Maintenance

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

PART NO. 524154896 2200 YRM 1007

 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.
Electrical System Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description of Operation...................................................................................................................................... 2
Special Precautions............................................................................................................................................. 4
Moving a Disabled Lift Truck................................................................................................................................ 5
Electrical System Checks .................................................................................................................................... 6
Safety Precautions .......................................................................................................................................... 6
Repairs ................................................................................................................................................................ 7
Controller, Replace.......................................................................................................................................... 7
Remove....................................................................................................................................................... 7
Install .......................................................................................................................................................... 8
Contactor Coil, Check ..................................................................................................................................... 10
Contactor, Replace.......................................................................................................................................... 10
Remove....................................................................................................................................................... 10
Install .......................................................................................................................................................... 10
Key Switch Removal and Installation................................................................................................................... 11
Remove ........................................................................................................................................................... 11
Install............................................................................................................................................................... 11
Battery Indicator/Hourmeter Display ................................................................................................................... 11
Remove ........................................................................................................................................................... 11
Install............................................................................................................................................................... 11
Fuses................................................................................................................................................................... 12
MPB040-E....................................................................................................................................................... 12
MPW045/050-E............................................................................................................................................... 12
MSW020/025-E............................................................................................................................................... 12
MSW025/030-F ............................................................................................................................................... 12
Control Handle Arm Proximity Switch.................................................................................................................. 12
Repair.............................................................................................................................................................. 12
Check and Adjust........................................................................................................................................ 12
Remove....................................................................................................................................................... 13
Install .......................................................................................................................................................... 13
Control Handle..................................................................................................................................................... 14
Disassemble.................................................................................................................................................... 14
Control Handle Card (Old Style) ..................................................................................................................... 15
Control Handle Card (New Style) .................................................................................................................... 16
Configure .................................................................................................................................................... 16
Calibrate...................................................................................................................................................... 17
Assemble ........................................................................................................................................................ 18
Switches (ON/OFF and Proportional) ............................................................................................................. 20
Remove....................................................................................................................................................... 20
Install .......................................................................................................................................................... 20
Traction Motor...................................................................................................................................................... 21
Disassemble.................................................................................................................................................... 21
Assemble ........................................................................................................................................................ 22
Lift Pump Motor ................................................................................................................................................... 22
Repair (MSW020/025-E and MSW025/030-F)................................................................................................ 22
Lift Link Proximity Sensor (MPW050-E) .............................................................................................................. 23
Check .............................................................................................................................................................. 24
Repair.............................................................................................................................................................. 24
Remove....................................................................................................................................................... 24
Test ............................................................................................................................................................. 24
Install .......................................................................................................................................................... 25

©2011 Yale Materials Handling Corp. i

Table of Contents Electrical System

TABLE OF CONTENTS (Continued)

Adjust .......................................................................................................................................................... 25
Battery Charger (Moran®)................................................................................................................................... 25
Description ...................................................................................................................................................... 25
Operation ........................................................................................................................................................ 25
Charging ..................................................................................................................................................... 25
Equalize ...................................................................................................................................................... 26
Signals ........................................................................................................................................................ 26
Protections .................................................................................................................................................. 26
Troubleshooting ............................................................................................................................................... 26
Battery Charger (DPI®) ....................................................................................................................................... 28
Description ...................................................................................................................................................... 28
Operation ........................................................................................................................................................ 29
LED Display ................................................................................................................................................ 29
Charging ..................................................................................................................................................... 29
Charger Mode/Battery Type Selection (DPI Gen II Models)............................................................................ 29
Changing Mode Setting (DPI Gen II Models) ............................................................................................. 30
Charger Mode/Battery Type Selection (DPI Gen III Models)........................................................................... 31
Changing Mode Setting (DPI Gen III Models) ............................................................................................ 34
Troubleshooting (DPI Chargers)...................................................................................................................... 34
General ....................................................................................................................................................... 34
Error Modes ................................................................................................................................................ 35
Battery Pack Troubleshooting ..................................................................................................................... 36
Battery Charger (Accusense® 20A) .................................................................................................................... 36
Description ...................................................................................................................................................... 36
Operation ........................................................................................................................................................ 37
LED Display ................................................................................................................................................ 37
Charging ..................................................................................................................................................... 37
Charger Mode/Battery Type Selection (Accusense 20A) ................................................................................ 38
Changing Mode Setting (Accusense 20A) .................................................................................................. 41
Troubleshooting (Accusense 20A Chargers)................................................................................................... 41
General ....................................................................................................................................................... 41
Error Modes ................................................................................................................................................ 42
Battery Pack Troubleshooting ..................................................................................................................... 43
Troubleshooting ................................................................................................................................................... 44

This section is for the following models:

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

ii
2200 YRM 1007 General

General
This section includes removal, disassembly, checks, MPB040-E [B827], MPW045-E [B802], and MPW050-E
adjustments, assembly, and installation proce- [C802] truck models. This section does NOT include
dures for the electrical system components on the the electrical components covered in other sections
MSW020/025-E [A895], MSW025/030-F [B895], such as motors and industrial batteries. See Figure 1.

1. BATTERY CONNECTOR 9. MAIN CONTACTOR

2. BATTERY INDICATOR/HOURMETER DISPLAY 10. CONTROL FUSE
3. KEY SWITCH 11. HORN
4. POSITIVE BATTERY CABLE 12. ZAPI™ MOTOR CONTROLLER
5. LIFT PUMP MOTOR 13. POWER FUSE
6. WIRING HARNESS 14. NEGATIVE BATTERY CABLE
7. CONTROL HANDLE ARM PROXIMITY SWITCH 15. LOWERING VALVE
8. DRIVE MOTOR

Figure 1. Electrical Components

1
Description of Operation
See the section ZAPI™ Controllers 2200 YRM 1064
for models MSW020/025-E [A895] and MSW025/030-F
[B895]; ZAPI™ Controllers 2200 YRM 1006 for mod-
els MPB040-E [B827]; ZAPI™ Controllers 2200 YRM
1067 for models MPW045-E [B802] and MPW050-E
[C802] for additional information on the ZAPI™ display
and for information on troubleshooting fault codes, ad-
justing parameters, and testing the ZAPI™ motor con-
troller.
See the section DC Motor Maintenance 620 YRM 294
for general information on DC motors.See the section
Periodic Maintenance 8000 YRM 1048 for models
Description of Operation
See Figure 2 for the logic diagram.
This section includes information on the following com-
ponents:
• Control handle switches (ON/OFF and proportional)
• Hall effect directional/speed control
• Control handle card
• ZAPI™ motor controller
• Traction motor
• Main contactor
• Brake coil
• Lift pump motor
• Lift time-out
• Batteries
ON/OFF switches are used for:
• Single speed lift and lower functions
• Half speed lift and lower functions
• Horn
• Traction reversing
• Creep (Turtle) speed
• Throttle neutral signal
MSW020/025-E and MSW025/030-F: Standard lift
switches are ON/OFF type. Standard left-side lift
switches are at half speed. The right-side lift switches
are at full speed. Optional proportional lifting switches
are available on the right side. Proportional switches
provide a variable output to regulate the speed of the
lift and lower functions.
All lower switches are proportional type switches which
allow the operator to maintain maximum control of the
load when lowering.
MPB040/45/50-E: Use only full speed lift and lower
switches.
2
2200 YRM 1007
MSW020/025-E [A895]; Periodic Maintenance 8000
YRM 1009 for models MPB040-E [B827], MPW045-E
[B802], and MPW050-E [C802]; Periodic Mainte-
nance 8000 YRM 1379 for models MSW025/030-F
[B895].
See the section Diagrams 8000 YRM 1050 for models
MSW020/025-E [A895]; Diagrams 8000 YRM 1011 for
models MPB040-E [B827] and MPW045-E [B802]; Dia-
grams 8000 YRM 1228 for models MPW050-E [C802];
Diagrams 8000 YRM 1381 for models MSW025/030-F
[B895].
A Hall effect throttle control is used to provide a di-
rectional/speed signal. The neutral switch verifies the
neutral position during the self check at startup. The
Hall effect throttle control, neutral switch, traction re-
versing switch, horn switch, and creep (turtle) speed
switch are an integral part of the control handle card and
not serviced separately. The switches that control the
hydraulic functions mount into the control handle and
are serviced separately.
The Hall effect throttle control, the proportional switches
and all the ON/OFF switches provide input signals to the
control handle card. The control handle card uses se-
rial communication to send these signals to the ZAPI™
motor controller.
The ZAPI™ motor controller contains the system logic.
The motor controller receives the inputs, processes the
commands, and provides outputs to the appropriate
component to activate them.
The traction motor armature and separately excited
field are powered directly by the motor controller. No
contactors are involved in the traction circuit.
The main contactor opens to remove power from the
truck to disable all traction and lift functions in the event
of an electric failure.
Energizing the brake coil pulls the brake pressure plate
away from the friction disc to disengage the brake. The
controller powers the brake coil based on signals from
the control handle arm proximity switch and the Direc-
tional/Speed Control. The controller also contains logic
to engage the brake regardless of handle position if the
truck is stationary.
2200 YRM 1007
MSW020/025-E and MSW025/030-F: The motor con-
troller energizes the series wound lift pump motor when
either lift function switch is depressed. The applied volt-
age to the motor varies to adjust motor RPM and pump
output to the lift function.
MPB040/045/050-E: The motor controller energizes the
series wound lift pump motor when either lift function
switch is depressed.
MSW020/025-E and MSW025/030-F: All trucks have a
solenoid operated lowering valve at the pump. The mo-
tor controller activates the solenoid coil to open the low-
ering valve. The motor controller varies the voltage to
the lowering solenoid to provide proportional lowering.
MPB040/045/050-E: All trucks have a solenoid oper-
ated lowering valve at the pump. The motor controller
activates the solenoid coil to open the lowering valve.
The lift time-out protects the lift pump and motor as-
sembly, eliminating the need for a height limit switch.
Lift is disabled after the pump runs for a programmed
amount of time. Lift is disabled on the MSW020/025-E
Figure 2. Logic Diagram
Description of Operation
and MSW025/030-F trucks after operating continuously
for approximately 45 seconds. Lift is disabled on the
MPB040/045/050-E trucks after operating continuously
for approximately six seconds. The lift time-out feature
is reset once lower is selected.
The standard MSW020-E, MSW025-F, and MPB040-E
trucks are equipped with a battery pack consisting of
4, 6 volt, deep cycle, automotive style batteries and an
onboard 25-amp charger. The battery pack uses a 175-
amp, X-type connector. This connector provides two
auxiliary contacts for the truck inhibit circuit, allowing
the batteries to remain connected to the truck while the
charger is operating. The MSW020-E, MSW025-F, and
MPB040-E can be configured with a standard 175-amp
battery connector to accept the optional GNB PalletPro.
The MSW025-E, MSW030-F, and MPW045/050-E are
shipped without batteries. Standard trucks have a 175-
amp battery connector and will accept industrial flooded
cell batteries or maintenance free batteries, such as the
GNB PalletPro.
3
Special Precautions 2200 YRM 1007

Special Precautions
WARNING
DO NOT make repairs or adjustments unless you
have both authorization and training. Repairs and
adjustments that are not correct can create danger-
ous operating conditions. DO NOT operate a lift
truck that needs repairs. Report the need for repairs
to your supervisor immediately. If repair is neces-
sary, attach a DO NOT OPERATE tag to the control
handle.
WARNING
Disconnect the battery and separate the connector
before opening the drive unit compartment cover
or inspecting or repairing the electrical system. If
a tool causes a short circuit, the high current flow
from the battery can cause personal injury or prop-
erty damage.
or motor terminal to the battery. Make sure to use
proper procedure when servicing the controller.
1. Block load wheels to prevent lift truck from moving.
See the section Periodic Maintenance 8000 YRM
1048, Periodic Maintenance 8000 YRM 1009, or
Periodic Maintenance 8000 YRM 1379 for your lift
truck.
2. Turn the key switch to the OFF position and discon-
nect the battery.
3. Discharge the capacitors in the controllers by
connecting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals. DO NOT short
across the motor controller terminals with a screw-
driver or jumper wire. See Figure 3 or Figure 4.
4. Remove the 200-ohm, 2-watt resistor before recon-
necting the battery.

WARNING
Some checks and adjustments are done with the
battery connected. DO NOT connect the battery un-
til the procedure tells you to do so. Never have any
metal on your fingers, arms, or neck. Metal items
can accidentally make an electrical connection and
cause injury.

