Mpb040e PDF
Mpb040e PDF
Mpb040e PDF
FRAME
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]
• 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.
• 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.
• 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.
Frame Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Description ...................................................................................................................................................... 1
Frame Repair....................................................................................................................................................... 2
Features .......................................................................................................................................................... 2
Frame Separation and Assembly ........................................................................................................................ 2
Separation....................................................................................................................................................... 2
Assembly......................................................................................................................................................... 2
Battery Compartment .......................................................................................................................................... 3
Battery Compartment Specifications............................................................................................................... 3
Changing the Battery ...................................................................................................................................... 3
Remove....................................................................................................................................................... 4
Install .......................................................................................................................................................... 4
Battery Spacer Adjustment ......................................................................................................................... 4
Label Replacement.............................................................................................................................................. 4
Painting Instructions ............................................................................................................................................ 6
Load Wheels........................................................................................................................................................ 6
Remove ........................................................................................................................................................... 6
Install............................................................................................................................................................... 7
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]
General
DESCRIPTION lifting mechanism. The base of the forks and the bat-
tery end of the weldment are lifted by the cylinder to
The main frame has mounts for the lifting mechanism, raise the load. At the same time, the fork tips are lifted
the electrical system parts, the hydraulic pump assem- by linkage operating the load wheel assembly. There
bly, and the master drive unit (MDU). Repair procedures is also a mount for the optional casters. The mounting
for major systems/parts that fasten to the main frame holes for the casters are in the main frame weldment.
are found in separate YRM manuals.
Models with a fork frame weldment have mounts for the
lifting mechanism. See Figure 1. The fork frame weld-
ment is fastened to the main frame by the links of the
1
Frame Separation and Assembly 100 YRM 1015
Frame Repair
Most lift truck repairs are performed on the individual
WARNING components that are bolted to the frame and not to the
Forklift truck frames and components may have frame itself.
polyurethane paint. Welding, burning, or other heat
sufficient to cause thermal decomposition of the FEATURES
paint may release isocyanates. These chemicals
are allergic sensitizers to the skin and respiratory The lift truck frames are offered in combinations of the
tract and overexposure may occur without odor following options:
warning. Always utilize good industrial hygiene
practices including removal of all paint (prime and 1. Weight Capacity
finish coats) to the metal around the area to be a. 1814 kg (4000 lb)
welded, local ventilation, and/or supplied-air respi- b. 2041 kg (4500 lb)
ratory protection when repairing the frame. c. 2268 kg (5000 lb)
2. Fork Length
WARNING a. 900 mm (36 in.)
Do not make any repairs or adjustments unless you b. 1050 mm (42 in.)
have proper authorization and training. Repairs and c. 1200 mm (48 in.)
adjustments that are not correct can cause a dan- d. 1400 mm (54 in.)
gerous operating condition. Do not operate a lift e. 1500 mm (60 in.)
truck that needs repairs. Report the need for re-
3. Battery Compartment Size
pairs to your supervisor immediately. If repair is
a. 206 mm (8 in.) × 724 mm (29 in.)
necessary, put a DO NOT OPERATE tag on the con-
b. 206 mm (8 in.) × 804 mm (32 in.)
trol handle. Remove the key from the key switch.
c. 232 mm (9 in.) × 724 mm (29 in.)
2
100 YRM 1015 Battery Compartment
4. Install the pivot pin to secure the hydraulic cylinder 7. Connect the battery and turn the key switch to the
to the fork frame. See Hydraulic Cylinder, Install in ON position.
Walkie Hydraulic Systems 1900 YRM 1018.
8. Remove the blocks and lower the lift truck to the
5. Install the battery. floor.
6. Install the drive unit compartment covers. 9. Test the operation of the truck before returning to
service.
Battery Compartment
BATTERY COMPARTMENT Never allow tools or other objects to be placed on top of
SPECIFICATIONS the battery. Water levels in the battery must be checked
regularly and filled to specifications if the level is too low.
WARNING NOTE: Battery water levels can be maintained without
Batteries are heavy. Use care to avoid injury. Al- removing the battery from the truck.
ways use a battery roller stand or tray when trucks
are equipped with optional battery rollers or slide. See Periodic Maintenance 8000 YRM 1009 for more
Always wear protective clothing and eye protection information on regularly scheduled battery mainte-
when working with or near the battery. nance.
