Repair replace connector or wiring associated with faults found Refer to the appropriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Disconnect battery and discharge the capacitor Connect batter...

Page 309: ...erminal and B Is precharge voltage same as battery voltage YES Proceed to Cause C NO Inspect B cable for damage or loose connections CAUSE C FAULTY CONTROLLER PROCEDURE OR ACTION 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 ELECTRICAL SYSTEM Di...

Page 310: ...DTC 30086 Cont LowBatt END FAULT Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 40 ...

Page 311: ...re any faults detected observed YES Repair replace connector or wiring associated with faults found Refer to the appropriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present 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 CAUSE A HIGH VOLTAGE AT CONTROLLER ...

Page 312: ... B cable for damage or loose connections CAUSE C FAULTY CONTROLLER PROCEDURE OR ACTION 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 Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible u...

Page 313: ...DTC 30087 Cont OverVolt END FAULT ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 43 ...

Page 314: ...he appropriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Step 3 NO Problem may be intermittent 3 Using the PC Service Tool locate input diagnostics Is thumb switch activation detected YES Fault may be intermittent NO Proceed to Cause A CAUSE A WIRING FAULT PROCEDURE OR ACTION NOTE Key in ON position 1 Disconnect battery display connect...

Page 315: ...e of excessive resistance CAUSE B BATTERY DISPLAY FAULT PROCEDURE OR ACTION 1 If faults are found when reconnecting replace BDI Make sure to indicate the DTC code s on the warranty claim to include an accurate problem description leading to controller replacement CAUSE C ENCODER FAULT PROCEDURE OR ACTION 1 if faults are found when reconnecting replace encoder make sure to indicate the DTC code s o...

Page 316: ...0090 Cont 12 Vdc 5 Vdc Supply Output END FAULT Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 46 ...

Page 317: ...orm multiplexing checks see the Multiplexing Section Are any CANbus circuit faults present YES Repair and retest system NO Proceed to Step 4 4 Measure resistance between frame and CANbus circuits Is resistance 1M ohm YES Proceed to Cause A NO Suspect short to frame CAUSE A CANBUS COMMUNICATION FAULT PROCEDURE OR ACTION NOTE Perform Step 1 and Step 2 with key in ON position NOTE Connector CJ2 is an...

Page 318: ...ller card LCD display and re key truck Does LCD display illuminate YES Proceed to Step 3 NO Proceed to Step 4 3 Continue to observe tiller card LCD display and re key truck Is LCD display properly configured YES Proceed to Cause C NO Refer to 2200 YRM 1507 to configure tiller card 4 Disconnect CRS03 from tiller card JP1 Measure voltage between socket 1 and B Is voltage same as battery voltage YES ...

Page 319: ...CANcomm DTC 30106 CANCOMM DIAGRAMS Control Card END FAULT ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 49 ...

Page 320: ...ing associated with the fault code Are any faults detected observed YES Repair replace connector or wiring associated with faults found Refer to the appropriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Cause B NO Problem may be intermittent CAUSE A INCORRECT START UP SEQUENCE PROCEDURE OR ACTION 1 The fault code may occur when the ope...

Page 321: ...nation resistors connected in parallel One resistor is between the tiller card and the traction controller The second resistor is connected to the traction controller With the tiller card and traction controller disconnected from the harness CANbus resistance is 120 ohms at the harness Measuring resistance between the traction controller connector CPS01 pins 21 and 34 will measure 120 ohms When bo...

Page 322: ...eeded Use Electrical System manual for reference CAUSE E TILLER CONTROL CARD FAULT PROCEDURE OR ACTION 1 Replace tiller control card Make sure to indicate the DTC code s on the warranty claim to include an accu rate problem description leading to card replacement CAUSE F FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 1 Replace faulty handle Make sure to indicate the DTC code s on the warranty clai...

Page 323: ... Cont ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 53 ...

Page 324: ... Cont END FAULT Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 54 ...