WARNING
Before doing any tests or adjustments, raise the ve-
hicle off the ground and block the lift truck to pre-
vent unexpected movement. See the section Peri-
odic Maintenance 8000 YRM 1048, Periodic Main-
tenance 8000 YRM 1009, or Periodic Maintenance
8000 YRM 1379 for your lift truck. Refer to How to
Put a Lift Truck on Blocks.

WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is dis-
connected. To prevent an electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component in the drive
unit compartment. Wear safety glasses. Make
certain that the battery has been disconnected. 1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
3. 200-OHM, 2-WATT RESISTOR
CAUTION 4. INSULATED JUMPER WIRES
To avoid controller damage, always disconnect Figure 3. Discharging the Capacitor
the battery, discharge the capacitor, and never put (MSW020/025-E, MPW045/050-E, and
power to the controller while any power wires are MSW025/030-F)
disconnected. Never short any controller terminal

4
2200 YRM 1007 Moving a Disabled Lift Truck

Legend for Figure 4

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

Figure 4. Discharging the Capacitor (MPB040-E)

Moving a Disabled Lift Truck

In order to move a disabled lift truck, the electric brake
must be released by powering the brake coil with battery
voltage. A jumper is provided in the wiring harness to
supply battery voltage directly to the electric brake to
release it. The truck will roll freely, but the drive motor
will not activate while the jumper is installed.
WARNING
Prior to releasing the electric brake, make sure the
lift truck is blocked correctly to prevent movement,
causing personal injury or damage to equipment.
1. Turn the key switch to the OFF position.
2. Disconnect and separate the battery connectors.
3. Remove the upper drive unit compartment cover.
4. Remove the lower drive unit compartment cover.
5. 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 connec-
tion with wire ties.
6. Disconnect the connectors and connect the brake
wiring harness to the brake override connector.
See Figure 5.
NOTE: The brake will release when battery is con-
nected. The brake will remain released until the battery
is disconnected or the brake override circuit is discon-
nected.
7. Connect the battery connectors.
8. Roll the lift truck to a safe, level area prior to per-
forming any repairs on it.

5
Electrical System Checks 2200 YRM 1007

CAUTION
Always unplug the Brake Override Circuit and con-
nect the Brake Harness prior to operating the lift
truck.

9. Make sure the brake override circuit is discon-

nected from the brake harness. The brake will
remain released until the battery or the brake over-
ride circuit is disconnected. Restore the harness
connector to the normal operation connector cor-
rectly before attempting to operate the lift truck.

1. BRAKE HARNESS CONNECTOR

2. BRAKE OVERRIDE CIRCUIT CONNECTOR
3. NORMAL OPERATION CONNECTOR

Figure 5. Brake Override Connector

Electrical System Checks

SAFETY PRECAUTIONS
NOTE: On some models, the dash indicator will display
the code: EP 107 (or a higher number) for 1 to 2 sec-
onds every time the key switch is turned to the ON posi-
tion. This code represents the EEPROM software ver-
sion and DOES NOT INDICATE A FAULT CODE.
1. Block lift truck so the drive wheels are off the floor.
See the section Periodic Maintenance 8000 YRM
1048, Periodic Maintenance 8000 YRM 1009, or
Periodic Maintenance 8000 YRM 1379 lift trucks.
Refer to How to Put a Lift Truck on Blocks.
2. Turn the key switch to the OFF position.

NOTE: These checks require a volt-ohmmeter. Specific 3. Disconnect and separate the battery connectors.
checks require additional equipment.
4. Remove the upper drive unit compartment cover.
NOTE: The correct meter polarity is necessary for the
checks. The voltage checks are made between the in- 5. Remove the lower drive unit compartment cover.
dividual points and battery negative. Connect the meter
negative to battery negative.

6
2200 YRM 1007
6. Discharge the capacitor. See Special Precautions.
7. Check the specific gravity of the battery. If the spe-
cific gravity is less than 1.260, the battery is not
fully charged or is damaged. A fully-charged bat-
tery has a specific gravity of 1.270 to 1.290. A dis-
charged battery has a specific gravity of approxi-
mately 1.165.
8. The truck has an isolated electrical system; neither
battery terminal is connected to the truck frame.
Check for 50,000 ohms or more between each ter-
minal, one at a time, of the battery connector of the
lift truck and a clean connection on the frame. Re-
move any circuit paths between the controller and
the frame of the lift truck, such as a dirty battery
case. Carbon dust in a motor or other parts can
cause a circuit path. Check for additional equip-
ment that may cause a circuit path to the frame.
Repairs
CONTROLLER, REPLACE
When experiencing problems with the hydraulic func-
tions, the controller may not be at fault. ALWAYS
troubleshoot to verify the component(s) at fault before
replacing the controller. Refer to the section ZAPI™
Controllers 2200 YRM 1064, ZAPI™ Controllers
2200 YRM 1006, or ZAPI™ Controllers 2200 YRM
1067 for your lift truck for additional information on the
ZAPI™ display and for information on troubleshooting
fault codes, adjusting parameters, and testing the
ZAPI™ motor controller.
Remove
1. Move lift truck to a safe, level area.
NOTE: Some new controllers may have software up-
grades which will not allow previous controller parame-
ters and settings to be transferred.
2. If possible, prior to replacing the controller, note all
special customer parameters and settings.
3. Turn the key switch to the OFF position.
4. Disconnect and separate the battery connectors.
5. Block drive tire to prevent movement. See the sec-
tion Periodic Maintenance 8000 YRM 1048, Pe-
riodic Maintenance 8000 YRM 1009, or Periodic
Maintenance 8000 YRM 1379 for your lift truck.
Repairs
9. Check for voltage between each terminal of the
connector that fastens to the battery and a clean
connection on the frame. Normally there is small
voltage (less than 30% of the battery voltage) be-
tween the battery and the frame, even though the
resistance is very high. A higher voltage can indi-
cate a dirty or damaged battery. Clean battery and
battery compartment as necessary.
10. Visually check for parts or wires that are loose or
damaged.
NOTE: Make an identification of any wires before you
disconnect them. The wires must be connected cor-
rectly after checks or repairs.
NOTE: If removing the entire control panel assembly to
include the electrical panel plate, it will be necessary to
perform Step 6. If only removing the controller, contac-
tor, horn, fuses, or wires, it is not necessary to perform
Step 6. See Figure 6 or Figure 7.
6. Remove battery to gain access to control panel
screws. Refer to the section Periodic Mainte-
nance 8000 YRM 1048, Periodic Maintenance
8000 YRM 1009, or Periodic Maintenance 8000
YRM 1379 for your lift truck, for instructions on how
to remove the battery.
7. Remove the upper drive unit compartment cover.
8. Remove the lower drive unit compartment cover.
9. Discharge the capacitor. See Special Precautions.
10. Remove the jumper assembly connector from the
"E" terminal of the motor controller. If equipped,
remove the LED assembly connector from the "D"
terminal of the motor controller.
11. Tag and remove the control wiring from the motor
controller.
12. Tag and disconnect the power wires from the motor
controller.
13. Remove four capscrews and lockwashers that hold
controller to plate and remove controller.
7
Repairs 2200 YRM 1007

Install lockwasher, and nut on countersunk capscrews.

NOTE: If installing the entire control panel assembly to
include the electrical panel plate, it will be necessary to
perform Step 1. If only installing the controller, contac-
tor, horn, fuses, or wires, it is not necessary to perform
Step 1.
2. Install replacement controller on electrical panel
1. Install control panel assembly to lift truck by aligning
four holes of electrical panel plate with four holes
in frame and inserting countersunk capscrews into
holes from the battery box side. Install washer,
Replace battery. See the section Periodic Main-
tenance 8000 YRM 1048, Periodic Maintenance
8000 YRM 1009, or Periodic Maintenance 8000
YRM 1379 for your lift truck, for instructions on how
to install the battery.
plate by aligning four holes of controller with four
holes in electrical panel plate. Install four cap-
screws and lockwashers.

1. MOUNTING PLATE 10. NUT

2. BATTERY CONNECTOR (RED) 11. FUSE (175 AMP)
3. CONTROLLER 12. FUSE (5 AMP)
4. HORN 13. BOLT
5. WASHER 14. LOCKWASHER
6. LOCKWASHER 15. NUT
7. CAPSCREW 16. DISPLAY
8. CAPSCREW 17. IGNITION SWITCH
9. CAPSCREW

Figure 6. Control Panel (MPB040-E)

8
2200 YRM 1007 Repairs

1. MOUNTING PLATE 12. WASHER

2. CONTROLLER 13. LOCKWASHER
3. CAPSCREW 14. CAPSCREW
4. CONTACTOR 15. NUT
5. BATTERY CONNECTOR MOUNT 16. DISPLAY
6. WIRE CLAMP 17. IGNITION SWITCH
7. LOCKWASHER 18. CAPSCREW
8. CONVERTER (12 V TRUCKS ONLY) 19. LOCKWASHER
9. CAPSCREW 20. NUT
10. CAPSCREW 21. FUSE (250 AMP)
11. WASHER 22. HORN

Figure 7. Control Panel (MPW045/050-E, MSW020/025-E, and MSW025/030-F)

9
Repairs 2200 YRM 1007

3. Connect wires and cables to the same terminals as 10. Connect contactor wires to the correct terminals.
identified during the removal procedure.
Table 1. Contactor Coil Resistance Values
4. Connect the jumper assembly to the "E" terminal,
located on the bottom of the controller. See Spe- Model Resistance
cial Precautions for location. Use procedure that
MSW020/025-E and 21 ±2.1
applies to your lift truck:
MSW025/030-F
a. To use a maintenance free battery, discon- MPB040-E 52 ±5.2
nect the wire terminals on the battery selector
jumper. MPW045/050-E 21 ±2.1

b. To use a flooded cell battery, connect the wire CONTACTOR, REPLACE

terminals on the battery selector jumper.

5. Reconnect battery connectors.

Remove
1. Move lift truck to a safe, level area.
6. Turn the key switch to the ON position.
2. Block drive tire to prevent movement. See the sec-
7. If available, install customer parameters and set-
tion Periodic Maintenance 8000 YRM 1048, Pe-
tings.
riodic Maintenance 8000 YRM 1009, or Periodic
8. Test lift truck in a safe area away from other person- Maintenance 8000 YRM 1379 for your lift truck.
nel and equipment.
3. Turn the key switch to the OFF position and discon-
9. Install the lower drive unit compartment cover. nect battery connectors.

10. Install the upper drive unit compartment cover. 4. Remove the upper drive unit compartment cover.

CONTACTOR COIL, CHECK 5. Discharge the capacitor. See Special Precautions.

1. Move lift truck to a safe, level area. 6. Tag, identify, and disconnect the wires and cables.

2. Turn the key switch to the OFF position and discon- 7. Disconnect all wires and cables from the contactor.
nect battery connectors. 8. Loosen two mounting screws and lockwashers that
3. Block drive tire to prevent movement. See the sec- hold contactor to plate and remove contactor.
tion Periodic Maintenance 8000 YRM 1048, Pe-
riodic Maintenance 8000 YRM 1009, or Periodic
Install
Maintenance 8000 YRM 1379 for your lift truck. 1. Install contactor by aligning it with mounting screws
on electrical plate and sliding into place. Tighten
4. Remove the upper drive unit compartment cover.
mounting screws.
5. Discharge the capacitor. See Special Precautions.
2. Connect wires and cables to the same terminals as
6. Tag, identify, and disconnect the contactor coil identified during the removal procedure.
wires.
3. Reconnect battery connectors.
7. Test contactor coil using an ohmmeter.
4. Install the upper drive unit compartment cover.
8. Touch the probes of the ohmmeter to the coil termi-
5. Turn the key switch to the ON position.
nals and measure the resistance between the ter-
minals. 6. Test lift truck in a safe area away from other person-
nel and equipment.
9. Replace contactor if coil resistance readings mea-
sure outside of specifications. For contactor coil re-
sistance values, refer to Table 1.

