Yale MPB045VG Electric Walkie Pallet Jack Maintenance Manual

Yale MPB045VG Electric Walkie Pallet Jack Maintenance

Safety Precautions TROUBLESHOOTING

PROCEDURES

• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by
  trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use the correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
  remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

Group 03

General Maintenance and Diagnostic Data

GENERAL TROUBLESHOOTING

• In the event the lift truck does not operate correctly, a status code is displayed on the display panel. Once the status code is obtained, follow the procedures
  outlined in this manual only after reviewing the following information regarding the truck’s unique electrical system and troubleshooting procedures.
• NOTE: Due to the interaction of the traction controller with all truck functions, almost any status code or controller fault could be caused by an internal failure of the traction controller. After all other status code procedures have been followed and no problem is found, the traction controller should be tested and replaced as the last option to correct the problem.
• Prior to troubleshooting systems and components on the vehicle, ensure the battery voltage is correct and within specifications. Make sure the battery connector contacts are clean of corrosion and the battery polarity within the connector is correct. Inspect that all fuses are correct and are not the cause of component failure. Ensure the key switch is in the ON position when conducting voltage checks or verifying the operation of a component. Make sure the brake switch is functioning properly and is closed.
• Many faults noted by lift truck’s electrical system may be the result of loose wiring connections and/or broken or shorted wiring within the lift truck. Begin the
  troubleshooting process by carefully inspecting the wiring involving the device or devices noted by the onboard diagnostic system. .
• The controllers are sealed units with no serviceable components. Troubleshooting is usually limited to accessing status codes and following the diagnostic
  procedure provided for each status code. Use standard testing procedures to verify inputs and outputs when necessary.

1. Move the lift truck to a safe, level area and completely lower the forks. Turn the key switch to the OFF position and attach a DO NOT OPERATE tag to the control handle. Block the drive wheel to prevent unexpected movement.
2. Disconnect the battery power cable connector from the truck connector located on the top-left side of the frame. Pull the battery cable connector handle to separate the battery connector from the truck connector
   1. TRACTION CONTROLLER
   2. POSITIVE CONNECTION
   3. INSULATED JUMPER WIRES
   4. 200-OHM, 2-WATT RESISTOR
   5. NEGATIVE CONNECTION

Electrical Test Equipment

• ELECTRICAL TEST EQUIPMENT
• Before beginning intrusive circuit checks, verify the vehicle battery’s state of charge. Visually inspect suspected connectors for loose, damaged, or corroded
  terminals. Check for blown fuses and inspect circuits for causes of overcurrent conditions. Physically check mechanical operation to ensure a switch, relay, or
  solenoid is not sticking or damaged.
• NOTE: Measuring the continuity between two terminals of a switch while operating the switch will determine its functionality.
• PC Service Tool
• The PC Service Tool is a Windows-based service application that is used to communicate with the truck’s electrical control system. It can be used to monitor the status and condition of various systems. With this capability, the PC Service Tool can be used to monitor component operation, or determine if abnormal events have occurred in the truck, and assist with diagnostics and troubleshooting.
• Digital Multimeter (DMM)
• Digital multimeters provide several measurement functions in one tool. A DMM should be capable of accurately measuring voltage, amperage, and resistance. Ensure that the multimeter used in troubleshooting procedures is accurate and that the test leads do not have excessive resistance. A faulty meter or damaged test leads will cause inaccurate readings and incorrect electrical diagnoses

Basic Electrical Troubleshooting

• ELECTRICAL CHECKS
• The following electrical checks are used to diagnose circuit and component faults on trucks. Review the  following information so that it may be applied when
  diagnosing a fault or status code.
• Voltage Checks
• Voltage is electrical pressure or force that pushes current through a circuit. The force is measured in volts. Low voltage to a load device will cause the device to be inoperative or operate poorly. This can be caused by a low battery source, high circuit resistance, poor connections, or an open circuit; the resistance of poor connections or poor ground acts as an additional load in the circuit, causing low voltage pushing current, or amperage, through a device.
• A voltmeter is used to perform:
  • Measurement of force
  • Presence of voltage
  • Voltage drops
• When using a voltmeter to determine if the voltage is present and capable of operating a device, connect the positive meter to the power circuit of a device’s connector and connect the negative meter to the negative battery terminal.
• Measuring the voltage drop is performed by connecting the positive test lead to the positive side of the device while simultaneously connecting the negative meter lead to the negative side of the device. The test can also be performed across a section of wire that is faulty and suspected of having excessive resistance. A voltage drop must be performed while the device 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 the battery voltage, it can be assumed that the circuits are using the remaining voltage as a source of excessive resistance or a poor connection exists, assuming the battery state of charge is correct.

