Maintenance

BRAKES
MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]

PART NO. 524154893 1800 YRM 1005

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 manual:

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 background.
The CAUTION symbol and word are on yellow background.
Brakes Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Special Precautions............................................................................................................................................. 2
Brake Assembly Repair ....................................................................................................................................... 3
Brake Override ................................................................................................................................................ 3
Remove ........................................................................................................................................................... 4
Repair.............................................................................................................................................................. 6
Install............................................................................................................................................................... 7
Troubleshooting ................................................................................................................................................... 8

This section is for the following models:

MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]

©2008 Yale Materials Handling Corp. i

1800 YRM 1005
General
WARNING
DO NOT operate a lift truck that needs repairs. If a
repair is necessary, put a DO NOT OPERATE tag on
the control handle. Remove the key from the key
switch.
WARNING
Before performing repairs or adjustments on the
brake system, blocks must be placed under each
side of the frame to raise the drive tire off the
ground. The blocks must prevent the lift truck from
falling and causing personal injury or property
damage. See Periodic Maintenance 8000 YRM
1009, Periodic Maintenance 8000 YRM 1379, or
Periodic Maintenance 8000 YRM 1048, How to Put
a Lift Truck on Blocks.
Description
Motorized hand trucks have three methods of braking:
1. Regenerative (Neutral) braking
2. Controlled plugging
3. Application of the spring-applied/electrically re-
leased friction brake
NOTE: The preferred method of stopping the truck is:
Regenerative (Neutral) braking
or
Controlled plugging
Regenerative (Neutral) braking applies a retarding force
to the drive wheel through the traction motor, allowing
the unit to slow to a gradual stop. It is applied by re-
turning the speed/direction control to the NEUTRAL po-
sition or by placing the hand brake lever(s) in the first
stage 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 NEUTRAL
position to remain stopped. If the speed/direction
control is not returned to the NEUTRAL position after
Description
WARNING
Always disconnect and separate the battery con-
nector so that the connector is completely free be-
fore performing any service or repairs. If the con-
nector is not completely free, it can reconnect. Tag
the connector: DO NOT CONNECT.
This section has the description and repair procedures
for the electric brake on the MSW020-E, MSW025-E,
MSW025-F, MSW030-F, MPB040-E, MPW045-E, and
MPW050-E lift trucks. Brake assemblies may vary in
appearance. Although some assemblies may APPEAR
to be adjustable, brake assemblies used on these trucks
ARE NOT ADJUSTABLE. Friction between parts inside
the brake will produce brake dust, squeaking, and ex-
treme heat under normal operating conditions. Brake
assemblies can generate surface temperatures up to
130 C (266 F) and odors during heavy operation. Func-
tions of the brake assembly depend on a dry and clean
environment. Small amounts of oil or grease on the fric-
tion surfaces of the brake can seriously compromise the
brakes ability to function.
the truck is stopped, the lift truck will accelerate in the
direction the handle is being turned. Controlled plug-
ging should stop the truck within a few feet, depending
on speed and load.
The parking brake is a spring-applied, electrically re-
leased friction brake mounted to the drive motor. When
the parking brake is applied, springs inside the brake
assembly compress a rotating friction disk against two
stationary plates.
To release the brake:
1. Connect the battery.
2. Turn the key switch to the ON position.
3. Lower the control handle arm to the operating or
BRAKE OFF position. Refer to Figure 1.
4. Rotate direction/speed control (butterfly knobs) in
the direction of travel.
1
Special Precautions
Figure 1. Brake Operation
Special Precautions
WARNING
Block each side of the truck under the drive unit
frame. Position blocks on both sides of the load
wheels. The blocks must prevent the lift truck from
falling and causing personal injury or property
damage.
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. 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.
Discharge the capacitors in the controller by con-
necting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals with insulated
jumper wires. DO NOT use a screwdriver to dis-
charge the traction motor controller. See Figure 2
or Figure 3.
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments, and
before connecting or disconnecting a handset or
computer.
2
1800 YRM 1005
The parking brake is applied when the control han-
dle arm is moved to the BRAKE ON position (full
up or full down position) or if a traction fault occurs.
The lift truck must meet the applicable HOLD ON
GRADE requirements; the parking brake should be
capable of holding the lift truck on a 10 percent
grade with the maximum rated load.
CAUTION
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. Refer to the proper section for your truck:
Periodic Maintenance 8000 YRM 1009, Periodic
Maintenance 8000 YRM 1379, or Periodic Main-
tenance 8000 YRM 1048 - How to Put a Lift Truck
on Blocks.
2. Turn the key switch to the OFF position and discon-
nect the battery.
3. Discharge the capacitors in the controllers by con-
necting a 200-ohm, 2-watt resistor across the con-
troller’s B+ and B terminals. See Figure 2 or Fig-
ure 3 for your truck. DO NOT short across the mo-
tor controller terminals with a screwdriver or jumper
wire. Remove the 200-ohm, 2-watt resistor before
reconnecting the battery.
1800 YRM 1005 Brake Assembly Repair