10
2200 YRM 1007
Key Switch Removal and Installation
REMOVE
1. Move the lift truck to a safe, level area.
2. Block drive wheel to prevent truck from rolling.
3. Disconnect battery connectors and turn the key
switch to the OFF position.
4. Remove the upper drive unit compartment cover.
5. Remove the lower drive unit compartment cover.
6. Discharge the capacitor. See Special Precautions.
7. Remove nut retaining the key switch to bracket.
8. Remove the key switch.
9. Identify and disconnect electrical wires to switch.
Battery Indicator/Hourmeter Display
NOTE: On some models, the dash indicator will display
the code: EP 107 (or a higher number) for 1 to 2 sec-
onds every time the key switch is turned to the ON posi-
tion. This code represents the EEPROM software ver-
sion and DOES NOT INDICATE A FAULT CODE.
The Battery Indicator/Hourmeter Display shows battery
charge status, truck hours, and fault codes. See Fig-
ure 8.
Figure 8. Battery Indicator/Hourmeter Display
REMOVE
1. Turn the key switch to the OFF position and discon-
nect battery.
2. Remove the upper drive unit compartment cover.
Battery Indicator/Hourmeter Display
INSTALL
1. Connect wires to proper terminals.
2. Mount the key switch in bracket.
3. Install nut to retain the key switch. Make certain
switch is properly aligned before tightening retain-
ing nut.
4. Connect battery connectors.
5. Test the key switch by turning it ON and OFF.
6. Install the drive unit compartment covers as re-
moved.
3. Discharge the capacitor. See Special Precautions
in this section.
4. Disconnect the wire harness plug from the back of
the display. Locking tab is hidden underneath rub-
ber boot.
5. Remove nuts and washers holding retaining
bracket. Remove bracket and gauge from control
panel.
INSTALL
1. Install gauge in control panel.
2. Install retaining bracket, washers, and nuts.
Tighten nuts.
3. Reconnect display wire harness plug.
4. Connect battery and turn the key switch to the ON
position.
5. Test operation of lift truck in a safe area.
6. Install the upper drive unit compartment cover.
11
Control Handle Arm Proximity Switch
Fuses
WARNING
Before checking or changing any fuses, make cer-
tain the battery has been disconnected.
Always wear safety glasses. Block the tires, remove
the key from the key switch, disconnect battery, and
discharge the capacitors before making checks or re-
pairs in the drive unit compartment. See Special Pre-
cautions.
MPB040-E
The MPB040-E 24-volt motorized hand trucks have two
fuses. They are:
1. 175-amp (FU 1) protects both the lift pump motor
and the drive motor
2. 5-amp (FU 2) protects the control circuits
MPW045/050-E
The MPW045-E and MPW050-E 24-volt lift trucks have
two fuses. They are:
1. 250-amp (FU 1) protects both the lift pump motor
and the drive motor.
2. 5-amp (FU 2) protects the control circuits.
The MPW045-E and MPW050-E 12-volt lift trucks have
three fuses. They are:
1. 250-amp (FU 1) protects both the lift pump motor
and the drive motor.
2. 5-amp (FU 2) protects the control circuits.
3. 5-amp (FU 3) protects the 12-volt DC to 24-volt DC
converter circuit.
Control Handle Arm Proximity Switch
REPAIR
A proximity switch is used to sense the position of the
control handle arm. A target, cast into the base of the
control handle arm moves in front of the proximity switch
when the handle is in the RUN position, activating the
switch and sending a signal to the ZAPI™ Controller.
A red LED on the switch illuminates when the target is
sensed. Refer to Brakes 1800 YRM 1005.
Check and Adjust
Check the proximity switch for proper operation. All con-
nections must be attached. Take voltage readings from
the back of the connector.
12
2200 YRM 1007
MSW020/025-E
The MSW020/025-E 24-volt lift trucks have two fuses.
They are:
1. 250-amp (FU 1) protects both the lift pump motor
and the drive motor.
2. 5-amp (FU 2) protects the control circuits.
If it cannot be determined visually that any of the fuses
have failed, check for continuity using an ohmmeter. To
replace FU 1, loosen retaining capscrews. Install a new
fuse and tighten capscrews. FU 2 is retained by a fuse
holder. Make certain that any replacement fuse is of the
right amperage before installation.
MSW025/030-F
The MSW025/030-F 24-volt lift trucks have three fuses.
They are:
1. FU 1 protects both the lift pump motor and the drive
motor.
2. FU 2 protects the control circuits.
3. FU 3 protects the control circuits.
If it cannot be determined visually that any of the fuses
have failed, check for continuity using an ohmmeter. To
replace FU 1, loosen retaining capscrews. Install a new
fuse and tighten capscrews. FU 2 or FU 3 are retained
by a fuse holder. Make certain that any replacement
fuse is of the right amperage before installation.
1. Move the lift truck to a safe, level area before per-
forming any repairs.
2. Turn the key switch to the OFF position.
3. Remove the upper drive unit compartment cover.
4. Remove the lower drive unit compartment cover.
5. Remove the four capcrews from the two-piece
shield over the MDU and remove the shields.
6. Turn the key switch to the ON position.
7. Verify battery voltage at the proximity switch con-
nector between pin #1 and pin #2.
2200 YRM 1007 Control Handle Arm Proximity Switch

8. Place negative lead on the battery ( ).

9. Place positive lead on the black wire pin #3 of the

proximity switch connector.

10. Place the control handle arm in the operating posi-

tion. Verify that battery voltage is present and the
proximity switch LED is lit.

11. Place the control handle arm in the full up or down

position. Verify that battery voltage is not present
and the proximity switch LED is not lit.

If the proximity switch does not operate properly, check

that the gap measurement is within specification and
that the wiring harness and connections are good. Ad-
just the switch gap if necessary or repair any wiring
problems. If the proximity switch continues not to func-
tion properly, it must be replaced. 1. PROXIMITY SWITCH
2. CAPSCREW
Remove 3. SWITCH BRACKET

1. Move the lift truck to a safe, level area before per-
forming any repairs.
2. Turn the key switch to the OFF position and discon-
nect the battery.
3. Remove the upper drive unit compartment cover.
4. Remove the lower drive unit compartment cover.
Figure 9. Proximity Switch Assembly
Install
1. Insert the proximity switch fully into the switch
bracket. Route the proximity switch wire so that it
will not be pinched or damaged when the control
handle is installed.

5. Remove the four capscrews from the two-piece CAUTION

shield over the MDU and remove the shields.
6. Discharge the capacitor. See Special Precautions.
7. Cut the tie wrap located at the end of the proximity
switch harness.
8. Remove the proximity switch harness clamp, lo-
cated beneath the drive unit housing.
DO NOT damage the plastic switch bracket or prox-
imity switch by overtightening screws.
2. Install the proximity switch assembly to the drive
unit housing with two capscrews through the switch
bracket into the drive unit housing. DO NOT tighten
the capscrews until after the switch has been ad-
justed.

9. Disconnect the proximity switch from the wiring har-
ness.
10. Fully lower the control handle arm. Remove the two
capscrews that mount the proximity switch assem-
bly to the control handle arm. See Figure 9. Re-
move the proximity switch assembly.
3. Check the gap between the proximity switch as-
sembly and the control handle. The gap should
measure 3.0 to 5.0 mm (0.12 to 0.20 in.) See Fig-
ure 10. If the gap distance is different, horizontally
adjust the location of the proximity switch.
4. Connect the switch to the wiring harness.

13
Control Handle
1. PROXIMITY SWITCH ASSEMBLY
2. GAP 3.0 to 5.0 mm (0.12 to 0.20 in.)
3. PROXIMITY SWITCH WIRE
Figure 10. Proximity Switch Assembly Location
Control Handle
DISASSEMBLE
NOTE: It is not always necessary to remove and dis-
assemble all the components that make up the control
section of the steering handle to replace a damaged
part. Perform only the steps necessary to replace the
damaged parts. See Figure 15.
1. Move the lift truck to a safe, level area and block the
drive wheel to prevent movement of the lift truck.
2. Turn the key switch to the OFF position and discon-
nect the battery.
3. Discharge the capacitor. See Special Precautions.
NOTE: The handle is comprised of two molded-plastic
halves and is held together by three capscrews.
4. Remove the three capscrews retaining the upper
half of the control handle to the lower half.
5. Disengage the hooks under the auto-reverse
switch. Slide the upper half off of the lower half us-
ing a gentle rocking motion while lifting and pulling
the upper half away from lower half. See Figure 15.
14
2200 YRM 1007
5. Connect the battery and turn the key switch to the
ON position.
6. With the handle at 10° from vertical, move the prox-
imity switch until the LED turns on.
7. Slowly move the proximity switch in the opposite
direction until the LED just turns off.
8. Torque the two capscrews to 4.17 N•m (37 lbf in).
9. Verify that the truck operates correctly with the han-
dle in the following positions:
a. LED comes on with the handle in RUN position.
b. LED should go off with the handle approxi-
mately 10° from vertical position.
10. Install the two shield covers using four capscrews
11. Install the lower drive unit compartment cover.
12. Install the upper drive unit compartment cover.
6. Unplug the handle wiring harness from the control
handle card.
7. Place upper half of the handle upside down on a
secure, level work surface so the internal parts are
facing up.
8. Remove lower half of the cover (only if damaged or
needs replacing) from the control handle shaft by
removing two capscrews.
NOTE: Make note of the position of the butterfly knobs
relative to the handle BEFORE removal.
9. Remove one of the butterfly knobs by removing the
screw that holds it on the shaft.
10. Using the remaining butterfly knob, slide the shaft
out of the handle. Be careful not to rotate the shaft
within the control handle card.
11. Refer to the wiring diagram, or draw a sketch
of where each of the push button switches are
plugged into the control handle card. Unplug
switches from the control handle card and remove
the card.
2200 YRM 1007 Control Handle

CONTROL HANDLE CARD (OLD STYLE)
After servicing the control handle head, it is necessary
to calibrate the control handle card. If replacing with a
new style card (usually blue in color), refer to Control
Handle Card (New Style).
1. Install the control handle card in the upper half of
the control handle.
NOTE: When inserting knobs make sure that flange on
one of the butterfly knobs inserts between the spring on
the control handle.
2. Slide shaft and butterfly knob into the control handle
card. Be careful not to rotate the shaft inside the
control handle card.
3. Connect the switches and wire harness connectors.
4. Install the remaining butterfly knob. Apply Loctite®
242 to the screw attaching the butterfly knob onto
the upper half of the handle and tighten the screw
to 1 N•m (9 lbf in).
13. Slowly press the proportional LIFT button and hold
down five seconds.
14. Slowly release the proportional LIFT button and
wait for five seconds.
15. Slowly press the proportional LOWER button and
hold down for five seconds.
16. Slowly release the proportional LOWER button and
wait for five seconds.
17. Move the jumper on the J1 terminal to the RUN
mode. See Figure 11, view A.
18. Turn the key switch to the OFF position.
19. Install the upper half on the lower half. Refer to As-
semble for instructions on how to install the upper
half on the lower half.
20. Test the lift truck to verify correct travel, lift, and
lower speeds.

5. Lubricate friction points on the butterfly knobs with

silicone spray lubricant.

6. Connect the battery.

7. Move the jumper on the J1 terminal to the calibrate

mode. See Figure 11, view B.

8. With the handle in the full upright position, turn the

key switch to the ON position.

9. Slowly rotate the butterfly knobs in the forward di-

rection and hold at maximum rotation for 5 seconds.

10. Slowly rotate the butterfly knobs back to the neutral

position and leave for 5 seconds.

11. Slowly rotate the butterfly knobs in the reverse di-

rection and hold at maximum rotation for 5 seconds.

12. Slowly rotate the butterfly knobs back to the neutral

position and leave for 5 seconds.

