Yale MPB040E Manual
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Yale MPB040E Manual

Yale MPB040E Manual

Walkie hydraulic systems
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Maintenance
WALKIE HYDRAULIC
SYSTEMS
MPB040E [B827];
MPW045-E [B802];
MPW050-E [C802]
PART NO. 524154894
1900 YRM 1018

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Summary of Contents for Yale MPB040E

  • Page 1 Maintenance WALKIE HYDRAULIC SYSTEMS MPB040E [B827]; MPW045-E [B802]; MPW050-E [C802] PART NO. 524154894 1900 YRM 1018...
  • Page 2 • 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.

  • Page 3: Table Of Contents

    Install................................Relief Valve Adjustment............................Relief Valve Pressure Check........................... Relief Valve Adjust ............................Troubleshooting ..............................Lift Assemblies ..............................Hydraulic Cylinders ............................Hydraulic Pump............................... This section is for the following models: MPB040E [B827]; MPW045-E [B802]; MPW050-E [C802] ©2007 Yale Materials Handling Corp.

  • Page 5: General

    1900 YRM 1018 Operation General The hydraulic system provides the force required to lift The hydraulic pump and motor assemblies are mechan- the loads on all motorized lift trucks. ically joined together as a compact unit, combining the reservoir, pump, and motor together as a single assem- The hydraulic system on the motorized lift truck consists bly.

  • Page 6: Hydraulic Oil

    Operation 1900 YRM 1018 CLEANLINESS 2. When making repairs, use the least number of fit- tings and connections to minimize flow resistance Adhere to the following precautionary steps to ensure and the possibility of leakage. that the hydraulic system remains clean. HYDRAULIC OIL 1.

  • Page 7: Sound Level

    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.

  • Page 8: Hydraulic Unit

    Hydraulic Unit 1900 YRM 1018 Hydraulic Unit REMOVE 6. Remove the hydraulic lines from the hydraulic unit. 7. Loosen and remove the three capscrews attaching WARNING the hydraulic unit to the frame. Remove the hy- Batteries are heavy and can cause personal injury. draulic unit and place in a clean work area.

  • Page 9: Hydraulic Pump

    1900 YRM 1018 Hydraulic Pump 4. Remove the blocks and lower the lift truck to the 6. Install the battery and connect the battery. Operate floor. the lift truck until the hydraulic oil reaches operating temperature. Add additional oil if necessary. Check 5.
  • Page 10 Hydraulic Pump 1900 YRM 1018 Figure 4. Hydraulic Unit...

  • Page 11: Hydraulic Pump Reservoir

    1900 YRM 1018 Hydraulic Pump Reservoir Legend for Figure 4 3. HYDRAULIC SUB UNIT 1. MOTOR 2. ELECTRO-POPPET VALVE 4. FILLER TANK Hydraulic Pump Reservoir REMOVE NOTE: On 24-volt trucks, the capscrews that hold the reservoir to the subunit also hold the motor to the sub- The reservoir of the hydraulic pump unit can be re- unit.

  • Page 12: Hydraulic Cylinder

    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.

  • Page 13: Repacking

    1900 YRM 1018 Hydraulic Cylinder INSTALL 7. Drive the roll pin retaining the top clevis pin out of the frame and clevis pin. Remove the top clevis pin. WARNING 8. Remove the roll pin retaining the bottom clevis pin. Be careful when removing or installing snap rings. Remove the bottom clevis pin and the hydraulic The snap rings can come loose during removal or cylinder.

  • Page 14: Relief Valve Adjustment

    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.

  • Page 15: Relief Valve Adjust

    1900 YRM 1018 Relief Valve Adjustment 14. Turn key switch to OFF position. Disconnect the 6. Install the hydraulic reservoir as removed. battery. Connect the battery and turn key to ON position. 15. Discharge the capacitor. See Special Precautions. 7. Recheck the relief pressure. See Relief Valve Pres- 16.

  • Page 16: Troubleshooting

    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.

  • Page 17: Hydraulic Pump

    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.
  • Page 18 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.
  • Page 20 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.
  • Page 21 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...
  • Page 22 • 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.
  • Page 23 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.
  • Page 24 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...

  • Page 25: General

    2200 YRM 1007 General General This section includes removal, disassembly, checks, fault codes, adjusting parameters, and testing the adjustments, assembly, and installation procedures ZAPI™ motor controller. See the section DC Motor for the electrical system components on the Maintenance 0620YRM0294 for general information MSW020/025-E [A895], MSW025/030-F [B895], on DC motors.
  • Page 26 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.

