Maintenance

STEERING MECHANISM
MP20 [A249];MPB045VG [A245]

PART NO. 550036881 1600 YRM 1504

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and 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.
 Table of Contents

TABLE OF CONTENTS
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]

©2017 Yale Materials Handling Corp. i

1600 YRM 1504 General

General
The control handle assembly is designed to perform
several functions. The standard control handle
includes the speed/direction control and buttons for the
horn, traction reversing, and hydraulic functions. The
control handle is connected to the Master Drive Unit
(MDU) and is used to steer the truck as it turns the
MDU. Move the control handle left or right to turn the
drive/steer tire and steer the truck. Controls mounted
in the handle are linked to the control panel by a wiring
harness that passes through the center of the handle.
The brake is applied when the handle is in the full up
or down position.

Special Precautions
3. Discharge the capacitors in the controllers by
WARNING connecting a 200-ohm, 2-watt resistor across the
The capacitor in the controller can hold an controller's B+ and B− terminals using insulated
electrical charge after the battery is disconnected. jumper wires. See Figure 1.
To prevent electrical shock and personal injury,
discharge the capacitor before inspecting or
repairing any component. Wear safety glasses.
Make certain the battery has been disconnected.
DO NOT use a screwdriver 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. 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 drive unit compartment.
1. CONTROLLER
2. POSITIVE CONNECTION
CAUTION 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
DO NOT short across the motor controller 5. NEGATIVE CONNECTION
terminals with a screwdriver or jumper wire.
Figure 1. Discharging Controller

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Control Handle Head
4. Remove the 200-ohm, 2-watt resistor before
reconnecting the battery.
Control Handle Head
Refer to the section Electrical System 2200YRM1508
for instructions on removing and installing the control
handle head from the control handle. The instructions
Control Handle
REMOVE
WARNING
The gas springs used on the control handle are
installed under tension and can release with
enough force to cause personal injury or property
damage.
WARNING
The capacitor in the controller can hold an
electrical charge after the battery is disconnected.
To prevent electrical shock and personal injury,
discharge the capacitor before inspecting or
repairing any component in the drive unit
compartment. Wear safety glasses. Make certain
the battery has been disconnected. Refer to the
Special Precautions section of this manual.
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1600 YRM 1504
for disassembly and assembly of the control handle
head can be located in the same section.
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. Remove the drive unit compartment cover. Refer
to AC Motor Repair 0620YRM1513.
4. Discharge the capacitor in the controller by
connecting a 200-ohm, 2 watt resistor between
the B+ and B- connectors on the controller. See
Figure 1.
5. Disconnect the control handle wiring harness plug
and the control handle arm prox sensor plug
located on top of the drive motor.
For the following instructions refer to Figure 2,
Figure 3, or Figure 4.
1600 YRM 1504 Control Handle

Figure 2. Control Handle Assembly, Lift Truck Models MP20 (A249)

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Control Handle 1600 YRM 1504

Legend for Figure 2.

1. CONTROL HANDLE HEAD 9. CAPSCREW

2. CAPSCREW 10. PIVOT SHAFT
3. LOCKNUT 11. STRAP CLAMP
4. LOCKNUT 12. BUSHING
5. HOLE PLUG 13. SENSOR
6. GAS SPRING 14. BALL STUD
7. SCREW 15. CONTROL HANDLE ARM
8. CAPSCREW 16. RETAINING NUT

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1600 YRM 1504 Control Handle

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

Figure 3. Control Handle Assembly, Lift Truck

Models MPB045VG (A245)

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Control Handle 1600 YRM 1504

Figure 4. Delivery Handle (Optional)

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1600 YRM 1504 Control Handle

Legend for Figure 4.

1. CONTROL HANDLE HEAD 11. MOUNTING WELDMENT

2. CONTROL HANDLE ARM 12. GROMMET
3. GAS SPRING 13. PIVOT SHAFT
4. BALL STUD 14. CAPSCREW
5. NUT 15. NUT
6. PLUG 16. CAPSCREW
7. BUSHING 17. CAPSCREW
8. COVER 18. STRAP CLAMP
9. CAPSCREW 19. SHIM
10. WASHER

6. If necessary, remove the control handle head. 14. Remove retaining nuts securing the prox sensor
See the section Electrical System to the control handle arm and remove the prox
2200YRM1508. sensor. See Figure 3

15. If bushings are worn, remove the bushings from

CAUTION the control handle arm.
Discharging the gas spring is a destructive
operation.

7. Discharge and remove the gas spring. Refer to

Gas Spring in this section.

8. Remove the capscrew securing the pivot shaft to

the support bracket and remove the pivot shaft.

9. Remove the control handle arm from the support

bracket.

NOTE: For lift truck models MP20 (A249) perform

Step 10 to remove prox sensor.
10. Remove retaining nuts securing the prox sensor
to control handle arm and remove the prox
sensor. See Figure 2.

NOTE: On lift truck models MPB045VG (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
1. BUTTON TIE WRAP
Step 14 for removal procedures. 2. CONTROL HANDLE ARM WIRE HARNESS
11. Remove button tie wrap from side of mounting 3. PROX SENSOR CABLE
4. HEAT SHRINK
weldment. See Figure 4. 5. PROX SENSOR
6. CONTROL HANDLE ARM
12. Remove button tie wrap from yellow heat shrink
on prox sensor cable and control handle arm wire Figure 5. Prox Sensor With Bellville Washers and
harness. See Figure 5. Yellow Heat Shrink, Remove

13. Remove two retaining nuts and two Bellville

washers. Remove prox sensor from control
handle arm. See Figure 5.