NOTE: If control handle includes the optional propor-

tional switches, it will be necessary to perform Step 13
through Step 16. If control handle includes only the full
A. RUN MODE B. CALIBRATE MODE
speed and half speed ON/OFF lift and lower switches,
then go to Step 17. Figure 11. Control Handle Card Calibration

15
Control Handle
CONTROL HANDLE CARD (NEW STYLE)
NOTE: New style control handle cards will be blue in
color and should be used as replacement cards regard-
less of color of the card removed. If simply calibrating
an existing old style card (green in color), refer to Con-
trol Handle Card (Old Style).
NOTE: Verify that the magnetic holder of the thumb-
wheel switch has been installed in the proper position.
See Figure 12.
After servicing the control handle head, it may be nec-
essary to configure and/or calibrate the control handle
card.
Configure
Refer to Figure 12 for the following instructions.
1. Partially assembly the control handle head. Refer
to Assemble.
2. Connect the control handle card wiring, verify that
the battery is connected, and turn the key switch to
the ON position.
1. JUMPER TERMINALS (SV2)
2. HORN SWITCH (S1)
3. THUMBWHEEL SWITCH (MAGNETIC HOLDER)
Figure 12. Control Handle Card (New Style)
16
2200 YRM 1007
3. The LED will display the program setting for ap-
proximately five seconds. The proper control han-
dle card setting for this model is number 3 for mod-
els MPB040-E and MPW045/050-E or 4 for models
MSW020/025-E and MSW025/030-F. If the correct
number is displayed on the LED, the control handle
card is configured correctly.
4. To begin configuring the card, turn the key switch to
the OFF position.
5. Move the jumper from P (park) to C (configure).
See Figure 13.
6. Turn the key switch to the ON position and view the
LED display.
7. Press and release the S2 (turtle) switch or S3 (horn)
switch to change the number displayed on the LED
to the correct value.
8. Press and release the S (belly) switch to save the
value. A decimal will appear on the LED display
beside the number showing it has been saved.
4. LED DISPLAY SCREEN
5. BELLY SWITCH (S)
6. TURTLE SWITCH (S2)
2200 YRM 1007 Control Handle

option) connects to the JP14 socket and the

leads from the Left Lower switch (or shift left
switch if equipped with sideshift option) con-
nects to the JP15 socket. See Figure 12.

c. Ensure the tiller harness connects to JP1

socket. See Figure 12.

3. Verify that the battery is connected and turn the key

switch to the ON position. The LED will display a
symbol (see Figure 14 view A or B) to signal that
the card is in calibration mode.

a. If LED displays as shown in Figure 14 view

A, return butterfly to neutral then press left lift
button (or side shift right button if equipped
with sideshift option). The LED will display as
shown in Figure 14 view B.

1. P (PARK/ HOME POSITION)

2. D (NOT USED)
3. T (TEACH/CALIBRATE)
4. C (CONFIGURE)
5. JUMPER TERMINAL (SV2)

Figure 13. Jumper Terminal (SV2)

9. Turn the key switch to the OFF position and move

the jumper to the park (P) position.

10. Turn the key to the ON position and view the LED to
verify the correct number has been saved. The LED
will display the program setting for approximately
five seconds.

Calibrate
Refer to Figure 12 for the following instructions.

1. Verify that the key switch is in the OFF position.

2. Move the jumper from P (park) to T (teach). See

Figure 13. A. CALIBRATION MODE
B. CALIBRATION MODE
a. Ensure the leads from the Right Lift switch con- C. ROTATION RIGHT SEGMENT COMPLETE
nects to the JP10 socket and the leads from D. ROTATION LEFT SEGMENT COMPLETE
the Right Lower switch connects to the JP12 E. ALL SEGMENTS COMPLETE AND SAVED
socket. See Figure 12.
Figure 14. LED Views
b. Ensure the leads from the Left Lift switch (or
shift right switch if equipped with sideshift

17
Control Handle
NOTE: "Rotation Right" and "Rotation Left" directions
are specified by labels printed on face of card.
4. Rotate the thumbwheel in the "Rotation Right" di-
rection (toward the forks) and hold to the mechani-
cal stop. Press the left side lift button (sideshift right
button if equipped with sideshift option).
5. The LED screen will change to show this segment
complete. See Figure 14, view C. Release the
thumbwheel so it returns to the neutral position.
NOTE: "Rotation Right" and "Rotation Left" directions
are specified by labels printed on face of card.
6. Rotate the thumbwheel in the "Rotation Left" direc-
tion (toward the operator) and hold to the mechan-
ical stop. Press the left side lower button (sideshift
left button if equipped with sideshift option).
7. The LED screen will change to show this segment
complete. See Figure 14, view D. Release the
thumbwheel so it returns to the neutral position.
8. Move the jumper from T (teach) to P (park). See
Figure 13.
9. The LED screen will change to show a decimal be-
side the completed segments indicating they have
been saved. See Figure 14, view E.
10. Use diagnostic from handset to verify the "Accel"
output 95% and above for both directions.
11. Recycle the key switch OFF and ON and test all
truck functions for proper operation.
ASSEMBLE
1. Install control handle card in the upper half of con-
trol handle. See Figure 15.
NOTE: When inserting knobs, make sure that flange
on one of the butterfly knobs inserts between spring on
handle (9).
18
2200 YRM 1007
2. Slide shaft and butterfly knob into control handle
card. Be careful not to rotate the shaft inside the
control handle card.
3. Connect the switches and wire harness connectors.
4. Install the remaining butterfly knob. Apply Loctite
242™ to the screw attaching the butterfly knob
onto the upper half of the handle and tighten screw.
Tighten screw to 1 N•m (9 lbf in).
5. Lubricate friction points on the butterfly knobs with
silicone spray lubricant.
NOTE: It may not have been necessary to remove the
lower half of the control handle cover. If the cover (lower
half) is already installed to the control handle shaft, skip
to Step 7.
6. Install lower half of control handle cover to con-
trol handle shaft and secure with two capscrews.
Torque to 27 N•m (20 lbf ft).
7. Plug handle wiring harness into control handle
card.
CAUTION
DO NOT force the upper half onto the lower half as
this will cause damage to the retaining hooks of the
upper half.
8. To install upper half of handle onto the lower half:
a. Tip the upper half up and align the hooks under
the auto-reverse switch.
b. Lower the upper half onto the lower half.
9. Install capscrews to retain upper half of control han-
dle to lower half.
10. Connect battery cable and test control handle op-
eration.
2200 YRM 1007 Control Handle

1. COVER (LOWER HALF) 12. SPRING

2. COVER (UPPER HALF) 13. SWITCH COVER
3. CONTROL HANDLE CARD ASSEMBLY 14. BUTTONS
4. SHAFT 15. SWITCH - ON/OFF
5. BUSHING 16. HORN SWITCH COVER
6. BUTTERFLY KNOB (LH) 17. LABEL
7. WASHER 18. LABEL
8. SCREW 19. LABEL
9. SPRING 20. SWITCH
10. BUTTERFLY KNOB (RH) 21. PROPORTIONAL SWITCH (OPTIONAL)
11. SWITCH COVER

Figure 15. Control Handle

19
Control Handle
SWITCHES (ON/OFF AND
PROPORTIONAL)
Remove
NOTE: It is not always necessary to remove and dis-
assemble all the components that make up the control
section of the steering handle to replace a damaged
part. Do only the steps necessary to replace the dam-
aged parts. See Figure 15.
1. Move lift truck to a safe, level area and block the
drive wheel to prevent movement of the lift truck.
2. Turn the key switch to the OFF position and discon-
nect battery.
3. Discharge the capacitor. See Special Precautions.
NOTE: The handle is comprised of two molded-plastic
halves and is held together by three capscrews.
4. Remove the three capscrews retaining upper half
of control handle to lower half.
5. Disengage hooks under the auto-reverse switch.
Slide upper half off the lower half using a gentle
rocking motion while lifting and pulling upper half
away from lower half. See Figure 15.
6. Unplug handle wiring harness from control handle
card.
7. Place upper half of handle upside down on a se-
cure, level work surface so the internal parts are
facing up.
8. Refer to the wiring diagram, or draw a sketch of
where the failed push button switch is plugged into
the control handle card. Unplug failed switch from
control handle card.
NOTE: Both ON/OFF and proportional switches use
three tabs to keep the switches attached to the upper
half of the control handle.
9. Remove the switch by pressing the three tabs to-
ward the switch and pushing the switch through up-
per half of cover.
20
2200 YRM 1007
10. Replace ON/OFF Switch:
a. Separate the button from the switch by spread-
ing the four tabs to allow the switch to slide out
of the button.
b. To assemble, slide the ON/OFF switch into the
ON/OFF button. Verify that the switch assem-
bly locks into position.
Install
1. Install the switch assembly into the control handle.
Verify that the switch assembly locks into position
in the control handle.
2. Connect the switch assembly wiring to the control
handle card.
3. Plug handle wiring harness into control handle
card.
CAUTION
DO NOT force the upper half onto the lower half as
this will cause damage to the retaining hooks of the
upper half.
4. Install upper half of handle onto the lower half:
a. Tip the upper half up and align the hooks under
the auto-reverse switch.
b. Lower the upper half onto the lower half.
5. Install three capscrews to retain upper half of con-
trol handle to lower half.
6. Connect battery cable and test control handle op-
eration.
NOTE: If adding optional proportional switches for the
first time, make sure to perform Control Handle Card
(Old Style).
2200 YRM 1007 Traction Motor

Traction Motor
DISASSEMBLE
1. Remove the traction motor and brake assembly
from the MDU. See Brakes 1800 YRM 1005.
CAUTION
The pinion end cover and the armature are heavy
components. Work carefully so the field coils, pole
pieces, and armature are not damaged during dis-
4. Remove capscrews from commutator end of motor.
assembly and assembly.
2. Clean outside surfaces of motor before disassem-
bly. Make index marks on the ends of the motor and
field ring to ensure proper reassembly.
a. Brush replacement is REQUIRED when the
height of the brush measures 11 mm (0.44 in.)
below the brush box. If the brush is worn 8 mm
(0.31 in.) below the brush box, then brush re-
placement is RECOMMENDED. See the sec-
tion DC Motor Maintenance 620 YRM 294 for
the replacement of brushes and spring assem-
blies.
Carefully slide end cover from motor and armature
shaft. DO NOT damage parts. A puller is often
necessary to separate the end cover from the field
ring.

3. Remove brush cover, if used. Measure the brush 5. Remove screws that fasten pinion end cover to field
in the brush holder, use a tire tread depth gauge or ring. Remove end cover and armature. Use a plas-
small scale to measure from the top of the brush tic or rubber hammer, as necessary, to loosen end
holder to the back of the brush. cover.

6. Remove pinion end cover from armature.

1. END COVER 5. HOUSING AND WINDINGS

2. ARMATURE 6. BRUSH AND SPRING
3. BEARING 7. COMMUTATOR END CAP
4. MOUNTING STUD 8. COVER BAND

Figure 16. Disassembled Traction Motor

21
Lift Pump Motor
7. Remove screws that fasten brush holder assembly
to commutator end cover.
8. Disassemble components of motor, as necessary,
to make repairs. See Figure 16 and the section DC
Motor Maintenance 620 YRM 294.
ASSEMBLE
1. Make sure all components are clean. If bearings
are worn, install new bearings in end cap.
2. Make sure field coils and pole pieces are installed
correctly in housing.
3. Install brush holder assembly in commutator end
cap.
Lift Pump Motor
The MPB040-E, MPW045-E, and MPW050-E lift
pumps cannot be disassembled. The motors are ser-
viced as an assembly.
REPAIR (MSW020/025-E AND
MSW025/030-F)
The lift pump motor is an electric motor mounted on top
of the lift pump and hydraulic tank. The motor drives the
lift pump supplying oil pressure to the hydraulic system.
When repairing the lift pump motor ALWAYS check that
the battery is charged and check all electrical connec-
tions BEFORE removing the motor from the truck:
1. Check the specific gravity of the battery or the op-
tional battery discharge indicator for proper battery
charge. See Electrical System Checks for informa-
tion on how to check the specific gravity.
2. Block the drive wheels to prevent movement.
3. Disconnect battery.
The lift pump motor used on the MSW020/025-E and
MSW025/030-F is a 24-VDC motor and has only two
serviceable items (see Figure 17):
22
2200 YRM 1007
4. Carefully install armature in housing. Install retain-
ing rings.
5. Carefully install commutator end cover to housing.
Install and tighten capscrews.
6. Install brushes and spring assemblies. Replace
brush cover, if used. See Figure 16.
7. Install brake assembly to drive motor. See Brakes
1800 YRM 1005.
8. Install drive motor to MDU. Secure in place using
motor mount studs.
• Brushes
• Brush Plate
Remove brush cover, if used. Measure the brush in the
brush holder, use a tire tread depth gauge or small scale
to measure from the top of the brush holder to the back
of the brush.
Brush replacement is REQUIRED when the height
of the brush measures 5.5 mm (0.22 in.) below the
brush box. If the brush is worn 4 mm (0.16 in.) below
the brush box, then brush replacement is RECOM-
MENDED.
See the section DC Motor Maintenance 620 YRM 294
for replacement of the brushes.
If other components of the motor are damaged, then
the entire motor must be replaced. The lift pump mo-
tor for the MPB040-E is a 24-VDC motor where the
MPW045/050-E offers both a 12-VDC and 24-VDC mo-
tor. These motors are not serviceable and must be
replaced when not functioning properly. Repair or re-
place the lift pump motor and install. See Walkie Hy-
draulic Systems 1900 YRM 1018 or Walkie High Lift
Hydraulic System 2000 YRM 1044.
2200 YRM 1007 Lift Link Proximity Sensor (MPW050-E)

Legend for Figure 17

A. MINIMUM DIMENSION
1. TAPERED END 2. WEAR END
(SPRING) 3. BRUSH SPRING

Figure 17. Pump Motor Brushes Inspection

Lift Link Proximity Sensor (MPW050-E)

The lift link proximity sensor is located near the bottom
of the control panel. This sensor detects the lift link-
age position when the forks reach maximum lift height
and stops the lift pump motor. In the event that the
lift pump motor continues to run after the forks reach
maximum height, check the lift link proximity switch for
proper function and adjustment. See Figure 18.

