Maintenance

WALKIE HYDRAULIC
SYSTEMS
MPB040E [B827];
MPW045-E [B802];
MPW050-E [C802]

PART NO. 524154894 1900 YRM 1018

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Walkie Hydraulic Systems Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Operation............................................................................................................................................................. 1
Lifting a Load................................................................................................................................................... 1
Lowering a Load.............................................................................................................................................. 1
Hydraulic Lines................................................................................................................................................ 1
Hydraulic Oil.................................................................................................................................................... 2
Cleanliness...................................................................................................................................................... 2
Sound Level .................................................................................................................................................... 3
Hydraulic Unit ...................................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Special Precautions ........................................................................................................................................ 4
Install............................................................................................................................................................... 4
Hydraulic Pump ................................................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Install............................................................................................................................................................... 5
Hydraulic Pump Reservoir................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Install............................................................................................................................................................... 7
Hydraulic Cylinder ............................................................................................................................................... 8
Remove ........................................................................................................................................................... 8
Repacking ....................................................................................................................................................... 9
Install............................................................................................................................................................... 9
Relief Valve Adjustment....................................................................................................................................... 10
Relief Valve Pressure Check........................................................................................................................... 10
Relief Valve Adjust .......................................................................................................................................... 11
Troubleshooting ................................................................................................................................................... 12
Lift Assemblies ................................................................................................................................................ 12
Hydraulic Cylinders ......................................................................................................................................... 12
Hydraulic Pump............................................................................................................................................... 13

This section is for the following models:

MPB040E [B827];
MPW045-E [B802];
MPW050-E [C802]

©2007 Yale Materials Handling Corp. i

1900 YRM 1018
General
The hydraulic system provides the force required to lift
the loads on all motorized lift trucks.
The hydraulic system on the motorized lift truck consists
of the following individual components:
• Pump Motor Assembly
• Hydraulic Pump Assembly
• Solenoid Lowering Valve
• Pilot Relief Valve
• Lift Cylinder
• Reservoir
Operation
LIFTING A LOAD
To raise a load, the lift button must be depressed. De-
pressing this switch will activate the pump motor. This
torque is transferred to the pump from the motor through
the motor shaft and shaft coupling.
Hydraulic oil is pumped through the system as the
pump begins to operate. A vacuum created inside of
the pump draws oil out of the reservoir through the suc-
tion line. Air which is drawn into the reservoir through
the breather displaces the pumped oil, allowing it to
be sent through the system. See Figure 1, Figure 2,
and Figure 3. If the breather is clogged or blocked the
ability of the system to lift a load will be greatly reduced.
Figure 1. Hydraulic Schematic
Operation
The hydraulic pump and motor assemblies are mechan-
ically joined together as a compact unit, combining the
reservoir, pump, and motor together as a single assem-
bly. The pump is located inside of the hydraulic tank and
coupled to the motor by an adapter plate, coupler drive,
and four capscrews.
Hydraulic unit servicing is best performed by removing
the unit from the truck to a clean work area.
As oil is pushed out of the pump, it passes through a
one-way check valve to the lift cylinder. The check valve
prevents oil from flowing back to the pump when lifting
ceases, holding the lift cylinder in the raised position
until lowered.
The piston will begin to lift the load when fluid pressure
acting against it is high enough to overcome the weight
of the load at rest on the forks/platform.
When the piston is fully extended to the end of its stroke
or if the load is too heavy, pressure will continue to
build until the rated pressure needed to operate the
relief valve is reached. When this occurs, the relief
valve, which is normally closed, is forced back against
its spring, creating a path for the fluid to flow back to the
reservoir.
Once relief valve pressure is reached, hydraulic oil will
continue to be diverted from the lift cylinder to the reser-
voir until the lift button is released or electrical power is
interrupted.
LOWERING A LOAD
A load is lowered by depressing the lower button. When
the lower button is depressed, electric current is sent
to the normally closed solenoid lowering valve, which
causes it to change position and open a path for the
trapped hydraulic oil to flow from the cylinder back to
the reservoir.
HYDRAULIC LINES
1. All hydraulic lines must be thoroughly cleaned be-
fore installation.
1
Operation 1900 YRM 1018

2. When making repairs, use the least number of fit- CLEANLINESS

tings and connections to minimize flow resistance
and the possibility of leakage. Adhere to the following precautionary steps to ensure
that the hydraulic system remains clean.
HYDRAULIC OIL
1. Flush the entire system when a failure is encoun-
The hydraulic oil in the system performs the dual func- tered to make sure all paint, metal chips, welding
tion of the power transmission and lubrication. Using shot, and debris are removed.
the correct fluid is essential to proper system operation.
2. Filter each change of oil to prevent the introduction
Refer to the Lubrication Charts for the recommended
of contaminants into the system.
hydraulic oil to be used.
3. Provide continuous protection from airborne con-
Check the reservoir level when troubleshooting lifting
tamination by keeping the breather clean and ser-
problems. Low oil levels will make it appear that a prob-
viceable.
lem exists with the battery or hydraulic system.

1. HYDRAULIC POWER UNIT 6. FITTING 11. FITTING

2. CAPSCREW 7. HOSE 12. LIFT CYLINDER
3. WASHER 8. TUBE 13. SPACER PLATE
4. LOCKWASHER 9. FITTING
5. CAPSCREW 10. ADAPTER

Figure 2. Hydraulic System - 12 Volt

2
1900 YRM 1018 Operation

SOUND LEVEL • Aerated Hydraulic Oil - Results in system noise that is

similar to cavitation. Aerated oil is caused by the in-
Hydraulic system noise is caused by both improperly gestion of air through the pipe joints of the inlet lines
selected oil and loose or damaged system components. and high velocity discharge lines, as well as cylinder
• Hydraulic oil with high or moderately high viscosities - rod packing. Aeration can also be caused by oil dis-
At startup, temperatures can cause pump noises due charging above the fluid level.
to cavitation and also impedes the release of trapped
air. Air does not have sufficient time to purge itself
from the fluid while in the reservoir before recycling
through the system.

1. HYDRAULIC POWER UNIT 7. HOSE

2. CAPSCREW 8. TUBE
3. WASHER 9. FITTING
4. LOCKWASHER 10. ADAPTER
5. CAPSCREW 11. FITTING
6. FITTING 12. LIFT CYLINDER

Figure 3. Hydraulic System - 24 Volt

3
Hydraulic Unit
Hydraulic Unit
REMOVE
WARNING
Batteries are heavy and can cause personal injury.
Use care to avoid injury. DO NOT put hands, arms,
feet, and/or legs between the battery and a solid
object. Make sure the capacity of the crane and
spreader bar is greater than the weight of the bat-
tery. The weight of the battery is normally shown
on the battery case. The maximum battery weight
is shown on the lift truck nameplate. The spreader
bar must NOT be made of metal or it must have in-
sulated straps.
WARNING
Put blocks under each side of the truck under the
drive unit frame. Position blocks on both sides of
the load wheels. The blocks must prevent the lift
truck from falling and causing personal injury or
property damage.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. To prevent electrical shock and personal
injury, discharge the capacitor before inspecting
or repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected. Refer to the sec-
tion Steering Mechanism 1600 YRM 1004.
CAUTION
Make certain the hydraulic cylinder is fully col-
lapsed.
1. Remove the drive unit compartment cover.
2. Disconnect the battery. Use a spreader bar and
lifting device to remove the battery. DO NOT allow
the battery move from side to side. Make sure the
battery cables have clearance.
3. Raise the drive wheel off the floor and put blocks
under both sides of the drive unit frame.
4. Drain the hydraulic oil from the hydraulic unit into
an appropriate container.
5. Tag and disconnect all of the electrical wires from
the hydraulic unit.
4
1900 YRM 1018
6. Remove the hydraulic lines from the hydraulic unit.
7. Loosen and remove the three capscrews attaching
the hydraulic unit to the frame. Remove the hy-
draulic unit and place in a clean work area.
SPECIAL PRECAUTIONS
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before perform-
ing any troubleshooting and/or adjustments, and
connecting or disconnecting a handset or PC.
CAUTION
To avoid controller damage always disconnect the
battery. Discharge the capacitor, and never put
power to the controller with any power wire dis-
connected. Never short any controller terminal or
motor terminal to battery. Make sure to use proper
procedure when servicing the controller. Refer to
the section Steering Mechanism 1600 YRM 1004.
1. Block the lift truck so that the drive wheels are off
the floor. See the section Periodic Maintenance
8000 YRM 1009, How to Put a Lift Truck on Blocks.
2. Turn the key switch to the OFF position and unplug
the battery.
3. After key-off, the capacitors in the unit remain
charged for several minutes. To discharge the
capacitors, connect a 200-ohm, 2-3W resistor be-
tween +BATT and BATT on the controller. Hold
for 5 seconds.
4. Tag and disconnect all electrical wires to the hy-
draulic unit.
5. Disassemble and plug the hydraulic lines to the hy-
draulic unit.
INSTALL
1. Align the hydraulic unit with the mounting holes in
the frame and install the three capscrews. Tighten
the hydraulic unit mounting capscrews to 49 N•m
(36 lbf ft).
2. Install the hydraulic lines to the hydraulic unit.
3. Connect all the electrical wires to the hydraulic unit.
1900 YRM 1018
4. Remove the blocks and lower the lift truck to the
floor.
5. Remove the breather and add the recommended
hydraulic oil until the oil level reaches the full level
mark. Replace the breather. If too much hydraulic
oil is added, the oil will leak from the breather during
operation.
Hydraulic Pump
REMOVE
1. Remove the hydraulic unit from the lift truck. Refer
to the Hydraulic Unit in this section.
2. Clean the reservoir and pump area to prevent con-
taminants from entering the hydraulic system.
3. Remove the capscrews retaining the reservoir to
the hydraulic unit. Tap around the perimeter to
break the seal and separate the reservoir from the
motor assembly.
4. Remove the spring retaining screw from the suction
tube.
5. Remove the suction tube and strainer by pulling
down and out.
6. Remove the four capscrews retaining the pump to
the drive motor.
7. Disassemble the pump assembly and coupling from
the adapter.
INSTALL
NOTE: The hydraulic unit includes four separate kits as
shown in Figure 4.
1. Clean and lubricate all components using clean hy-
draulic oil.
2. Replace all O-rings and seals within the unit.
3. Grease the coupler and coupler cavity with the mo-
tor resting with the adapter plate up. Align the pump
mounting holes with the holes in the motor. Ensure
that the tank is seated into the motor.
4. Install the four capscrews and tighten to 13.6 to
16.3 N•m (10 to 12 lbf ft).
Hydraulic Pump
6. Install the battery and connect the battery. Operate
the lift truck until the hydraulic oil reaches operating
temperature. Add additional oil if necessary. Check
for hydraulic oil leaks.
7. Install the drive unit compartment cover. Test the
operation of the lift truck prior to returning the truck
to service.
5. Install the O-rings into the pump cavities. Apply
grease to the return tubes. Insert tubes into pump
cavities and O-rings. Grease the suction tube and
insert into locking device with hole. Install and
tighten the spring retaining screw to secure the
suction tube.
6. Remove the retainer and replace the O-ring. Lightly
grease the O-ring before installation.
7. Align the reservoir so the hose connections will be
in the same position as they were prior to removal.
Install the four capscrews to retain the reservoir.
8. Install the hydraulic unit. Refer to Hydraulic Unit,
Install in this manual.
9. Remove the breather and fill the reservoir with the
recommended oil. See the section Capacities and
Specifications 8000 YRM 1010. Add oil until the
oil is up to the full mark. If too much oil is added,
the oil will leak from the breather during operation.
If too much oil has been added, drain the excess or
use a suction device to remove some of the oil.
10. Run the pump for 5 seconds and energize the low-
ering valve at the same time so that oil gets through
the pump body and valve at 0.0 psi. Operate the
forks up and down three or four times to remove air
from the system. Operate the lift truck until the hy-
draulic oil reaches operating temperature. Remove
the breather and check the hydraulic oil level. Add
additional oil if necessary. Check for hydraulic oil
leaks.
11. Install the drive unit compartment cover. Test the
operation of the motorized hand truck before return-
ing the truck to service.
5
Hydraulic Pump 1900 YRM 1018

Figure 4. Hydraulic Unit

6
1900 YRM 1018
Legend for Figure 4
1. MOTOR
2. ELECTRO-POPPET VALVE
Hydraulic Pump Reservoir
REMOVE
The reservoir of the hydraulic pump unit can be re-
moved without removing the complete hydraulic unit.
The motor will also come loose, with one set of screws
holding the reservoir to the subunit to the motor.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. To prevent electrical shock and personal
injury, discharge the capacitor before inspecting
or repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected. Refer to the sec-
tion Steering Mechanism 1600 YRM 1004.
CAUTION
Make certain the hydraulic cylinder is fully col-
lapsed.
NOTE: The reservoir must be lowered below the suc-
tion tube before attempting to move the reservoir away
from the lift truck. Remember the reservoir may contain
hydraulic oil. Dispose of all used oil in accordance with
local regulations.
1. Move the key to the OFF position. Disconnect the
battery.
2. Remove the drive unit compartment cover.
3. Discharge the capacitor in the transistor controller.
4. Disassemble and plug the hydraulic lines to the hy-
draulic unit.
5. Remove the four capscrews retaining the reservoir
to the hydraulic unit. Carefully remove the reservoir.
6. Clean the reservoir and the suction screen. Inspect
the screen for damage and replace if necessary.
Hydraulic Pump Reservoir
3. HYDRAULIC SUB UNIT
4. FILLER TANK
NOTE: On 24-volt trucks, the capscrews that hold the
reservoir to the subunit also hold the motor to the sub-
unit. When the capscrews are removed, the motor will
be resting on the subunit. When reinserting the cap-
screws, ensure that the motor is located correctly and
the coupler is seated properly.
INSTALL
1. Lubricate a new O-ring using clean hydraulic oil and
install into the pump body.
2. Align the reservoir in the proper position and install
the four capscrews to retain the reservoir to the hy-
draulic unit.
3. Install the hydraulic lines to the hydraulic unit.
4. Remove the blocks and lower the lift truck to the
floor.
5. Remove the breather and add the recommended
hydraulic oil until it reaches the full mark. Replace
the breather. If too much hydraulic oil is added, the
oil will leak from the breather during operation. If
too much oil has been added, drain or use a suction
device to remove excess oil.
6. Connect the battery. Run the pump for 5 seconds
and energize the lowering valve at the same time
so that oil gets through the pump body and valve
at 0.0 psi. Operate the forks up and down three or
four times to remove air from the system. Operate
the lift truck until the hydraulic oil reaches operating
temperature. Remove the breather and check the
hydraulic oil level. Add additional oil if necessary.
Check for hydraulic oil leaks.
7. Install the drive unit compartment cover. Test the
operation of the lift truck prior to returning the truck
to service.
7
Hydraulic Cylinder 1900 YRM 1018

Hydraulic Cylinder
REMOVE 1. Raise the motorized lift truck forks/platform to one
half its maximum height.
WARNING 2. Place blocks under the forks. Block the drive wheel.
Put blocks under each fork. Position blocks on both See the section Periodic Maintenance 8000 YRM
sides of the drive wheel. The blocks must prevent 1009, How to Put a Lift Truck on Blocks.
the lift truck from falling and causing personal in-
jury or damage. 3. Remove the drive unit compartment cover.

4. Separate the frames. Refer to the section Frame

WARNING
Be careful when removing or installing snap rings.
The snap rings can come loose during removal or
installation with enough force to cause a personal
injury. Always use the correct snap ring pliers, and
wear eye and face protection during removal and
installation.
100 YRM 1015.
5. Manually collapse the piston into the cylinder while
depressing the lower switch.
6. Relieve pressure from the hydraulic cylinder. See
Figure 5.