3
Label Replacement 100 YRM 1015
Install
WARNING
Before connecting the battery, make sure the key
switch is in the OFF position and the control handle
is in the UP position (brake applied).
CAUTION
The replacement battery must fit the battery com-
partment correctly. Adjust the brackets on each
side of the battery and tighten the capscrews, lock-
washers, and nuts to retain the battery.
CAUTION
Make sure the voltage and weight of the replace-
ment battery is correct as shown on the nameplate.
Make sure the battery is the correct size and weight for
the lift truck.
1. CRANE 3. INSULATED
2. SPREADER BAR STRAPS 1. Remove any obstructions in battery compartment
4. BATTERY (i.e., battery cables or tools).
Figure 2. Changing the Battery 2. Lower new battery into battery compartment.
For the following instructions, refer to Figure 2. 3. Connect battery cable connector. Adjust location of
battery to allow proper connection of cables.
Remove
4. Adjust the brackets on each side of the battery and
1. Move lift truck under overhead crane or other suit-
tighten the capscrews, lockwashers, and nuts to re-
able lifting device.
tain the battery.
2. Block drive tire to prevent movement of lift truck.
5. Remove spreader bar and insulated straps from
3. Turn key switch OFF, disconnect battery connector, battery.
and move it out of the way.
Battery Spacer Adjustment
4. Loosen one of the battery spacers and move it out
of the way. See Figure 2. The battery spacers are designed to hold the battery
in place during normal operation. The spacers are ad-
5. Connect spreader bar to battery using insulated justed by adding or removing spacers as required to
straps and lift battery out of lift truck. prevent the battery from moving.
Label Replacement
NOTE: The nameplate cover is installed using rivets.
WARNING Remove old rivets before installing a new nameplate
Replace damaged Warning or Caution labels imme- cover. See your Yale® lift truck dealer to make sure the
diately. nameplate cover information is correct and complete
before installing a new nameplate cover. Fasten the
If labels or information plates are missing or damaged, nameplate cover with the rivet heads outside.
they must be replaced. See Figure 3.
4
100 YRM 1015 Label Replacement
1. Make sure the surface is dry and free of oil or 3. Carefully hold the label in the correct position above
grease. DO NOT use solvent on new paint. Clean the surface. Put the label in the correct position
the surface of old paint using a cleaning solvent. on the surface. Make sure all air is removed from
under the label and the corners and edges are tight.
2. Remove the paper from the back of the label. DO
NOT touch the adhesive surface.
5
Load Wheels 100 YRM 1015
Painting Instructions
2. Remove the top surface of paint and all rust from
WARNING the metal using sandpaper. Paint all metal sur-
Always use solvents and paints in an area with ven- faces where the paint is completely removed using
tilation. DO NOT use solvents or paints near heat or primer. Apply the primer before applying the color
fire. paint.
Cleaning solvents can be flammable and toxic and 3. Protect all surfaces that will not be painted. DO
can cause skin irritation. Wear protection for eyes NOT paint cylinder rods, cables, labels, plates, or
and skin. When using cleaning solvents, always controls.
follow the recommendations of the manufacturer.
4. Paint all the surfaces the original color, using Yale®
1. Remove all dirt from the surface to be painted. paint. Follow the directions on the container.
Clean the area to be painted using a solvent for
painted surfaces. Remove all oil and grease.
Load Wheels
REMOVE 3. Drive the roll pin retaining the axle shaft to the rear
axle link out of the link and axle.
WARNING 4. Lower the hoist cylinder using the lower button.
Put blocks under both forks and on both sides of This will raise the load wheels off the floor.
the drive tire. The blocks must prevent the lift truck
from falling and causing personal injury or property 5. Move the key to the OFF position. Disconnect the
damage. battery. Remove the battery.
1. Use the lift button to raise the lift truck to its maxi- 6. Remove the axle shaft. Remove bearings and load
mum height. wheel from the link. It may be necessary to drive
the bearing out of the wheel. Drive the bearing out
2. Put blocks under both forks and on both sides of the from the opposite sides. See Figure 4.
drive tire. See the section How to Put a Lift Truck
on Blocks in the Periodic Maintenance manual.