1. CONTROLLER
2. PROXIMITY SENSOR
3. HORN

Figure 18. Lift Proximity Sensor Location

23
Lift Link Proximity Sensor (MPW050-E) 2200 YRM 1007

CHECK Remove
1. Remove the electrical compartment covers. Turn 1. Disconnect the sensor wiring connector from the
the key switch to the ON position and move the con- truck wiring harness.
trol handle arm to the RUN position. Check the bat-
tery discharge indicator for proper battery charge. 2. Remove the front jam nut from the position sensor
threads. See Figure 19.
2. Completely lower the forks then press and hold the
lift button. The lift pump and motor assembly should 3. Remove the sensor from the mounting bracket on
activate, raise the forks to their maximum lift height, the truck frame.
and turn off while the lift button is still depressed.
4. Remove the rear jam nut if replacing the senor.
a. If the lift pump and motor activates but does
not raise the forks, the problem may be in the
hydraulic or lift linkage systems.

b. If the lift pump and motor does not activate,

troubleshoot the electrical system.

c. If the forks raise properly but the lift pump and

motor does not shut off when the forks reach
maximum lift height, unplug and clean the prox-
imity sensor connector. Reconnect the sensor 1. SENSOR CONNECTOR
with the wiring harness and check operation 2. SENSOR WIRING
3. REAR JAM NUT
again. If the problem remains, proceed to the 4. FRONT JAM NUT
next step. 5. SENSOR FACE

Figure 19. Sensor and Jam Nuts

CAUTION
Keep hands and fingers clear of lift linkage to avoid Test
injury from pinch points.
1. Remove the lift linkage proximity sensor. See Re-
3. Cover the face of the proximity switch with a piece move.
of metal then press and release the lift button.

a. If the lift pump and motor shut down when the CAUTION
sensor is covered, properly adjust the lift link- DO NOT connect jumper wires to the truck wiring
age proximity sensor. See Adjust. harness.

b. If the lift pump and motor assembly continues
to operate when covered, test the lift linkage
proximity switch. See Test.
REPAIR
The following repairs are performed with the key switch
in the OFF position and the electrical compartment
cover removed unless otherwise noted. Replace the
cover when repairs are complete.
2. Connect jumper wires to the sensor wiring harness:
a. Connect positive (24 volts) to the pin #1 of the
connector. See Figure 20.
b. Connect a ground to the pin #2 of the connec-
tor.
c. Connect a voltmeter between pin #3 of the con-
nector and a ground.

24
2200 YRM 1007
1. PIN #1 (BROWN WIRE)
2. PIN #2 (BLUE WIRE)
3. PIN #3 (BLACK WIRE)
Figure 20. Sensor Connector (Front View)
3. Position a piece of metal within 5.0 mm (0.2 in.) of
the face of the sensor to activate the sensor. Re-
move your hand to deactivate. Voltmeter should
Battery Charger (Moran®)
DESCRIPTION
Some early model lift trucks are equipped with a
Moran® battery charger which can be identified by its
LED configuration. See Figure 21. This charger is
a self contained 120 volt AC powered charger. The
charger comes equipped with a short lead plug to allow
connection to the 120 volt AC outlet using a 20 amp
rated extension cord. The charger will operate from
any wall outlet capable of supplying 108 to 126 volts
AC protected by a 20 amp circuit breaker.
OPERATION
Charging
Pressing the ON button at the top of the charger starts
the charging cycle. A yellow LED will illuminate to in-
dicate that charging has begun. Battery charging is
Battery Charger (Moran®)
read 24 volts when the sensor is activated and no
voltage when it is deactivated. If the sensor does
not operate correctly, it must be replaced.
Install
1. Position the rear jam nut onto the position sensor
threads.
2. Install the position sensor into the bracket on the
frame of the lift truck as removed.
3. Install the front jam nut onto the position sensor
threads. Snug jam nut to secure sensor in place.
4. Connect the sensor wiring connector to the truck
wiring harness connector as removed.
Adjust
1. Slightly loosen the front jam nut of the lift linkage
proximity sensor.
2. Adjust both jam nuts equally to position the proxim-
ity sensor 2.5 mm (0.1 in.) from the upper lift linkage
when the forks are in the fully raised position.
3. Tighten the front jam nut to secure the proximity
sensor in position. Verify the measurement.
4. Check for proper operation.
automatic once the charging cycle has started. The
green LED will illuminate once the charging cycle has
been completed. Refer to Figure 21.
Figure 21. Battery Charger (Early Models)
25
Battery Charger (Moran®)
Equalize
The charger will automatically begin a equalizing cycle
to equalize the charge of the batteries immediately after
the batteries have been fully charged. The charger is
equalizing when the yellow LED is flashing.
Signals
The battery charger comes with a red LED that will illu-
minate or flash if a malfunction of the charger or battery
occurs.
One of the following may be the cause in the event of
charger failure and the red LED is blinking:
• AC mains failure
• DC fuse blown
• Power circuit break down
One of the following may be the cause in the event of
battery failure and the red LED is ON:
• The total security time, 14 or 15 hours, has expired.
• The security time before the battery gassing voltage,
10 hours, has expired.
• The battery voltage is lower than 2.05V per cell after
one hour of charge.
Protections
The following describes the protections of the battery
charger:
1. INPUT FUSE
Figure 22. Input Fuse Location
If the charger will power up, but does not charge, pro-
ceed with the following:
• Check condition of battery connections and clean
them, if necessary.
• Verify that the batteries are properly connected. See
Diagrams 8000 YRM 1011, Diagrams 8000 YRM
1050, Diagrams 8000 YRM 1381, or Diagrams 8000
26
2200 YRM 1007
• A fuse protects the DC circuit in the event of pro-
longed over-current or possible polarity inversion.
• An automatic device allows the charge to begin only
after five minutes from the connection to the battery.
• In case of mains failure, the charge is cut off tem-
porarily, the red LED blinks. The charge continues
when the mains is restored.
TROUBLESHOOTING
NOTE: If all the below steps have been taken and the
charger still does not function properly, the charger
should be replaced.
If the charger will not power up, proceed with the follow-
ing:
• Check AC wall outlet for power. Acceptable power
range at the outlet should be between 108 and 126
volts on a 20 amp circuit.
• Check for blown AC input fuse, that is located on the
charger bottom. See Figure 22.
• If the AC input fuse is blown, replace and reconnect
the charger to the AC outlet. Check AC voltage while
in operation to confirm the AC wall circuit is still within
the acceptable range, 108 to 126 volts. If the AC wall
circuit is still within the acceptable limits, return the
charger to service. If it is not, DO NOT return the
charger to service until a building circuit with accept-
able output can be found.
YRM 1228 for your lift truck. Identify and replace any
batteries with open or shorted cells.
• Check battery output voltage to verify charge is actu-
ally necessary. Charger may not run if batteries are
already sufficiently charged.
• If battery output voltage indicates need for charging
and the unit will not charge, check the internal 50
amp DC output fuse and replace if necessary. First
2200 YRM 1007
remove the four Phillips head screws on the side of
the charger and slide the cover off to access the fuse.
See Figure 23.
• If the DC output fuse requires replacement, this could
be an indication of an improperly wired battery pack.
Verify that all battery connections are correct and re-
move all debris and metal fragments from the blown
fuse before putting charger back in service.
• If the DC output fuse is good, verify that both retaining
nuts are adequately tightened. Exercise caution not
to over tighten the nuts, which could result in board
damage.
Figure 23. 50 Amp DC Output Fuse
Figure 24. Battery Charger
Battery Charger (Moran®)
NOTE: If the 50 amp DC output fuse has blown, some
debris can be expected on the circuit board next to
the fuse. However, care should be taken to remove
the debris before putting the unit back in service. See
Figure 24.
• Visually inspect for signs of heat damage on the cir-
cuit board and or transformer. If any heat damage is
evident, reassemble and replace the charger.
Legend for Figure 24
1. TRANSFORMER
2. RECTIFIER BRIDGE
3. CIRCUIT BOARD
4. DC OUTPUT FUSE
5. AC INPUT FUSE
If the charger begins the charge cycle, but stops before
it is complete and an error light comes on, this usually
indicates a problem with the batteries.
NOTE: The charger has an electronic safety timer that
will detect if the batteries are not responding to the
charge within the prescribed time period. The charger
will shut itself down if it determines there is a problem
with the batteries.
1. If the charger is unable to raise the battery volt-
age above 1.7 volts/cell (20.4 volts total) within one
minute after start up, it will stop charging and a con-
stant red LED will light up.
2. If the charger is unable to raise the battery voltage
above 2.05 volts/cell (24.6 volts total) within one
hour after start up, it will stop charging and a con-
stant red LED will light up.
3. If the charger is unable to raise the battery volt-
age above 2.42 volts/cell (29.0 volts total) within 10
hours after start up, it will stop charging and a con-
stant red LED will light up.
27
Battery Charger (DPI®)
4. If at any time during the charge cycle the trans-
former overheats, the charger will stop, the yel-
low LED will stay on, and the red LED will flash.
This may appear to be a charger issues, but it is
caused by the batteries. If the battery voltage does
not rise as it should, the charger output current
will increase, which raises the transformer tempera-
ture. Eventually, it will become too hot, causing the
charger to shut down to protect itself. The charger
will restart itself and begin charging again after the
transformer has cooled down, but the same situa-
tion may occur again. If this happens within one
hour after start up, the one hour timer will expire
and shut the charger down as described in item 2
above.
All of the cases above are indicative of a set of batteries
that are not responding properly to the charger due to
one or more weak or failing cells.
Battery Charger (DPI®)
DESCRIPTION
Some lift trucks are equipped with DPI® brand battery
chargers. DPI Gen II chargers and DPI Gen III chargers
differ slightly and can be distinguished by their appear-
ance. See Figure 25 and Figure 26.
Figure 25. DPI Gen II Chargers
28
2200 YRM 1007
When any one of these situations occur, it is best to
unplug the charger and inspect the batteries for one or
more bad cells. This can be done with a load tester
or a specific gravity test. If the variation between the
highest and lowest specific gravity reading between the
three cells in any one battery is 0.050 (50 gravity points)
or more, there is a reason to suspect a weak or failing
cell.
If a battery has a bad cell, it must be replaced. To im-
prove battery life, and to get the maximum amount of
run time out of each charge cycle, it is best to replace
all four batteries at the same time.
If all the above steps have been taken and the charger
still does not function properly, the charger should be
replaced.
Figure 26. DPI Gen III Chargers
DPI chargers are self contained, 120 volt, AC powered
chargers. Each charger comes equipped with a short
lead plug to allow connection to the 120 volt AC outlet
using a 20 amp rated extension cord. The charger will
operate from any wall outlet capable of supplying 108
to 126 volts AC protected by a 20 amp circuit breaker.
NOTE: Some markets use a special 230 volt AC
charger which require connection to a 230 volt AC
outlet. Users with 230 volt AC chargers should sub-
stitute 230 volts AC in the place of 120 volts AC when
instructed to connect the charger to a power source.
2200 YRM 1007 Battery Charger (DPI®)

OPERATION The charger uses a 5-step charging process:

LED Display 1. Pre Qualification Test. During this step, the yellow,
CHARGING, LED will flash on and off every two
The charger has five colored LEDs located on the top of seconds. The charger is checking for faults prior to
the charger. The LEDs are used to indicate the status the start of charging. Depending on the condition
of the charger during operation. The order of the LEDs and state of charge of the batteries, this step can
may vary with models, but are labeled to identify their take from 45 seconds up to 5 hours.
function. See Table 2.
2. Regulating Current. During this step, the charger
Table 2. Charger LEDs will be regulating current to the batteries and will be
operating at full rated output. The yellow, CHARG-
Indicator Color Function ING, LED will be constantly illuminated during this
step.
Power On Red Illuminates continuously
when AC power is present. 3. Regulating Voltage. During this step, the charger
Abnormal Red Flashes if abnormal will be regulating voltage to the batteries. The
Shutdown shutdown has occurred. yellow, CHARGING, LED will remain illuminated.
When the batteries have reached 80 to 90 percent
Detection Red Illuminates continuously of full charge, the yellow, CHARGING, and the
Error when battery is not green, CHARGED, LEDs will be illuminated.
connected to charger or
battery voltage is less 4. Charge Complete. During this step, the green,
than 2V. CHARGED, LED will remain illuminated. AC power
can now be disconnected from the charger.
Charging Yellow Charge status indicator -
flashes during charging 5. Recycle Stage. If the charger remains connected to
cycle. power for 28 days, a completely new charge cycle
Charged Green Illuminates continuously will begin to keep batteries fully charged during long
when battery is fully periods of not being used.
charged.
NOTE: If the charger noted an abnormal charge con-
dition during the charging, the charger will attempt to
Charging shutdown and will flash one or all three of the red LEDs
on the top of the charger. If this condition occurs, see
CAUTION Troubleshooting (DPI Chargers), Error Modes in this
section.
The charger comes factory set to charge mode
2 and must be changed if using batteries not
CHARGER MODE/BATTERY TYPE
specified for charger mode 2. Using an improper
charger mode for your battery pack may cause SELECTION (DPI GEN II MODELS)
severe damage to batteries or charger.Refer to
Charger Mode/Battery Type Selection (DPI Gen II CAUTION
Models) or Charger Mode/Battery Type Selection DO NOT use batteries types that are not approved
(DPI Gen III Models) in this section to verify the for the charger or improper mode settings. Damage
proper mode setting for your battery pack. to the batteries or charger may occur if the mode
setting is not correct for the type of batteries being
Plugging the charger to the 120 volt AC outlet will begin
used.
the start up cycle. Approximately three seconds after
connection to the AC power, all five LEDs on the top of NOTE: Gen II and Gen III version DPI chargers have
the charger will illuminate and flash two times. This in- different procedures for changing charger modes for
dicates the charger is set to charge U1800 type batter- charging different battery types. Use the proper proce-
ies. Following the start up flashing of the LEDs, the red, dure for your lift truck. See Charger Mode/Battery Type
POWER ON, LED will illuminate to indicate AC power is Selection (DPI Gen II Models) or Charger Mode/Battery
applied to the charger and will begin the charging cycle. Type Selection (DPI Gen III Models).

29
Battery Charger (DPI®) 2200 YRM 1007

NOTE: Mode settings can be checked by connecting 1. Remove the charger from the battery tray and place
the battery charger to a 120V AC power source and on a clean flat surface.
watching the LED display. The LED display will flash
once if the mode is set to Mode 1, twice if the mode 2. Remove the screws used to retain the cover to the
is set to Mode 2, and three times if the charger is set charger and remove the cover.
to Mode 3. If the LEDs do not flash when initially con-
3. Locate the jumpers on the circuit board. See Fig-
nected to power, refer to Troubleshooting (DPI Charg-
ure 27. The two jumpers used to make the model
ers) in this section.
setting are labeled J3 and J4 on the circuit board.
The battery charger has three battery mode settings. These jumpers are located near the center red LED
The mode setting is determined by the type batteries on the circuit board.
being used in the battery pack. See Table 3.
4. For Mode 1, remove the existing jumper from J3.
Table 3. Battery Modes (DPI Gen II Chargers Only) For Mode 3, remove the existing jumper from J3
and install on J4.
Mode Battery
5. Replace the cover on the charger and install the
1 24 V Exide E3600 mounting screws.
2 24 V Interstate U1800 6. Install the charger in the battery tray.
3 24 V Trojan Battery T-605
NOTE: Store the jumper in a safe place in case of future
battery type retrofits.
CAUTION
DO NOT use batteries types that are not approved
for the charger or improper mode settings. Damage
to the batteries or charger may occur if the mode
setting is not correct for the type of batteries being
used.

The charger is set to a default Mode 2 at the factory. Any

batteries other than U1800 type will require the mode
setting to be changed.

Changing Mode Setting (DPI Gen II

Models)
NOTE: Mode settings can be checked by connecting
the battery charger to a 120V AC power source and
watching the LED display. The LED display will flash
once if the mode is set to Mode 1, twice if set to Mode
2, and three times if set to Mode 3. If the LEDs do not
flash when initially connected to power, refer to Trou-
bleshooting (DPI Chargers) in this section.

Modes are set by the position of the jumpers on the

main circuit board located inside the battery charger.
Changing the mode setting requires removal of the bat- 1. J3 JUMPER 2. J4 JUMPER
tery charger from the battery tray assembly on DPI Gen
II chargers. Figure 27. Circuit Board

30
2200 YRM 1007 Battery Charger (DPI®)

CHARGER MODE/BATTERY TYPE
SELECTION (DPI GEN III MODELS)
CAUTION
DO NOT use batteries types that are not approved
for the charger or improper mode settings. Damage
to the batteries or charger may occur if the mode
setting is not correct for the type of batteries be-
ing used. If the battery manufacturer of the battery
you are using is not listed, contact Resident Ser-
vice Engineering through the Contact Management
System.
once if the mode is set to Mode 1, twice if set to Mode 2,
three times if set to Mode 3, and four times if the charger
is set to Mode 4. If the LEDs do not flash when ini-
tially connected to power, refer to Troubleshooting (DPI
Chargers) in this section.
The battery charger has four mode settings. The mode
setting is determined by the type batteries being used
in the battery pack. See Figure 28 and Table 4.

NOTE: Gen II and Gen III version DPI chargers have

different procedures for changing charger modes for
charging different battery types. Use the proper proce-
dure for your lift truck. See Charger Mode/Battery Type
Selection (DPI Gen II Models) or Charger Mode/Battery
Type Selection (DPI Gen III Models).

NOTE: Mode settings can be checked by connecting

the battery charger to a 120V AC power source and
watching the LED display. The LED display will flash Figure 28. Jumper Ports

Table 4. Battery Chart for DPI Gen III Chargers Only

Mfg Part Voltage Capacity Application Batt Type DPI Gen III
20HR/ Mode
RC@25A
(AmpHrs)
Exide COM-1H-P 6 67 Heavy Duty Flooded 1
Technologies Comm
COM-4EC-P 6 125 Heavy Duty Flooded 1
Comm
COM-5D 6 117 Heavy Duty Flooded 1
Comm
COM-7D 6 138 Heavy Duty Flooded 1
Comm
DC6V27 6 - - Flooded 1
DC6Z-27 6 - - Flooded 1
E3600 Flooded 6 163 Deep Cycle Flooded 1
E4800 Flooded 8 121 Deep Cycle Flooded 1
F-2E 6 77 Heavy Duty Flooded 1
Comm
F-3EH 6 117 Heavy Duty Flooded 1
Comm
F-4EH 6 125 Heavy Duty Flooded 1
Comm

31
Battery Charger (DPI®) 2200 YRM 1007

Table 4. Battery Chart for DPI Gen III Chargers Only (Continued)

Mfg Part Voltage Capacity Application Batt Type DPI Gen III
20HR/ Mode
RC@25A
(AmpHrs)
Exide FS2-D 6 225 Starting/Deep Flooded 1
Technologies Cycle
(Cont)
FS6-D 6 338 Starting/Deep Flooded 1
Cycle
FS8-D 6 281 Starting/Deep Flooded 1
Cycle
GC-110 6 163 Deep Cycle Flooded 1
GC-135HP 6 200 Deep Cycle Flooded 1
GC2-H 6 219 Deep Cycle Flooded 1
GC2-Z 6 163 Deep Cycle Flooded 1
GC8V-110 8 121 Deep Cycle Flooded 1

Full River AGM 6-12 50-100 Deep Cycle AGM N/A

AGM 6-12 150-200 Deep Cycle AGM N/A
AGM 6-12 250-300 Deep Cycle AGM N/A

Interstate 19L 6 50 Starting Flooded 1

2300S 6 242 Deep Cycle Flooded 4
2300UTL 6 242 Deep Cycle Flooded 4
2400S 6 251 Deep Cycle Flooded 4
2400UT 6 251 Deep Cycle Flooded 4
2400UTL 6 251 Deep Cycle Flooded 4
2500S 6 258 Deep Cycle Flooded 4
3050HCS 6 340 Deep Cycle Flooded 4
3050S 6 310 Deep Cycle Flooded 4
GC2-HD-UTL 6 216 Deep Cycle Flooded 4
GC2-RD-UTL 6 208 Deep Cycle Flooded 4
GC2-XHD-S 6 232 Deep Cycle Flooded 4
GC2-XHD-UT 6 232 Deep Cycle Flooded 4
GC2-XHD-UTL 6 232 Deep Cycle Flooded 4

32
2200 YRM 1007 Battery Charger (DPI®)

Table 4. Battery Chart for DPI Gen III Chargers Only (Continued)

Mfg Part Voltage Capacity Application Batt Type DPI Gen III
20HR/ Mode
RC@25A
(AmpHrs)
Interstate GC2-XHD- 6 232 Deep Cycle Flooded 4
(Cont) UTLIVC
L-16S 6 380 Deep Cycle Flooded 4
L-16L 6 380 Deep Cycle Flooded 4
L-16HCL 6 420 Deep Cycle Flooded 4
L-16HCS 6 420 Deep Cycle Flooded 4

Yuasa / Rittar AGM 6-12 50-100 Deep Cycle AGM N/A

AGM 6-12 150-200 Deep Cycle AGM N/A
AGM 6-12 250-300 Deep Cycle AGM N/A

Trojan Battery T105 6 225 Deep Cycle LV Flooded 4

T605 6 210 Deep Cycle LV Flooded 4
T875 8 170 Deep Cycle LV Flooded 3
T1275 12 150 Deep Cycle LV Flooded 3

US - Battery US1800 6 208 Deep Cycle HV Flooded 2

US2000 6 216 Deep Cycle HV Flooded 2
US2200 6 232 Deep Cycle HV Flooded 2
AGM2000 6 210 Deep Cycle AGM 1

East Penn GEL 6-12 150-200 Deep Cycle GEL N/A

Enersys Pure Lead 6-12 150-200 Deep Cycle PRLA N/A

Special LiPolymer ? 24 200 - LiPmr N/A

Reserved

33
Battery Charger (DPI®)
Changing Mode Setting (DPI Gen III
Models)
NOTE: Mode settings can be checked by connecting
the battery charger to a 120V AC power source and
watching the LED display. The LED display will flash
once if the mode is set to Mode 1, twice if set to Mode 2,
three times if set to Mode 3, and four times if the charger
is set to Mode 4. If the LEDs do not flash when ini-
tially connected to power, refer to Troubleshooting (DPI
Chargers) in this section.
Modes are set by the position of the jumpers on the
jumper port. Accessing the jumper port requires re-
moval of a plate on the front of the battery charger on
DPI Gen III chargers.
1. Remove the screws used to retain the jumper port
cover to the charger and remove the cover.
2. Locate the jumpers on the port.
3. Arrange the jumpers in the proper configuration for
your battery type.
4. Replace the cover on the charger and install the
mounting screws.
TROUBLESHOOTING (DPI CHARGERS)
General
NOTE: The charger runs a pre-qualifying test (yellow
charging light flashing) at the beginning of the charge
cycle to determine the condition of the battery. This test
may last from 45 minutes to five hours. After the test
is complete, the charger should begin charging (yellow
charging light continuous) or may display an Error Mode
by flashing one or more of the red LEDs. If an Error
Mode is displayed, stop the general troubleshooting and
follow the chart and procedures in Error Modes in this
section.
1. Check AC power supply to charger:
a. Connect the charger plug to a 120 volt AC
power source using a 20 amp rated extension
cord.
b. Do all 5 LEDs simultaneously flash at least
once upon connection? (LEDs should flash be-
tween one to four times depending on battery
type/mode configuration.)
(1) YES: Proceed to Step 2.
34
2200 YRM 1007
(2) NO: Check AC power supply to charger:
Inspect all cabling for proper connections
(check for loose or corroded connectors)
or broken wires. Repair as necessary and
repeat Step 1. If LEDs still do not flash
at least once upon connecting power, re-
place the charger.
2. Check that the charger is configured for the proper
battery mode/type:
a. What is the proper charger mode for the type
batteries being used?
(1) Refer to Charger Mode/Battery Type Se-
lection (DPI Gen II Models) or Charger
Mode/Battery Type Selection (DPI Gen III
Models).
b. What mode is the charger currently set on?
(1) Connect the charger plug to a 120 volt
AC power source using a 20 amp rated
extension cord.
(2) How many times do all 5 LEDs flash upon
connection?
c. Is the charger currently set to the proper mode
for the battery type being used?
(1) YES: Proceed to Step 3.
(2) NO: Change the charger mode to the
proper setting for the battery type being
used. See Changing Mode Setting (DPI
Gen II Models) or Changing Mode Setting
(DPI Gen III Models). After changing the
mode setting repeat Step b to verify the
proper mode has been selected.
NOTE: The charger runs a pre-qualifying test (yellow
charging light flashing) at the beginning of the charge
cycle to determine the condition of the battery. This test
may last from 45 minutes to five hours. After the test
is complete, the charger should begin charging (yellow
charging light continuous) or may display an Error Mode
by flashing one or more of the red LEDs. If an Error
Mode is displayed, stop the general troubleshooting and
follow the chart and procedures in Error Modes in this
section.
3. Is the Power On LED illuminated continuously when
the charger is connected to a 120 volt AC power
source?
a. YES: Proceed to Step 4.
2200 YRM 1007 Battery Charger (DPI®)