1. ROD 6. GLAND 11. NUT

2. SEAL 7. SEAL 12. BEARING
3. RING 8. BARREL 13. RING
4. SEAL 9. PISTON
5. SEAL 10. SEAL

Figure 5. Hydraulic Cylinder

8
1900 YRM 1018
7. Drive the roll pin retaining the top clevis pin out of
the frame and clevis pin. Remove the top clevis pin.
8. Remove the roll pin retaining the bottom clevis pin.
Remove the bottom clevis pin and the hydraulic
cylinder.
REPACKING
CAUTION
Lubricate the seals, packing, and O-rings with clean
hydraulic oil before assembling. Make certain to
install spacers, if any were removed.
CAUTION
Make certain that none of the sealant gets into the
cylinder. Allowing sealant to get into the hydraulic
system may cause damage to the components
within the hydraulic system.
1. Move the cylinder toward the rear of the truck.
Loosen the gland nut. Extract the piston, gland
nut, and rod from the cylinder.
2. Disassemble the nut and piston from the cylinder
rod. Remove the spacers, if used, and slide the rod
out of the gland nut.
3. Replace all seals, packing, and O-rings.
4. Install the seals, packing, and O-rings as necessary
into the gland and piston after coating them with
clean hydraulic oil.
5. Carefully install the rod through the gland nut. In-
stall the piston, spacer (if necessary), and the lock
nut. Tighten the lock nut (lubricated) to 150 N•m
(110 lbf ft).
6. Carefully install the rod assembly into the cylinder.
Apply Loctite® 242 or equivalent to the threads of
the gland nut. Tighten the gland nut to 27 N•m
(20 lbf ft).
Hydraulic Cylinder
INSTALL
WARNING
Be careful when removing or installing snap rings.
The snap rings can come loose during removal or
installation with enough force to cause a personal
injury. Always use the correct snap ring pliers and
wear eye and face protection during removal and
installation.
1. Align the bottom of the cylinder with the frame and
install the bottom clevis pin.
2. Install the roll pin to retain the clevis pin.
3. Align the top of the cylinder rod with the frame and
install the top clevis pin. Install the roll pin to retain
the clevis pin.
4. Assemble the frames. Refer to the section Frame
100 YRM 1015.
5. Remove the blocks and lower the lift truck to the
floor.
6. Remove the breather and add the recommended
hydraulic oil until the oil is up to the full mark.
Replace the breather. If too much hydraulic oil is
added, the oil will leak from the breather during
operation. If too much oil has been added, drain
the excess or use a suction device to remove some
of the oil.
7. Run the pump for 5 seconds and energize the low-
ering valve at the same time so that oil gets through
the pump body and valve at 0.0 psi. Operate the
forks up and down three or four times to remove air
from the system. Operate the lift truck until the hy-
draulic oil reaches operating temperature. Check
the hydraulic oil level. If necessary add additional
oil. Check for hydraulic oil leaks.
8. Install the drive unit compartment cover. Test the
operation of the lift truck prior to returning the truck
to service.
9
Relief Valve Adjustment 1900 YRM 1018

Relief Valve Adjustment

RELIEF VALVE PRESSURE CHECK 5. Remove the drive unit compartment covers.

6. Discharge the capacitor. See Special Precautions.

WARNING
DO NOT make repairs or adjustments unless you 7. Clean any buildup of dirt from around the lift pump
have been properly trained and authorized to do so. and motor assembly.
Improper repairs and adjustments can create dan-
gerous operating conditions. DO NOT operate a lift
WARNING
truck that needs repair. Report the problem to your
supervisor immediately. If repairs are necessary, Hydraulic oil hoses and lines may be under pres-
turn the key switch to the OFF position, attach a DO sure. Slowly loosen the hydraulic connections to
NOT OPERATE tag to the control handle, and dis- ensure pressure has been relieved.
connect the battery. 8. Disconnect the hydraulic hose at the pump.
Always wear the proper protective equipment in- 9. Install a tee fitting and a pressure gauge of at least
cluding eye protection and petroleum resistant 24.8 MPa (3600 psi).
gloves when servicing hydraulic components.
Thoroughly wash oil from exposed areas of skin as 10. Verify the oil is at an operating temperature of 43 to
soon as possible. 49 C (110 to 120 F).
Completely lower all lift components and relieve 11. Raise the forks completely and continue to hold the
pressure before disassembling any part of the lift lift button. Read the pressure gauge while the pump
pump or disconnecting any hydraulic hoses. is in relief. See Relief Valve Settings for correct
pressures.
The hydraulic oil is hot at normal operating temper-
atures. Be careful when draining the oil. Table 1. Relief Valve Settings
Never put your hands on pressurized hydraulic
Model Relief Setting*
components. Pressurized hydraulic oil escaping
through pin-hole leaks can be injected into the 4000 lb 16.9 MPa (2450 psi)
skin. 4500 lb 19.3 MPa (2800 psi)
12 Volt
CAUTION
4500 lb 18.6 MPa (2700 psi)
DO NOT OVERFILL. Oil will leak from the breather/ 24 Volt
filler cap if too full.
5000 lb 22.0 MPa (3200 psi)
NOTE: Check the hydraulic oil level in the reservoir
when oil is at room temperature. Remove breather cap * +0.6 0.0 MPa (+87 0 psi)@ 21 C (70 F)
and add recommended hydraulic oil to proper level, as Oil Temperature Full Flow
required. See Hydraulic Pump Reservoir.
NOTE: The pump will stop after a short period of time.
1. Operate lift truck until hydraulic oil reaches operat- Release the lower button then press and hold again to
ing temperature (43 to 49 C (110 to 120 F)). continue.

2. Lower the forks completely to relieve pressure from 12. If the relief pressure is incorrect, refer to Relief
hydraulic circuit. Valve Adjust.

3. Turn key to the OFF position and disconnect the 13. After the proper relief pressure is obtained, lower
battery. the forks completely to relieve pressure from hy-
draulic circuit.
4. Block load wheels to prevent lift truck from moving.

10
1900 YRM 1018 Relief Valve Adjustment

14. Turn key switch to OFF position. Disconnect the
battery.
15. Discharge the capacitor. See Special Precautions.
16. Remove the pressure gauge and tee.
6. Install the hydraulic reservoir as removed.
Connect the battery and turn key to ON position.
7. Recheck the relief pressure. See Relief Valve Pres-
sure Check.

17. Reconnect the hydraulic hose to pump. 8. Repeat as necessary, until the correct relief pres-
sure is measured.
18. Connect the battery and turn the key switch to ON
position. 9. Perform Step 13 through Step 23 in Relief Valve
Pressure Check to complete procedure.
19. Operate the hydraulic functions several times to
purge the air from the hydraulic circuit.

20. Remove blocks from wheels.

21. Test the lift truck by lifting and lowering a load sev-
eral times. Visually check for leaks.

CAUTION
DO NOT OVERFILL RESERVOIR. Oil will leak from
the breather/filler cap during operation if reservoir
is over filled.

22. Check the hydraulic oil level in the reservoir.

Remove breather cap and add recommended
hydraulic oil to proper level, as required. See
Hydraulic Pump Reservoir.

23. Install the drive unit compartment covers.

RELIEF VALVE ADJUST

Refer to Relief Valve Pressure Check to determine if
adjustment is necessary.

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

battery is disconnected.

2. Remove the hydraulic reservoir. See Hydraulic

Pump Reservoir. 1. LIFT MOTOR
2. PUMP HOUSING
3. Loosen the locking nut on the relief valve. See Fig- 3. TUBE
4. CLAMP
ure 6. 5. INLET ADAPTER
6. SCREEN
4. Adjust the relief valve screw in small increments. 7. SNAP RING
Turn the adjustment screw clockwise to increase 8. ADJUSTMENT SCREW
pressure. Turn the adjustment screw counterclock- 9. LOCK NUT
wise to decrease pressure. 10. RELIEF VALVE ASSEMBLY

5. Tighten the lock nut and torque to 15 N•m (11 lbf ft). Figure 6. Relief Valve Adjust

11
Troubleshooting 1900 YRM 1018

Troubleshooting
LIFT ASSEMBLIES

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Forks fail to elevate. Faulty hydraulic equipment. See Pumps and Hydraulic Cylinders
below.

Deformed lifting components. Disassemble and replace damaged

parts.

Slow lifting speed and insuffi- Faulty hydraulic equipment. See Pumps and Hydraulic Cylinders
cient handling capacity. below.

Deformed lifting components. Disassemble and replace damaged

parts.

Forks fail to lower. Deformed forks. Disassemble, repair, or replace.

Deformed lifting components. Disassemble, repair, or replace.

Bent hydraulic cylinder piston rod. See Hydraulic Cylinders below.

HYDRAULIC CYLINDERS

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Oil leaks from cylinder gland Foreign matter on packing. Replace packing.
around piston rod (An oil ring
appears on the piston rod).

Score on piston rod. Remove any foreign matter. Smooth

rod surface with an oil stone. If oil still
leaks, disassemble and repack cylin-
der.

Scores on wiper ring lip. Replace wiper ring.

Unusual distortion of wiper ring. Replace wiper ring.

Chrome plating is stripped. Replace piston rod or renew chrome

plating.

Oil leaks from welded portion. Cylinder tube damaged. Replace cylinder tube.

12
1900 YRM 1018 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Rod spontaneously retracts. Scores on inner surface of tube. Smooth surface with an oil stone.

Score on tube. Replace cylinder tube.

Score on piston ring. Replace piston ring.

Foreign matter on packing ring. Replace packing.

Considerable score on lip of packing Replace packing.

ring.

Unusual distortion of packing ring. Replace packing.

Wear limit (clearance between Excessive clearance between cylinder Replace wear ring (included in packing
cylinder tube and wear ring). tube and wear ring. kit).

HYDRAULIC PUMP

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Pump not delivering oil. Pump does not draw oil. Check pump, piping, and valves for
leaks.

Low oil level in reservoir. Check fluid level.

Clogged screen at pump inlet. Change oil and clean screen.

Pump pressure fails to rise. Improperly adjusted relief valve. Increase to specified pressure using a
pressure gauge.

Relief valve clogged. Disassemble and clean with fresh oil.

Interfering relief valve or broken relief Disassemble valve and replace spring.
spring.

Air suction. Check piping on suction side for leaks.

Add oil to reservoir.
Check pump seals.

13
Troubleshooting 1900 YRM 1018

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Pump produces noise. Cavitation caused by collapsed suc- Drain and clean system.
tion hose or clogged screen.

Faulty oil suction. Add oil to specified level.

Air suction through loose connections Tighten all hose connections on suc-
on suction side. tion side.

Air suction from pump oil seal. Disassemble pump and replace oil
seals.

Breather clogged. Clean or replace breather.

Cavitation caused by high oil viscosity. Change to recommended oil and op-
erate pump in recommended temper-
ature ranges.

Abnormal temperature rise of Overwork. Adjust workload to fall within pump’s

hydraulic oil. operating range.

Improper viscosity or contaminated oil. Drain and replace oil with recom-
mended oil.

Pump case or drive gear bro- Incorrect pressure setting. Check for excessive resistance in hy-
ken. draulic circuit. Make certain relief pres-
sure is properly adjusted and valve is
working properly.

14
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

1900 YRM 1018 4/07 (8/05)(9/03)(1/02) Printed in U.S.A.

 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
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Description of Operation ........................................................................................................................................... 3
Special Precautions .................................................................................................................................................. 5
Moving a Disabled Lift Truck .................................................................................................................................... 7
Electrical System Checks ......................................................................................................................................... 8
Safety Precautions ............................................................................................................................................... 8
Repairs ......................................................................................................................................................................9
Controller, Replace ...............................................................................................................................................9
Remove ............................................................................................................................................................9
Install ..............................................................................................................................................................12
Contactor Coil, Check .........................................................................................................................................12
Contactor, Replace .............................................................................................................................................13
Remove ..........................................................................................................................................................13
Install ..............................................................................................................................................................13
Key Switch Removal and Installation ......................................................................................................................13
Remove .............................................................................................................................................................. 13
Install .................................................................................................................................................................. 13
Battery Indicator/Hourmeter Display .......................................................................................................................14
Remove .............................................................................................................................................................. 14
Install .................................................................................................................................................................. 14
Fuses ...................................................................................................................................................................... 15
MPB040-E........................................................................................................................................................... 15
MPW045/050-E................................................................................................................................................... 15
MSW020/025-E................................................................................................................................................... 15
MSW025/030-F................................................................................................................................................... 15
Control Handle Arm Proximity Switch......................................................................................................................16
Repair ................................................................................................................................................................. 16
Check and Adjust ........................................................................................................................................... 16
Remove ..........................................................................................................................................................16
Install ..............................................................................................................................................................17
Control Handle ........................................................................................................................................................18
Disassemble ....................................................................................................................................................... 18
Control Handle Card (Old Style) .........................................................................................................................18
Control Handle Card (New Style) ....................................................................................................................... 19
Configure ........................................................................................................................................................20
Calibrate .........................................................................................................................................................21
Assemble ............................................................................................................................................................23
Switches (ON/OFF and Proportional) .................................................................................................................25
Remove ..........................................................................................................................................................25
Install ..............................................................................................................................................................25
Traction Motor .........................................................................................................................................................26
Disassemble ....................................................................................................................................................... 26
Assemble ............................................................................................................................................................28
Lift Pump Motor ...................................................................................................................................................... 28
Repair () MSW020/025-E and MSW025/030-F................................................................................................... 28
Lift Link Proximity Sensor (MPW050-E).................................................................................................................. 30
Check ................................................................................................................................................................. 30
Repair ................................................................................................................................................................. 30
Remove ..........................................................................................................................................................30
Test ................................................................................................................................................................ 30

©2016 Yale Materials Handling Corp. i

Table of Contents

TABLE OF CONTENTS (Continued)

Install ..............................................................................................................................................................31
Adjust ............................................................................................................................................................. 31
Battery Charger (Moran®) ....................................................................................................................................... 32
Description ..........................................................................................................................................................32
Operation ............................................................................................................................................................32
Charging .........................................................................................................................................................32
Equalize ......................................................................................................................................................... 32
Signals ........................................................................................................................................................... 32
Protections ..................................................................................................................................................... 32
Troubleshooting ..................................................................................................................................................32
Battery Charger (Accusense by DPI®) ....................................................................................................................36
Description ..........................................................................................................................................................36
Operation ............................................................................................................................................................36
LED Display ................................................................................................................................................... 36
Charging .........................................................................................................................................................37
Charger Mode/Battery Type Selection (DPI Gen II Models) ...............................................................................38
Changing Mode Setting (DPI Gen II Models) .................................................................................................38
Charger Mode/Battery Type Selection (DPI Gen III Models) ..............................................................................39
Changing Mode Setting (DPI Accusense Gen III Models with Jumper Ports) ............................................... 40
Accusense Gen III with Dip Switches .............................................................................................................40
Changing Mode Setting ..................................................................................................................................42
Troubleshooting (DPI Chargers) .........................................................................................................................42
General .......................................................................................................................................................... 42
Error Modes ................................................................................................................................................... 43
Battery Pack Troubleshooting ........................................................................................................................ 44
Battery Charger (Accusense® 20A) ........................................................................................................................ 45
Description ..........................................................................................................................................................45
Operation ............................................................................................................................................................45
LED Display ................................................................................................................................................... 45
Charging .........................................................................................................................................................46
Charger Mode/Battery Type Selection (Accusense 20A) ................................................................................... 47
Changing Mode Setting (Accusense 20A) ..................................................................................................... 50
Troubleshooting (Accusense 20A Chargers) ......................................................................................................50
General .......................................................................................................................................................... 50
Error Modes ................................................................................................................................................... 51
Battery Pack Troubleshooting ........................................................................................................................ 53
Troubleshooting ...................................................................................................................................................... 54

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
This section includes removal, disassembly, checks,
adjustments, assembly, and installation procedures
for the electrical system components on the
MSW020/025-E [A895], MSW025/030-F [B895],
MPB040-E [B827], MPW045-E [B802], and MPW050-
E [C802] truck models. This section does NOT
include the electrical components covered in other
sections such as motors and industrial batteries. See
Figure 1.
See the section ZAPI™ Controllers 2200YRM1064
for models MSW020/025-E [A895] and MSW025/030-
F [B895]; ZAPI™ Controllers 2200YRM1006 for
models MPB040-E [B827]; ZAPI™ Controllers
2200YRM1067 for models MPW045-E [B802] and
MPW050-E [C802] for additional information on the
ZAPI™ display and for information on troubleshooting
General
fault codes, adjusting parameters, and testing the
ZAPI™ motor controller. See the section DC Motor
Maintenance 0620YRM0294 for general information
on DC motors. See the section Periodic
Maintenance 8000YRM1048 for models
MSW020/025-E [A895]; Periodic Maintenance
8000YRM1009 for models MPB040-E [B827],
MPW045-E [B802], and MPW050-E [C802]; Periodic
Maintenance 8000YRM1379 for models
MSW025/030-F [B895]. See the section Diagrams
8000YRM1050 for models MSW020/025-E [A895];
Diagrams 8000YRM1011 for models MPB040-E
[B827] and MPW045-E [B802]; Diagrams
8000YRM1228 for models MPW050-E [C802];
Diagrams 8000YRM1381 for models MSW025/030-F
[B895].
1
General 2200 YRM 1007