6
100 YRM 1015 Load Wheels
7. Remove all old lubricant. Clean and inspect all 5. Install the battery in the battery compartment and
parts. Replace all defective parts. connect the battery.
INSTALL 6. Remove the blocks from under the forks and from
each side of the drive tire. Turn the key to the ON
1. Prelubricate the bearings with the recommended position and use the lower button to lower the lift
grease. Install the bearings in the load wheel. truck to its minimum height. The truck should lift
and lower evenly.
2. Align the load wheel and bearings inside the link
and insert the axle shaft. 7. Test the operation of the motorized hand truck be-
fore returning the truck to service.
3. Install the roll pin in the link and through the axle
shaft. The function of the load wheels is further explained in
Lifting Mechanism 4000 YRM 1008.
4. Raise the load wheels. Lubricate the load wheel.
7
NOTES
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____________________________________________________________
____________________________________________________________
8
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
• 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.
• 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.
• 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.
Master Drive Unit Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Special Precautions............................................................................................................................................. 1
Master Drive Unit Repair ..................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Disassemble.................................................................................................................................................... 5
Repair.............................................................................................................................................................. 6
Assemble ........................................................................................................................................................ 6
Install............................................................................................................................................................... 6
Troubleshooting ................................................................................................................................................... 7
MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]
General
This section has the description and repair procedures See the section Steering Mechanism 1600 YRM 1004
for the master drive unit (MDU). The traction motor, for troubleshooting and repairs on the steering compo-
steering, and brake repair procedures are in separate nents.
sections. The main parts of the drive unit are the hous-
ing, pinion (motor), first intermediate gear set, second See the section Electrical System 2200 YRM 1007
intermediate gear set, drive gear, bearings, axle, wheel, and DC Motor Maintenance 620 YRM 294 for trou-
and spindle. The spindle is bolted to the top of the drive bleshooting and repairs on the electrical components
unit has tapered bearings installed for the mounting of of the MDU.
the MDU to the frame. The steering control handle fas-
See the section Brakes 1800 YRM 1005 for trou-
tens to the MDU. The traction motor fastens to the drive
bleshooting and repairs of the brake components.
unit. The drive unit and the traction motor turn as a unit
for steering. See the section Periodic Maintenance 8000 YRM
1048, Periodic Maintenance 8000 YRM 1379, or Pe-
In some instances, it may only be necessary to remove
riodic Maintenance 8000 YRM 1009 for instructions
the drive motor and brake assembly to work on the
on checking and changing the drive unit gear oil.
MDU, while in other cases, the MDU must be com-
pletely removed. Determine the extent of disassembly
required before proceeding with any repairs.
Description
The MDU is a triple reduction drive unit. The three sets gear. The drive gear is mounted on the drive axle. The
of gears do not need adjustment for wear. All the parts drive axle is the mount for the final drive gear and the
that rotate have ball bearings or tapered roller bearings. wheel.
The ball bearings are lubed by gear oil and the tapered
roller bearings are packed with multipurpose #2 grease A spring applied/electrically released friction brake is
with 2% to 4% molybdenum disulfide. A pinion gear on mounted to the drive motor between the motor and the
the motor armature drives the first of the three reduction MDU. See the section Brakes 1800 YRM 1005 for ad-
gears. The second intermediate gear engages the drive ditional information on the electrical brake.
Special Precautions
to make a short circuit across the B+ and B
WARNING terminals of the transistor controller. Always wear
Block each side of the truck under the drive unit safety glasses.
frame. Position blocks on both sides of the load
wheels to prevent the truck from falling.
WARNING
Perform the following steps before performing any
WARNING troubleshooting or adjustments, and before con-
The capacitor in the transistor controller can hold necting or disconnecting a handset or personal
an electrical charge after the battery is discon- computer to avoid personal injury and prevent
nected. Discharge the capacitor before inspecting electrical shock.
or repairing any component in the MDU compart-
ment to prevent personal injury and damage to 1. Verify that the key switch is in the OFF position and
the electrical system. Make certain the battery has the battery connector is completely disconnected.