b. NO: Replace the charger.
4. Is the Detection LED illuminated continuously when
the charger is connected to a 120 volt AC power
source?
a. YES: Battery is not connected to charger or
battery voltage is less than 2V. Check connec-
tions. If connections are clean and tight, trou-
bleshoot the battery pack. See Battery Pack
Troubleshooting.
battery terminals. Record the voltage and then
monitor it for approximately 3 minutes. Did the
voltage INCREASE while monitoring?
(1) YES:The charger is functioning correctly.
Proceed to Step 7.
(2) NO: Replace the charger.
7. Was the voltage reading in Step 6 higher than
16VDC?

b. NO: Proceed to Step 5. a. YES: Proceed to Battery Pack Troubleshooting.

5. Is the Charging LED either flashing or illuminated
continuously when the charger is connected to a
120 volt AC power source?
a. YES: Proceed to Step 6.
b. NO: If no other LEDs are flashing, replace
charger.
6. Check the output of the charger using a digital volt-
meter:
b. NO: It is recommended that all batteries in the
battery pack be replaced.
Error Modes
The three red LEDs are used to troubleshoot the
charger. Observe the operation of the Power On,
Abnormal Shutdown, and the Detection Error LEDs
to determine the cause for the error notification. See
Table 5.

a. Connect the voltmeter to the charger’s positive

(Red) and negative (Black) connections at the

Table 5. LED Error Codes

Abnormal Shutdown
Condition Power On LED Detection Error LED
LED
Battery Voltage High Off Off Flashing
Battery Polarity Reversed Off Flashing Off
Output Overload Off Flashing Flashing
Charge Level Unbalanced Flashing Off Off
Excessive Charging Time Flashing Off Flashing
Excessive Overload Flashing Flashing Off
Excessive Discharged Flashing Flashing Flashing

Battery Voltage High indicates the charger is sensing Charge Level Unbalanced indicates some batteries
it is connected to a battery pack with a voltage rating are at a much higher state of charge than other bat-
greater than 24 volts. Verify the battery pack is the cor- teries in the battery pack. Check the condition of each
rect voltage. battery.

Battery Polarity Reversed indicates an incorrect con-
nection of the battery charger to the battery pack. Verify
charger connections.
Output Overload indicates the charger sensed a high
current draw during the charging cycle. Verify there is
no load on the batteries during charging.
Excessive Charging Time error occurs when the pre-
set maximum charge time has been exceeded. Verify
there is no load on the battery pack during charging.
Verify all batteries are in good condition and will accept
a charge.

35
Battery Charger (Accusense® 20A) 2200 YRM 1007

Excessive Overload error occurs if a heavy load is
placed on the battery pack during charging and the
charger senses a decreasing battery voltage. Remove
external load.
Excessive Discharged error occurs when a battery
pack will not reach 21 volts within five hours of charging.
Battery Pack Troubleshooting
WARNING
Disconnect the charger from the AC power source
before proceeding.
Always wear protective gear including eye protec-
tion and suitable gloves when servicing battery
packs.
NOTE: For general information about battery mainte-
nance and procedures, refer to Industrial Battery 2240
YRM 1.
1. Measure the specific gravity (SG) level for each bat-
tery cell (after a charging cycle).
After a charging cycle, the SG measurement for each
cell should be 1.265 or greater.
From cell to cell within one battery: The SG measure-
ments should not vary more than 0.020. If variance is
greater than 0.020, it is recommended that the battery
be replaced with the same type of battery as the other
three batteries in that pack.
From battery to battery within one battery pack: The
SG measurements should not vary more than 0.050.
If one of the batteries has an SG reading 0.050 below
the other three batteries and the voltage is less than
6.3VDC after allowing the batteries to set four hours
without any load, it is recommended that the battery
with lowest SG be replaced with the same type of bat-
tery as the other 3 batteries in that pack.
WARNING
DO NOT overfill battery cells.
2. Verify water level in each cell of each battery:
• Before Charging: Only add minimal amount of
distilled water to cover top of plates if needed.
• After Charging: Add distilled water as needed to
fill to the bottom of cell opening.
3. Battery Replacement: Each battery manufacturer
has a specific "charge set-up" that will give your
truck the best battery life and drive time for your
truck. If the "charge set-up" is not correct, you can
damage the batteries and will not get the full per-
formance you expect. Make sure that the battery
charger is set to the proper charging mode for your
battery pack.
• DO NOT mix manufacturers or battery types in
the power pack
• It is not recommended to change out batteries
independently. All batteries should be changed
together when battery pack is updated.

Battery Charger (Accusense® 20A)

DESCRIPTION
Lift trucks equipped with Accusense® battery chargers
can be distinguished by the battery changer label. See
Figure 29. Accusense 20A chargers are self contained,
120 volt, AC powered chargers. Each charger comes
equipped with a short lead plug to allow connection to
the 120 volt AC outlet using a 20 amp rated extension
cord. The charger will operate from any wall outlet ca-
pable of supplying 108 to 126 volts AC protected by a
20 amp circuit breaker.

NOTE: Some markets use a special 230 volt AC

charger which require connection to a 230 volt AC
outlet. Users with 230 volt AC chargers should sub- Figure 29. Accusense 20A Chargers
stitute 230 volts AC in the place of 120 volts AC when
instructed to connect the charger to a power source.

36
2200 YRM 1007 Battery Charger (Accusense® 20A)

OPERATION flash when initially connected to power, refer to Trou-

LED Display
The charger has five colored LEDs located on the top of
the charger. The LEDs are used to indicate the status
of the charger during operation. The order of the LEDs
may vary with models, but are labeled to identify their
function. See Table 6.
Table 6. Charger LEDs
bleshooting (Accusense 20A Chargers) in this section.
Plugging the charger to the 120 volt AC outlet will begin
the start up cycle. Approximately three seconds after
connection to the AC power, all five LEDs on the top
of the charger will illuminate and flash two times. This
indicates the charger is set to Mode 2. Following the
start up flashing of the LEDs, the red, POWER ON,
LED will illuminate to indicate AC power is applied to
the charger and will begin the charging cycle.

Indicator Color Function The charger uses a 5-step charging process:

Power On Red Illuminates continuously 1. Pre Qualification Test: During this step, the yellow,
when AC power is present. CHARGING, LED will flash on and off every two
Abnormal Red Flashes if abnormal seconds. The charger is checking for faults prior to
Shutdown shutdown has occurred. the start of charging. Depending on the condition
and state of charge of the batteries, this step can
Detection Red Illuminates continuously take from 45 seconds up to 5 hours.
Error when battery is not
connected to charger or 2. Constant Current Charge (Bulk Peak Charge): Dur-
battery voltage is less ing this step, the charger will be regulating current
than 2V. to the batteries and will be operating at full rated
output. The yellow, CHARGING, LED will be con-
Charging Yellow Charge status indicator -
stantly illuminated during this step.
flashes during charging
cycle. 3. Regulating Voltage: During this step, the charger
Charged Green Illuminates continuously will be regulating voltage to the batteries. The
when battery is fully yellow, CHARGING, LED will remain illuminated.
charged. When the batteries have reached 80 to 90 percent
of full charge, the yellow, CHARGING, and the
green, CHARGED, LEDs will be illuminated.
Charging
4. Charge Complete: During this step, the green,
WARNING CHARGED, LED will remain illuminated. AC power
can now be disconnected from the charger.
The charger comes factory set to the battery in-
stalled at the factory and must be changed if us- 5. Recycle Stage: If the charger remains connected to
ing different batteries. Using an improper charger power for 28 days, a completely new charge cycle
mode for your battery pack may cause severe dam- will begin to keep batteries fully charged during long
age to batteries or charger. Refer to Charger Mode/ periods of not being used.
Battery Type Selection (Accusense 20A) in this sec-
tion to verify the proper mode setting for your bat- NOTE: If the charger noted an abnormal charge con-
tery pack. dition during the charging, the charger will attempt
to shutdown and will flash one or all three of the red
Mode settings can be checked by connecting the bat- LEDs on the top of the charger. If this condition occurs,
tery charger to a 120V AC power source and watching see Troubleshooting (Accusense 20A Chargers), Error
the LED display. The LED display will flash once if the Modes in this section.
mode is set to Mode 1, twice if set to Mode 2, three
times if set to Mode 3, and so forth. If the LEDs do not

37
Battery Charger (Accusense® 20A) 2200 YRM 1007

CHARGER MODE/BATTERY TYPE set the charger to the proper mode by installing the cor-
SELECTION (ACCUSENSE 20A) responding mode key for that mode into the mode port.
Refer to Figure 30 for key position and the Parts Man-
ual for mode key part numbers. A USB port located to
WARNING the left of the mode port is for factory use only.
DO NOT use batteries types that are not approved
for the charger or improper mode settings. Damage
to the batteries or charger may occur if the mode
setting is not correct for the type of batteries being
used. If the battery manufacturer of the battery you
are using is not listed, contact Service Engineering
through the Contact Management System.