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

2
2200 YRM 1007
Description of Operation
See Figure 2 for the logic diagram.
This section includes information on the following
components:
• Control handle switches (ON/OFF and propor-
tional)
• 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.
A Hall effect throttle control is used to provide a direc-
tional/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
Description of Operation
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 serial communication to send these signals
to the ZAPI™ motor controller.
The ZAPI™ motor controller contains the system
logic. The motor controller receives the inputs, pro-
cesses 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 Directional/Speed Control. The controller also
contains logic to engage the brake regardless of han-
dle position if the truck is stationary.
MSW020/025-E and MSW025/030-F : The motor
controller energizes the series wound lift pump motor
when either lift function switch is depressed. The ap-
plied voltage 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 func-
tion switch is depressed.
MSW020/025-E and MSW025/030-F : All trucks have
a solenoid operated lowering valve at the pump. The
motor controller activates the solenoid coil to open the
lowering valve. The motor controller varies the voltage
to the lowering solenoid to provide proportional lower-
ing.
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.
3
Description of Operation
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
and MSW025/030-F trucks after operating continu-
ously for approximately 45 seconds. Lift is disabled on
the MPB040/045/050-E trucks after operating continu-
ously 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
Figure 2. Logic Diagram
4
2200 YRM 1007
175-amp, X-type connector. This connector provides
two auxiliary contacts for the truck inhibit circuit, al-
lowing 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 op-
tional 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.
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 dan-
gerous operating conditions. DO NOT operate a
lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag to the
control handle.
WARNING
Disconnect the battery and separate the connec-
tor before opening the drive unit compartment
cover or inspecting or repairing the electrical sys-
tem. If a tool causes a short circuit, the high cur-
rent flow from the battery can cause personal in-
jury or property damage.
WARNING
Some checks and adjustments are done with the
battery connected. DO NOT connect the battery
until the procedure tells you to do so. Never have
any metal on your fingers, arms, or neck. Metal
items can accidentally make an electrical connec-
tion and cause injury.
WARNING
Before doing any tests or adjustments, raise the
vehicle off the ground and block the lift truck to
prevent unexpected movement. See the section
Periodic Maintenance 8000YRM1048, Periodic
Maintenance 8000YRM1009, or Periodic Mainte-
nance 8000YRM1379 for your lift truck. Refer to
How to Put a Lift Truck on Blocks.
Special Precautions
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent an electrical shock and personal
injury, discharge the capacitor before inspecting
or repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain that
the battery has been disconnected.
CAUTION
To avoid controller damage, always disconnect
the battery, discharge the capacitor, and never
put power to the controller while any power wires
are disconnected. Never short any controller ter-
minal or motor terminal to the battery. Make sure
to use proper procedure when servicing the con-
troller.
1. Block load wheels to prevent lift truck from mov-
ing. See the section Periodic Maintenance
8000YRM1048, Periodic Maintenance
8000YRM1009, or Periodic Maintenance
8000YRM1379 for your lift truck.
2. Turn the key switch to the OFF position and dis-
connect the battery.
3. Discharge the capacitors in the controllers by con-
necting a 200-ohm, 2-watt resistor across the
controller's B+ and B- terminals. DO NOT short
across the motor controller terminals with a
screwdriver or jumper wire. See Figure 3 or Fig-
ure 4.
4. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery.
5
Special Precautions 2200 YRM 1007

1. NEGATIVE CONNECTION 1. POSITIVE CONNECTION

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

Figure 3. Discharging the Capacitor (MSW020/025- Figure 4. Discharging the Capacitor (MPB040-E)
E, MPW045/050-E, and MSW025/030-F)

6
2200 YRM 1007 Moving a Disabled Lift Truck

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 elec-
tric brake to release it. The truck will roll freely, but the
drive motor will not activate while the jumper is instal-
led.
WARNING
Prior to releasing the electric brake, make sure
the lift truck is blocked correctly to prevent move-
ment, causing personal injury or damage to
equipment.
CAUTION
Always unplug the Brake Override Circuit and
connect the Brake Harness prior to operating the
lift truck.
9. Make sure the brake override circuit is disconnec-
ted from the brake harness. The brake will remain
released until the battery or the brake override cir-
cuit is disconnected. Restore the harness connec-
tor to the normal operation connector correctly be-
fore attempting to operate the lift truck.

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
connection 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 bat-
tery is disconnected or the brake override circuit is
disconnected.

7. Connect the battery connectors.

8. Roll the lift truck to a safe, level area prior to per- 1. BRAKE HARNESS CONNECTOR
2. BRAKE OVERRIDE CIRCUIT CONNECTOR
forming any repairs on it. 3. NORMAL OPERATION CONNECTOR

Figure 5. Brake Override Connector

7
Electrical System Checks
Electrical System Checks
SAFETY PRECAUTIONS
NOTE: On some models, the dash indicator will dis-
play the code: EP 107 (or a higher number) for 1 to 2
seconds every time the key switch is turned to the ON
position. This code represents the EEPROM software
version and DOES NOT INDICATE A FAULT CODE.
NOTE: These checks require a volt-ohmmeter. Spe-
cific checks require additional equipment.
NOTE: The correct meter polarity is necessary for
the checks. The voltage checks are made between
the individual points and battery negative. Connect
the meter negative to battery negative.
1. Block lift truck so the drive wheels are off the
floor. See the section Periodic Maintenance
8000YRM1048, Periodic Maintenance
8000YRM1009, or Periodic Maintenance
8000YRM1379 lift trucks. Refer to How to Put a
Lift Truck on Blocks.
2. Turn the key switch to the OFF position.
3. Disconnect and separate the battery connectors.
4. Remove the upper drive unit compartment cover.
5. Remove the lower drive unit compartment cover.
6. Discharge the capacitor. See Special Precau-
tions.
7. Check the specific gravity of the battery. If the
specific gravity is less than 1.260, the battery is
not fully charged or is damaged. A fully-charged
8
2200 YRM 1007
battery has a specific gravity of 1.270 to 1.290. A
discharged battery has a specific gravity of ap-
proximately 1.165.
8. The truck has an isolated electrical system; nei-
ther battery terminal is connected to the truck
frame. Check for 50,000 ohms or more between
each terminal, one at a time, of the battery con-
nector of the lift truck and a clean connection on
the frame. Remove 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 addi-
tional equipment that may cause a circuit path to
the frame.
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.
2200 YRM 1007
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 2200YRM1064, ZAPI™ Controllers
2200YRM1006, or ZAPI™ Controllers
2200YRM1067 for your lift truck for additional infor-
mation 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 param-
eters 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
section Periodic Maintenance 8000YRM1048,
Periodic Maintenance 8000YRM1009, or Peri-
odic Maintenance 8000YRM1379 for your lift
truck.
Repairs
NOTE: If removing the entire control panel assembly
to include the electrical panel plate, it will be neces-
sary to perform Step 6. If only removing the controller,
contactor, 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 8000YRM1048, Periodic Maintenance
8000YRM1009, or Periodic Maintenance
8000YRM1379 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 Precau-
tions.
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 mo-
tor controller.
13. Remove four capscrews and lockwashers that
hold controller to plate and remove controller.
9
Repairs 2200 YRM 1007

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)

10
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)

11
Repairs
Install
NOTE: If installing the entire control panel assembly
to include the electrical panel plate, it will be neces-
sary to perform Step 1. If only installing the controller,
contactor, horn, fuses, or wires, it is not necessary to
perform Step 1.
1. Install control panel assembly to lift truck by align-
ing four holes of electrical panel plate with four
holes in frame and inserting countersunk cap-
screws into holes from the battery box side. Install
washer, lockwasher, and nut on countersunk cap-
screws. Replace battery. See the section Peri-
odic Maintenance 8000YRM1048, Periodic
Maintenance 8000YRM1009, or Periodic Main-
tenance 8000YRM1379 for your lift truck, for in-
structions on how to install the battery.
2. Install replacement controller on electrical panel
plate by aligning four holes of controller with four
holes in electrical panel plate. Install four cap-
screws and lockwashers.
3. Connect wires and cables to the same terminals
as identified during the removal procedure.
4. Connect the jumper assembly to the "E" terminal,
located on the bottom of the controller. See Spe-
cial Precautions for location. Use procedure that
applies to your lift truck:
a. To use a maintenance free battery, disconnect
the wire terminals on the battery selector
jumper.
b. To use a flooded cell battery, connect the wire
terminals on the battery selector jumper.
5. Reconnect battery connectors.
6. Turn the key switch to the ON position.
7. If available, install customer parameters and set-
tings.
8. Test lift truck in a safe area away from other per-
sonnel and equipment.
12
2200 YRM 1007
9. Install the lower drive unit compartment cover.
10. Install the upper drive unit compartment cover.
CONTACTOR COIL, CHECK
1. Move lift truck to a safe, level area.
2. Turn the key switch to the OFF position and dis-
connect battery connectors.
3. Block drive tire to prevent movement. See the
section Periodic Maintenance 8000YRM1048,
Periodic Maintenance 8000YRM1009, or Peri-
odic Maintenance 8000YRM1379 for your lift
truck.
4. Remove the upper drive unit compartment cover.
5. Discharge the capacitor. See Special Precau-
tions.
6. Tag, identify, and disconnect the contactor coil
wires.
7. Test contactor coil using an ohmmeter.
8. Touch the probes of the ohmmeter to the coil ter-
minals and measure the resistance between the
terminals.
9. Replace contactor if coil resistance readings
measure outside of specifications. For contactor
coil resistance values, refer to Table 1.
10. Connect contactor wires to the correct terminals.
Table 1. Contactor Coil Resistance Values
Model Resistance
MSW020/025-E and 21 ±2.1 ?
MSW025/030-F
MPB040-E 52 ±5.2 ?
MPW045/050-E 21 ±2.1 ?
2200 YRM 1007
CONTACTOR, REPLACE
Remove
1. Move lift truck to a safe, level area.
2. Block drive tire to prevent movement. See the
section Periodic Maintenance 8000YRM1048,
Periodic Maintenance 8000YRM1009, or Peri-
odic Maintenance 8000YRM1379 for your lift
truck.
3. Turn the key switch to the OFF position and dis-
connect battery connectors.
4. Remove the upper drive unit compartment cover.
5. Discharge the capacitor. See Special Precau-
tions.
6. Tag, identify, and disconnect the wires and ca-
bles.
7. Disconnect all wires and cables from the contac-
tor.
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 Precau-
tions.
7. Remove nut retaining the key switch to bracket.
8. Remove the key switch.
Repairs
8. Loosen two mounting screws and lockwashers
that hold contactor to plate and remove contactor.
Install
1. Install contactor by aligning it with mounting
screws on electrical plate and sliding into place.
Tighten mounting screws.
2. Connect wires and cables to the same terminals
as identified during the removal procedure.
3. Reconnect battery connectors.
4. Install the upper drive unit compartment cover.
5. Turn the key switch to the ON position.
6. Test lift truck in a safe area away from other per-
sonnel and equipment.
9. Identify and disconnect electrical wires to switch.
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.
13
Battery Indicator/Hourmeter Display
Battery Indicator/Hourmeter Display
NOTE: On some models, the dash indicator will dis-
play the code: EP 107 (or a higher number) for 1 to 2
seconds every time the key switch is turned to the ON
position. This code represents the EEPROM software
version and DOES NOT INDICATE A FAULT CODE.
The Battery Indicator/Hourmeter Display shows bat-
tery charge status, truck hours, and fault codes. See
Figure 8.
Figure 8. Battery Indicator/Hourmeter Display
Figure 9. Battery Indicator/Hourmeter Display
14
2200 YRM 1007
REMOVE
1. Turn the key switch to the OFF position and dis-
connect battery.
2. Remove the upper drive unit compartment cover.
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.
2200 YRM 1007
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 mo-
tor 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 mo-
tor 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 mo-
tor 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.
Fuses
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 mo-
tor 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 ohm-
meter. To replace FU 1, loosen retaining capscrews.
Install a new fuse and tighten capscrews. FU 2 is re-
tained by a fuse holder. Make certain that any re-
placement fuse is of the right amperage before instal-
lation.
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 ohm-
meter. 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 in-
stallation.
15
Control Handle Arm Proximity Switch 2200 YRM 1007

Control Handle Arm Proximity Switch

REPAIR Remove

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, acti-
vating 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 1800YRM1005.
Check and Adjust
Check the proximity switch for proper operation. All
connections must be attached. Take voltage readings
from the back of the connector.
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 dis-
connect the battery.
3. Remove the upper drive unit compartment cover.
4. Remove the lower drive unit compartment cover.
5. Remove the four capscrews from the two-piece
shield over the MDU and remove the shields.
6. Discharge the capacitor. See Special Precau-
tions.

1. Move the lift truck to a safe, level area before per- 7. Cut the tie wrap located at the end of the proxim-
forming any repairs. ity switch harness.

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 capscrews 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.
8. Remove the proximity switch harness clamp, lo-
cated beneath the drive unit housing.
9. Disconnect the proximity switch from the wiring
harness.
10. Fully lower the control handle arm. Remove the
two capscrews that mount the proximity switch
assembly to the control handle arm. See Fig-
ure 10. Remove the proximity switch assembly.

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 po-

sition. 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 specifica-
tion and that the wiring harness and connections are
good. Adjust the switch gap if necessary or repair any 1. PROXIMITY SWITCH
wiring problems. If the proximity switch continues not 2. CAPSCREW
to function properly, it must be replaced. 3. SWITCH BRACKET
Figure 10. Proximity Switch Assembly

16
2200 YRM 1007 Control Handle Arm Proximity Switch

Install a. LED comes on with the handle in RUN posi-

tion.
1. Insert the proximity switch fully into the switch
bracket. Route the proximity switch wire so that it b. LED should go off with the handle approxi-
will not be pinched or damaged when the control mately 10° from vertical position.
handle is installed.
10. Install the two shield covers using four capscrews

CAUTION 11. Install the lower drive unit compartment cover.

DO NOT damage the plastic switch bracket or 12. Install the upper drive unit compartment cover.
proximity 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 adjusted.

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 11. If the gap distance is different, horizontally
adjust the location of the proximity switch.

4. Connect the switch to the wiring harness.

5. Connect the battery and turn the key switch to the

ON position.

6. With the handle at 10° from vertical, move the

proximity 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).
1. PROXIMITY SWITCH ASSEMBLY
2. GAP 3.0 TO 5.0 mm (0.12 TO 0.20 in.)
3. PROXIMITY SWITCH WIRE
Figure 11. Proximity Switch Assembly Location

9. Verify that the truck operates correctly with the

handle in the following positions:

17
Control Handle
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 16.
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 dis-
connect the battery.
3. Discharge the capacitor. See Special Precau-
tions.
NOTE: The handle is comprised of two molded-plas-
tic 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
using a gentle rocking motion while lifting and
pulling the upper half away from lower half. See
Figure 16.
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.
18
2200 YRM 1007
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 plug-
ged into the control handle card. Unplug switches
from the control handle card and remove the card.
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 han-
dle card. Be careful not to rotate the shaft inside
the control handle card.
3. Connect the switches and wire harness connec-
tors.
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).
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 cali-
brate mode. See Figure 12, view B.
2200 YRM 1007
A. RUN MODE B. CALIBRATE MODE
Figure 12. Control Handle Card Calibration
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 sec-
onds.
10. Slowly rotate the butterfly knobs back to the neu-
tral position and leave for 5 seconds.
11. Slowly rotate the butterfly knobs in the reverse di-
rection and hold at maximum rotation for 5 sec-
onds.
12. Slowly rotate the butterfly knobs back to the neu-
tral position and leave for 5 seconds.
Control Handle
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 speed and half speed ON/OFF lift and
lower switches, then go to Step 17.
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 12, view A.
18. Turn the key switch to the OFF position.
19. Install the upper half on the lower half. Refer to
Assemble for instructions on how to install the up-
per half on the lower half.
20. Test the lift truck to verify correct travel, lift, and
lower speeds.
CONTROL HANDLE CARD (NEW STYLE)
NOTE: New style control handle cards will be blue in
color and should be used as replacement cards re-
gardless of color of the card removed. If simply cali-
brating an existing old style card (green in color), refer
to Control Handle Card (Old Style).
NOTE: Verify that the magnetic holder of the thumb-
wheel switch has been installed in the proper position.
See Figure 13.
After servicing the control handle head, it may be nec-
essary to configure and/or calibrate the control handle
card.
19
Control Handle
Configure
Refer to Figure 13 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.
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
1. JUMPER TERMINALS (SV2)
2. HORN SWITCH (S1)
3. THUMBWHEEL SWITCH (MAGNETIC HOLDER)
Figure 13. Control Handle Card (New Style)
20
2200 YRM 1007
models 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 14.
4. LED DISPLAY SCREEN
5. BELLY SWITCH (S)
6. TURTLE SWITCH (S2)
2200 YRM 1007 Control Handle

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 approxi-
mately five seconds.

Calibrate

Refer to Figure 13 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 14.

a. Ensure the leads from the Right Lift switch con-

nects to the JP10 socket and the leads from
the Right Lower switch connects to the JP12
socket. See Figure 13.

b. Ensure the leads from the Left Lift switch (or

shift right switch if equipped with sideshift op-
1. P (PARK/ HOME POSITION) tion) connects to the JP14 socket and the
2. D (NOT USED) leads from the Left Lower switch (or shift left
3. T (TEACH/CALIBRATE)
4. C (CONFIGURE) switch if equipped with sideshift option) con-
5. JUMPER TERMINAL (SV2) nects to the JP15 socket. See Figure 13.

Figure 14. Jumper Terminal (SV2) c. Ensure the tiller harness connects to JP1
socket. 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.
3. Verify that the battery is connected and turn the
key switch to the ON position. The LED will dis-
play a symbol (see Figure 15 view A or B) to sig-
nal that the card is in calibration mode.

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.

21
Control Handle 2200 YRM 1007

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 mechan-
ical 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 15, 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" di-

rection (toward the operator) and hold to the me-
chanical stop. Press the left side lower button
(sideshift left button if equipped with sideshift op-
tion).

7. The LED screen will change to show this segment

complete. See Figure 15, view D. Release the
thumbwheel so it returns to the neutral position.

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

Figure 14.
A. CALIBRATION MODE 9. The LED screen will change to show a decimal
B. CALIBRATION MODE beside the completed segments indicating they
C. ROTATION RIGHT SEGMENT COMPLETE
D. ROTATION LEFT SEGMENT COMPLETE have been saved. See Figure 15, view E.
E. ALL SEGMENTS COMPLETE AND SAVED
10. Use diagnostic from handset to verify the "Accel"
Figure 15. LED Views
output 95% and above for both directions.

a. If LED displays as shown in Figure 15 view A, 11. Recycle the key switch OFF and ON and test all
return butterfly to neutral then press left lift but- truck functions for proper operation.
ton (or side shift right button if equipped with
sideshift option). The LED will display as
shown in Figure 15 view B.

