Maintenance

BRAKES
MSW020/025-E [A895];
MPB040-E [B827];
MPW045-E [B802]

PART NO. 524154893 1800 YRM 1005

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly 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!
Brakes Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 2
Special Precautions............................................................................................................................................. 3
Brake Assembly Repair ....................................................................................................................................... 4
Brake Override ................................................................................................................................................ 4
Remove ........................................................................................................................................................... 5
Repair.............................................................................................................................................................. 7
Install............................................................................................................................................................... 7
Troubleshooting ................................................................................................................................................... 9

This section is for the following models:

MSW020/025-E [A895];
MPB040-E [B827];
MPW045-E [B802]

©2003 Yale Materials Handling Corp. i

1800 YRM 1005
General
WARNING
Do not operate a lift truck that needs repairs. If a
repair is necessary, put a DO NOT OPERATE tag on
the control handle. Remove the key from the key
switch.
WARNING
Before performing repairs or adjustments on the
brake system, blocks must be placed under each
side of the frame to raise the drive tire off the
ground. The blocks must prevent the lift truck from
falling and causing personal injury or property
damage. See Periodic Maintenance for your truck,
8000 YRM 1009 or 8000 YRM 1048 - How to Put a
Lift Truck on Blocks.
WARNING
Always disconnect and separate the battery con-
nector so that the connector is completely free be-
fore performing any service or repairs. If the con-
nector is not completely free, it can reconnect. Tag
the connector: DO NOT CONNECT.
General
This section has the description and repair procedures
for the electric brake on the MSW020-E, MSW025-E,
MPB040-E, and MPW045-E lift trucks. Brake assem-
blies may vary in appearance. Although some assem-
blies may APPEAR to be adjustable, brake assemblies
used on these trucks ARE NOT ADJUSTABLE. Fric-
tion between parts inside the brake will produce brake
dust, squeaking, and extreme heat under normal oper-
ating conditions. Brake assemblies can generate sur-
face temperatures up to 130oC (266oF) and odors dur-
ing heavy operation. Functions of the brake assem-
bly depend on a dry and clean environment. Small
amounts of oil or grease on the friction surfaces of the
brake can seriously compromise the brakes ability to
function.
1
Description 1800 YRM 1005

Description
Motorized hand trucks have three methods of braking:
1. Regenerative (Neutral) Braking.
2. Controlled Plugging.
3. Application of the spring applied/electrically re-
leased friction brake.
NOTE: The preferred method of stopping the truck is:
Regenerative (Neutral) Braking
or
Controlled Plugging
Regenerative (Neutral) braking applies a retarding force
to the drive wheels through the traction motor, allowing
the unit to slow to a gradual stop. It is applied by return-
ing the speed/direction control to the OFF position.
Controlled plugging is reversing the speed/direction
control while traveling, causing the unit to slow to a
stop. Return the speed/direction control to the OFF po-
sition to remain stopped. If the speed/direction control
is not returned to the OFF position, the lift truck will ac-
celerate in the opposite direction. Controlled plugging
should stop the truck within a few feet, depending on
speed and load.
A spring applied/electrically released friction brake is
mounted to the drive motor. When the control handle
arm is moved to the BRAKE ON position, springs inside
the brake assembly apply the brake by compressing a
rotating friction disk against two stationary plates.
To release the brake:
1. Connect the battery.
2. Turn the key switch to the ON position.
3. Lower the control handle arm to the operating posi-
tion or BRAKE OFF position. Refer to Figure 1.
4. Rotate direction/speed control (butterfly knobs) in
the direction of travel.
The brake is applied when the control handle arm is in
the BRAKE ON position (full up or full down position) or
if a traction fault occurs. The brake is released by low-
ering the control handle arm to the BRAKE OFF posi-
tion and selecting a direction with the speed/direction
control. When the direction/speed control is rotated,
the brake coil will energize and pull the armature plate
away from the friction disk, releasing the brake as the
drive motor is activated. The lift truck must meet the
applicable HOLD ON GRADE requirements; it should
be capable of holding on a 10 percent grade with the
maximum rated load.