Page 325: ...llowing test The traction controller and brake will be OFF 2 With key in OFF position locate the brake override connectors on left and right side of traction motor Discon nect CRP04 B and CRP04 A connect CRP04 B to the electromagnetic brake connector Move the truck back and forward and move handle side to side Does truck move and rotate freely YES Connect CRP04 B AND CRP04 A and proceed to Step 3 ...

Page 326: ...PS03 Is resistance 1 ohm YES Proceed to Cause C NO Inspect signal circuit 577 for open or source of excessive resistance CAUSE B FAULTY TRACTION ENCODER PROCEDURE OR ACTION 1 Measure voltage between sockets 31 32 and B of the traction connector CPS01 operate traction motor Was voltage present YES Proceed to Cause D NO Replace encoder Make sure to indicate the DTC code s on the warranty claim to in...

Page 327: ...oller 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 ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 57 ...

Page 328: ...resent YES Proceed to Cause A NO Fault may be intermittent CAUSE A INCORRECT PARAMETER SOFTWARE INSTALLATION PROCEDURE OR ACTION 1 Connect PC Service Tool and observe Truck Report Connect to FST download software and CDF file Once download is complete rekey the truck Is the code still present YES Clear error fault code from history Make sure to indicate the DTC code s on the warranty claim to in c...

Page 329: ...ociated with faults found Refer to the appropriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Cause A NO Fault may be intermittent CAUSE A INCORRECT PARAMETER SOFTWARE INSTALLATION PROCEDURE OR ACTION 1 Connect PC Service Tool and observe Truck Report Connect to FST download software and CDF file Once download is complete rekey the truc...

Page 330: ...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 Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 60 ...

Page 331: ...ults detected observed YES Repair replace connector or wiring associated with faults found Refer to the appropriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to NO Fault may be intermittent 3 Remove truck from austere environment and turn key to ON position The system will recover once truck is able to achieve an internal temperature of 3...

Page 332: ...ceed to Step 3 NO Inspect circuit 367 for open short or source of excessive resistance 3 Measure resistance between CPS02 socket 2 and B Is resistance 1 ohm YES Proceed to Cause B NO Inspect circuit 101 for open short or source of excessive resistance CAUSE B FAULTY TRACTION CONTROLLER PROCEDURE OR ACTION 1 If no faults are found replace controller Make sure to indicate the DTC code s on the warra...

Page 333: ... the appropriate Electrical System YRM NO Proceed to Step 2 2 Re key the vehicle Is the code still present YES Proceed to Step 3 NO Problem may be intermittent 3 Using the PC Service Tool locate input diagnostics and view belly switch input Is belly switch operational YES fault may be intermittent Inspect belly switch for damage NO Proceed to Cause A CAUSE A START UP SEQUENCE PROCEDURE OR ACTION 1...

Page 334: ...voltage YES Proceed to Step 2 NO Inspect circuit 010 for open or short 2 Measure voltage between pin 22 and B of connector CPS01 Perform test with tiller arm up and emergency reverse button depressed Is the voltage same as key switch voltage YES Disconnect battery and proceed to Step 3 NO Proceed to Cause D 3 Measure resistance between CPS01 socket 22 and CRR03 socket 05 Is resistance 1 ohm YES Pr...

Page 335: ... Cont DIAGRAMS ELECTRICAL SYSTEM Diagnostic Trouble Codes Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 65 ...

Page 336: ... Cont Emergency Reverse END FAULT Diagnostic Trouble Codes ELECTRICAL SYSTEM Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins 9030 20 66 ...

Page 337: ......

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: ...ound cable on internal combustion lift trucks Always use correct blocks to prevent the unit from rolling or falling See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repai...