NOTE: Mode settings can be checked by connecting

the battery charger to a 120V AC power source and
watching the LED display. The LED display will flash
once if the mode is set to Mode 1, twice if set to Mode
2, three times if set to Mode 3, and so forth. If the
LEDs do not flash when initially connected to power,
refer to Troubleshooting (Accusense 20A Chargers) in
this section.
1. USB PORT
NOTE: If the battery manufacturer of the battery you are
2. MODE KEY IN MODE PORT
using is not listed, contact Service Engineering through
the Contact Management System. Figure 30. Mode Port
The battery charger has 16 mode settings. The proper To determine which mode should be used to charge a
mode setting is determined by the type batteries being particular battery with an Accusense 20A charger, refer
used in the battery pack. See Table 7. After you de- to Table 7.
termine the proper mode for the replacement batteries,

Table 7. Battery Chart for Accusense 20A Chargers Only

Mfg Part Voltage Capacity Application Batt Type Accusense

20HR/ 20A Mode
RC@25A
(AmpHrs)
Exide Tech- COM-1H-P 6 67 Heavy Duty Flooded 9
nologies Comm
COM-4EC-P 6 125 Heavy Duty Flooded 9
Comm
COM-5D 6 117 Heavy Duty Flooded 9
Comm
COM-7D 6 138 Heavy Duty Flooded 1
Comm
DC6V27 6 - - Flooded 1
DC6Z-27 6 - - Flooded 1
E3600 Flooded 6 163 Deep Cycle Flooded 1
E4800 Flooded 8 121 Deep Cycle Flooded 1

38
2200 YRM 1007 Battery Charger (Accusense® 20A)

Table 7. Battery Chart for Accusense 20A Chargers Only (Continued)

Mfg Part Voltage Capacity Application Batt Type Accusense

20HR/ 20A Mode
RC@25A
(AmpHrs)
Exide Tech- F-2E 6 77 Heavy Duty Flooded 9
nologies Comm
(Cont)
F-3EH 6 117 Heavy Duty Flooded 9
Comm
F-4EH 6 125 Heavy Duty Flooded 9
Comm
FS2-D 6 225 Starting/Deep Flooded 1
Cycle
FS6-D 6 338 Starting/Deep Flooded 5
Cycle
FS8-D 6 281 Starting/Deep Flooded 5
Cycle
GC-110 6 163 Deep Cycle Flooded 1
GC-135HP 6 200 Deep Cycle Flooded 1
GC2-H 6 219 Deep Cycle Flooded 1
GC2-Z 6 163 Deep Cycle Flooded 1
GC8V-110 8 121 Deep Cycle Flooded 9

Full River AGM 6-12 50-100 Deep Cycle AGM 12

AGM 6-12 150-200 Deep Cycle AGM 4
AGM 6-12 250-300 Deep Cycle AGM 8

Interstate 19L 6 50 Starting Flooded 9

2300S 6 242 Deep Cycle Flooded 5
2300UTL 6 242 Deep Cycle Flooded 5
2400S 6 251 Deep Cycle Flooded 5
2400UT 6 251 Deep Cycle Flooded 5
2400UTL 6 251 Deep Cycle Flooded 5
2500S 6 258 Deep Cycle Flooded 5
3050HCS 6 340 Deep Cycle Flooded 5
3050S 6 310 Deep Cycle Flooded 5
GC2-HD-UTL 6 216 Deep Cycle Flooded 1

39
Battery Charger (Accusense® 20A) 2200 YRM 1007

Table 7. Battery Chart for Accusense 20A Chargers Only (Continued)

Mfg Part Voltage Capacity Application Batt Type Accusense

20HR/ 20A Mode
RC@25A
(AmpHrs)
Interstate GC2-RD-UTL 6 208 Deep Cycle Flooded 1
(Cont)
GC2-XHD-S 6 232 Deep Cycle Flooded 5
GC2-XHD-UT 6 232 Deep Cycle Flooded 5
GC2-XHD-UTL 6 232 Deep Cycle Flooded 5
GC2-XHD- 6 232 Deep Cycle Flooded 5
UTLIVC
L-16S 6 380 Deep Cycle Flooded 5
L-16L 6 380 Deep Cycle Flooded 5
L-16HCL 6 420 Deep Cycle Flooded 5
L-16HCS 6 420 Deep Cycle Flooded 5

Yuasa / AGM 6-12 50-100 Deep Cycle AGM 12

Rittar
AGM 6-12 150-200 Deep Cycle AGM 4
AGM 6-12 250-300 Deep Cycle AGM 8

Trojan T105 6 225 Deep Cycle LV Flooded 3

Battery
T605 6 210 Deep Cycle LV Flooded 3
T875 8 170 Deep Cycle LV Flooded 3
T1275 12 150 Deep Cycle LV Flooded 3

US - Battery US1800 6 208 Deep Cycle HV Flooded 2

US2000 6 216 Deep Cycle HV Flooded 2
US2200 6 232 Deep Cycle HV Flooded 6
AGM2000 6 210 Deep Cycle AGM 1

East Penn GEL 6-12 150-200 Deep Cycle GEL 13

Enersys Pure Lead 6-12 150-200 Deep Cycle PRLA 14

40
2200 YRM 1007 Battery Charger (Accusense® 20A)

Table 7. Battery Chart for Accusense 20A Chargers Only (Continued)

Mfg Part Voltage Capacity Application Batt Type Accusense

20HR/ 20A Mode
RC@25A
(AmpHrs)
Special LiPolymer ? 24 200 - LiPmr 15
Reserved

Changing Mode Setting (Accusense 20A)
NOTE: Mode settings can be checked by connecting
the battery charger to a 120V AC power source and
watching the LED display. The LED display will flash
once if the mode is set to Mode 1, twice if set to Mode
2, three times if set to Mode 3, and so forth. If the
LEDs do not flash when initially connected to power,
refer to Troubleshooting (Accusense 20A Chargers) in
this section.
a. Connect the charger plug to a 120 volt AC
power source using a 20 amp rated extension
cord.
b. Do all 5 LEDs simultaneously flash at least
once upon connection? (LEDs should flash be-
tween one to four times depending on battery
type/mode configuration.)
(1) YES: Proceed to Step 2.

Modes are set by the position of the jumpers on the
jumper port. Accessing the jumper port requires re-
moval of a plate on the front of the battery charger on
Accusense 20A chargers.
1. Remove the screws used to retain the jumper port
cover to the charger and remove the cover.
(2) NO: Check AC power supply to charger:
Inspect all cabling for proper connections
(check for loose or corroded connectors)
or broken wires. Repair as necessary and
repeat Step 1. If LEDs still do not flash
at least once upon connecting power, re-
place the charger.

2. Locate the jumpers on the port. 2. Check that the charger is configured for the proper
battery mode/type:
3. Arrange the jumpers in the proper configuration for
your battery type. a. What is the proper charger mode for the type
batteries being used?
4. Replace the cover on the charger and install the
mounting screws. (1) Refer to Charger Mode/Battery Type Se-
lection (Accusense 20A).
TROUBLESHOOTING (ACCUSENSE 20A
CHARGERS) b. What mode is the charger currently set on?

(1) Connect the charger plug to a 120 volt

General AC power source using a 20 amp rated
NOTE: The charger runs a pre-qualifying test (yellow extension cord.
charging light flashing) at the beginning of the charge (2) How many times do all 5 LEDs flash upon
cycle to determine the condition of the battery. This test connection?
may last from 45 minutes to five hours. After the test
is complete, the charger should begin charging (yellow c. Is the charger currently set to the proper mode
charging light continuous) or may display an Error Mode for the battery type being used?
by flashing one or more of the red LEDs. If an Error
Mode is displayed, stop the general troubleshooting and (1) YES: Proceed to Step 3.
follow the chart and procedures in Error Modes in this
section. (2) NO: Change the charger mode to the
proper setting for the battery type being
1. Check AC power supply to charger: used. See or Changing Mode Setting

41
Battery Charger (Accusense® 20A) 2200 YRM 1007

(Accusense 20A). After changing the a. YES: Proceed to Step 6.

mode setting repeat Step b to verify the
proper mode has been selected.
NOTE: The charger runs a pre-qualifying test (yellow
charging light flashing) at the beginning of the charge
cycle to determine the condition of the battery. This test
may last from 45 minutes to five hours. After the test
is complete, the charger should begin charging (yellow
charging light continuous) or may display an Error Mode
by flashing one or more of the red LEDs. If an Error
Mode is displayed, stop the general troubleshooting and
follow the chart and procedures in Error Modes in this
section.
3. Is the Power On LED illuminated continuously when
the charger is connected to a 120 volt AC power
source?
a. YES: Proceed to Step 4.
b. NO: Replace the charger.
4. Is the Detection LED illuminated continuously when
the charger is connected to a 120 volt AC power
source?
a. YES: Battery is not connected to charger or
battery voltage is less than 2V. Check connec-
tions. If connections are clean and tight, trou-
bleshoot the battery pack. See Battery Pack
Troubleshooting.
b. NO: Proceed to Step 5.
b. NO: If no other LEDs are flashing, replace
charger.
6. Check the output of the charger using a digital volt-
meter:
a. Connect the voltmeter to the charger’s positive
(Red) and negative (Black) connections at the
battery terminals. Record the voltage and then
monitor it for approximately 3 minutes. Did the
voltage INCREASE while monitoring?
(1) YES:The charger is functioning correctly.
Proceed to Step 7.
(2) NO: Replace the charger.
7. Was the voltage reading in Step 6 higher than
16VDC?
a. YES: Proceed to Battery Pack Troubleshooting.
b. NO: It is recommended that all batteries in the
battery pack be replaced.
Error Modes
The three red LEDs are used to troubleshoot the
charger. Observe the operation of the Power On,
Abnormal Shutdown, and the Detection Error LEDs
to determine the cause for the error notification. See
Table 8.

5. Is the Charging LED either flashing or illuminated

continuously when the charger is connected to a
120 volt AC power source?

Table 8. LED Error Codes

Abnormal Shutdown
Condition Power On LED Detection Error LED
LED
Battery Voltage High Off Off Flashing
Battery Polarity Reversed Off Flashing Off
Output Overload Off Flashing Flashing
Charge Level Unbalanced Flashing Off Off
Excessive Charging Time Flashing Off Flashing
Excessive Overload Flashing Flashing Off
Excessive Discharged Flashing Flashing Flashing

42
2200 YRM 1007
Battery Voltage High indicates the charger is sensing
it is connected to a battery pack with a voltage rating
greater than 24 volts. Verify the battery pack is the cor-
rect voltage.
Battery Polarity Reversed indicates an incorrect con-
nection of the battery charger to the battery pack. Verify
charger connections.
Output Overload indicates the charger sensed a high
current draw during the charging cycle. Verify there is
no load on the batteries during charging.
Charge Level Unbalanced indicates some batteries
are at a much higher state of charge than other bat-
teries in the battery pack. Check the condition of each
battery.
Excessive Charging Time error occurs when the pre-
set maximum charge time has been exceeded. Verify
there is no load on the battery pack during charging.
Verify all batteries are in good condition and will accept
a charge.
Excessive Overload error occurs if a heavy load is
placed on the battery pack during charging and the
charger senses a decreasing battery voltage. Remove
external load.
Excessive Discharged error occurs when a battery
pack will not reach 21 volts within five hours of charging.
Battery Pack Troubleshooting
WARNING
Disconnect the charger from the AC power source
before proceeding.
Always wear protective gear including eye protec-
tion and suitable gloves when servicing battery
packs.
NOTE: For general information about battery mainte-
nance and procedures, refer to Industrial Battery 2240
YRM 1.
Battery Charger (Accusense® 20A)
1. Measure the specific gravity (SG) level for each bat-
tery cell (after a charging cycle).
After a charging cycle, the SG measurement for each
cell should be 1.265 or greater.
From cell to cell within one battery: The SG measure-
ments should not vary more than 0.020. If variance is
greater than 0.020, it is recommended that the battery
be replaced with the same type of battery as the other
three batteries in that pack.
From battery to battery within one battery pack: The
SG measurements should not vary more than 0.050.
If one of the batteries has an SG reading 0.050 below
the other three batteries and the voltage is less than
6.3VDC after allowing the batteries to set four hours
without any load, it is recommended that the battery
with lowest SG be replaced with the same type of bat-
tery as the other 3 batteries in that pack.
WARNING
DO NOT overfill battery cells.
2. Verify water level in each cell of each battery:
• Before Charging: Only add minimal amount of
distilled water to cover top of plates if needed.
• After Charging: Add distilled water as needed to
fill to the bottom of cell opening.
3. Battery Replacement: Each battery manufacturer
has a specific "charge set-up" that will give your
truck the best battery life and drive time for your
truck. If the "charge set-up" is not correct, you can
damage the batteries and will not get the full per-
formance you expect. Make sure that the battery
charger is set to the proper charging mode for your
battery pack.
• DO NOT mix manufacturers or battery types in
the power pack
• It is not recommended to change out batteries
independently. All batteries should be changed
together when battery pack is updated.
43
Troubleshooting 2200 YRM 1007

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Lift truck will not move. Dead battery. Recharge or replace battery.

Failed (Open) fuse. Replace Failed (Open) fuse.

Brake is applied. Test the brake to ensure wiring to brake

is good.

Drive motor not operating. Repair or replace drive motor.

Sequencing fault. Return handle to rest and recycle.

Mast will not raise the forks. Dead battery. Recharge or replace battery.

Failed (Open) fuse. Replace Failed (Open) fuse.

Lift pump motor wiring loose or discon- Reconnect or tighten loose wiring con-
nected. nections.

Lift pump motor not operating. Repair or replace lift pump motor.

Operator controls do not work. Dead battery. Recharge or replace battery.

Failed (Open) fuse. Replace Failed (Open) fuse.

Control handle wiring loose or discon- Check wiring and tighten or connect as
nected. needed.

An individual switch is damaged. Check switch and replace if inopera-

tive.

44
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 1007 7/11 (1/11)(2/10)(8/09)(9/08)(4/08)(1/07)(9/05)(5/05)(8/03)(5/03)(1/02) Printed in U.S.A.