been disconnected. DO NOT use a screwdriver
1
Special Precautions 630 YRM 1003
1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
3. 200-OHM, 2-WATT RESISTOR
4. INSULATED JUMPER WIRES
2
630 YRM 1003 Master Drive Unit Repair
4. Use the following procedure that applies to your lift 12. Lower MDU from frame.
truck:
3
Master Drive Unit Repair 630 YRM 1003
4
630 YRM 1003 Master Drive Unit Repair
5
Master Drive Unit Repair 630 YRM 1003
Assembly of the MDU is basically the opposite of disas- (3) Install cover to housing using eight cap-
sembly. The major difference is installation of the bear- screws (40) and washers (39).
ing assemblies. Use a bearing driver and hammer to (4) Torque capscrews to 23 N•m (17 lbf ft).
drive the bearings into place. Be careful not to damage
the casting with the bearing driver and make sure the 3. Install steering spindle to MDU using the
bearing is completely seated. The following instructions Allen-head screws (11). Apply Loctite 242™ to
refer to the assembly of new or undamaged parts in a the Allen-head screws and torque to 23 N•m
clean work environment. (17 lbf ft).
CAUTION INSTALL
Use a hammer and proper size driver when in- The following steps refer to the installation of clean parts
stalling bearings to avoid damage to bearings that are new or that have been inspected and meet
and/or casting. specifications.
1. Install drive axle and bearings: 1. Support MDU with sling and hoist or overhead
crane and raise to a vertical position.
a. Clean and inspect the tapered roller bearings
for wear or damage. Replace as needed. 2. Clean and inspect the steer bearings for wear or
damage. Replace as needed.
b. Grease the tapered roller bearings, using a
standard bearing packing device, with multipur- 3. Grease the steer bearings, using a standard bear-
pose #2 grease with 2% to 4% molybdenum ing packing device, with multipurpose #2 grease
disulfide. with 2% to 4% molybdenum disulfide.
c. Install bearing cone and seal assembly (27) 4. Install lower steer bearing on spindle.
into casting and properly position seals.
6
630 YRM 1003 Troubleshooting
5. Raise MDU slowly and insert steer shaft through 12. Install control handle. Refer to the section Steering
drive frame. Mechanism 1600 YRM 1004.
6. Install upper steer bearing, flat washer, lockwasher, 13. Remove fill plug (41) and fill MDU to correct level
lock nut, and wire guard sleeve. with gear oil. Install fill plug and torque to 40 N•m
(30 lbf ft).
7. Torque steer bearing lock nut to 54 N•m (40 lbf ft).
Loosen nut and retorque to 34 N•m (25 lbf ft). 14. Install two piece shield on the MDU using the four
Allen-head screws to secure.
8. Bend locking tab into slot on bearing lockwasher.
15. Use the following procedure that applies to your lift
9. Feed main wire harness through the spindle. truck:
11. Mount drive wheel on axle shaft; install washers, 17. Lower truck and connect battery. Check for proper
and wheel bolts. Torque wheel bolts to 115 N•m operation before returning to service.
(85 lbf ft).
Troubleshooting
Lift truck will not move. Battery not properly connected. Check electrical connections.
MDU makes noise. The wrong lubricant is used. Drain incorrect lubricant and refill with
correct gear oil. Refer to Periodic
Maintenance 8000 YRM 1009, Peri-
odic Maintenance 8000 YRM 1379,
or Periodic Maintenance 8000 YRM
1048.
There is not enough lubricant. Fill with gear oil to proper level.
7
Troubleshooting 630 YRM 1003
Worn or damaged axle oil seal. Replace bearing cone and seal assem-
bly.
8
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
STEERING MECHANISM
MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]
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
Special Precautions .................................................................................................................................................. 1
Control Handle Head ................................................................................................................................................ 2
Control Handle ..........................................................................................................................................................2
Remove ................................................................................................................................................................ 2
Install .................................................................................................................................................................... 3
Gas Spring ................................................................................................................................................................5
Discharging the Gas Spring ..................................................................................................................................5
Troubleshooting ........................................................................................................................................................ 6
(MSW020/025-E) [A895];
(MSW025/030-F) [B895];
(MPB040-E) [B827];
(MPW045-E) [B802];
(MPW050-E) [C802]
General
The control handle assembly is designed to perform A bottom-mounted control handle assembly is used
several functions. The standard control handle on the MSW020/025-E, MSW025/030-F, MPB040-E,
includes the speed/direction control and buttons for MPW045-E, and MPW050-E. The handle is designed
the horn, traction reversing, and hydraulic functions. to be used while the operator is walking beside the lift
The control handle is connected to the Master Drive truck.