Page 341: ...LED Status Display 8 Charging 8 Charger Troubleshooting 9 General 9 Error Modes 10 A C Convenience Port Accessory 13 General Troubleshooting 13 Wake Up Circuit 13 Wake up Relay 14 Lithium Ion Pack 14 Battery Ratings 15 Kilowatt Hours 15 Battery Maintenance 15 Safety Procedures 15 Cleaning Battery 16 Charging Battery 16 Troubleshooting Charger 16 Knowing When Battery Is Fully Charged 16 Where to Ch...

Page 342: ......

Page 343: ...k Lithium Ion Configurations The existing lithium ion battery weldment is capable of storing two additional lithium battery packs Additional battery packs can be easily added with the use of an inline 175 amp fuse and wake up harness The harness allows the configuration of two or three battery pack designs however additional fuses and battery cables will be needed for each battery added The 55 Ah ...

Page 344: ...urs in which less than 1000mA is applied The lithium ion battery is programmed to conserve power during long periods of inactivity To preserve battery voltage the lithium ion battery will remove power to the terminals and the lift truck s electrical system The battery pack will continue to draw a very low amount of current amperage during sleep mode Even in sleep mode the battery can be fully disc...

Page 345: ...arger may occur if the mode setting is not correct for the type of batteries being used If the battery manufacturer of the battery you are using is not listed contact Service Engineering through the Contact Management System NOTE Mode settings can be checked by connecting the battery charger to a 120V AC power source while connected to the battery and watching the LED display See charger manual fo...

Page 346: ...rger Figure 3 Gen IV Charger For more information about these chargers refer to the following Service Manuals Electrical System 2200YRM1508 for lift trucks A245 equipped with Gen III chargers Accusense GEN IV Charger 2200YRM2030 for lift trucks A245 equipped wiht Gen IV chargers Electrical System 2200YRM2076 for lift trucks B245 equipped with Gen III and IV chargers 1 USB PORT FACTORY USE ONLY 2 M...

Page 347: ...LED display while connected to the battery reference Table 2 for LED display of mode setting If the battery voltage is below 12V no lights illuminate Modes are set by the sequence of the dip switches Tampering with the Charging Mode Label voids warranty For the Lithium Ion battery the charger should always be set to Mode 15 2240 YRM 1890 Charging and Troubleshooting 5 ...

Page 348: ...he charger via two connectors One connector will connect the charger to the AC Input while the other connector is for serial communication and transmission of the LED status lights The convenience port LED status lights display diagnostic codes according to Table 8 The convenience port also flashes from the center LED to the outer LED in a back and forth pattern if communication between the charge...

Page 349: ...Figure 6 Battery Charger Diagram GPT 2240 YRM 1890 Charging and Troubleshooting 7 ...

Page 350: ...PWR RED Illuminates continuously when AC power is present If flashing refer to Troubleshooting procedures Abnormal Shutdown SDN RED Flashes if abnormal shutdown has occurred Refer to Troubleshooting procedures Detection Error DET RED Illuminates continuously when battery is not connected to charger or battery voltage is less than 2V If flashing refer to Troubleshooting procedures Charging CHG YELL...

Page 351: ...d LEDs on the top of the charger If this condition occurs see Troubleshooting in this section Operating temperature range for the charger is 10 to 55 C 14 to 131 F If charger is below or above indicated temperatures move lift truck to an area where charger can return to the correct operating temperature range CHARGER TROUBLESHOOTING General NOTE The charger runs a pre qualifying test yellow chargi...

Page 352: ...r 6 Check the output of the charger using a digital voltmeter a Connect the voltmeter to the charger s positive Red and negative Black connections at the battery terminals Record the voltage and then monitor it for approximately 3 minutes Did the voltage INCREASE while monitoring 1 YES The charger is functioning correctly Proceed to Step 7 2 NO Replace the charger 7 Was the voltage reading in Step...

Page 353: ...ing Battery Testing Error Sulphate Flashing Off Flashing Off Off Battery Testing Error Discharged Flashing Off Flashing Off Flashing Bulk Charge Safety Time Error Flashing Flashing Off Off Flashing Absorption Safety Time Error Flashing Flashing Off Flashing Off Excessive Safety Time Error 1 Off Off Off Off Flashing Mode Selected Not Valid Empty 1 Off Off Off Flashing Off Product Not Operational 1 ...