1. POSITIVE CONNECTION 1. NEGATIVE CONNECTION

2. NEGATIVE CONNECTION 2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES 3. 200-OHM, 2-WATT RESISTOR
4. 200-OHM, 2-WATT RESISTOR 4. INSULATED JUMPER WIRES

Figure 2. Discharging Controller MPB040-E Figure 3. Discharging Controller MSW020/025-E,

MSW025/030-F, and MPW045/050-E

Brake Assembly Repair

BRAKE OVERRIDE
CAUTION
Never operate the lift truck while the brake override
feature is being used.
The brake can be disengaged when a truck cannot be
operated but needs to be moved. On the main wiring
harness approximately 300 mm (12 in.) above the
MDU, the brake wiring harness is connected. An extra
four pin connector for the brake override feature is
secured near this connection with wire ties. Disconnect
the connectors and connect the brake wiring harness
to the brake override connector. This will energize
the brake coil which will release the brake. The drive
motor will not activate while the jumper is installed.
Roll the lift truck to a safe location and disconnect
the brake override connector. The brake will apply
when the brake override connector is disconnected or
when power to the brake override circuit is interrupted.
Reconnect the brake wiring harness to the main wiring
harness and proceed with repairs. If the battery does
not have sufficient charge, or if certain components of
the lift truck are damaged, the brake may not release
with the brake override circuit engaged. In this case,
the malfunction must be corrected before the brake can
be released. See Figure 4.

3
Brake Assembly Repair
1. BRAKE WIRING HARNESS
2. MAIN WIRING HARNESS
3. BRAKE OVERRIDE CONNECTOR
Figure 4. Brake Override Connector
REMOVE
Move the truck to a safe location before beginning work
and block the wheels to prevent movement. Remove
the key from the switch and disconnect the battery con-
nector.
NOTE: For the following instructions, refer to Figure 5.
1. Turn key switch to OFF position and disconnect bat-
tery. Block the drive tire to prevent movement.
2. Remove drive unit compartment covers and MDU
covers.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. Discharge the capacitor before inspecting
4
1800 YRM 1005
or repairing any component in the MDU compart-
ment to prevent personal injury and damage to the
electrical system. Always wear safety glasses.
3. Discharge capacitors. Refer to Special Precautions
in the front of this section.
4. Remove Allen-head screws (7) and washers (8)
from the cover that secure motor and brake assem-
bly to MDU.
5. Support drive motor with one hand and remove re-
maining Allen-head screw (2) and washer (3) with
other hand.
6. Remove motor and brake assembly from MDU.
7. Tag and remove wires and cables from motor and
unplug brake wire harness.
8. Place motor on workbench securely supported in
an upright position.
9. Remove O-ring from housing.
10. Remove nut (9) from motor shaft.
11. Remove gear (11) and woodruff key (16) from drive
motor shaft.
12. Using a standard puller, remove the bearing (13)
and oil slinger (12) from drive motor shaft.
CAUTION
Brake assemblies may vary in appearance. Some
assemblies have three Allen-head screws on top of
the brake coil. DO NOT REMOVE the Allen-head
screws on TOP of the brake coil. This can change
the factory preset adjustment, rendering the brake
inoperable. These brakes are preset from the fac-
tory and are NOT ADJUSTABLE.
13. Using a 3 mm Allen-head insert at least 55 mm long
with a square socket adaptor, remove three Allen-
head capscrews securing bottom plate of brake as-
sembly to motor.
14. Slide brake from drive motor shaft.
15. Remove spacer (10), hub (18), and woodruff key
(17).
1800 YRM 1005 Brake Assembly Repair

1. MDU HOUSING 7. ALLEN-HEAD SCREW 13. BALL BEARING

2. ALLEN-HEAD SCREW 8. WASHER 14. O-RING
3. WASHER 9. NUT 15. BRAKE ASSEMBLY
4. DRIVE MOTOR 10. SPACER 16. WOODRUFF KEY (GEAR)
5. COVER 11. GEAR 17. WOODRUFF KEY (HUB)
6. FILL PLUG 12. OIL SLINGER 18. HUB

Figure 5. Brake Assembly

5
Brake Assembly Repair 1800 YRM 1005

REPAIR
If a brake assembly is malfunctioning, the cause may
be electrical, mechanical, or a combination of both. If
the brake electrical system is functioning correctly, the
brake should release with one solid "click" when ener-
gized. The brake coil is a large 24 V coil that acts as an
electromagnet to pull the armature plate away from the
friction disk. If the brake coil is too weak to compress
the brake springs and release the friction disk, the brake
must be replaced.
1. Disconnect the brake wiring harness (if brake is in-
stalled to truck).
If removing the drive motor assembly from the lift truck,
visually inspect the brake. Use a feeler gauge to check
the gap between the brake coil and armature plate in
several places around the brake to determine if the
brake is near the end of normal service life. Proper air
gap measurements range from 0.2 to 0.6 mm (0.0078
to 0.024 in.). See Figure 6. The brake must be replaced
if it no longer meets the proper air gap specifications
or if otherwise malfunctioning. The brake hub and the
brake assembly can be replaced separately. However,
if there is damage to the brake hub, there is most likely
damage to the brake assembly.