Unit (MDU) and is used to steer the truck as it turns
the MDU. Move the control handle left or right to turn
the drive/steer tire and steer the truck. Controls
mounted in the handle are linked to the control panel
by a wiring harness that passes through the center of
the handle. The brake is applied when the handle is in
the full up or down position.
Special Precautions
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before trouble-
shooting or adjusting and before connecting or
disconnecting a handset or personal computer.
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 the proper procedure when servicing the
controller.
1
Special Precautions 1600 YRM 1004
1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
3. 200-OHM, 2-WATT RESISTOR
4. INSULATED JUMPER WIRES
Control Handle
REMOVE repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected. Refer to Figure 1
WARNING and Figure 2 in the Special Precautions section of
The gas springs used on the control handle are this manual.
installed under tension and can release with
enough force to cause personal injury or property 1. Move the lift truck to a safe, level area and block
damage. the wheels to prevent movement.
2
1600 YRM 1004 Control Handle
4. Discharge the capacitor in the controller by con- 2. If previously removed, install the bushings into the
necting a 200-ohm, 2 watt resistor between the B support bracket pivot pin holes.
+ and B- connectors on the controller.
NOTE: Install the switch to the bracket with wire to
5. Disconnect the control handle wiring harness plug bottom of the bracket.
and the control handle arm prox switch plug loca-
ted on top of the drive motor. 3. Install the control handle arm prox switch into the
mounting bracket and mount onto the support
For the following instructions refer to Figure 3. bracket with retaining screws. Leave retaining
screws loose until the control handle arm is instal-
6. Remove the rubber bumper retaining screw and led.
wire clamp.
4. Install the bumper and wire clamp with retaining
7. If necessary, remove the control handle head. screw and tighten to 10.5 N•m (93 lbf in).
See the section Electrical System
5. If removed, install the control handle head. See
2200YRM1007, Figure 3.
the section Electrical System 2200YRM1007,
Figure 3.
CAUTION
6. Install the control arm into the support bracket.
Discharging the gas spring is a destructive opera-
Apply Loctite® 242 to the threaded portion of the
tion.
pivot pins and install pivot pins. Torque to 190
8. Discharge and remove the gas spring. Refer to ±7 N•m (140 ±5 lbf ft).
Gas Spring.
7. Install and tighten setscrews.
9. Remove setscrews.
8. Drive the pin through lower end of gas spring to
10. Remove both threaded control arm pivot pins and secure to support bracket.
washers.
9. Adjust control handle arm prox switch. Refer to
11. Remove the control arm from the support bracket. the section Electrical System 2200YRM1007,
Control Handle Arm Prox Switch - Install.
12. Remove two screws from the support bracket and
remove the control handle arm prox switch. 10. Install the MDU covers and drive unit compart-
ment covers.
13. If bushings are worn, remove the bushings from
the support bracket pivot pin holes. 11. Connect the battery and test the operation of the
lift truck prior to returning to service.
INSTALL
1. Install the new gas spring to the control handle
arm. Refer to Gas Spring.
3
Control Handle 1600 YRM 1004
4
1600 YRM 1004 Control Handle
Gas Spring
DISCHARGING THE GAS SPRING
WARNING
Disconnect the battery by separating the battery
connector before opening the compartment cover WARNING
and before inspecting or repairing the electrical Goggles and a face shield must be worn for per-
system. DO NOT place tool on top of the battery. If sonal protection as metal chips and hydraulic lu-
a tool causes a short circuit, the high-current flow bricant may be ejected from the drill operation
from the battery can cause personal injury or due to the high internal pressure.
property damage.