22
2200 YRM 1007
ASSEMBLE
1. Install control handle card in the upper half of con-
trol handle. See Figure 16.
NOTE: When inserting knobs, make sure that flange
on one of the butterfly knobs inserts between spring
on handle (9).
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 connec-
tors.
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.
Control Handle
6. Install lower half of control handle cover to control
handle shaft and secure with two capscrews. Tor-
que 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
handle to lower half.
10. Connect battery cable and test control handle op-
eration.
23
Control Handle 2200 YRM 1007

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 16. Control Handle

24
2200 YRM 1007
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 16.
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 dis-
connect battery.
3. Discharge the capacitor. See Special Precau-
tions.
NOTE: The handle is comprised of two molded-plas-
tic 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 16.
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
upper half of cover.
Control Handle
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 han-
dle. Verify that the switch assembly locks into po-
sition 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).
25
Traction Motor 2200 YRM 1007

Traction Motor
DISASSEMBLE brush replacement is RECOMMENDED. See
the section DC Motor Maintenance
1. Remove the traction motor and brake assembly 0620YRM0294 for the replacement of brushes
from the MDU. See Brakes 1800YRM1005. and spring assemblies.

4. Remove capscrews from commutator end of mo-

CAUTION tor. Carefully slide end cover from motor and ar-
The pinion end cover and the armature are heavy mature shaft. DO NOT damage parts. A puller is
components. Work carefully so the field coils, often necessary to separate the end cover from
pole pieces, and armature are not damaged dur- the field ring.
ing disassembly and assembly.
5. Remove screws that fasten pinion end cover to
2. Clean outside surfaces of motor before disassem- field ring. Remove end cover and armature. Use a
bly. Make index marks on the ends of the motor plastic or rubber hammer, as necessary, to loosen
and field ring to ensure proper reassembly. end cover.

3. Remove brush cover, if used. Measure the brush 6. Remove pinion end cover from armature.
in the brush holder, use a tire tread depth gauge
or small scale to measure from the top of the 7. Remove screws that fasten brush holder assem-
brush holder to the back of the brush. bly to commutator end cover.

a. Brush replacement is REQUIRED when the 8. Disassemble components of motor, as necessary,

height of the brush measures 11 mm (0.44 in.) to make repairs. See Figure 17 and the section
below the brush box. If the brush is worn DC Motor Maintenance 0620YRM0294.
8 mm (0.31 in.) below the brush box, then

26
2200 YRM 1007 Traction Motor

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 17. Disassembled Traction Motor

27
Traction Motor
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.
4. Carefully install armature in housing. Install retain-
ing rings.
Lift Pump Motor
The MPB040-E, MPW045-E, and MPW050-E lift
pumps cannot be disassembled. The motors are serv-
iced 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 hy-
draulic system. When repairing the lift pump motor
ALWAYS check that the battery is charged and check
all electrical connections BEFORE removing the mo-
tor from the truck:
28
2200 YRM 1007
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 17.
7. Install brake assembly to drive motor. See
Brakes 1800YRM1005.
8. Install drive motor to MDU. Secure in place using
motor mount studs.
1. Check the specific gravity of the battery or the op-
tional battery discharge indicator for proper bat-
tery charge. See Electrical System Checks for in-
formation 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 18):
• Brushes
• Brush Plate
2200 YRM 1007 Lift Pump Motor

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

0620YRM0294 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
motor. 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 1900YRM1018 or Walkie High Lift
Hydraulic System 2000YRM1044.

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

Figure 18. Pump Motor Brushes Inspection

29
Lift Link Proximity Sensor (MPW050-E)
Lift Link Proximity Sensor (MPW050-E)
The lift link proximity sensor is located near the bot-
tom of the control panel. This sensor detects the lift
linkage 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 Fig-
ure 19.
1. CONTROLLER
2. PROXIMITY SENSOR
3. HORN
Figure 19. Lift Proximity Sensor Location
CHECK
1. Remove the electrical compartment covers. Turn
the key switch to the ON position and move the
control handle arm to the RUN position. Check
the battery discharge indicator for proper battery
charge.
2. Completely lower the forks then press and hold
the lift button. The lift pump and motor assembly
should activate, raise the forks to their maximum
lift height, and turn off while the lift button is still
depressed.
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.
30
2200 YRM 1007
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
proximity sensor connector. Reconnect the
sensor with the wiring harness and check oper-
ation again. If the problem remains, proceed to
the next step.
CAUTION
Keep hands and fingers clear of lift linkage to
avoid injury from pinch points.
3. Cover the face of the proximity switch with a piece
of metal then press and release the lift button.
a. If the lift pump and motor shut down when the
sensor is covered, properly adjust the lift link-
age proximity sensor. See Adjust.
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 compart-
ment cover removed unless otherwise noted. Replace
the cover when repairs are complete.
Remove
1. Disconnect the sensor wiring connector from the
truck wiring harness.
2. Remove the front jam nut from the position sensor
threads. See Figure 20.
3. Remove the sensor from the mounting bracket on
the truck frame.
4. Remove the rear jam nut if replacing the senor.
Test
1. Remove the lift linkage proximity sensor. See Re-
move.
2200 YRM 1007 Lift Link Proximity Sensor (MPW050-E)

1. SENSOR CONNECTOR
2. SENSOR WIRING
3. REAR JAM NUT
4. FRONT JAM NUT
5. SENSOR FACE
Figure 20. Sensor and Jam Nuts

CAUTION
DO NOT connect jumper wires to the truck wiring
harness.

2. Connect jumper wires to the sensor wiring har-

ness:
a. Connect positive (24 volts) to the pin #1 of the
connector. See Figure 21.
b. Connect a ground to the pin #2 of the connec-
tor.
c. Connect a voltmeter between pin #3 of the
connector and a ground.
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
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. PIN #1 (BROWN WIRE)
2. PIN #2 (BLUE WIRE)
3. PIN #3 (BLACK WIRE)
Figure 21. Sensor Connector (Front View)
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 prox-
imity sensor 2.5 mm (0.1 in.) from the upper lift
linkage when the forks are in the fully raised posi-
tion.

1. Position the rear jam nut onto the position sensor 3. Tighten the front jam nut to secure the proximity
threads. sensor in position. Verify the measurement.

2. Install the position sensor into the bracket on the 4. Check for proper operation.
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.

31
Battery Charger (Moran®)
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 22. This charger is a
self contained 120 volt AC powered charger. The
charger comes equipped with a short lead plug to al-
low 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.
Figure 22. Battery Charger (Early Models)
OPERATION
Charging
Pressing the ON button at the top of the charger
starts the charging cycle. A yellow LED will illuminate
to indicate that charging has begun. Battery charging
is automatic once the charging cycle has started. The
green LED will illuminate once the charging cycle has
been completed. Refer to Figure 22.
Equalize
The charger will automatically begin a equalizing cy-
cle 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 il-
luminate or flash if a malfunction of the charger or bat-
tery occurs.
32
2200 YRM 1007
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 ex-
pired.
• 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:
• A fuse protects the DC circuit in the event of
prolonged over-current or possible polarity in-
version.
• 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
temporarily, 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 fol-
lowing:
• 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 23.
2200 YRM 1007 Battery Charger (Moran®)

• If the AC input fuse is blown, replace and re-
connect 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
acceptable output can be found.
necessary. First remove the four Phillips head
screws on the side of the charger and slide the
cover off to access the fuse. See Figure 24.
• 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 remove all debris and metal
fragments from the blown fuse before putting
charger back in service.

If the charger will power up, but does not charge, pro- • If the DC output fuse is good, verify that both
ceed with the following: retaining nuts are adequately tightened. Exer-
cise caution not to over tighten the nuts, which
• Check condition of battery connections and could result in board damage.
clean them, if necessary.
NOTE: If the 50 amp DC output fuse has blown,
• Verify that the batteries are properly connec-
some debris can be expected on the circuit board
ted. See Diagrams 8000YRM1011, Diagrams
next to the fuse. However, care should be taken to re-
8000YRM1050, Diagrams 8000YRM1381, or
move the debris before putting the unit back in serv-
Diagrams 8000YRM1228 for your lift truck.
ice. See Figure 25.
Identify and replace any batteries with open or
shorted cells. • Visually inspect for signs of heat damage on
the circuit board and or transformer. If any heat
• Check battery output voltage to verify charge is
damage is evident, reassemble and replace
actually necessary. Charger may not run if bat-
the charger.
teries 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

1. INPUT FUSE

Figure 23. Input Fuse Location

33
Battery Charger (Moran®) 2200 YRM 1007

Figure 24. 50 Amp DC Output Fuse

Legend for Figure 25

1. TRANSFORMER
2. RECTIFIER BRIDGE
3. CIRCUIT BOARD
4. DC OUTPUT FUSE
5. AC INPUT FUSE

Figure 25. Battery Charger

34
2200 YRM 1007
If the charger begins the charge cycle, but stops be-
fore 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 constant red LED will light up.
2. If the charger is unable to raise the battery volt-
age above 2.05 volts/cell (24.6 volts total) within
one hour after start up, it will stop charging and a
constant 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
constant red LED will light up.
4. If at any time during the charge cycle the trans-
former overheats, the charger will stop, the yellow
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 cur-
rent will increase, which raises the transformer
Battery Charger (Moran®)
temperature. 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 situation may occur again. If this hap-
pens within one hour after start up, the one hour
timer will expire and shut the charger down as de-
scribed in item 2 above.
All of the cases above are indicative of a set of batter-
ies that are not responding properly to the charger
due to one or more weak or failing cells.
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.
35
Battery Charger (Accusense by DPI®) 2200 YRM 1007

Battery Charger (Accusense by DPI®)

DESCRIPTION

Some lift trucks are equipped with DPI® brand battery

chargers. DPI Gen II chargers and DPI Gen III charg-
ers differ slightly and can be distinguished by their ap-
pearance. See Figure 26 and Figure 27. 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.

1. USB PORT (FACTORY USE ONLY)

2. MODE PORT DIP SWITCHES

Figure 27. DPI Gen III Chargers

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 substi-
tute 230 volts AC in the place of 120 volts AC when
instructed to connect the charger to a power source.

OPERATION

LED Display

The charger has five colored LEDs located on the top

of the charger. The LEDs are used to indicate the sta-
tus of the charger during operation. The order of the
Figure 26. DPI Gen II Chargers LEDs may vary with models, but are labeled to iden-
tify their function. See Table 2.

36
2200 YRM 1007 Battery Charger (Accusense by DPI®)

Table 2. Charger LEDs the red, POWER ON, LED will illuminate to indicate
AC power is applied to the charger and will begin the
Indicator Color Function charging cycle.
Power On Red Illuminates continuously
when AC power is present. The charger uses a 5-step charging process:
Abnormal Red Flashes if abnormal shut-
1. Pre Qualification Test. During this step, the yel-
Shutdown down has occurred.
low, CHARGING, LED will flash on and off every
Detection Red Illuminates continuously two seconds. The charger is checking for faults
Error when battery is not con- prior to the start of charging. Depending on the
nected to charger or bat- condition and state of charge of the batteries, this
tery voltage is less than step can take from 45 seconds up to 5 hours.
2V.
2. Regulating Current. During this step, the charger
Charging Yellow Charge status indicator -
will be regulating current to the batteries and will
flashes during charging cy-
be operating at full rated output. The yellow,
cle.
CHARGING, LED will be constantly illuminated
Charged Green Illuminates continuously during this step.
when battery is fully
charged. 3. Regulating Voltage. During this step, the charger
will be regulating voltage to the batteries. The yel-
low, CHARGING, LED will remain illuminated.
Charging
When the batteries have reached 80 to 90 per-
cent of full charge, the yellow, CHARGING, and
CAUTION the green, CHARGED, LEDs will be illuminated.
The charger comes factory set to charge mode 2
4. Charge Complete. During this step, the green,
and must be changed if using batteries not speci-
CHARGED, LED will remain illuminated. AC
fied for charger mode 2. Using an improper
power can now be disconnected from the charger.
charger mode for your battery pack may cause se-
vere damage to batteries or charger. Refer to 5. Recycle Stage. If the charger remains connected
Charger Mode/Battery Type Selection (DPI Gen II to power for 28 days, a completely new charge
Models) or Charger Mode/Battery Type Selection cycle will begin to keep batteries fully charged
(DPI Gen III Models) in this section to verify the during long periods of not being used.
proper mode setting for your battery pack.
NOTE: If the charger noted an abnormal charge con-
Plugging the charger to the 120 volt AC outlet will be- dition during the charging, the charger will attempt to
gin the start up cycle. Approximately three seconds shutdown and will flash one or all three of the red
after connection to the AC power, all five LEDs on the LEDs on the top of the charger. If this condition oc-
top of the charger will illuminate and flash two times. curs, see Troubleshooting (DPI Chargers), Error
This indicates the charger is set to charge U1800 type Modes in this section.
batteries. Following the start up flashing of the LEDs,

37
Battery Charger (Accusense by DPI®)
CHARGER MODE/BATTERY TYPE
SELECTION (DPI GEN II MODELS)
CAUTION
DO NOT use batteries types that are not approved
for the charger or improper mode settings. Dam-
age to the batteries or charger may occur if the
mode setting is not correct for the type of batter-
ies being used.
NOTE: Gen II and Gen III version DPI chargers have
different procedures for changing charger modes for
charging different battery types. Use the proper pro-
cedure 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
once if the mode is set to Mode 1, twice if the mode is
set to Mode 2, and three times if the charger is set to
Mode 3. If the LEDs do not flash when initially con-
nected to power, refer to Troubleshooting (DPI Charg-
ers) in this section.
The battery charger has three battery mode settings.
The mode setting is determined by the type batteries
being used in the battery pack. See Table 3.
Table 3. Battery Modes (DPI Gen II Chargers
Only)
Mode Battery
1 24 V Exide E3600
2 24 V Interstate U1800
3 24 V Trojan Battery T-605
38
2200 YRM 1007
CAUTION
DO NOT use batteries types that are not approved
for the charger or improper mode settings. Dam-
age to the batteries or charger may occur if the
mode setting is not correct for the type of batter-
ies 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
battery charger from the battery tray assembly on DPI
Gen II chargers.
1. Remove the charger from the battery tray and
place on a clean flat surface.
2. Remove the screws used to retain the cover to
the charger and remove the cover.
3. Locate the jumpers on the circuit board. See Fig-
ure 28. The two jumpers used to make the model
setting are labeled J3 and J4 on the circuit board.
These jumpers are located near the center red
LED on the circuit board.
2200 YRM 1007 Battery Charger (Accusense by DPI®)

mode setting is not correct for the type of batter-

ies being used. If the battery manufacturer of the
battery you are using is not listed, contact Resi-
dent Service Engineering through the Contact
Management System.

NOTE: Gen II and Gen III version DPI chargers have

different procedures for changing charger modes for
charging different battery types. Newer versions of
DPI Accusense Gen III use dip switches to change
charge modes, while older version use four jumper
ports. Use the proper procedure 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: On older versions of the charger, mode set-

tings 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 initially
connected to power, refer to Troubleshooting (DPI
1. J3 JUMPER 2. J4 JUMPER Chargers) in this section.
Figure 28. Circuit Board
The battery charger has four mode settings. The
mode setting is determined by the type batteries be-
4. For Mode 1, remove the existing jumper from J3. ing used in the battery pack. See Figure 29 and Ta-
For Mode 3, remove the existing jumper from J3 ble 4.
and install on J4.

5. Replace the cover on the charger and install the

mounting screws.

6. Install the charger in the battery tray.

NOTE: Store the jumper in a safe place in case of fu-

ture battery type retrofits.

CHARGER MODE/BATTERY TYPE

SELECTION (DPI GEN III MODELS)

CAUTION
DO NOT use batteries types that are not approved Figure 29. Jumper Ports
for the charger or improper mode settings. Dam-
age to the batteries or charger may occur if the

39
Battery Charger (Accusense by DPI®) 2200 YRM 1007

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)
US - Battery US1800 24 208 Deep Cycle HV Flooded 2
Lead Acid AGM2224 24 224 Deep Cycle Absorbent Glass 4
Batteries Mat

Changing Mode Setting (DPI Accusense Gen 1. Remove the screws used to retain the jumper port
III Models with Jumper Ports) cover to the charger and remove the cover.

NOTE: Mode settings can be checked by connecting 2. Locate the jumpers on the port.
the battery charger to a 120V AC power source and
3. Arrange the jumpers in the proper configuration
watching the LED display. The LED display will flash
for your battery type.
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 4. Replace the cover on the charger and install the
charger is set to Mode 4. If the LEDs do not flash mounting screws.
when initially connected to power, refer to Trouble-
shooting (DPI Chargers) in this section. Accusense Gen III with Dip Switches
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.