Page 354: ...off completely to avoid adding to the decaying process Using a voltmeter check if battery voltage is well under its 100 depth of charge Remove all loads from battery including charger and allow time for battery pack to spring back to above 1Vdc cell Reconnect only the charger to battery pack and allow to charge Batt Temperature Sensor Open Shorted If a Battery Temperature Sensor Cable was installe...

Page 355: ... the factory or your point of distribution A C Convenience Port Accessory If the optional A C Convenience Port Accessory is include with your system the LED display mirrors the Charger LED Display with one exception If an LED pattern flashes from the center LED out in a repeating pattern the Port is indicating a Lost Communications error Check wiring for continuity GENERAL TROUBLESHOOTING Wake Up ...

Page 356: ... external temperature if over temp conditions exists allow to cool for 1 hour If below the minimum temperature move battery into a warmer area for 1 2 hours Attempt a wake up and check for battery voltage across the B and B terminals If fault remains proceed to check Under Voltage condition Step 2 2 Under Voltage The pack is designed to shutdown before over discharging at voltage of 20 5 volts or ...

Page 357: ...oltage by ampere hours To measure the kilowatt hours divide the watt hours by 1000 volts amperes hours kilowatt hours or kWh 1000 To calculate the kilowatt hours for a battery that has a rating of 600 ampere hours and a 48 volt system use this formula 48 volts 600 amperes hours 28 8 kWh 1000 The watt hours can be converted to kilowatt hours to indicate the battery needed for the operation Always s...

Page 358: ...operating correctly Refer to Charging Knowing When Battery Is Fully Charged WARNING Always connect the positive cable to the positive terminal and connect the negative cable to the negative terminal Any other connection will cause injury and damage NEVER connect the battery charger plug to the plug of the lift truck You can damage the traction control circuit Make sure the charger voltage is the c...

Page 359: ...pped with equipment follow UN3481 2 NEVER alter remove deface or obscure Li Ion warning labels 3 When provided always return batteries in the packaging provided 4 Shipping container must provide documentation indications that a Li Ion battery is enclosed a statement of hazards procedure if damaged and contact information Shipping container cannot exceed 30kg gross mass 5 Package must be able to wi...

Page 360: ...NOTES 18 ...

Page 361: ......

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: ...ound cable on internal combustion lift trucks Always use correct blocks to prevent the unit from rolling or falling See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use YALE APPROVED parts when making repai...

Page 365: ...tage Charging 5 LED Display Multi Stage Charge 7 Cell Battery and Battery Pack Voltage 8 Voltages 8 Troubleshooting 9 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 Table of Contents i ...

Page 366: ......

Page 367: ... mass with ballast if used to compensate for lack of battery mass NOTE Gen IV Q Series chargers can be identified by the MFR MOD number on the charger label If the first two digits of the MFR MOD number read 1Q or 2Q the equipment is a Gen IV Q Series charger Table 1 Charger Identification MODEL NUMBER PREFIX DESCRIPTION 1Q Gen IV 120V 2Q Gen IV 230V 1 Gen III 120V 2 Gen III 230V There are also ph...

Page 368: ...tails in diagnosing charger LED flashes if the LEDs do not flash when initially connected to power NOTE If the battery manufacturer of the battery you are using is not listed contact Service Engineering through the Contact Management System The battery charger has 7 mode settings The proper mode setting is determined by the type batteries be ing used in the battery pack Note that batteries must be...

Page 369: ...hes Tampering with the Charging Mode Label voids war ranty NOTE If the charger has been Field Reprogrammed during first time charger is used startup time can take up to 10 minutes The LEDs will not flash and the charger will appear to be frozen Do not unplug the charger as it rebuilds internal database information Table 2 LED Charge Mode Indicator MODE SETTING LED 1 LED 2 LED 3 LED 4 LED 5 1 Off O...