CAUTION
WARNING The control handle return spring is charged with
The capacitor in the traction motor controller can pressurized gas and contains a hydraulic oil lubri-
hold an electrical charge after the battery is dis- cant.
connected. To prevent electrical shock and per-
sonal injury, discharge the capacitor before in- NOTE: This process is a destructive operation to the
specting or repairing any component. Make cer- gas spring. A new gas spring must be used during re-
tain the battery has been disconnected and al- assembly. This is necessary because internal dam-
ways wear safety glasses. See Special Precau- age to the spring components which are not detecta-
tions in this section. DO NOT attempt to discharge ble could cause damage or injury when the spring is
the capacitors by shorting the controller. removed.
5
Gas Spring 1600 YRM 1004
2. Locate and drill a 7 mm (0.25 in.) access hole 3. Locate the gas spring inside the control handle
through the center of the control handle tube, ap- through the newly drilled access hole and drill a
proximately 50 mm (2 in.) below the existing ac- 3 mm (0.125 in.) hole into the gas spring cylinder
cess hole. shell to relieve pressure.
Troubleshooting
Bearing retaining nut torque incor- Loosen retaining nut and tighten to
rect. correct torque. See the section
Master Drive Unit 0630YRM1003.
Drive unit housing bearing (steer) Replace drive unit housing bearing
damaged. (steer).
Steering handle does not return to Gas spring is weak or broken. Replace gas spring.
the vertical position.
6
1600 YRM 1004 10/15 (3/08)(10/06)(9/05)(8/05)(7/05)
Maintenance
BRAKES
MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]
• 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.
• 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.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Brakes Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Special Precautions............................................................................................................................................. 2
Brake Assembly Repair ....................................................................................................................................... 3
Brake Override ................................................................................................................................................ 3
Remove ........................................................................................................................................................... 4
Repair.............................................................................................................................................................. 6
Install............................................................................................................................................................... 7
Troubleshooting ................................................................................................................................................... 8
MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]
General
WARNING WARNING
DO NOT operate a lift truck that needs repairs. If a Always disconnect and separate the battery con-
repair is necessary, put a DO NOT OPERATE tag on nector so that the connector is completely free be-
the control handle. Remove the key from the key fore performing any service or repairs. If the con-
switch. nector is not completely free, it can reconnect. Tag
the connector: DO NOT CONNECT.
WARNING This section has the description and repair procedures
Before performing repairs or adjustments on the for the electric brake on the MSW020-E, MSW025-E,
brake system, blocks must be placed under each MSW025-F, MSW030-F, MPB040-E, MPW045-E, and
side of the frame to raise the drive tire off the MPW050-E lift trucks. Brake assemblies may vary in
ground. The blocks must prevent the lift truck from appearance. Although some assemblies may APPEAR
falling and causing personal injury or property to be adjustable, brake assemblies used on these trucks
damage. See Periodic Maintenance 8000 YRM ARE NOT ADJUSTABLE. Friction between parts inside
1009, Periodic Maintenance 8000 YRM 1379, or the brake will produce brake dust, squeaking, and ex-
Periodic Maintenance 8000 YRM 1048, How to Put treme heat under normal operating conditions. Brake
a Lift Truck on Blocks. assemblies can generate surface temperatures up to
130 C (266 F) and odors during heavy operation. Func-
tions of the brake assembly depend on a dry and clean
environment. Small amounts of oil or grease on the fric-
tion surfaces of the brake can seriously compromise the
brakes ability to function.
Description
Motorized hand trucks have three methods of braking: the truck is stopped, the lift truck will accelerate in the
1. Regenerative (Neutral) braking direction the handle is being turned. Controlled plug-
2. Controlled plugging ging should stop the truck within a few feet, depending
3. Application of the spring-applied/electrically re- on speed and load.
leased friction brake
The parking brake is a spring-applied, electrically re-
NOTE: The preferred method of stopping the truck is: leased friction brake mounted to the drive motor. When
Regenerative (Neutral) braking the parking brake is applied, springs inside the brake
or assembly compress a rotating friction disk against two
Controlled plugging stationary plates.
1
Special Precautions 1800 YRM 1005
Special Precautions
WARNING CAUTION
Block each side of the truck under the drive unit To avoid controller damage, always disconnect
frame. Position blocks on both sides of the load the battery. Discharge the capacitor and never put
wheels. The blocks must prevent the lift truck from power to the controller with any power wire dis-
falling and causing personal injury or property connected. Never short any controller terminal or
damage. motor terminal to battery. Make sure to use proper
procedure when servicing the controller.