40
2200 YRM 1007 Battery Charger (Accusense by DPI®)

Figure 30. Switch Position Mode Chart

41
Battery Charger (Accusense by DPI®)
Changing Mode Setting
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 on the
charger will flash to indicate the selected battery
mode. Consult Figure 30 to determine the selected
mode. If the LEDs do not flash when initially connec-
ted to power, refer to Troubleshooting (DPI Chargers)
in this section.
Modes are set by the sequence of the dip switches.
Tampering with the Charging Mode Label voids war-
ranty. See Figure 30 for dip switch settings.
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 trou-
bleshooting and follow the chart and procedures in Er-
ror 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.
(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 re-
42
2200 YRM 1007
peat Step 1. If LEDs still do not flash at
least once upon connecting power, replace
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 exten-
sion 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 Accusense Gen III Models with
Jumper Ports). 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 trou-
bleshooting and follow the chart and procedures in Er-
ror Modes in this section.
2200 YRM 1007 Battery Charger (Accusense by DPI®)

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?
7. Was the voltage reading in Step 6 higher than
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.
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.
16VDC?
a. YES: Proceed to Battery Pack Troubleshoot-
ing.
b. NO: It is recommended that all batteries in the
battery pack be replaced.

5. Is the Charging LED either flashing or illuminated Error Modes

continuously when the charger is connected to a
120 volt AC power source? The three red LEDs are used to troubleshoot the
a. YES: Proceed to Step 6. charger. Observe the operation of the Power On, Ab-
normal Shutdown, and the Detection Error LEDs to
b. NO: If no other LEDs are flashing, replace determine the cause for the error notification. See Ta-
charger. ble 5.

6. Check the output of the charger using a digital

voltmeter:

Table 5. LED Error Codes

Condition Power On LED Abnormal Shutdown LED Detection Error 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

43
Battery Charger (Accusense by DPI®)
Battery Voltage High indicates the charger is sens-
ing it is connected to a battery pack with a voltage rat-
ing greater than 24 volts. Verify the battery pack is the
correct voltage.
Battery Polarity Reversed indicates an incorrect
connection 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
preset 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 charg-
ing.
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
2240YRM0001.
1. Measure the specific gravity (SG) level for each
battery cell (after a charging cycle).
44
2200 YRM 1007
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 nee-
ded 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 bat-
teries independently. All batteries should
be changed together when battery pack is
updated.
2200 YRM 1007 Battery Charger (Accusense® 20A)

Battery Charger (Accusense® 20A)

DESCRIPTION

Lift trucks equipped with Accusense® battery chargers

can be distinguished by the battery charger label. See
Figure 31 for lift trucks manufactured before May,
2013. See Figure 32 for lift trucks manufactured after
May, 2013. Accusense 20A chargers are self con-
tained, 120 volt, AC powered chargers. Each charger
comes equipped with a short lead plug to allow con-
nection 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 pro-
tected by a 20 amp circuit breaker.
Figure 32. Accusense 20A Chargers,
NOTE: Chargers can be identified by the MFR MOD Manufactured After May, 2013
number on the charger label. If the first two digits of
the MFR MOD number read 1Q or 2Q, the equipment
is a Gen IV Q-Series charger. NOTE: Some markets use a special 230 volt AC
charger which require connection to a 230 volt AC
For the Gen IV chargers, refer to Accusense® Gen IV outlet. Users with 230 volt AC chargers should substi-
Charger 2200YRM2030. For other charger models, tute 230 volts AC in the place of 120 volts AC when
use this manual. instructed to connect the charger to a power source.

OPERATION

LED Display

The charger has five colored LEDs located on the top

of the charger. The LEDs are used to indicate the sta-
tus of the charger during operation. The order of the
LEDs may vary with models, but are labeled to iden-
tify their function. See Table 6.

Figure 31. Accusense 20A Chargers,

Manufactured Before May, 2013

45
Battery Charger (Accusense® 20A) 2200 YRM 1007

Table 6. Charger LEDs the start up flashing of the LEDs, the red, POWER
ON, LED will illuminate to indicate AC power is ap-
Indicator Color Function plied to the charger and will begin the charging cycle.
Power On Red Illuminates continuously
when AC power is present. The charger uses a 6-step charging process:
Abnormal Red Flashes if abnormal shut-
1. Pre-Qualification Test
Shutdown down has occurred.
During this step, the yellow, CHARGING, LED
Detection Red Illuminates continuously will flash on and off every two seconds. The
Error when battery is not con- charger is checking for faults prior to the start
nected to charger or bat- of charging. Depending on the condition and
tery voltage is less than state of charge of the batteries, this step can
2V. take from 5 seconds up to 5 hours. This stage
Charging Yellow Charge status indicator - lasts 15 seconds unless battery voltage is be-
flashes during charging cy- low 21V. If the battery voltage is below 21V,
cle. the charger will charge the battery with low cur-
rent until battery voltage reaches 21V. When
Charged Green Illuminates continuously battery voltage is above 21V, regular charging
when battery is fully begins.
charged.
2. Regulating Current
This step is sometimes referred to as Bulk
Charging Charge. During this step, the charger will
charge at constant current mode, which is nor-
WARNING mally the charger's full rated RMS output. The
The charger comes factory set to the battery in- yellow, CHARGING, LED will be constantly illu-
stalled at the factory and must be changed if us- minated during this step.
ing different batteries. Using an improper charger 3. Constant Charge
mode for your battery pack may cause severe This step is sometimes referred to as Absorp-
damage to batteries or charger. Refer to Charger tion Charge or Top Off stage. During this step,
Mode/Battery Type Selection (Accusense 20A) in the charger will regulate the voltage at a con-
this section to verify the proper mode setting for stant rate while slowly decreasing the bulk
your battery pack. charge current. The yellow, CHARGING, LED
will remain illuminated. When the batteries
Mode settings can be checked by connecting the bat- have reached 80 to 90 percent of full charge,
tery charger to a 120V AC power source and watch- the yellow, CHARGING, and the green,
ing the LED display. The LED display on the charger CHARGED, LEDs will be illuminated.
will flash to indicate the selected battery mode. Con- 4. Charge Complete
sult Table 7 to determine the selected mode. If the During this step, only the green, CHARGED,
LEDs do not flash when initially connected to power, LED will remain illuminated. AC power can now
refer to Troubleshooting (Accusense 20A Chargers) in be disconnected from the charger.
this section.
5. Recycle Stage
Plugging the charger to the 120 volt AC outlet will be- If the charger remains connected to power for
gin the start up cycle. Approximately three seconds a period of days (40 days when Mode 2 is se-
after connection to the AC power, all five LEDs on the lected), a completely new charge cycle will be-
top of the charger will illuminate and flash two times. gin to keep batteries fully charged during long
This indicates the charger is set to Mode 2. Following periods of not being used.

46
2200 YRM 1007 Battery Charger (Accusense® 20A)

6. Equalization Stage
Equalization stage will happen only when
Mode 2 is selected. During this stage, the
Power LED flashes.
Equalization mode takes 2-4 hours longer than
the regular cycle.
The charger will go through an equalization cy-
cle every 15 charge cycles or if the battery has
been without charging for more than 30 days. If
an equalization cycle is not desired, disconnect
and reconnect AC power to reset the charge
counter to 1 and skip the Equalization Stage.
NOTE: If the charger noted an abnormal charge con-
dition during the charging, the charger will attempt to
shutdown and will flash one or all three of the red
LEDs on the top of the charger. If this condition oc-
curs, see Troubleshooting (Accusense 20A Charg-
ers), Error Modes in this section.
Operating temperature range for the charger is -10 to
50°C (14 to 122°F). If charger is below or above indi-
cated temperatures, locate the truck to an area where
charger can return to the operating temperature
range.
CHARGER MODE/BATTERY TYPE
SELECTION (ACCUSENSE 20A)
mode setting is not correct for the type of batter-
ies 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.
NOTE: If the battery manufacturer of the battery you
are using is not listed, contact Service Engineering
through the Contact Management System.
The battery charger has 6 mode settings. The proper
mode setting is determined by the type batteries be-
ing used in the battery pack. See Table 8.
After you determine the proper mode for the replace-
ment batteries (for lift trucks manufactured before
May, 2013), set the charger to the proper mode by in-
stalling the corresponding mode key for that mode
into the mode port. Refer to Figure 33 for key position
and the Parts Manual for mode key part numbers.

WARNING
DO NOT use batteries types that are not approved
for the charger or improper mode settings. Dam-
age to the batteries or charger may occur if the

Table 7. LED Charge Modes

MODE LED 1 LED 2 LED 3 LED 4 LED 5

1 OFF OFF OFF OFF ON
2 OFF OFF OFF ON OFF
4 OFF OFF ON OFF OFF
5 OFF OFF ON OFF ON
15 OFF ON ON ON ON
16 ON OFF OFF OFF OFF

47
Battery Charger (Accusense® 20A) 2200 YRM 1007

1. USB PORT (FACTORY USE ONLY) 1. USB PORT (FACTORY USE ONLY)
2. MODE KEY IN MODE PORT 2. DIP SWITCHES IN MODE PORT
Figure 33. Mode Port, Lift Trucks Manufactured Figure 34. Mode Port, Lift Trucks Manufactured
Before May, 2013 After May, 2013

For lift trucks manufactured after May, 2013, the
mode key has been replaced with a dip switch. See
Switch Position Mode Chart for correct switch posi-
tion. Removing the Charging Mode Label voids war-
ranty. Contact Service Engineering to set charging
mode for replacement batteries. See Figure 34.
A USB port located to the left of the mode port is for
factory use only.
For lift trucks manufactured before May, 2013, refer to
Table 8 to determine which mode should be used to
charge a particular battery.

Table 8. Battery Chart for Accusense 20A Chargers Only

Mfg Part Voltage Capacity Application Batt Type Accusense

20HR/ 20A Mode
RC@25A
(AmpHrs)
US - US1800 24 208 Deep Cycle HV Flooded 2
BatteryLead AGM2224 24 224 Deep Cycle Absorbent Glass 4
Acid Mat
Batteries

48
2200 YRM 1007 Battery Charger (Accusense® 20A)

For lift trucks manufactured after May, 2013, refer to

Figure 35 to determine which mode switch setting
should be used to charge a particular battery.

Figure 35. Switch Position Mode Chart

49
Battery Charger (Accusense® 20A)
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.
For lift trucks manufactured before May, 2013, modes
are set by the position of the jumpers on the jumper
port (behind mode key). Accessing the jumper port re-
quires removal 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. 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.
For lift trucks manufactured after May, 2013, modes
are set by the sequence of the dip switches. Contact
Service Engineering for dip switch settings. Tamper-
ing with the Charging Mode Label voids warranty.
Contact Service Engineering to set dip switches.
TROUBLESHOOTING (ACCUSENSE 20A
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 trou-
bleshooting and follow the chart and procedures in Er-
ror 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.
50
2200 YRM 1007
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.
(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 re-
peat Step 1. If LEDs still do not flash at
least once upon connecting power, replace
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 (Accusense 20A).
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 exten-
sion 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 or Changing Mode Setting (Ac-
cusense 20A). 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 trou-
bleshooting and follow the chart and procedures in Er-
ror Modes in this section.
2200 YRM 1007 Battery Charger (Accusense® 20A)

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?
7. Was the voltage reading in Step 6 higher than
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.
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.
16VDC?
a. YES: Proceed to Battery Pack Troubleshoot-
ing.
b. NO: It is recommended that all batteries in the
battery pack be replaced.

5. Is the Charging LED either flashing or illuminated Error Modes

continuously when the charger is connected to a
120 volt AC power source? The three red LEDs are used to troubleshoot the
a. YES: Proceed to Step 6. charger. Observe the operation of the Power On, Ab-
normal Shutdown, and the Detection Error LEDs to
b. NO: If no other LEDs are flashing, replace determine the cause for the error notification. See Ta-
charger. ble 9.

6. Check the output of the charger using a digital

voltmeter:

Table 9. LED Error Codes

CONDITION LED 1 LED 2 LED 3 LED 4 LED 5

Battery Voltage High Off Off Off Off Flash
Battery Pack Unbalanced Off Off Flash Off Off
Excessive Charging Time Off Off Flash Flash Flash
Battery Testing - 1 Off Flash Off Off Flash
Battery Testing - 2 Off Flash Off Flash Off
Inhibit Control Defective Off Flash Off Flash Flash
Internal Over Temperature Off Flash Flash Off Flash
Mode Selected Not Valid Flash Off Off Flash Off
Database Save Error Flash Off Off Flash Flash
Discharge Error Flash Flash Off Off Off
Severe Discharge Error Flash Flash Flash Off Off
Battery Storage Error Flash Off Flash Off Flash
Critical Battery Error On On Off Off Off

51
Battery Charger (Accusense® 20A)
LEDs Frozen (no activity) or Charger seems inop-
erable: Battery may have been subjected to an Over-
Discharge condition. Using a voltmeter check if bat-
tery voltage is well under its 100% depth of discharge
level defined as 1.75V per cell for lead acid batteries.
For example, if a 24V lead acid battery measures well
under 21V, then this condition may have occurred as
a result of batteries left in lengthy storage without a
trickle charge applied to it. Try removing the output
leads from the battery pack (while A.C. Power is dis-
connected from the charger) and reconnecting the
output leads.
Battery Voltage High: Charger’s DC cord set possi-
bly connected to a battery pack with voltage higher
than the output rating of the charger.
Battery Pack Unbalanced: Caused by unbalanced
battery condition and or excessive battery plate sul-
phation. Example: some batteries are at a much
higher state of charge than others. This may require
replacement of the batteries. Refer to the Equipment’s
Operators manual for instructions on servicing the
battery pack.
Excessive Charging Time: Occurs when charging
took too long. Possible causes include: use of a bat-
tery load that is draining energy from the battery while
the charger is trying to charge that same battery,
aged or unbalanced battery cell conditions, etc.
Battery Testing: This error is only generated by one
of two conditions found during the Pre-Qualification
Test Stage. Condition 1: A severely discharged bat-
tery pack did not charge up to 1.75Vdc per cell
( 21Vdc for 24V-battery ), within 4 hrs. Condition 2: A
heavy load applied prevents charger from charging
battery pack above 1.75Vdc per cell.
Inhibit Lockout Control Defective: If an Equipment
Lockout Cable (Inhibit) is installed and supposed to
be active, but it is not. Check Inhibit vehicle wiring. If
correct, internal inhibit switch may have been over-
load. Contact factory.
52
2200 YRM 1007
Internal Over Temperature: Charger shut down due
to an internal over temperature condition. Check fan
operation and remove blockages, if any.
Mode Selected Empty: The selected Charge Algo-
rithm, set via the dip switches, is empty and not a
valid setting for charging batteries. Reset the mode
select switches to a valid value.
Database Write Error: While disconnecting the
charger output leads from a battery pack, if the
charger was in the process of saving information back
into memory, this error may be produced. Contact the
factory to have a reset programming cable sent to you
to field reset the charger.
Discharge Error: Based on 1.75V/cell, this error is
produced when cell voltage falls below this value (ex-
ample: 21Vdc for 24V Battery Pack). A.C. Power
should be connected to charger and charging initiated
immediately.
Severe Discharge Error: Based on 1.417V/cell, this
error is produced when cell voltage falls below this
value (example: 17Vdc for 24V Battery Pack). A.C.
Power should be connected to charger and charging
initiated immediately. Damage to battery pack, result-
ing in reduced capacity, may have occurred and may
be permanent. Check battery with Load Tester after
re-charge complete.
Battery Storage Error: Battery has sat in storage for
greater than 30 days and requires charging. Connect
A.C. Power and Charge Battery.
Critical Battery Error: Battery has drained to a criti-
cally low level possibly resulting from many months of
storage, parasitic drains including equipment key left
in ‘ON’ position. Disconnect the charger’s positive bat-
tery lead, wait a few seconds and then reconnect the
lead.
2200 YRM 1007
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
2240YRM0001.
1. Measure the specific gravity (SG) level for each
battery 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
Battery Charger (Accusense® 20A)
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 nee-
ded 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 bat-
teries independently. All batteries should
be changed together when battery pack is
updated.
53
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 dis- Reconnect or tighten loose wiring
connected. connections.

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 dis- Check wiring and tighten or con-
connected. nect as needed.

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

ative.