Multiplexing

• MULTIPLEXING AND THE CANBUS
• Controller Area Network (CAN) Bus communication allows multiple modules to communicate with each other using the same digital data on a shared network,
  this method of communication is known as multiplexing. The CANbus is a pair of twisted insulated wires that interconnect all the modules on the network.
  The data transmitted is a digitally encoded format.
• Digital means only two states are used to transmit data, High/On and Low/Off. This eliminates the need for each module to be hard-wired to each sensor. Using Multiplexing, sensor information that may be received by one module can then be shared with all other modules. The information is sent out over the
  CANbus in an encoded form and any other module that requires the information can pick it out from the data stream.
• The CANbus has two termination resistors (120 ohms) that are connected in parallel. When resistance checks are performed, a normal operating system will display 60 ohms between the CAN LO and CAN HI circuits. The first 120-ohm termination resistor is located inside the Tiller Control Card. To diagnose, proceed to Troubleshoot the Tiller Control Card Termination Resistor. The second 120-ohm termination resistor is located in the Traction Controller. To diagnose, proceed to Troubleshoot the Traction Controller Termination Resistor.

User Interface

USER INTERFACE, SETUP, AND TROUBLESHOOTING

• The dash display has an LCD screen for displaying truck system information. The dash display also contains a battery state-of-charge indicator.
• Status Code Indication
• This feature indicates if a status code is available. If a status code is present, the fault code number followed by the status code description will be displayed. If
  other status codes are present, the subsequent status code and description will be displayed. Two seconds will lapse between display screens before displaying
  the code sequencing
• Response-Full Accel Rate HS
• This parameter will set the rate (in seconds) at which the speed command increases when full throttle is applied at high vehicle speeds. Larger values represent slower responses. See Figure 9030-03-2 for the relationship between Full Accel Rate HS, Full Accel Rate LS, and Low Accel Rate.
• NOTE: IN THIS EXAMPLE, HS = 70%, LS = 30%, TYPICAL MAX SPEED = 5000 RPM
• Fine Tuning-Max Speed Accel
• In some applications, the Max Speed value is changed frequently over the CANbus. The Max Speed Accel parameter controls the rate at which the maximum
  speed setpoint is allowed to change when the value of Max Speed is raised. The rate set by this parameter is the time to ramp from 0 RPM to Typical Max Speed
  RPM. If the maximum speed is raised from 1000 RPM to 3000 RPM, the Typical Max Speed is 3200 RPM and the rate is 10.0 seconds, it will take 10.0 * (3000–1000) /3200 = 6.25 seconds to ramp from 1000 RPM to 3000 RPM.
• Fine Tuning-Max Speed Decel
• This parameter is like the Max Speed Accel parameter, except that it controls the rate at which the maximum speed setpoint is allowed to change when the value of Max Speed is lowered. If one changes the Max Speed from 300 RPM to 1500 RPM, the Typical Max Speed is 3200 RPM and the rate is 5.0 seconds, it will take 5.0 (3000–1500) / 3200 = 2.34 seconds to ramp from 3000 RPM to 1500 RPM
• Turtle Alarm enable
• This parameter sets an alarm to indicate when the truck has transitioned from turtle mode (TM1) to turtle mode 2 (TM2). The truck will transition from TM1 to TM2 when the truck is been driven in TM1 and turtle button is depressed while the tiller arm transitions from operational region A to operational region B. See Figure 9030-03-3.
• A. OPERATIONAL REGION A
• B. OPERATIONAL REGION B
• C. OPERATIONAL REGION C

Status Codes and Descriptions

• STATUS CODES
• Status codes indicate to the operator that a possible malfunction or incorrect truck use has occurred. Status codes are the code number of a symptom or malfunction. The wrench symbol will flash and the status code number will be shown on the LCD screen if an incorrect truck use or malfunction occurs
  during operation. Have an authorized service person check and repair the lift truck if a status code number appears

  DISPLAY	LINE DESCRIPTION
  First Display String	Diagnostic Trouble Code
  Subsequent Display String	Code Description/Affected Circuit

STATUS CODE DESCRIPTIONS

Table 9030-03-2. Node 30 Status Codes

Group 20

Diagnostic Trouble Codes

POSSIBLE CAUSE

• A. INTERNAL FAULT

COMPONENT OPERATIONAL CHECK

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 SystemYRM.
   • NO: Proceed to Step 2.
2. Re-key the vehicle.
   • Is the code still present?
   • YES: Proceed to CAUSE A.
   • NO: The problem may be intermittent.

CAUSE C – FAULTY TRACTION CONTROLLER

PROCEDURE OR ACTION:

1. If no faults are found, replace the controller. Make sure to indicate the DTC code(s) on the warranty claim to include an accurate problem description leading to controller replacement.

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 terminal TS007 and B(-).
   • Is voltage 24 ± 2.5 Vdc?
   • YES: Proceed to Step 2.
   • NO: Inspect circuit W239-B for open or short.

DIAGRAMS

END POSSIBLE CAUSES

DIAGRAMS

POSSIBLE CAUSE

• A. ENCODER WIRING FAULT
• B. ENCODER FAULT
• C. FAULTY TRACTION CONTROLLER

COMPONENT OPERATIONAL CHECK

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 SystemYRM.
   • NO: Proceed to Step 2.
2. Re-key the vehicle.
   • Is the code still present?
   • YES: Proceed to CAUSE A.
   • NO: The problem may be intermittent.

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Yale MPB045VG Electric Walkie Pallet Jack Maintenance-FAQs