2. Check voltage to the brake using a voltmeter.

a. Turn the key switch to the ON position.

b. Place the control handle arm in the BRAKE

OFF position.

c. Lightly rotate the directional controls to activate

the brake coil circuit.

d. Touch each lead of a voltmeter to each side

of the MAIN WIRING HARNESS connector
where the brake wiring harness connects.

e. Voltage to the brake should read approximately

24 V.

3. Check the resistance of the brake coil using an

ohmmeter.

a. Touch each lead of the ohmmeter to each side

of the brake wiring harness connector.

b. If the brake coil resistance reads between

30.24 and 27.36 (ohms), the brake coil is
functioning properly.

c. If the resistance reading falls outside the spec-

ified range, the entire brake assembly must be
replaced. 1. BRAKE COIL
2. AIR GAP
If the brake mechanical functions are not operating 3. ARMATURE PLATE
correctly, the brake will not hold a fully loaded lift truck 4. FEELER GAUGE
on a 10% grade. The brake is NOT ADJUSTABLE and
must be replaced when it will not hold to specification. Figure 6. Brake Assembly

6
1800 YRM 1005 Brake Assembly Repair

INSTALL 8. Place motor shaft assembly into housing. Position

For the following instructions, refer to Figure 5.
1. Install woodruff key (17) to drive motor shaft and
slide hub onto shaft and key. Make sure groove and
key are aligned properly.
2. Install spacer (10) and brake assembly on to motor
shaft and slide down on to hub. Make sure brake
spline align with teeth on the hub.
CAUTION
Brake assemblies may vary in appearance. Some
assemblies have three Allen-head screws on top
of the brake coil. DO NOT TURN the Allen-head
screws on TOP of the brake coil. This can change
the factory preset adjustment, rendering the brake
inoperable. These brakes are preset from the fac-
tory and are NOT ADJUSTABLE.
motor and brake correctly to align brake wiring har-
ness in notch. See Figure 7. Hold the motor in
place until next step is complete.
9. Install Allen-head screw (2) and washer (3).
10. Install Allen-head screws (7) and washers (8).
Torque all three Allen-head screws to 10 N•m
(7 lbf ft).
11. Install MDU covers and drive unit compartment cov-
ers.
12. Reconnect battery, and remove blocks from wheels.
13. Brake should hold parked lift truck loaded to capac-
ity on a 10% grade. Test for proper operation before
returning to service.

3. Using a 3 mm Allen-head insert at least 55 mm long

with a square socket adaptor, install three Allen-
head capscrews securing bottom plate of brake as-
sembly to motor. Torque to 2.8 N•m (25 lbf in)

4. Install bearing assembly (13), and oil slinger (12),

on to shaft using a standard press.

5. Install woodruff key (16), gear (11), and nut (9) to

shaft. Torque nut to 26 N•m (19 lbf ft).

6. Install O-ring into housing. Lubricate O-ring with

grease to ensure proper installation of drive motor
shaft assembly.

7. Reconnect wiring as removed.

CAUTION 1. MDU HOUSING

The brake wiring harness must be aligned with the 2. BRAKE WIRE NOTCH
notch in the MDU housing. If the motor and brake
assembly is secured to the MDU incorrectly, the Figure 7. MDU Brake Wire Notch
brake wiring harness may be damaged.

7
Troubleshooting 1800 YRM 1005

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Brake does not release. Key switch is in the OFF position. Turn key switch to the ON position.

Handle is not in the BRAKE OFF po- Move the handle to the BRAKE OFF
sition. position.

Control handle arm prox switch is out Adjust/replace control handle arm prox
of adjustment/damaged. switch. See the section Electrical
System 2200 YRM 1007.

Coil is open. Measure coil resistance. If resistance

is too high (above 30.24 ), replace the
brake assembly.

Coil has shorted to frame or between Measure coil resistance. If resistance

the windings. is too low (below 27.36 ), replace the
brake assembly.
Check coil for short to frame using an
ohmmeter. If shorted to frame, replace
the brake assembly.

Incorrect or no voltage supplied to Measure voltage to brake using a volt-

brake. meter. If voltage is not 24 VDC ±10%,
check connector.
Troubleshoot electrical system.

Air gap is too large. Replace the brake assembly.

Brake does not hold truck Air gap is too large. Replace the brake assembly.
loaded to capacity on 10%
grade.

Friction disk is too worn. Replace the brake assembly.

Brake hub damaged. Replace brake and hub assembly.

8
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

1800 YRM 1005 3/08 (8/05)(5/03 )(1/02) Printed in U.S.A.