54
2200 YRM 1007 10/16 (8/16)(1/14)(9/13)(12/12)(7/11)
 Maintenance

LIFTING MECHANISM
MPB040E [B827]; MPW045-E [B802];
MPW050-E [C802]

PART NO. 524154897 4000 YRM 1008

 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.
Lifting Mechanism Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Lift Linkage...................................................................................................................................................... 1
Load Wheel ......................................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install............................................................................................................................................................... 3
Rear Link and Load Wheel .................................................................................................................................. 3
Remove ........................................................................................................................................................... 3
Install............................................................................................................................................................... 3
Compression Rod................................................................................................................................................ 4
Remove ........................................................................................................................................................... 4
Install............................................................................................................................................................... 4
Lower Link ........................................................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Install............................................................................................................................................................... 6
Upper Link ........................................................................................................................................................... 6
Remove ........................................................................................................................................................... 6
Install............................................................................................................................................................... 7
Caster Wheels (Optional) .................................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Install............................................................................................................................................................... 8
Replace ........................................................................................................................................................... 8

This section is for the following models:

MPB040E [B827];
MPW045-E [B802];
MPW050-E [C802]

©2009 Yale Materials Handling Corp. i

4000 YRM 1008
General
LIFT LINKAGE
This section has the description and repair procedures
for the MPB040-E, MPW045-E, MPW050-E units. The
lifting mechanism is operated by the hydraulic system.
Hydraulic fluid extends the lift cylinder, operates the lift
linkage, and raises the forks.
On all motorized lift trucks, when the lift button on the
control handle is depressed, the hydraulic pump sends
1. LOWER LINK (LH)
2. LOWER LINK (RH)
Figure 1. Lift Linkage
General
high pressure hydraulic fluid to the lift cylinder. This
action extends the cylinder, operates the lift linkage, and
raises the forks. At the same time, the rocker arms
and the rear links mounted under the drive unit platform
are pulled upward. This causes the push rod assembly
to be pushed toward the load wheel end of the truck.
The movement of the push rods in this direction causes
the load wheels to pivot down on their pivot pins. See
Figure 1.
3. FORK
4. LOAD WHEEL (LH)
1
Load Wheel 4000 YRM 1008

Load Wheel
REMOVE
WARNING
Put blocks under both forks and on both sides of
the drive tire. The blocks must prevent the lift truck
from falling and causing personal injury or property
damage.
1. Remove the battery from the lift truck. Position
the battery close enough to the lift truck to allow
power cable connection during servicing. Connect
the battery and turn the key switch to the ON posi-
tion.
2. Use the lift button to raise the lift truck to its maxi-
mum height.
3. Put blocks under both forks and under the drive end
of truck. See the section How to Put a Lift Truck on
Blocks.
4. Press the lower button just enough to relieve pres-
sure from the load wheels.
5. Move the key to the OFF position. Disconnect the
battery.
6. Drive out the roll pin retaining the load wheel axle
shaft to the link. Repeat for other side.
7. Remove the axle shaft and bushings from the link.
Remove bearings and load wheel assembly from
the link. It may be necessary to drive the bearing
out of the wheel using a soft punch. Drive the bear-
ing out from the opposite side. See Figure 2.

1. LINK 5. BUSHING
2. GREASE FITTING 6. AXLE SHAFT
3. ROLLER 7. FITTING
4. BEARING

2
4000 YRM 1008 Rear Link and Load Wheel

8. ROLL PIN

Figure 2. Load Wheel and Link Assembly

NOTE: Some models are equipped with sealed bear- bearings. Insert a punch to align the roll pin hole in
ings. Do not attempt to clean or lubricate sealed bear- the axle shaft with the hole in the link.
ings. Sealed bearings in need of service must be re-
placed. 3. Install the roll pin through the link to secure the axle
shaft.
8. Remove all old lubricant. Clean and inspect all
parts. Replace all defective parts. 4. Reconnect the battery. Move the key to the ON
position.
INSTALL
5. Press the lift button to fully extend the lift link.
NOTE: Some models are equipped with sealed bear-
6. Remove the blocks from under the forks and drive
ings. Do not attempt to clean or lubricate sealed bear-
end of truck. Lubricate the load wheel and link fit-
ings. Sealed bearings in need of service must be re-
tings then press the lift and lower buttons to raise
placed.
and lower the forks. The truck should lift and lower
1. Prelubricate the bearings with the recommended evenly.
grease. Install bearings into the load wheel and
7. Install the battery in the battery compartment.
install the bushings into the bearings.
8. Test the operation of the motorized hand truck be-
2. Position the load wheel assembly into the link. In-
fore returning the truck to service.
sert the axle shaft through the link, bushings, and

Rear Link and Load Wheel

REMOVE
WARNING
Put blocks under both forks and on both sides of
the drive tire. The blocks must prevent the lift truck
from falling and causing personal injury or property
damage.
1. Remove the battery from the lift truck. Position
the battery close enough to the lift truck to allow
power cable connection during servicing. Connect
the battery and turn the key switch to the ON posi-
tion.
2. Use the lift button to raise the lift truck to its maxi-
mum height.
3. Put blocks under both forks and under the drive end
of truck. See the section How to Put a Lift Truck on
Blocks.
4. Press the lower button just enough to relieve pres-
sure from the load wheels.
6. Disconnect the load wheel link from the compres-
sion rod yoke:
a. Remove the roll pin securing the pivot pin in the
yoke.
b. Remove the pivot pin.
7. Remove the load wheel link from the fork frame:
a. Remove the roll pin securing the link and exit
roller to the fork.
b. Drive out the roll pin securing the pivot pin to
the fork.
c. Remove the pivot pins.
d. Remove any bushings as necessary.
8. Disassemble the load wheel. See Load Wheel.
9. Remove all old lubricant. Clean and inspect all
parts for damage. Replace all defective parts.

5. Move the key to the OFF position. Disconnect the

INSTALL
battery. 1. Assemble the load wheel assembly to the link. See
Load Wheel.

3
Compression Rod
NOTE: Some models are equipped with bushings in
the load roller link where the compression rod yoke at-
taches. Install new bushings if removed as required.
2. Install the load wheel and link assembly to the fork:
a. Align the pallet exit roller and load wheel link
with mounting holes in fork.
b. Install the connecting pivot pin and align holes
with a punch.
c. Secure with the roll pin.
3. Connect the load wheel link with the compression
rod:
a. Check condition of yoke components including
bushings and compression rod jam nuts. Re-
place as required.
Compression Rod
REMOVE
WARNING
Put blocks under both forks and on both sides of
the drive tire. The blocks must prevent the lift truck
from falling and causing personal injury or property
damage.
WARNING
Batteries are heavy and can cause a personal injury.
Use care to avoid injury. Do NOT put hands, arms,
feet, and/or legs between the battery and a solid ob-
ject. Make sure the capacity of the lifting device and
spreader bar is greater than the weight of the bat-
tery. The weight of the battery is normally shown
on the battery case. The maximum battery weight
is shown on the lift truck nameplate. The spreader
bar must NOT be made of metal or it must have in-
sulated straps.
1. Use the lift button to raise the lift truck to its maxi-
mum height.
2. Put blocks under both forks and on both sides of the
drive tire. See How to Put a Lift Truck on Blocks.
3. Lower the hoist cylinder using the lower button.
This will raise the load wheels off the floor.
4. Move the key to the OFF position. Disconnect the
battery. Remove the battery.
4
4000 YRM 1008
b. Align the compression rod yoke and the load
wheel link.
c. Install the connecting pivot pin and secure with
the roll pin.
4. Connect the power cables and turn the key switch to
the ON position. Press the lift button to fully extend
the load wheels. Remove the blocks from under the
forks and from each side of the drive tire.
5. Lubricate the load wheel link fittings. Lift and lower
the lift truck to check for proper operation. The truck
should lift and lower evenly.
6. Install the battery into the battery compartment.
5. Remove the roll pin retaining the load wheel link
pivot pin to the fork frame. Remove the pivot pin.
6. Remove drive unit and lower cover.
7. Remove the roll pin retaining the lower link pivot pin
to the compression rod. Remove the pivot pin.
8. Remove all old lubricant. Clean and inspect all
parts. Replace defective parts.
INSTALL
1. Install pivot pin retaining lower link and compres-
sion rod. Install roll pin.
2. Align and install the pivot pin connecting the com-
pression rod and the load wheel. Install roll pin.
3. Install the pivot pin connecting the load wheel link
and pallet entry/exit roller and install the roll pin to
retain the pivot pin.
4. Raise the load wheels. Lubricate the load wheel
and all linkage pivot pins.
5. Install the battery in the battery compartment and
connect the battery.
6. Remove the blocks from under the forks and from
each side of the drive tire. Turn the key to the ON
position and use the lower button to lower the lift
truck to its minimum height. The truck should lift
and lower evenly.
4000 YRM 1008 Lower Link

7. Test the operation of the motorized hand truck be-

fore returning the truck to service.

Lower Link
REMOVE
WARNING
Batteries are heavy and can cause a personal injury.
Use care to avoid injury. Do NOT put hands, arms,
feet, and/or legs between the battery and a solid ob-
ject. Make sure the capacity of the lifting device and
spreader bar is greater than the weight of the bat-
tery. The weight of the battery is normally shown
on the battery case. The maximum battery weight
is shown on the lift truck nameplate. The spreader
bar must NOT be made of metal or it must have in-
sulated straps.
WARNING
Put blocks under both forks and on both sides of
the drive tire. The blocks must prevent the lift truck
from falling and causing personal injury or property
damage.
1. Use the lift button to raise the lift truck to its maxi-
mum height.
2. Move the key to the OFF position. Disconnect and
remove the battery.
3. Put blocks under both forks and on both sides of the
drive tire. See the section How to Put a Lift Truck
on Blocks.
4. Remove covers.
5. Remove the roll pin retaining the drive frame pivot
pin to the lower link. Use a drift to drive the pivot
pin out of the lower link and the drive frame. See
Figure 3.

1. FITTING
2. PIN
3. FITTING
4. PIVOT PIN

5
Upper Link
5. PIN
Figure 3. Lower Link
6. Remove the roll pin retaining the lower link pin to
the fork frame. Drive the pin out of the frame using
a drift pin.
7. Remove the bushings from the lower link.
8. Remove all old lubricant. Clean and inspect all
parts. Replace all defective parts.
INSTALL
1. Install new bushings into the lower link using the
grease fitting hole as a guide.
2. Align the lower link with the fork frame and install
the lower link pivot pin. Install the roll pin to retain
the pivot pin.
3. Align the lower link with the drive frame and install
the drive frame pivot pin. Install the roll pin to retain
the drive frame pivot pin.
Upper Link
REMOVE
WARNING
Put blocks under both forks and on both sides of
the drive tire. The blocks must prevent the lift truck
from falling and causing personal injury or property
damage.
6
4000 YRM 1008
4. Align the pull rod and the lower link and install the
pivot pin. Install the roll pin to retain the pivot pin.
5. Lubricate the grease fittings.
6. Remove the blocks from under the forks and from
each side of the drive tire.
7. Install the battery in the battery compartment. Con-
nect the battery.
8. Turn the key to the ON position and use the lower
button to lower the lift truck to its minimum height.
9. Test the operation of the motorized hand truck be-
fore returning the truck to service.
1. Disconnect the battery.
2. Put blocks under both forks and on both sides of the
drive tire. See the section How to Put a Lift Truck
on Blocks.
3. Remove the drive unit compartment cover to ac-
cess the upper link. See Figure 4.
4000 YRM 1008 Caster Wheels (Optional)

1. FITTING 5. NUT
2. UPPER LINK 6. PIN
3. CAPSCREW 7. PIVOT PIN
4. LOCKWASHER

Figure 4. Upper Link

4. Use a drift pin to remove the roll pin retaining the and nut to retain the pivot pin to the fork frame.
pivot pin to the drive unit frame. Drive the pivot pin Repeat for opposite side.
out of the frame and upper link.
2. Align the pivot pin with the drive unit frame and the
5. Remove the screw, washer, and nut retaining the upper link and install the pivot pin. Install a roll pin
pivot pin to the fork frame. Drive the pivot pin out of to retain the pivot pin.
the fork frame and upper link.
3. Install the drive unit compartment cover.
INSTALL
4. Remove the blocks from under the forks and from
1. Align the pivot pin with the fork frame and upper link each side of the drive tire. Connect the battery.
and install the pivot pin. Install the screw, washer,
5. Test for proper operation before returning the truck
to service.

Caster Wheels (Optional)

REMOVE 1. Raise the drive wheel off the floor. Block the lift
truck. See How to Put a Lift Truck on Blocks. Dis-
WARNING connect the battery.
Put blocks under both forks and on both sides of 2. Remove the three screws retaining the caster and
the drive tire. The blocks must prevent the lift truck spacer to the frame. Remove the caster wheel. See
from falling and causing personal injury or property Figure 5.
damage.

7
Caster Wheels (Optional) 4000 YRM 1008

2. Repeat Step 1 to install other caster if necessary.

3. Remove the blocks from under the lift truck and

lower the truck to the floor. Test the operation of
the truck prior to returning the truck to service.

REPLACE

WARNING
Put blocks under both forks and on both sides of
the drive tire. The blocks must prevent the lift truck
from falling and causing personal injury or property
damage.

NOTE: The caster wheel does not have to be removed

from the lift truck frame to replace the wheel or the
wheel axle. To replace the wheel or wheel axle, follow
these steps:

1. Raise the drive wheel off the floor. Block the lift
truck. See How to Put a Lift Truck on Blocks.

1. CASTER 4. LOCKWASHER 2. Remove the lock nut retaining the wheel on the
ASSEMBLY 5. NUT wheel axle. Drive the wheel axle out of the arms
2. PLATE and remove the wheel.
3. BOLT
3. Align the wheel between both arms and install
Figure 5. Caster Wheel the wheel axle. Install the nut on the wheel axle.
Tighten the nuts to 34 to 47 N•m (25 to 35 lbf ft).
3. Repeat Step 2 to remove other caster if necessary.
4. Remove the blocks from under the lift truck and
INSTALL lower the truck to the floor. Test the operation of
the truck prior to returning the truck to service.
1. Align the caster and spacer with the holes in the
frame and install the three screws. Tighten the nuts
to 56 N•m (42 lbf ft).

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

4000 YRM 1008 8/09 (9/05)(1/02) Printed in U.S.A.

 Maintenance

DC MOTOR
MAINTENANCE
ALL ELECTRIC LIFT TRUCKS

PART NO. 524158039 0620 YRM 0294

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Brush and Commutator Inspection ........................................................................................................................... 2
Hydraulic Pump Motor and Traction Motor ...........................................................................................................2
Steering Pump Motor ............................................................................................................................................5
Normal Commutator Surface ................................................................................................................................5
Commutator Problems ..........................................................................................................................................5
Brush Replacement ................................................................................................................................................ 10
Stoning the Commutator .........................................................................................................................................13
Motors Repair ......................................................................................................................................................... 15
Disassemble ....................................................................................................................................................... 15
Traction Motor and Hydraulic Pump Motor .................................................................................................... 15
Steering Pump Motor ..................................................................................................................................... 16
Assemble ............................................................................................................................................................20
Traction Motor and Hydraulic Pump Motor .................................................................................................... 20
Steering Pump Motor ..................................................................................................................................... 22
Brush Alignment, Traction and Hydraulic Motors ................................................................................................... 25
Tests for Damaged Field and Armature ..................................................................................................................25
Test for an Open Circuit in One Armature Winding ............................................................................................ 25
Test for Short Circuit in One Armature Winding ................................................................................................. 25
Test for Short Circuit to Armature Shaft ............................................................................................................. 26
Test for Open Circuit in Field Coil .......................................................................................................................26
Test for Short Circuit in Field Coil .......................................................................................................................27
Test for Short Circuit Between Field and Motor Case ........................................................................................ 27
Brush Holder Test ...............................................................................................................................................27
Troubleshooting ...................................................................................................................................................... 28

This section is for the following models:

©2016 Yale Materials Handling Corp. i

0620 YRM 0294
General
This section describes disassembly and assembly,
brush installation, inspection, and checks for
malfunctions of DC motors. Inspect the commutator
and brushes every 350 hours of operation. The
commutator is the rotating electric connection
between the armature and the electric power supplied
by the battery. Brushes made of carbon compounds
slide on the rotating commutator and are the path for
electricity from the battery to the commutator and the
armature. The maintenance of the commutator and
the brushes is important to the good operation of a
DC motor.
Traction motors and hydraulic pump motors are
similar in design. The hydraulic pump motors are
smaller than the traction motors, but the disassembly
and maintenance of these motors are similar. The
General
cooling fan in the traction motors is fastened to the
armature and can be removed from the armature. The
cooling fan can be removed during disassembly of the
traction motor.
The cooling fan in the hydraulic pump motors can be
a press fit on the armature shaft and is not easily
removed during disassembly of the motor. The
armature and cooling fan must be removed from the
drive end of the motor during disassembly.
The assembly and disassembly of the motor used for
the power steering pump is described in the Steering
System section. This motor is a permanent magnet
motor.
1
Brush and Commutator Inspection 0620 YRM 0294

Brush and Commutator Inspection

HYDRAULIC PUMP MOTOR AND
TRACTION MOTOR
NOTE: When inspecting brush conditions and motor
commutator conditions for head damage or abnormal
wear, the battery maintenance and condition should
be eliminated as a cause first. See Industrial Battery
2240YRM0001.

NOTE: The brushes and commutator can be inspec-

ted, the brushes can be replaced, and Stoning the
Commutator can be done with the motor installed in
the truck.

NOTE: Inspect the brushes and commutator every 1. ARMATURE 2. COOLING FAN
350 hours for best operation and to prevent motor (DRIVE) SHAFT 3. BRUSH COVER
damage. The hydraulic pump motor normally has Figure 1. Traction Motor
more start cycles than other motors, so it can have
more wear and possible damage.