Page 370: ...harger s minimum voltage for charging thresh old Verify the connection from the 4 pin connector from convenience port to the 4 socket connector from charger If flashing code continues disconnect the positive red B wire reconnect and try to charge system again If this does not work use an alternate charger to increase battery voltage reading to 21 volts sufficient for the charger to continue chargi...

Page 371: ...ely 80 of total charge is delivered to the battery The bulk charge is 20A DC RMS 10 Use a true RMS Amp meter to measure the current 3 ABSORPTION Charge Stage Constant Volt age Charger charges at a constant voltage level to provide adequate time for the battery plates to absorb the energy delivered Charge Amper age decreases as the energy is absorbed into the plates Termination of this stage occurs...

Page 372: ...nly use this method if the charge mode is set to 2 The charge cycle in which this additional Equalization Charge Stage will inject itself into will be announced by either flashing the Red Power On LED or flashing the LCD Backlight continually throughout the ENTIRE charge cy cle The flash will stop upon entry into the Float Maintenance Standby Stage 6 FLOAT MAINTENANCE STANDBY Charge Stage Entry in...

Page 373: ...tery is fully charged Menu Select Button RED Depressing and holding depressed this button for 10 seconds at power up forces charger to insert the Equalization Stage into the charge algorithm regiment IF and only IF that charge MODE selected would allow it After power up and if switch is again held depressed for 10 seconds the Equalization Charge Stage is toggled to OFF de asserted from the charge ...

Page 374: ...olts One 6 Vdc battery consisting of three cells has a mini mum voltage of 5 25 Vdc 1 75 Vdc X 3 cells 5 25 Vdc 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 1 BATTERY PACK 2 MAINTENANCE PORTS ONE PER CELL 3 BATTERY Figure 8 Battery Pack Assembly Cell Battery and Battery Pack Voltage 2200 YRM 2030 8 ...

Page 375: ...ition was detected and charg ing stopped due to a Charge Error Condition Refer to the following Table 4 for an extended description of the failure or condition and its possible remedy Table 4 Charge Errors Condition LED 1 LED 2 LED 3 LED 4 LED 5 Battery Over Voltage Off Off Off Off Flashing Battery Temperature Low Off Off Off Flashing Flashing Battery Temperature High Off Off Flashing Off Off Batt...

Page 376: ...ch than other batteries in the pack The indication is that a cell s within the pack may have shorted or experienced stratification of the electrolyte over charging due to incorrect MODE setting and may re quire replacement of the batteries Refer to the Equip ment s Operators manual for instructions on servicing the battery pack Batt Is 100 Discharged Based on 1 75Vdc cell this error is produced wh...

Page 377: ...es out AND the battery voltage was dragged below 2 17V cell Possible causes include use of a heavy battery load that drained energy from the battery while the charger was trying to charge that same battery Excessive Charge Time Error Occurs when charg ing took too long AND the battery voltage was not al lowed to increase above 2 17V cell Possible causes include use of a battery load that is draini...

Page 378: ...y removing the output leads from the battery pack while A C Power is dis connected from the charger and reconnecting the output leads Batteries Hot To Touch Charger Continues To Charge A hot battery signifies cells that are Shorted due to material coalesced at the bottom of the cell and not able to break down and recombine back onto the battery plates stratification of the acid into layers where a...

Page 379: ... is connected to your vehicle s lockout mecha nism 2 Where the Output Connector and Cable do not have an additional set of output leads for the Lockout Inhibit Control function These options may require you to disassemble the backshell on the cable connector install a pig tail Lock out Cable Contact Factory and speak with Customer Service concerning various premade cable assemblies that can fit yo...

Page 380: ...NOTES 14 ...

Page 381: ......

Page 382: ...2200 YRM 2030 6 17 11 16 10 16 ...

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