Yale MPB045VG Guide

Maintenance
CONTROLLER
DIAGNOSTICS
MPB045VG [A245]
PART NO. 550095689 9000 YRM 1671

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 correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2019 Yale Materials Handling Corp.
TABLE OF CONTENTS
SECTION 9030 - ELECTRICAL SYSTEM
Group 03 - General Maintenance and Diagnostic Data ..........................................................................9030-03-1
Group 20 - Diagnostic Trouble Codes .................................................................................................... 9030-20-1
This section is for the following models:
(MPB045VG) [A245]
CONTROLLER DIAGNOSTICS Table of Contents
i

How To Use This Troubleshooting Manual
GENERAL INSTRUCTIONS AND SAFETY
INFORMATION
WARNING
DO NOT add to or modify the lift truck. Any modifi-
cation that affects the safe operation of the truck
cannot be undertaken without written authoriza-
tion of the Yale company.
Any change to the lift truck, the tires, or its equip-
ment can change the lifting capacity. The lift truck
must be rated as equipped and the nameplate
must show the new rating capacity.
WARNING
The technician must be aware of, and follow, all
general safety precautions that are published in
the Operating Manual and that are posted as Safe-
ty Decals on and in the lift truck.
Before starting, the technician should be familiar with
certain policies, requirements, and instructions used in
the troubleshooting procedures. Using the
troubleshooting procedures correctly helps the
technician to perform the procedure safely and
prevents damage to the machine and support
equipment.
HOW TO USE DIAGNOSTIC
TROUBLESHOOTING MANUAL
Manual Layout:
Section: This manual consists of one section which is
further divided into groups.
• 9030 – Electrical System
Groups: The 9030 Electrical System is divided into
two groups that identify specific electrical
troubleshooting procedures.
• 03 – General Maintenance/Diagnostic Data
The General Maintenance and Diagnostic Data
group includes general troubleshooting,
discharging the capacitors, basic electrical
troubleshooting, 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 of all Diagnostic Trouble Codes and
descriptions, see the section of this manual.
GENERAL INSTRUCTIONS
1 Become familiar with the content, layout, and
access provisions of data in this manual. This
will improve your efficiency and decrease the
time required to resolve the problems.
2 Once you begin a troubleshooting procedure, do
not skip steps.
3 If you reach the end of a procedure without
resolving the problem and you are not directed
to another procedure contact Resident Service
Engineering through the Contact Management
System.
4 Do not limit yourself, remember to apply your
own experience and knowledge to assist in
resolving the problems, but do not compromise
safety in doing so.
5 Most of the cross-reference data in the manual
will be electronically linked for rapid and easy
access. Use the links wherever the cursor
highlights an item as a linkable option.
CONTROLLER DIAGNOSTICS How To Use This Troubleshooting Manual
Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
Confidential/Proprietary - Do Not Copy or Duplicate iii

SECTION 9030
ELECTRICAL SYSTEM
TABLE OF CONTENTS
Group 03 General Maintenance and Diagnostic Data
General Troubleshooting ........................................................................................................................ 9030-03-1
Discharging the Capacitors .................................................................................................................9030-03-1
Electrical Test Equipment ....................................................................................................................... 9030-03-3
PC Service Tool .............................................................................................................................. 9030-03-3
Digital Multimeter (DMM) ................................................................................................................ 9030-03-3
Jumper Wires, Test Leads, and Test Lights .................................................................................... 9030-03-3
Basic Electrical Troubleshooting .............................................................................................................9030-03-3
Electrical Checks ................................................................................................................................ 9030-03-3
Voltage Checks ...............................................................................................................................9030-03-3
Amperage Checks .......................................................................................................................... 9030-03-5
Resistance Checks ......................................................................................................................... 9030-03-5
Contactor and Contactor Coil Checks ............................................................................................ 9030-03-5
Lift and Lower Switch Check .......................................................................................................... 9030-03-5
Multiplexing .............................................................................................................................................9030-03-6
Multiplexing and the CANbus ............................................................................................................. 9030-03-6
Troubleshooting the CANbus ..........................................................................................................9030-03-6
Troubleshooting the Tiller Control Card Termination Resistor ........................................................ 9030-03-7
Troubleshooting the Traction Controller Termination Resistor ........................................................9030-03-7
User Interface .........................................................................................................................................9030-03-7
User Interface, Setup, and Troubleshooting ....................................................................................... 9030-03-7
Status Code Indication ....................................................................................................................9030-03-7
Parameters ......................................................................................................................................... 9030-03-7
Speed Steering Reduction ..............................................................................................................9030-03-8
Traction Steering Decel Ramp ........................................................................................................9030-03-8
Response-Full Accel Rate HS ........................................................................................................ 9030-03-8
Response-Full Accel Rate LS .........................................................................................................9030-03-8
Response-Low Accel Rate ............................................................................................................. 9030-03-8
Response-Neutral Decel Rate HS .................................................................................................. 9030-03-8
Response-Neutral Decel Rate LS ...................................................................................................9030-03-8
Fine Tuning-Partial Decel Rate .......................................................................................................9030-03-8
Fine Tuning-HS (High Speed) .........................................................................................................9030-03-8
Fine Tuning-LS (Low Speed) ..........................................................................................................9030-03-9
Fine Tuning-Reversal Soften .......................................................................................................... 9030-03-9
Fine Tuning-Max Speed Accel ........................................................................................................9030-03-9
Fine Tuning-Max Speed Decel ....................................................................................................... 9030-03-9
Interlock Timeout ............................................................................................................................ 9030-03-9
Mode (1 through 3) -Max Speed .....................................................................................................9030-03-9
Mode (1 through 3) -Max Accel ...................................................................................................... 9030-03-9
Mode (1 through 3) -Walk Accel ..................................................................................................... 9030-03-9
Mode (1 through 3) -Max Decel ...................................................................................................... 9030-03-9
Mode (1 through 3) -Neutral Braking .............................................................................................. 9030-03-9
Mode (1 through 3) -Max Braking ................................................................................................... 9030-03-9
Max Speed TM2 ............................................................................................................................. 9030-03-9
Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
Confidential/Proprietary - Do Not Copy or Duplicate 9030-1

