Yale 524150797 Maintenance Manual Download

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Wake-up Relay

The wake-up relay is provided constant 24 volt input.
When the key switch is closed, ground is supplied to
the relay, activating the coil, closing the relay contacts.
This process initiates the wake-up circuit. Refer to
Figure 6

Key in ON position. Measure continuity between
battery connector, socket 3 and B(-).

Is continuity present?

YES:

Proceed to Step 2.

NO:

Inspect ground control circuit 103 for open.

Verify key switch operation.

Key in ON position. Measure voltage between
battery B(+) and B(-) terminals.

Is voltage between 21 and 29.4 Vdc?

YES:

Proceed to Step 3.

NO:

Verify battery state of charge.

Remove relay and measure voltage between
socket 30/86 and B(-).

Is voltage same as battery ±1.5 Vdc?

YES:

Replace faulty relay.

NO:

Inspect input circuit 079 for open. Inspect

connector CPP01A-B for loose, damaged, or
corroded connections.

LITHIUM-ION PACK

If battery is installed on truck, placing the key in the
ON position can be used to perform "wake-up" of the
battery. If the pack is outside of the vehicle, performing
a manual wake-up can be used. Take an electrical wire
(22 AWG or larger), and connect one side to the
battery B- Terminal. Then momentarily (2 seconds)
connect the other end to pin 3 of the Lithium-Ion
connector.

The Lithium-Ion pack has on-board monitoring circuitry
capable of disabling voltage output under certain
conditions. Certain battery pack conditions may
prevent battery wake-up and turn-on if conditions
remain. See lithium-ion battery pack conditions below
prior to suspecting a faulty battery:

Temperature Shutdown:

The pack will charge

within temperatures of 0 to 45°C (32 to 113°F),
and discharge from -20 to 55°C (-7.6 to 131°F). If
the pack senses it is over or under these
temperatures, it will shutdown to protect itself. To

diagnose and repair, check pack 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.

Under Voltage:

The pack is designed to

shutdown before over discharging, at voltage of
20.5 volts or less. If this occurs, the pack will only
wake-up for 10-60 seconds, before turning back
off. This is done to allow an opportunity for a
charger to begin sensing and begin charging the
pack. To repair, connect pack to charger, wake-
up, and apply AC Power to charger.

NOTE:

In some charge cases, the pack may

shutdown before charger. When power is removed, the
charger does will not maintain operation, and the LEDs
of the charger turn OFF. If upon returning from charge
and charger is off, wake-up battery and measure the
voltage before assuming charge was successful.

Over Voltage:

The pack is designed to shutdown

before over charging occurs, at voltage of 28.6
volts or more. If this occurs, the pack will not
allow further charging, and the charger should be
turned OFF. To repair, stop charging and allow
pack to stabilize for 30 minutes and retest
system.

Water Detection:

The pack is designed to

shutdown in cases of high humidity / water
ingress. Check to ensure Lithium-Ion battery is
not in a moist/water environment. If so, remove
pack and place/hang in a dry environment to
allow moisture to drain or sublimate from pack.

WARNING

At no time is a technician to attempt opening the
pack and service the fuse, as is non-standard, and
improper work can cause a hazard.

NOTE:

In certain extreme shorts, or internal faults,

where normal shut down is not sufficient to protect the
battery, the internal fuse will blow. In these cases, the
battery pack will not recover from wake-up, or turn
back on. The pack must be sent for service to replace
the fuse.

Charging and Troubleshooting

2240 YRM 1890