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon- 1. Block the lift truck so that the drive wheel is off the
nected. To prevent electrical shock and personal floor. Refer to the proper section for your truck:
injury, discharge the capacitor before inspecting Periodic Maintenance 8000 YRM 1009, Periodic
or repairing any component. Wear safety glasses. Maintenance 8000 YRM 1379, or Periodic Main-
Make certain the battery has been disconnected. tenance 8000 YRM 1048 - How to Put a Lift Truck
Discharge the capacitors in the controller by con- on Blocks.
necting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals with insulated 2. Turn the key switch to the OFF position and discon-
jumper wires. DO NOT use a screwdriver to dis- nect the battery.
charge the traction motor controller. See Figure 2
3. Discharge the capacitors in the controllers by con-
or Figure 3.
necting a 200-ohm, 2-watt resistor across the con-
To avoid personal injury and prevent electrical troller’s B+ and B terminals. See Figure 2 or Fig-
shock, perform the following steps before per- ure 3 for your truck. DO NOT short across the mo-
forming any troubleshooting or adjustments, and tor controller terminals with a screwdriver or jumper
before connecting or disconnecting a handset or wire. Remove the 200-ohm, 2-watt resistor before
computer. reconnecting the battery.
2
1800 YRM 1005 Brake Assembly Repair
3
Brake Assembly Repair 1800 YRM 1005
Figure 4. Brake Override Connector 12. Using a standard puller, remove the bearing (13)
and oil slinger (12) from drive motor shaft.
REMOVE
Move the truck to a safe location before beginning work
CAUTION
and block the wheels to prevent movement. Remove Brake assemblies may vary in appearance. Some
the key from the switch and disconnect the battery con- assemblies have three Allen-head screws on top of
nector. the brake coil. DO NOT REMOVE the Allen-head
screws on TOP of the brake coil. This can change
NOTE: For the following instructions, refer to Figure 5. the factory preset adjustment, rendering the brake
inoperable. These brakes are preset from the fac-
1. Turn key switch to OFF position and disconnect bat- tory and are NOT ADJUSTABLE.
tery. Block the drive tire to prevent movement.
13. Using a 3 mm Allen-head insert at least 55 mm long
2. Remove drive unit compartment covers and MDU with a square socket adaptor, remove three Allen-
covers. head capscrews securing bottom plate of brake as-
sembly to motor.
WARNING
14. Slide brake from drive motor shaft.
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon- 15. Remove spacer (10), hub (18), and woodruff key
nected. Discharge the capacitor before inspecting (17).
4
1800 YRM 1005 Brake Assembly Repair
5
Brake Assembly Repair 1800 YRM 1005
REPAIR If removing the drive motor assembly from the lift truck,
visually inspect the brake. Use a feeler gauge to check
If a brake assembly is malfunctioning, the cause may the gap between the brake coil and armature plate in
be electrical, mechanical, or a combination of both. If several places around the brake to determine if the
the brake electrical system is functioning correctly, the brake is near the end of normal service life. Proper air
brake should release with one solid "click" when ener- gap measurements range from 0.2 to 0.6 mm (0.0078
gized. The brake coil is a large 24 V coil that acts as an to 0.024 in.). See Figure 6. The brake must be replaced
electromagnet to pull the armature plate away from the if it no longer meets the proper air gap specifications
friction disk. If the brake coil is too weak to compress or if otherwise malfunctioning. The brake hub and the
the brake springs and release the friction disk, the brake brake assembly can be replaced separately. However,
must be replaced. if there is damage to the brake hub, there is most likely
damage to the brake assembly.
1. Disconnect the brake wiring harness (if brake is in-
stalled to truck).
6
1800 YRM 1005 Brake Assembly Repair
7
Troubleshooting 1800 YRM 1005
Troubleshooting
Brake does not release. Key switch is in the OFF position. Turn key switch to the ON position.
Handle is not in the BRAKE OFF po- Move the handle to the BRAKE OFF
sition. position.
Control handle arm prox switch is out Adjust/replace control handle arm prox
of adjustment/damaged. switch. See the section Electrical
System 2200 YRM 1007.
Brake does not hold truck Air gap is too large. Replace the brake assembly.
loaded to capacity on 10%
grade.
8
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011