TABLE OF CONTENTS
Max Accel TM2 ............................................................................................................................... 9030-03-9
Max Decel TM2 ...............................................................................................................................9030-03-9
Neutral Braking TM2 .......................................................................................................................9030-03-9
Max Braking TM2 ............................................................................................................................9030-03-9
Turtle Alarm enable .......................................................................................................................9030-03-10
Quick Lift Window ......................................................................................................................... 9030-03-10
Initial Lift Interval ...........................................................................................................................9030-03-10
Full Lift Interval ............................................................................................................................. 9030-03-10
Lift Run Time .................................................................................................................................9030-03-10
BDI Warning (Lift Lock) Enable .....................................................................................................9030-03-10
Warning BDI (Lift Lock Out Percent) .............................................................................................9030-03-10
Battery-BDI Reset Volts ................................................................................................................ 9030-03-10
Battery- BDI Full Volts ...................................................................................................................9030-03-10
Battery-BDI Empty Volts ............................................................................................................... 9030-03-10
Battery-BDI Discharge Time ......................................................................................................... 9030-03-10
Battery-BDI Reset Percent ............................................................................................................9030-03-11
Undervoltage Cutback Range .......................................................................................................9030-03-11
User Undervoltage ........................................................................................................................ 9030-03-11
Total Maintenance Enable .............................................................................................................9030-03-11
Traction Maintenance Enable ....................................................................................................... 9030-03-11
Pump Maintenance Enable ...........................................................................................................9030-03-11
Maintenance Interval .....................................................................................................................9030-03-11
Reset Total Maintenance .............................................................................................................. 9030-03-11
Reset Traction Maintenance ......................................................................................................... 9030-03-11
Reset Pump Maintenance .............................................................................................................9030-03-11
Status Codes and Descriptions ............................................................................................................ 9030-03-12
Status Codes .................................................................................................................................... 9030-03-12
Status Code Descriptions ................................................................................................................. 9030-03-12
Group 20 Diagnostic Trouble Codes
DTC XX099 - Internal Fault............................................................................................................. 9030-20-1
DTC 30001 - LiftCoil........................................................................................................................ 9030-20-2
DTC 30003 - LwrCoil....................................................................................................................... 9030-20-4
DTC 30033 - Main Cont...................................................................................................................9030-20-6
DTC 30035 - Brake..........................................................................................................................9030-20-9
DTC 30037 - AlrmCoil....................................................................................................................9030-20-13
DTC 30039 - Audible Alarm (Opt)..................................................................................................9030-20-15
DTC 30060 - Mtr Curr.................................................................................................................... 9030-20-17
DTC 30061 - Mtr Open ................................................................................................................. 9030-20-17
DTC 30062 - Encoder....................................................................................................................9030-20-19
DTC 30067 - MainCont (Stuck Closed)......................................................................................... 9030-20-21
DTC 30068 - MainCont (Stuck Open)............................................................................................9030-20-25
DTC 30069 - Precharge.................................................................................................................9030-20-29
DTC 30080 30082 30083 - OverHeat............................................................................................9030-20-31
DTC 30086 - LowBatt.................................................................................................................... 9030-20-33
DTC 30087 - OverVolt................................................................................................................... 9030-20-35
DTC 30090 - 12 Vdc / 5 Vdc Supply Output.................................................................................. 9030-20-37
DTC 30106 - CANcomm................................................................................................................9030-20-40
DTC 30201 - Start Up.................................................................................................................... 9030-20-43
DTC 60211 - Start Up.................................................................................................................... 9030-20-43
DTC 30227 - Stalled ..................................................................................................................... 9030-20-48
DTC 30232 - Software .................................................................................................................. 9030-20-51
Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
9030-2 Confidential/Proprietary - Do Not Copy or Duplicate

TABLE OF CONTENTS
DTC 30247 - Parameter................................................................................................................ 9030-20-52
DTC 30248 - Low Temp.................................................................................................................9030-20-53
DTC 60050 - EmerRevr................................................................................................................. 9030-20-55
DTC 60210 - EmerRevr................................................................................................................. 9030-20-55
Check the Service Manual section in Yale Axcess Online for possible updates and check pertinent Bulletins
Confidential/Proprietary - Do Not Copy or Duplicate 9030-3

9030-4