NOTE: The following procedure is for inspecting the WARNING

brushes and commutator with the motor installed in
the lift truck. The same inspections can be done with
the motor removed. If the motor is removed, start at
Step 3.
1. To rotate the commutator of the traction motor
without moving the truck, the drive wheels must
be raised. See Figure 1. Raise drive wheels so
commutator of the traction motor can be rotated
without moving lift truck. See How To Raise
Drive Wheels in the Operating Manual or the
Periodic MaintenanceYRM section for your lift
truck.
NOTE: For some models of lift trucks, the battery
does not need to be removed to access the electric
motors. Other models will require the removal of the
battery before gaining access to the electric motors.
To remove the battery, either raise the hood panels or
unfasten the floor plate, depending on which motor
needs to be accessed.
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
NOTE: Vacuum cleaning, when possible, is the rec-
ommendation of manufacturers of electric motors.
The use of compressed air can send dirt particles into
the bearings and other areas of the motor that can
cause possible damage.
3. Remove brush covers at rear of motor. See Fig-
ure 2. Wear eye protection. Use a vacuum
cleaner or compressed air to remove dirt and
brush dust from commutator area.

2. Remove battery. See How to Remove Battery in

the Operating Manual or the Periodic Mainte-
nanceYRM section for your lift truck. Remove ac-
cess plate to motors. If the battery in your lift truck
does not need removal for access to the motors,
go to Step 3.

Figure 2. Brush Cover Removal From Motor

2
0620 YRM 0294 Brush and Commutator Inspection

4. Remove and inspect brushes for damage or un-
even wear. Replace all brushes if any brush is
worn or damaged. The brushes must be at least
half their original length. Move brush springs
away from top of each brush and pull brushes
from their holders to inspect surface that rides on
commutator. See Figure 3. That surface must
have the same shape as the commutator and
must not have cracks or defects. Some brushes
have wear sensor wires attached, even if they are
not connected to an indicator. Replace these
brushes if brushes are worn enough to see sen-
sor at commutator end of brush.
springs away from holders, and install new
brushes so brush commutator surface fully
touches commutator. Make sure the springs are
pushing on each brush. Install and tighten screws
for brush wires and bus connectors.
8. Carefully install brush covers so sparks are kept
inside motor housing. Install battery as described
in Operating Manual or the Periodic Mainte-
nanceYRM section for your lift truck.

5. Inspect commutator surface. See Table 1 and Ta-

ble 2. Carefully rotate armature. DO NOT damage
commutator if you use a tool to rotate armature.

The commutator wears slowly in normal service.

The mica must be cut below the surface of the
commutator bars after a long service period or after
a commutator has been turned in a lathe.

A commutator that has been in service will have a

smooth and polished surface with a darker brown
color where it rotates under the brushes. A varia-
tion of color on the commutator surface between
light brown and darker brown is normal. The sur-
face condition is the lubrication between the com-
mutator and the brushes. The brushes will wear
rapidly if this surface condition does not develop
during the first 6 to 10 hours of operation after a
commutator with a new surface is installed. If the
commutator has deep grooves, rough edges of the
bars, or a few bars that are black or raised above
the others, the motor must be removed for service.
1. BRUSH 3. MICA
6. Inspect white or gray insulation (mica) between 2. BRUSH SPRING
commutator bars. The mica must not touch the
brushes or the brushes will wear very rapidly. Figure 3. Brush Removal and Inspection

7. To replace a brush set, remove screw that holds

brush wires to bus. Pull brush end of springs from
brushes, and pull brushes from holders. Lift brush

3
Brush and Commutator Inspection 0620 YRM 0294

Table 1. Normal Commutator Surfaces

A light brown surface of the commutator where it ro- Variations between light brown and dark brown colors
tates on the brushes is a normal condition. The surface are also normal. The surface of the commutator must
of the commutator must be smooth. be smooth.

A condition called slot bar marking is also normal if the A very dark surface is also a normal and an acceptable
commutator surface is smooth. The variable color oc- condition if the commutator surface is smooth.
curs in a pattern according to the number of conductors
per slot.

4
0620 YRM 0294
STEERING PUMP MOTOR
NOTE: Some electrical trucks use a steering pump
motor. Refer to your truck model's service manual for
instructions on removal and installation of steering
pump motors.
1. Disconnect battery connector. Remove floor plate
from lift truck for access to steering pump motor.
Open hood for access to motor. Remove screws
that hold two brush cover plates to motor housing.
2. Inspect brushes and commutator as described in
previous paragraphs for traction and hydraulic
pump motors. The brush replacement procedure
is also the same, although there are only two
brushes for the steering pump motor. See Ta-
ble 3.
3. Install brush covers and screws. Install floor plate
or close hood and connect battery connector.
Brush and Commutator Inspection
NORMAL COMMUTATOR SURFACE
A commutator that has been in service will have a
smooth and polished surface with a darker brown
color where it rotates under the brushes. See Table 1.
A variation of color on the commutator surface be-
tween light brown and darker brown is normal. This
surface condition is the lubrication between the com-
mutator and the brushes. The brushes will wear rap-
idly if this surface condition does not develop during
the first 6 to 10 hours of operation after a commutator
with a new surface is installed.
COMMUTATOR PROBLEMS
Commutator and motor problems and are shown in
Table 2.
5
Brush and Commutator Inspection 0620 YRM 0294

Table 2. Commutator Problems

Problem Possible Cause Illustration

Heavy streaks and fine • Operation of the
grooves indicate the be- motor in dirty and
ginning of damage to the abrasive condi-
commutator. tions.
• Continuous opera-
tion of a motor with
a light load.
• Brush pressure is
too low.
• Worn brushes.

Grooves and lines that • Operation of the

have followed the heavy motor in dirty and
streaks and fine grooves abrasive condi-
shown above. The arma- tions.
ture must be removed • Continuous opera-
from the motor so the tion of a motor with
commutator can be re- a light load.
paired. A commutator
with this condition will • Brush pressure is
cause the brushes to too low.
wear rapidly. • Worn brushes.

6
0620 YRM 0294
Problem
Grooves that are the
width of the brushes.
A condition called copper
drag occurs when copper
from the commutator bar
is pulled into the slot be-
tween the commutator
bars. This condition will
cause a short circuit be-
tween the commutator
bars if it is not corrected.
The brushes will wear
rapidly.
Brush and Commutator Inspection
Table 2. Commutator Problems (Continued)
Possible Cause Illustration
• Operation of the
motor in dirty and
abrasive condi-
tions.
• Wrong type of
brushes for this
motor and opera-
tion.
• Brush pressure is
too high.
• Operation of the
motor in dirty and
abrasive condi-
tions.
• Brush holder is not
adjusted electri-
cally correct for the
motor.
• Wrong type of
brushes for this
motor and opera-
tion.
• Brush pressure is
wrong (too high or
too low).
7
Brush and Commutator Inspection 0620 YRM 0294

Table 2. Commutator Problems (Continued)

Problem Possible Cause Illustration

Electrical burns on com- • Open armature
mutator bars on opposite winding.
sides of the commutator. • Motor has been
stalled.

Copper wears rapidly at • Operation of the

the edge of the commuta- motor in dirty and
tor bars. abrasive condi-
tions.
• Wrong type of
brushes for this
motor and opera-
tion.

8
0620 YRM 0294 Brush and Commutator Inspection

Table 2. Commutator Problems (Continued)

Problem Possible Cause Illustration

1. Flashover causes • Motor has been
burning of the too hot. Wrong lift
ends of the com- truck for the appli-
mutator bar. cation.
2. Open circuit in • Motor has been
winding causes stalled.
deep burning of • Open armature
adjacent commu- winding.
tator bars.
• Open field coil.
3. Overheating cau-
ses damage to
varnish insulation.

Brush and commutator • Motor has been

damage occurs when the stalled. (High com-
high commutator hits and mutator bars at
forces the brush up. Arc- each brush posi-
ing and burns occur as tion can occur if
the brush moves back the motor is stal-
down to the normal sur- led.)
face. Check for loose or • Motor has been
high commutator bars. too hot.

High commutator bars1.at each brush position can

occur if the motor is stalled.
Rapid brush wear from
2. high commutator bars.

9
Brush Replacement 0620 YRM 0294

Brush Replacement
1. Motor brushes must be replaced before they are
worn enough to damage the surface of the com-
mutator. Move the brush spring and remove a
brush from its brush holder. Install new brushes
as a set if length of any brush is worn to a mini-
mum length. See Table 3. If the brush lead is fas-
tened to the brush with a rivet, install a new set of
brushes if it is worn to within 3 mm (0.118 in.) of
the rivet. If a brush does not move easily in its
holder, a new set of brushes must be installed.
The lead wire for some brushes is installed directly
into the carbon compound of the brush. New
brushes must be installed before the lead wire cuts
a groove in the commutator. Install a new brush set
when a brush is worn to a short length.
Brushes are made to different specifications for
motors used in different applications. Use only new
brushes approved by Yale Company for that motor.

Table 3. Brush Wear Replacement Guide

17 mm 22 mm 28 mm 30 mm 31 mm 32 mm 40 mm
Brush Height
(0.67 in.) (0.87 in.) (1.10 in.) (1.18 in.) (1.22 in.) (1.26 in.) (1.57 in.)
8 mm 12 mm 14 mm 15 mm 16 mm 16 mm 16 mm
Wear
(0.31 in.) (0.47 in.) (0.55 in.) (0.59 in.) (0.63 in.) (0.63 in.) (0.63 in.)
9 mm 10 mm 14 mm 15 mm 15 mm 16 mm 20 mm
Worn Brush Height
(0.35 in.) (0.39 in.) (0.55 in.) (0.59 in.) (0.59 in.) (0.63 in.) (0.79 in.)

NOTE: For some models of lift trucks, the battery
does not need to be removed to access the electric
motors. Other models will require the removal of the
battery before gaining access to the electric motors.
2. Remove battery as necessary for your lift truck.
See How To Remove Battery in the Operating
Manual or the YRM section Periodic Mainte-
nance for your lift truck.
WARNING
Compressed air can move particles so they cause
injury to the user or to other personnel. Verify the
path of the compressed air is away from all per-
sonnel. Wear protective goggles of a face shield
to prevent injury to the eyes.
3. Remove access plate to motors. Remove brush
covers to motor. See Figure 2. Wear eye protec-
tion. Use a vacuum cleaner or compressed air to
remove dirt and brush dust from commutator
area.
4. Make a note of the arrangement and connections
of the brush assembly. See Figure 4. The new
brushes must be installed in the same positions
from which the worn brushes were removed.
5. Loosen screw that fastens brush wire to its termi-
nal. Remove brush springs and brushes.
6. Inspect brush holders for burns and damage.
Make sure brush holders are fastened tightly to
brush mounting plate at end of motor. Make sure
new brushes will move freely and smoothly in
brush holders. Check that brush mounting plate is
holding brush holder so it does not move.

10
0620 YRM 0294 Brush Replacement

Brush springs normally have a spring pressure of

approximately:
1.0 to 2.0 Newtons per each cm2
(1.5 to 3.0 lbf per each in2) when measured
with a spring scale.

A brush for a traction motor has an area of approxi-

mately:
5.33 × 1.27 cm = 6.8 cm2
(2.1 × 0.5 in. = 1.05 in2).

Brush springs for the traction motor normally have

a spring force of approximately:
9.1 to 11.3 Newtons
(36 to 44 ozf) when measured with a spring
scale as shown in Figure 5.

1. BRUSH HOLDER (4)

2. BRUSH MOUNTING PLATE
3. BRUSH SPRING (4)
4. BRUSH SET

Figure 4. Brush Assembly

7. Connect new brush wire to its terminal mount.

NOTE: When new brushes must be installed, a rec-

ommendation is to also install new brush springs.
Damage from heat can cause the brush springs to
have the wrong spring pressure.

8. Check brush springs for damage from heat and

corrosion. If brush springs are damaged, install NOTE: SOME MOTORS HAVE SPRINGS AS
new brush springs. Check brush springs for ap- SHOWN IN FIGURE 7 AND FIGURE 11. SOME
proximately equal pressure. SPRINGS ARE IN PAIRS AT EACH BRUSH
HOLDER.
1. SPRING SCALE 3. COMMUTATOR
2. BRUSH IN BRUSH 4. BRUSH SPRING
HOLDER

Figure 5. Brush Spring Pressure Check

11
Brush Replacement
A brush for a hydraulic pump motor has an area of
approximately:
4.42 × 0.95 cm = 4.21 cm2
(1.74 × 0.375 in. = 0.653 in2).
Brush springs for the hydraulic pump motor nor-
mally have a spring force of approximately:
5.2 to 7.4 Newtons
(20 to 28 ozf) when measured with a spring
scale as shown in Figure 5.
WARNING
Wear eye protection. Raise the drive wheels. Op-
erate the motor at low speed. Protect your fingers.
You are doing work close to moving parts of the
motor. Do not use a brush seater stone less than
60 mm (2.4 in.) in length.
NOTE: The brush springs used in motors made by
Yale have a constant force design. The force of the
brush spring against the brush stays almost constant
as the brush wears and becomes shorter in its brush
holder.
12
0620 YRM 0294
NOTE: New brushes made by the manufacturer are
normally made to fit the surface of the commutator
when they are installed. This contact surface must be
checked when new brushes are installed. The contact
surface MUST be approximately 85 percent of the
brush surface where it touches the commutator. A
small contact surface can cause burns and a rough
surface on the commutator. If the contact surface is
less than approximately 86 percent, the new brushes
must be made to fit the commutator better.
9. If new brushes must be made to fit the surface of
the commutator, see Stoning the Commutator.
Use a Brush Seater and Commutator Stone (No.
23-007M from the Ideal Company or an equiva-
lent brush seater stone). Stoning the commutator
is most easily done when the motor rotates
slowly. When the motor rotates at higher speeds,
the centrifugal force removes the abrasive parti-
cles from the commutator more quickly.
NOTE: To rotate the commutator of the traction mo-
tor without moving the truck, the drive wheels must be
raised. See How to Raise Drive Wheels in the Oper-
ating Manual or the YRM section Periodic Mainte-
nance for your lift truck.
0620 YRM 0294
Stoning the Commutator
1. If the commutator has grooves or other damage,
the armature must be removed so the commuta-
tor can be repaired. Motors are normally repaired
by service persons that have the special equip-
ment required. Connect battery so the motor can
be operated. See Figure 6. The battery must be
removed for access to the motor. Use a jumper
cable to connect battery to lift truck. Raise drive
wheels. See How to Raise the Drive Wheels in
the Operating Manual or the YRM section Peri-
odic Maintenance for your lift truck.
2. Close seat switch and key switch so motor will op-
erate.
NOTE: A brush seater stone can also be fastened to
a wood stick with glue as shown in Figure 6. This ar-
rangement makes it easier to apply a brush seater
stone in small spaces.
3. Operate motor so commutator rotates slowly. Ap-
ply brush seater stone to moving commutator with
light pressure. Move brush seater stone backward
and forward across surface of commutator until
marks on commutator are removed. Apply brush
seater stone to commutator before each set of
brushes so the brush seater particles have an
even distribution.
Stoning the Commutator
CAUTION
Do not permit the brush seater stone to stay in
contact with the commutator too long and cause
more wear than necessary.
4. Turn key switch to OFF position and disconnect
battery. Check all brush contact surfaces. The
brushes fit correctly when 85 percent of the brush
contact surface touches the commutator. This
stoning procedure normally requires approxi-
mately 15 to 45 minutes.
5. When the brushes have the correct contact sur-
face with the commutator, use a vacuum cleaner
to remove abrasive dust from commutator area
and motor.
6. When the installation and checks are complete,
install brush cover. Make sure wires to brushes
do not touch any part of motor case and cause a
short circuit.
13
Stoning the Commutator 0620 YRM 0294

Legend for Figure 6

1. RAISE DRIVE WHEELS

2. JUMPER
3. BATTERY
4. BRUSH SEATER STONE

Figure 6. Stoning the Commutator

14
0620 YRM 0294
Motors Repair
DISASSEMBLE
See the Master Drive Unit section or the Frame sec-
tion for your lift truck for instructions on the removal
and installation of the traction motor.
See the Hydraulic System section for instructions to
remove and install the hydraulic pump and motor.
See the Brush and Commutator Inspection and Brush
Replacement in this section for more information on
these components of the motor.
Traction Motor and Hydraulic Pump Motor
NOTE: It is recommended that the bearings and the
seal be replaced every 3,000 hours or 36 months,
whichever comes first.
1. Clean outside surfaces of motor before disassem-
bly. See Figure 8, Figure 9, and Figure 10. Put
motor on its commutator (brush) end on a bench.
On hydraulic motor assemblies, make index
marks on pump and motor. Make index marks on
end frames of motor and field frame so correct as-
sembly is possible.
2. On hydraulic motor assemblies, remove two cap-
screws that fasten pump to pump motor. See Fig-
ure 11 or Figure 12. Remove pump. Put an index
Motors Repair
mark on armature shaft at the position of the cou-
pler hub for correct assembly. Remove coupler
hub from armature shaft by loosening setscrew
and sliding hub off shaft and key. Do not lose key.
3. Remove brush cover. Remove brushes and
spring assemblies.
4. Remove hex head screws from commutator end
of motor. Carefully slide end frame from motor
and armature shaft. Do not damage parts. A
puller is frequently necessary to separate end
frame from field frame.
CAUTION
The drive end frame and the armature are heavy
components. Work carefully so the field coils,
pole pieces, and armature are not damaged dur-
ing disassembly and assembly.
5. Remove screws that fasten drive end frame to
field frame. Remove end frame and armature.
Use a plastic or rubber hammer as necessary to
loosen end frame.
15
Motors Repair
6. Remove drive end frame from armature.
If the brush holder (1) must be loosened or re-
moved from the end frame for repairs, the brush
holder must be installed again in the same position.
See Figure 7. Make alignment marks between the
brush holder and the end frame before the brush
mounting plate (4) is released. The brush holder
must be installed again in the same position.
If a new brush holder must be installed, there will
not be an alignment mark on the new brush holder.
Make an alignment mark on end frame with a refer-
ence point on brush holder that must be removed.
Install new brush holder so reference point and
alignment mark are aligned. The new brush holder
must be installed in the same position as the old
holder so the timing will be correct.
1. BRUSH HOLDER
2. BRUSH SPRING
3. BRUSH
4. BRUSH MOUNTING PLATE
Figure 7. Brush Holder and Mounting Plate
16
0620 YRM 0294
7. Remove screws that fasten brush holder assem-
bly to commutator end frame.
8. Disassemble components of motor as necessary
to make repairs.
Steering Pump Motor
NOTE: Some lift trucks could be equipped with a
Brushless DC Power Steering motor, which is non-re-
pairable.
NOTE: Some electrical trucks use a steering pump
motor. Refer to the service manual for your truck
model for instructions on the removal and installation
of steering pump motors.
1. See Power Steering Motor and Pump for the re-
moval and installation procedures for the steering
pump motor. Make index marks on the steering
pump and the drive end frame of the motor. Re-
move two capscrews that hold steering pump to
motor. Remove pump and allow oil to drain from
drive end frame.
2. Remove brush covers. See Figure 2. Remove two
screws that hold brushes and terminal wires to
brush holders. Pull brush springs out of the way
and pull two brushes from holders.
0620 YRM 0294 Motors Repair