BRAKE ON

BRAKE OFF

BRAKE ON

HMQ4Q275

Figure 1. Brake Operation

2
1800 YRM 1005 Special Precautions

Special Precautions
2. Turn the key switch to the OFF position and discon-
WARNING nect the battery.
Block each side of the truck under the drive unit
frame. Position blocks on both sides of the load 3. Discharge the capacitors in the controllers by con-
wheels. The blocks must prevent the lift truck from necting a 200-ohm, 2-watt resistor across the con-
falling and causing personal injury or property troller’s B+ and B terminals. See Figure 2 or Fig-
damage. ure 3 for your truck. DO NOT short across the mo-
tor controller terminals with a screwdriver or jumper
wire. Remove the 200-ohm, 2-watt resistor before
WARNING reconnecting the battery.
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. To prevent electrical shock and personal
injury, discharge the capacitor before inspecting
or repairing any component. Wear safety glasses.
Make certain the battery has been disconnected.
Discharge the capacitors in the controller by con-
necting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals with insulated
jumper wires. Do NOT use a screwdriver to dis-
charge the traction motor controller. See Figure 2
or Figure 3.

WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments, and
before connecting or disconnecting a handset or
computer.

CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never put
power to the controller with any power wire dis- BM080062

connected. Never short any controller terminal or

motor terminal to battery. Make sure to use proper 1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
procedure when servicing the controller. 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
1. Block the lift truck so that the drive wheel is off
the floor. Refer to Periodic Maintenance for your Figure 2. Discharging Controller - MPB040-E
truck, 8000 YRM 1009 or - 8000 YRM 1048 - How
to Put a Lift Truck on Blocks.

3
Brake Assembly Repair 1800 YRM 1005

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

Figure 3. Discharging Controller - MSW020/025-E

and MPW045-E

+B
£>

BM080063

1. NEGATIVE CONNECTION

Brake Assembly Repair

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

4
1800 YRM 1005
BM040025
1. BRAKE WIRING HARNESS
2. MAIN WIRING HARNESS
3. BRAKE OVERRIDE CONNECTOR
Figure 4. Brake Override Connector
REMOVE
Move the truck to a safe location before beginning work
and block the wheels to prevent movement. Remove
the key from the switch and disconnect the battery con-
nector.
NOTE: For the following instructions, refer to Figure 5.
1. Turn key switch to OFF position and disconnect bat-
tery. Block the drive tire to prevent movement.
2. Remove drive unit compartment covers and MDU
covers.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. Discharge the capacitor before inspecting
Brake Assembly Repair
or repairing any component in the MDU compart-
ment to prevent personal injury and damage to the
electrical system. Always wear safety glasses.
3. Discharge capacitors. Refer to Special Precautions
in the front of this section.
4. Remove Allen-head screws (7) and washers (8)
from the cover that secure motor and brake assem-
bly to MDU.
5. Support drive motor with one hand and remove re-
maining Allen-head screw (2) and washer (3) with
other hand.
6. Remove motor and brake assembly from MDU.
7. Tag and remove wires and cables from motor and
unplug brake wire harness.
8. Place motor on workbench securely supported in
an upright position.
9. Remove O-ring from housing.
10. Remove nut (9) from motor shaft.
11. Remove gear (11) and woodruff key (16) from drive
motor shaft.
12. Using a standard puller, remove the bearing (13)
and oil slinger (12) from drive motor shaft.
CAUTION
Brake assemblies may vary in appearance. Some
assemblies have three Allen-head screws on top of
the brake coil. DO NOT REMOVE the Allen-head
screws on TOP of the brake coil. This can change
the factory preset adjustment, rendering the brake
inoperable. These brakes are preset from the fac-
tory and are NOT ADJUSTABLE.
13. Using a 3 mm Allen-head insert at least 55 mm long
with a square socket adaptor, remove three Allen-
head capscrews securing bottom plate of brake as-
sembly to motor.
14. Slide brake from drive motor shaft.
15. Remove spacer (10), hub (18), and woodruff key
(17).
5
Brake Assembly Repair 1800 YRM 1005

BM040020

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

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

Figure 5. Brake Assembly

6
1800 YRM 1005 Brake Assembly Repair

REPAIR Figure 6. The brake must be replaced if it no longer

meets the proper air gap specifications or if otherwise
If a brake assembly is malfunctioning, the cause may malfunctioning. The brake hub and the brake assembly
be electrical, mechanical, or a combination of both. If can be replaced separately. However, if there is dam-
the brake electrical system is functioning correctly, the age to the brake hub, there is most likely damage to the
brake should release with one solid "click" when ener- brake assembly.
gized. The brake coil is a large 24 V coil that acts as an
electromagnet to pull the armature plate away from the
friction disk. If the brake coil is too weak to compress
the brake springs and release the friction disk, the brake
must be replaced.