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Control Handle 1600 YRM 1504

INSTALL 11. If removed, install the control handle head. See

1. If previously removed, install the bushings into the
control handle arm.
2. Install the new gas spring into the control handle
arm. Refer to Gas Spring in the section.
NOTE: For lift truck models MP20 (A249) perform
Step 3 to install prox sensor.
3. Install the prox sensor onto the control handle
arm and secure with the retaining nuts. Leave
retaining nuts loose until the control handle arm is
installed. See Figure 2.
NOTE: On lift truck models MPB045VG (A245) the
installation 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 4 through Step 9. If prox sensor does not
include these parts, go to Step 10 for installation
procedures.
NOTE: When installing Bellville washers, the side with
the larger diameter faces the bracket, and the side
with smaller diameter faces the nut.
4. Install prox sensor into control handle arm using
two Bellville washers and two retaining nuts. See
Figure 6. Hand tighten retaining nuts for now.
the section Electrical System 2200YRM1508.
12. Position the control handle arm onto the support
bracket and install the pivot shaft. See Figure 3.
13. Install the capscrew as removed. Torque to
35 N•m (26 lbf ft).
14. Secure the lower end of the gas spring to the
support bracket with the capscrew and nut as
removed.
NOTE: Step 15 is only for lift truck models MP20
(A249) and lift truck models MPB045VG (A245) with
prox sensor arrangement that does not include
Bellville washers and yellow heat shrink.
15. Adjust the prox sensor so the end of the sensor is
no more than 4 mm (0.16 in.) from the support
bracket. Tighten the retaining nuts.
16. Reconnect the control handle wiring harness and
prox sensor.
17. Install the drive unit compartment cover.

5. Check to ensure the end of the prox sensor is no

more than 2.5 ±0.5 mm (0.10 ±0.02 in.) from the
support bracket. See Figure 6.

6. Take cable end of prox sensor 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. 1. PROX SENSOR
2. RETAINER NUT
9. Tighten retaining nuts to 24 N•m (212 lbf in). See 3. BELLVILLE WASHER
Figure 6. 4. CABLE END
5. SUPPORT BRACKET
10. Install the prox sensor onto the control handle
arm and secure with the retaining nuts. Leave Figure 6. Prox Sensor With Bellville Washers and
retaining nuts loose until the control handle arm is Yellow Heat Shrink, Install
installed. See Figure 3.

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1600 YRM 1504
18. Connect the battery and test the operation of the
lift truck prior to returning to service.
Gas Spring
WARNING
Disconnect the battery by separating the battery
connector before opening the compartment cover
and before inspecting or repairing the electrical
system. DO NOT place tool on top of the battery. If
a tool causes a short circuit, the high-current flow
from the battery can cause personal injury or
property damage.
WARNING
The capacitor in the traction motor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component. Make
certain the battery has been disconnected and
always wear safety glasses. See Special
Precautions in this section. DO NOT attempt to
discharge the capacitors by shorting the
controller.
WARNING
The gas spring used on the control handle is
installed under tension and can release with
enough force to cause personal injury or property
damage.
Review the following procedures 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.
Gas Spring
NOTE: This process is a destructive operation to the
gas spring. A new gas spring must be used during
reassembly. This is necessary because internal
damage to the spring components which are not
detectable could cause damage or injury when the
spring is removed.
1. Check that the handle return spring is installed
and properly secure the control handle arm in the
full upright position. Remove the plastic plugs to
increase visibility of the gas spring.
WARNING
Contents are under pressure. This process may
eject metal chips and oil.
2. Locate the gas spring inside the control handle
through the access hole on the front of the control
handle and drill a 3 mm (0.125 in.) hole into the
gas spring cylinder shell to relieve pressure.
3. Clean up any discharged oil and dispose of in
accordance with local regulations.
REMOVE
To remove the gas spring from the control handle:
1. Remove the plastic plugs to access the gas
spring.
CAUTION
DO NOT damage the control handle wiring harness
inside the control handle arm.
2. Discharge the pressure from the gas spring. See
Discharging the Gas Spring.
3. Remove the retention clip from the gas spring ball
socket. Disconnect the gas spring from the ball
stud.
4. Remove the ball stud from inside the control arm
as necessary.
5. Remove the capscrew and locknut securing the
rod end of the gas spring to the tiller swivel.
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Troubleshooting 1600 YRM 1504

INSTALL NOTE: Apply Loctite® 242 to the capscrew threads

1. Install ball stud and nut into control arm if
removed. Tighten to 35 N•m (26 lbf ft).
2. Lubricate both connection points with
multipurpose lithium complex grease with 2 to 4%
molybdenum.
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

CAUTION control handle shaft as removed.
DO NOT damage the control handle wiring harness
inside the control handle arm. 6. Test for proper operation. Install covers as
removed.
3. Make certain the control handle arm is secured in
the full upright position and position the new gas
spring into the control handle arm. Connect the
upper end of the gas spring to the ball stud inside
the control handle arm. Install the retention clip to
the gas spring ball socket as removed.

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Steering is rough or difficult. Damaged, worn, or defective Replace bearings.

steering handle swivel bearing(s).
Lubricate or repack bearings.
Steering handle swivel bearing(s)
Loosen retaining nut and tighten to
need lubrication.
correct torque. See the section
Bearing retaining nut torque Master Drive Unit 0630YRM1503.
incorrect.
Replace drive unit housing bearing
Drive unit housing bearing (steer) (steer).
damaged.

Steering handle does not return to Gas spring is weak or broken. Replace gas spring.
the vertical position.
Gas spring ball stud broken or Retighten or replace gas spring ball
loose. stud.

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1600 YRM 1504 11/17 (7/16)(3/15)(12/13)(4/12)