1. FIELD FRAME ASSEMBLY 10. SCREW (4) 19. SCREW (2)

2. ARMATURE 11. WASHER (8) 20. SNAP RING
3. BRUSH SPRING (4) 12. WASHER 21. OIL SEAL
4. BRUSH (4) 13. FAN COVER 22. BRUSH HOLDER
5. BEARING 14. BRUSH COVER 23. SCREW (4)
6. BEARING 15. SCREW (4) 24. WASHER (4)
7. DRIVE END FRAME 16. WASHER (4) 25. BRUSH MOUNTING PLATE
8. COMMUTATOR END FRAME 17. FAN HUB 26. MOUNT PLATE
9. SCREW (4) 18. FAN 27. SCREW (4)

Figure 8. Typical Traction Motor (Example 1)

17
Motors Repair 0620 YRM 0294

1. SNAP RING 11. BRUSH COVER

2. BEARING 12. COMMUTATOR END FRAME
3. SEAL 13. TERMINAL
4. DRIVE END FRAME 14. BRUSH MOUNTING PLATE
5. FAN COVER 15. BUS CONNECTOR
6. SNAP RING 16. WIRE
7. FAN 17. BRUSH SPRING
8. KEY 18. BRUSH
9. ARMATURE 19. BRUSH HOLDER
10. BEARING 20. FIELD FRAME
Figure 9. Typical Traction Motor (Example 2)

18
0620 YRM 0294 Motors Repair

1. BAND 16. DISC

2. SPRING 17. BRUSH SPRING
3. DRIVE END PLATE 18. BRUSH
4. SCREW 19. SCREW
5. WASHER 20. DISC (SPRING)
6. FAN 21. BRUSH HOLDER
7. RING 22. CIRCLIP
8. ARMATURE 23. BALL BEARING
9. FIELD COIL (FRAME) 24. END PLATE (CPL)
10. POLE SHOE 25. END FRAME (COMMUTATOR)
11. HOUSING 26. HEX HEAD BOLT
12. TUBE 27. LOCKWASHER
13. HEX HEAD BOLT 28. RING
14. SCREW 29. SPRING
15. LOCKWASHER 30. BRUSH COVER
Figure 10. Typical Traction Motor (Example 3)

19
Motors Repair 0620 YRM 0294

3. Make alignment marks on commutator end frame
and field frame. Remove four long screws that
hold commutator end frame to drive end frame.
Pry commutator end frame from field frame. The
bearing will stay with the armature. Make sure the
special spring stays in the end frame.
2. If cooling fan was removed, install it on armature.
Make sure field coils and pole pieces are installed
correctly in field frame.
3. Install brush holder assembly in commutator end
frame. Make sure alignment marks are aligned.

4. Make alignment marks on drive end frame and on 4. Install drive end frame on armature.
field frame. Use a soft hammer to tap drive end
5. Carefully install armature and drive end frame in
frame from field frame. The bearing will stay with
field frame. Make sure index marks are aligned.
the armature.
Install and tighten screws.
5. Pull armature assembly from field frame. The
6. Carefully install commutator end frame on arma-
force of the permanent magnets in the frame
ture and fasten it to field frame. Install and tighten
makes it difficult to remove the armature. Use a
hex head screws.
pry bar to help move armature assembly.
7. Install brushes and spring assemblies. See Brush
6. Make alignment marks on brush holder plate and
Replacement and Brush Alignment, Traction and
on commutator end frame. Remove two screws
Hydraulic Motors in this section.
that hold brush plate to commutator end frame.
Remove brush holder assembly. 8. On hydraulic motor assemblies, install key and
coupler hub to index mark on armature shaft.
ASSEMBLE Tighten setscrew. Install other key and align
pump with coupler and alignment marks. Install
Traction Motor and Hydraulic Pump Motor two capscrews that fasten pump to pump motor.
See Figure 11, Figure 12, or Figure 13.
1. Make sure all components are clean. If bearings
were worn, install new bearings in end frames.
See Figure 8 or Figure 9.

20
0620 YRM 0294 Motors Repair

1. BRUSH COVER 9. BEARING

2. COMMUTATOR END FRAME 10. ARMATURE
3. TERMINAL 11. FAN
4. BRUSH 12. BEARING
5. BRUSH HOLDER 13. DRIVE END FRAME
6. BRUSH SPRING (8) 14. FAN COVER
7. BUSH CONNECTOR (2) 15. WOODRUFF KEY
8. FIELD COILS 16. FIELD FRAME

Figure 11. Typical Hydraulic Pump Motor (Example 1)

21
Motors Repair
Steering Pump Motor
NOTE: Some lift trucks could be equipped with a
Brushless DC Power Steering motor, which is non-re-
pairable.
NOTE: Some electrical trucks use a steering pump
motor. Refer to your truck's service manual for in-
structions on the removal and installation of steering
pump motors.
1. Replace seal in drive end frame. Replace bear-
ings on armature by pushing only on inner races.
2. Install armature into field frame so commutator is
aligned with brush inspection openings in field
frame.
3. Lubricate seal lip with hydraulic oil. Align index
marks and carefully install drive end frame on ar-
mature and field frame assembly.
22
0620 YRM 0294
4. Align index marks and install brush holder assem-
bly in commutator end frame. Install and tighten
two screws.
5. Make sure special spring is in position in commu-
tator end frame. Align index marks and install
commutator end frame. Carefully install four long
screws through field frame into drive end frame.
Tighten screws.
6. Install brush springs and brushes. Make sure an-
gle of brush is in correct position on commutator.
Put end of brush spring on each brush. Connect
brush wires and wires for terminals to correct
brush holder. Install brush covers.
7. Install new O-ring on mounting surface of pump
and align index marks. Align pump drive tang with
armature and install pump on motor. Install and
tighten capscrews.
0620 YRM 0294 Motors Repair

1. WOODRUFF KEY 6. WOODRUFF KEY 12. BRUSHES

2. FAN COVER 7. ARMATURE 13. BRUSH HOLDER ASSEMBLY
3. DRIVE END FRAME 8. BEARING 14. BRUSH SPRING
4. BEARING 9. TERMINAL ASSEMBLY 15. BUS CONNECTOR
5. FAN 10. BRUSH COVER 16. FIELD FRAME
11. COMMUTATOR END FRAME

Figure 12. Typical Hydraulic Pump Motor (Example 2)

23
Motors Repair 0620 YRM 0294

1. DRIVE END COVER 7. HEX HEAD BOLT (8) 14. WASHER

2. ARMATURE 8. BRUSH COVER 15. BRUSH TERMINAL
3. TOLERANCE RING 9. BRUSH PLATE 16. END PLATE (COMMUTATOR
4. FIELD COIL 10. BRUSH HOLDER (4) CPL)
5. POLE PIECE (4) 11. BRUSH SPRING (4) 17. END PLATE
6. HOUSING 12. BRUSH (4) 18. FAN
13. SCREW (4) 19. SHROUD (FAN)

Figure 13. Typical Hydraulic Pump Motor (Example 3)

24
0620 YRM 0294
Brush Alignment, Traction and Hydraulic Motors
NOTE: The brush holder in these motors can be rota-
ted for timing of the brush alignment with the commu-
tator. This process normally requires special equip-
ment and training. A special repair service for electric
motors is required to align the bushes for the correct
timing with the commutator. If the brushes are not
timed correctly with the commutator, the motor will
have a low power output. The procedures for timing
an electric motor are not described in this section. Do
not rotate the brush holder from its original position.
If the brush holder must be loosened or removed from
the end frame for repairs, the brush holder must be in-
stalled again in the same position. See Figure 7.
Tests for Damaged Field and Armature
The tests described in the following paragraphs are to
help a service person check a motor for damage and
to determine if it must be sent to a repair service for
rebuilt motors. The resistance checks will not normally
indicate a short circuit in a motor winding. A resist-
ance greater than 1 to 2 ohms can indicate a dam-
aged winding. The motor must be removed from the
lift truck and disassembled as shown in the illustra-
tions before the tests can be done.
TEST FOR AN OPEN CIRCUIT IN ONE
ARMATURE WINDING
The armature windings in large electric motors nor-
mally have less than 1 ohm of resistance. The two
commutator bars for a winding are found 180 degrees
apart on the commutator. If an ohmmeter (R × 1
scale) is used to check the resistance between the
two commutator bars of the winding, a resistance of
more than 1 ohm indicates a problem in that winding.
A resistance of infinity (∞) indicates an open (dam-
aged) winding. See Figure 14.
If the armature has an open circuit, there will normally
be two burned commutator bars on opposite sides of
the commutator. These burned areas will cause the
brushes to wear rapidly. When the motor operates,
large electric sparks and arcs occur as the damaged
commutator bars rotate under each brush. See Ta-
ble 2.
Brush Alignment, Traction and Hydraulic Motors
Make alignment marks between brush holder and end
frame before brush mounting plate is released. The
brush holder must be installed again in the same posi-
tion.
If a new brush holder must be installed, there will not
be an alignment mark on the new brush holder. Make
an alignment mark on end frame with a reference
point on brush holder that must be removed. Install
new brush holder so the reference point and the align-
ment mark are aligned. The new brush holder must
be installed in the same position as the old holder so
the timing will be correct.
1. COMMUTATOR BARS
2. TEST PROBES AT 90-DEGREE SEPARATION
3. RESISTANCE SHOULD BE LESS THAN 1 OHM
Figure 14. Test for an Armature Open Circuit
TEST FOR SHORT CIRCUIT IN ONE
ARMATURE WINDING
A short circuit in a motor winding is difficult to test be-
cause of the normal low resistance (less than 1 ohm)
of a good armature. Special equipment is necessary
to check for a short circuit in a motor winding. A motor
with a short circuit in an armature winding will have a
different sound when it begins to operate, but a serv-
ice person must have experience to hear and under-
stand the difference in sound. A winding with a short
circuit will also run hotter than a good winding and
can have indications of heat damage. A winding that
shows heat damage when the other windings are nor-
mal can have a short circuit. See Figure 15.
25
Tests for Damaged Field and Armature
Another indication of a short circuit will be a higher
than normal current draw by the motor. A higher than
normal current draw can also indicate other problems
or needed adjustments and does not always indicate
a short circuit in a motor winding.
1. COMMUTATOR BARS
2. TEST FOR SHORT CIRCUIT BETWEEN WIND-
INGS
3. RESISTANCE SHOULD BE BETWEEN 1 OHM
AND INFINITY
Figure 15. Test for an Armature Winding Short
Circuit
TEST FOR SHORT CIRCUIT TO
ARMATURE SHAFT
NOTE: Clean the dirt and brush dust from the com-
mutator area before making a test for a short circuit.
An ohmmeter (R × 10,000 scale) can be used to test
for a short circuit between an armature winding and
the armature shaft. Put one probe on the armature
26
0620 YRM 0294
shaft and the other probe on a commutator bar. See
Figure 16. A resistance of less than 1 megohm indi-
cates a problem between a winding and the armature
shaft.
1. ARMATURE SHAFT
2. COMMUTATOR
3. PROBES TO OHMMETER
4. RESISTANCE SHOULD BE GREATER THAN
1 MEGOHM
Figure 16. Test for Short Circuit to Armature Shaft
TEST FOR OPEN CIRCUIT IN FIELD COIL
The field windings in large electric motors normally
have less than 1 ohm of resistance. If an ohmmeter
(R × 1 scale) is used to check the resistance between
the two terminals of the winding, a resistance greater
than 1 ohm indicates a problem in that winding or cor-
rosion in the terminal connection. See Figure 17.
0620 YRM 0294
1. FIELD COIL TERMINAL
2. RESISTANCE SHOULD BE LESS THAN 1 OHM
Figure 17. Test for Open Field Circuit
TEST FOR SHORT CIRCUIT IN FIELD
COIL
A short circuit in a motor field winding is difficult to test
because of the normal low resistance (less than
1 ohm) of a good field. Special equipment is neces-
sary to check for a short circuit in a motor winding. A
motor with a short circuit in a field winding will have a
different sound when it begins to operate, but a serv-
ice person must have experience to hear and under-
Tests for Damaged Field and Armature
stand the difference in sound. A winding with a short
circuit will also run hotter than a good winding and
can have indications of heat damage.
Another indication of a short circuit will be a higher
than normal current draw by the motor. A higher than
normal current draw can also indicate other problems
or needed adjustments and does not always indicate
a short circuit in a motor winding.
TEST FOR SHORT CIRCUIT BETWEEN
FIELD AND MOTOR CASE
Make sure that carbon dust has been cleaned from
the motor before making this test. An ohmmeter (R ×
10,000 scale) can be used to test for a short circuit
between the field and the motor case. Put one probe
on the motor case and the other probe on a field ter-
minal. Check the resistance between the field terminal
and the motor case. A resistance of less than 1 meg-
ohm indicates a problem between the field terminal
and the motor case.
BRUSH HOLDER TEST
Make sure the carbon dust has been removed from
the brush holders. Use an ohmmeter (R × 10,000
scale) to measure the resistance between the brush
holder and the motor case. The correct resistance is
an indication of infinity (∞).
27
Troubleshooting 0620 YRM 0294

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Heavy streaks and fine grooves Operation in a dirty or abrasive en- Clean commutator more fre-
(see Table 2). vironment. quently.

Continuous operation of motor with Increase load on motor from time

a light load. to time.

Brush pressure is too low. Increase brush pressure.

Worn brushes. Replace brushes.

Grooves and lines following heavy Operation in a dirty or abrasive en- Clean commutator more fre-
streaks. The armature must be re- vironment. quently.
placed or the brushes will wear rap-
idly (see Table 2).

Continuous operation of motor with Increase load on motor from time

a light load. to time.

Brush pressure is too low. Increase brush pressure.

Worn brushes. Replace brushes.

Grooves the width of the brushes Operation in a dirty or abrasive en- Clean commutator more fre-
(see Table 2). vironment. quently.

Wrong type of brushes for this mo- Replace brushes with correct type.
tor and operation.

Brush pressure is too high. Adjust brush pressure.

Copper drag occurs when copper Operation in a dirty or abrasive en- Clean commutator more fre-
from the commutator is pulled into vironment. quently.
the slot between the commutator
bars. This problem will cause a
short circuit between the commuta-
tor bars (see Table 2).

Brush holder is not correctly adjus- Adjust brush holder.

ted electrically for the motor.

Wrong type of brushes for this mo- Replace brushes with correct type.
tor and operation.

Brush pressure is incorrect (too Adjust brush pressure.

high or too low).

28
0620 YRM 0294 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Electrical burns on commutator bars Open armature winding. Replace armature.

on opposite sides of the commutator
(see Table 2).

Motor has been stalled. Use correct operating techniques.

Copper wears rapidly at the edge of Operation in a dirty or abrasive en- Clean commutator more fre-
the commutator bars (see Table 2). vironment. quently.

Wrong type of brushes for this mo- Replace brushes with correct type.
tor and operation.

Burning/Overheating Motor has been too hot. Wrong lift Use correct lift truck for the appli-
1. Flashover causes burning of truck for the application. Motor has cation. Use correct operating tech-
the commutator bar. been stalled. Open armature wind- niques. Replace armature or resur-
ing. Open field coil. face commutator in a lathe. Re-
2. Open circuit in winding cau- place field coil.
ses deep burning of adjacent
commutator bars.
3. Overheating causes damage
to varnish insulation (see Ta-
ble 2).

Commutator bars are either too high Motor has been stalled. Use correct operating techniques.
or too loose, both of which can
cause damage to brushes (see Ta-
ble 2).

Motor has been too hot. Use correct lift truck for the opera-
tion.

29
 NOTES

30
0620 YRM 0294 9/16 (3/08)(6/15)(3/06)(8/03)