1. Disconnect the brake wiring harness (if brake is in-

stalled to truck).

2. Check voltage to the brake using a voltmeter.

a. Turn the key switch to the ON position.

b. Place the control handle arm in the BRAKE

OFF position.

c. Lightly rotate the directional controls to activate

the brake coil circuit.

d. Touch each lead of a voltmeter to each side

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

e. Voltage to the brake should read approximately

24 V.

3. Check the resistance of the brake coil using an

ohmmeter.

a. Touch each lead of the ohmmeter to each side

of the brake wiring harness connector. BM040028

b. If the brake coil resistance reads between 1. BRAKE COIL

30.24 and 27.36 (ohms), the brake coil is 2. AIR GAP
functioning properly. 3. ARMATURE PLATE
4. FEELER GAUGE
c. If the resistance reading falls outside the spec-
ified range, the entire brake assembly must be Figure 6. Brake Assembly
replaced.
INSTALL
If the brake mechanical functions are not operating cor-
rectly, the brake will not hold a fully loaded lift truck on a For the following instructions, refer to Figure 5.
10% grade. The brake is NOT ADJUSTABLE and must 1. Install woodruff key (17) to drive motor shaft and
be replaced when it will not hold to specification. If re- slide hub onto shaft and key. Make sure groove and
moving the drive motor assembly from the lift truck, vi- key are aligned properly.
sually inspect the brake and check the air gap to deter-
mine if the brake is near the end of normal service life. 2. Install spacer (10) and brake assembly on to motor
Use a feeler gauge to check the gap between the brake shaft and slide down on to hub. Make sure brake
coil and armature plate. Proper air gap measurements spline align with teeth on the hub.
range from 0.2 to 0.6 mm (0.0078 to 0.024 in.). See

7
Brake Assembly Repair 1800 YRM 1005

10. Install Allen-head screws (7) and washers (8).

CAUTION Torque all three Allen-head screws to 10 N•m
Brake assemblies may vary in appearance. Some (7 lbf ft).
assemblies have three Allen-head screws on top
of the brake coil. DO NOT TURN the Allen-head 11. Install MDU covers and drive unit compartment cov-
screws on TOP of the brake coil. This can change ers.
the factory preset adjustment, rendering the brake
12. Reconnect battery, and remove blocks from wheels.
inoperable. These brakes are preset from the fac-
tory and are NOT ADJUSTABLE. 13. Brake should hold parked lift truck loaded to capac-
ity on a 10% grade. Test for proper operation before
3. Using a 3 mm Allen-head insert at least 55 mm long
returning to service.
with a square socket adaptor, install three Allen-
head capscrews securing bottom plate of brake as-
sembly to motor. Torque to 2.8 N•m (25 lbf in)

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

on to shaft using a standard press.

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

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

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

grease to ensure proper installation of drive motor
shaft assembly.

7. Reconnect wiring as removed.

CAUTION
The brake wiring harness must be aligned with the
notch in the MDU housing. If the motor and brake
assembly is secured to the MDU incorrectly, the BM040029

brake wiring harness may be damaged.

1. MDU HOUSING
8. Place motor shaft assembly into housing. Position 2. BRAKE WIRE NOTCH
motor and brake correctly to align brake wiring har-
ness in notch. See Figure 7. Hold the motor in Figure 7. MDU Brake Wire Notch
place until next step is complete.

9. Install Allen-head screw (2) and washer (3).

8
1800 YRM 1005 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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

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

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

Coil is open. Measure coil resistance. If resistance

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

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

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

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

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

Air gap is too large. Replace the brake assembly.

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

Friction disk is too worn. Replace the brake assembly.

Brake hub damaged. Replace brake and hub assembly.

9
 NOTES

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

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