Yale Maintenance

DIAGRAMS
MPB040-E [B827];
MPW045-E [B802]

PART NO. 524154900 8000 YRM 1011

 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!
Diagrams Table of Contents

TABLE OF CONTENTS

General Notes ..................................................................................................................................................... 1

B802 and B827 ............................................................................................................................................... 1
Schematics .......................................................................................................................................................... 2
Figure 1. 1.8 Ton Schematic ........................................................................................................................... 2
Figure 2. 1.8 Ton Diagram .............................................................................................................................. 4
Figure 3. 2.0 Ton, 24 Volt Schematic .............................................................................................................. 6
Figure 4. 2.0 Ton, 12 Volt Schematic .............................................................................................................. 8
Figure 5. 2.0 Ton, 24 Volt Schematic .............................................................................................................. 10
Figure 6. 2.0 Ton, 12 Volt Diagram ................................................................................................................. 12
Figure 7. 2.0 Ton Diagram .............................................................................................................................. 14

This section is for the following models:

MPB040-E [B827];
MPW045-E [B802]

©2002 Yale Materials Handling Corp. i

8000 YRM 1011 General Notes

General Notes
B802 AND B827 • Battery is disconnected.
• Reverse is travel in the direction of the forks.
All parts are shown in the normal position for the follow- • Broken lines are for option/s only. Some truck models
ing condition: may not have all options shown in this diagram.
• All unused terminals and connectors must be secured
• Truck stopped.
to a main wire harness branch.
• Control handle is upright.
• All connectors are drawn from front view.
• Operator is not operating truck.

1
2

Schematics
»

r«@>-i

TRACTION
ARMATURE

_ÿnm£
TRACTION
FIELD

ZAPI CONTROLLER

8000 YRM 1011

8000 YRM 1011 Schematics

GENERAL NOTES

• ALL PARTS ARE SHOWN IN THE NORMAL

POSITION FOR THE FOLLOWING CONDITIONS;
• UNIT STOPPED.
• OPERATOR IS OFF THE UNIT.
• WITH BATTERY DISCONNECTED.
• "REVERSE" IS TRAVEL IN THE DIRECTION
OF THE FORKS.

•• BROKEN LINES ARE FOR OPTION ONLY.

ALL UNUSED TERMINALS AND CONNECTORS MUST
BE SECURE TO A MAIN WIRE HARNESS BRANCH.

• ALL CONNECTORS ARE DRAWN FROM FRONT VIEW

AND ARE ENLARGED FOR CLARITY.

Q
0C
<
O
K ft IQ K
LU
I ft K
- BL« —s°
K n

ILIFT !
< - BL U - 1
X
_l
o
x
- BL" — |
LOWER
cc - BL J -
I
-
I K
—S?
<"> ft K

°5-1
'
o
o - BL U -1
LIFT :

I BL K
k o_|_o k

DISPLAY

HORN SW

BELLY SW

a- 5 BELLY

a-3 SNAIL & CONTROL HANDLE

1.8 TON SCHEMATIC

REV. 3-524153613

Figure 1. 1.8 Ton Schematic

3
Schematics 8000 YRM 1011

AC CONNECTION

KEY SWITCH

— RATTFRY
—

CONTACTOR PANEL

FUST tl _
ZAPI CONTROLLER
{ RED]

FUSE «2

TRACTION
MO I OH

DISPLAY CONNECT TO
CONNECT TO CONTROLLER CONTROLLER
" TERMINAL ÿC"TERMINAL

©003(3130 0000
E30QE3E]© |g||ii|Fllÿl

S
mam BRAKE S*ITCH/
PROXIMITY SWITCH 2
,p

©E3EB
000

THIS CONNECTION IS ALWAYS

COMPLETE FOR NORMAL OPERATION.
DISCONNECT FOR BRAKE OYER IDE
WHEN SERVICING.

1.8 TON DIAGRAM

REV. 3-524153613 BM080051

4
8000 YRM 1011 Schematics

PM2 PHI

MOTOR

SOLENOID

CONTROL
HANDLE
TILLER

CONTROL HANDLE - -

1.8 TON DIAGRAM

REV. 3-524153613 BM080087

Figure 2. 1.8 Ton Diagram

5
Schematics 8000 YRM 1011

A A
A A
DISCONNECT WITH 6NB PALLET PRO

ÿO TRACTION

I CONTACTOR -T-

2.0 TON. 24 VOLT SCHEMATIC.

REV. 2 524158303 BM080052

6
8000 YRM 1011 Schematics

NEUTROL SW i r% I ft
0LK
LIFT SWI
BLU

BLK
LOWER SWI
BLU

BLK
LIFT SW2
BLU

BLK
LOWER SW2
BLU
DASH
DISPLAY

o$

HORN SW
n Ift

SNAIL SW

BELLY SW

PWR

A-2 GND

A- 5 BELLY

A-4 DATA

A- 3 SNAIL & CONTROL HANDLE

2.0 TON. 24 VOLT SCHEMATIC

REV. 2-524158303 BM080088

Figure 3. 2.0 Ton, 24 Volt Schematic

7
Schematics 8000 YRM 1011

-CONNECT WITH INDUSTRIAL BATTERY

A A DISCONNECT WITH GNB PALLET PRO
A A

4 7D

"O TRACTION

I CONTACTOR

2.0 TON. 12 VOLT SCHEMATIC

GENERAL NOTES:
ALL PARTS ARE SHOWN IN THE NORMAL
POSITION FOR THE FOLLOWING CONDITIONS;
UNIT STOPPED.
OPERATOR IS OFF THE UNIT.
WITH BATTERY DISCONNECTED.
"REVERSE" IS TRAVEL IN THE DIRECTION
OF THE FORKS.
BROKEN LINES ARE FOR OPTION ONLY.
ALL UNUSED TERMINALS AND CONNECTORS MUST
BE SECURE TO A MAIN WIRE HARNESS BRANCH.
ALL CONNECTORS ARE DRAWN FROM FRONT VIEW
AND ARE ENLARGED FOR'CLARITY.

REV. 2-524158303 BM080053

8
8000 YRM 1011 Schematics

NEUTROL SW C ft I»K
HO H»

C ft I ft K

-aLKÿ
°n,
O
o - Rl II -1
C ft ID
ft w
H
o BLK

BLU
DASH
DISPLAY <_>

o®
r* I ft

HORN SW

SNAIL

BELLY SW

PWR

A- 2 GND

A- 5 BELLY

A- 4 DATA

A- 3 SNAIL & CONTROL HANDLE

2.0 TON. 12 VOLT SCHEMATIC

REV. 2-524158303 BM080089

Figure 4. 2.0 Ton, 12 Volt Schematic

9
Schematics 8000 YRM 1011

AC CONNECTION

— BATTERY —
BATTER
CHARGER

FUSE 2
ISI I

BRAKE OVER IDE

CONNECTOR FOR TERMINAL TERMINAL
USE DURING SERVICE

TERMINAL TERMINAL

CONNECT TO
CONTROLLER
D" TERMINAL

000
E3E30

DASH
DISPLAY

—
ÿ >—29B -'
ÿÿ

2.0 TON. 24 VOLT SCHEMATIC

REV. 2-524158303 BM080054

10
8000 YRM 1011 Schematics

KEY SWITCH

THIS CONNECTION IS ALWAYS

COMPLETE FOR NORMAL OPERATION
DISCONNECT FOR BRAKE OVER I DE
WHEN SERVICING.

TO 250A TO SB CONNECTOR
FUSE { + ) POS I T IVE TERMINAL

TOP VIEW OF 2.0 TON. 24 VOLT SCHEMATIC

CONTACTOR SHOWN
FOR CLARITY

REV. 2-524158303 BM080090

Figure 5. 2.0 Ton, 24 Volt Schematic

11
Schematics 8000 YRM 1011

( 24V DC/ ÿRED/QLACK-

BATTERY [O 12V DC
\ CONVERTER
BATTERY
CHARGER

BLACK

,|0;
BRAKE OVER IDE
CONNECTOR FOR
USE DURING SERVICE

CONNECT TO
CONTROLLER
"D" TERMINAL

DASH
DISPLAY
-CONNECT WITH INDUSTRIAL BATTERY
DISCONNECT WITH GNB PALLET PRO

2.0 TON, 12VOLT DIAGRAM

REV. 2-524158303 BM080055

12
8000 YRM 1011 Schematics

>

THIS CONNECT IOH IS ALWAYS

COMPLETE FOR NORMAL OPERATION
DISCONNECT FOR BRAKE OVERIDE
WHEN SERVICING.

TO ?50A
FUSE
-\
ÿ
S - T<> SB CONNECTOR
X L/S. / ( ÿ )POS IT IVE TERMINAL

m§\
\D*S
77
TOP VI EW OF
CONTACTOR SHOWN
FOR CLARITY

2.0 TON, 12VOLT DIAGRAM

REV. 2-524158303

Figure 6. 2.0 Ton, 12 Volt Diagram

13
Schematics 8000 YRM 1011

<3-
MOTOR

BLACK -A-I 3
BLACK - BLÿ

ELEC BRAKE SOLENOID

<o) _*i)©
@FM@

TRACT ION
MOTOR

10 @Q
E3®

<3-

SNAIL SW
OPTIONAL
. -0.
1
EKE]
_ 00 CONTROL
HANDLE
THROTTLE

00 CARD ©'
3
.L EFFECT

D
CONTROL HANDLE --

2.0 TON DIAGRAM

REV. 2-524158303

Figure 7. 2.0 Ton Diagram

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

8000 YRM 1011 11/02 (1/02) Printed in U.S.A.