  • Page 27: Description Of Operation

    2200 YRM 1007 Description of Operation Description of Operation See Figure 2 for the logic diagram. and not serviced separately. The switches that control the hydraulic functions mount into the control handle This section includes information on the following and are serviced separately. components: The Hall effect throttle control, the proportional •...
  • Page 28 Description of Operation 2200 YRM 1007 The lift time-out protects the lift pump and motor as- 175-amp, X-type connector. This connector provides sembly, eliminating the need for a height limit switch. two auxiliary contacts for the truck inhibit circuit, al- Lift is disabled after the pump runs for a programmed lowing the batteries to remain connected to the truck amount of time.

  • Page 29: Special Precautions

    2200 YRM 1007 Special Precautions Special Precautions WARNING WARNING DO NOT make repairs or adjustments unless you The capacitor in the transistor controller can hold have both authorization and training. Repairs and an electrical charge after the battery is disconnec- adjustments that are not correct can create dan- ted.
  • Page 30 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)

  • Page 31: Moving A Disabled Lift Truck

    2200 YRM 1007 Moving a Disabled Lift Truck Moving a Disabled Lift Truck In order to move a disabled lift truck, the electric CAUTION brake must be released by powering the brake coil with battery voltage. A jumper is provided in the wiring Always unplug the Brake Override Circuit and harness to supply battery voltage directly to the elec- connect the Brake Harness prior to operating the...

  • Page 32: Electrical System Checks

    Electrical System Checks 2200 YRM 1007 Electrical System Checks battery has a specific gravity of 1.270 to 1.290. A SAFETY PRECAUTIONS discharged battery has a specific gravity of ap- NOTE: On some models, the dash indicator will dis- proximately 1.165. play the code: EP 107 (or a higher number) for 1 to 2 8.

  • Page 33: Repairs

    2200 YRM 1007 Repairs Repairs NOTE: If removing the entire control panel assembly CONTROLLER, REPLACE to include the electrical panel plate, it will be neces- sary to perform Step 6. If only removing the controller, When experiencing problems with the hydraulic func- contactor, horn, fuses, or wires, it is not necessary to tions, the controller may not be at fault.
  • Page 34 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.
  • Page 35 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.

  • Page 36: Install

    Repairs 2200 YRM 1007 Install 9. Install the lower drive unit compartment cover. 10. Install the upper drive unit compartment cover. NOTE: If installing the entire control panel assembly to include the electrical panel plate, it will be neces- CONTACTOR COIL, CHECK sary to perform Step 1.

  • Page 37: Contactor, Replace

    2200 YRM 1007 Repairs CONTACTOR, REPLACE 8. Loosen two mounting screws and lockwashers that hold contactor to plate and remove contactor. Remove Install 1. Move lift truck to a safe, level area. 1. Install contactor by aligning it with mounting 2.

  • Page 38: Remove

    Battery Indicator/Hourmeter Display 2200 YRM 1007 Battery Indicator/Hourmeter Display NOTE: On some models, the dash indicator will dis- REMOVE play the code: EP 107 (or a higher number) for 1 to 2 1. Turn the key switch to the OFF position and dis- seconds every time the key switch is turned to the ON connect battery.

  • Page 39: Install

    2200 YRM 1007 Fuses Fuses MSW020/025-E WARNING Before checking or changing any fuses, make cer- The MSW020/025-E 24-volt lift trucks have two fuses. tain the battery has been disconnected. They are: 1. 250-amp (FU 1) protects both the lift pump mo- Always wear safety glasses.

  • Page 40: Control Handle Arm Proximity Switch

    Control Handle Arm Proximity Switch 2200 YRM 1007 Control Handle Arm Proximity Switch REPAIR Remove 1. Move the lift truck to a safe, level area before per- A proximity switch is used to sense the position of the forming any repairs. control handle arm.

  • Page 41: Install

    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 b. LED should go off with the handle approxi- bracket. Route the proximity switch wire so that it mately 10°...

  • Page 42: Control Handle

    Control Handle 2200 YRM 1007 Control Handle 10. Using the remaining butterfly knob, slide the shaft DISASSEMBLE out of the handle. Be careful not to rotate the NOTE: It is not always necessary to remove and dis- shaft within the control handle card. assemble all the components that make up the control 11.

  • Page 43: Control Handle Card (New Style)

    2200 YRM 1007 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.

  • Page 44: Configure

    Control Handle 2200 YRM 1007 Configure 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 Refer to Figure 13 for the following instructions. control handle card is configured correctly. 1.

  • Page 45: Calibrate

    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.
  • Page 46 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).

  • Page 47: Assemble

    2200 YRM 1007 Control Handle ASSEMBLE 6. Install lower half of control handle cover to control handle shaft and secure with two capscrews. Tor- 1. Install control handle card in the upper half of con- que to 27 N•m (20 lbf ft). trol handle.
  • Page 48 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.

  • Page 49: Switches (On/Off And Proportional)

    2200 YRM 1007 Control Handle SWITCHES (ON/OFF AND 10. Replace ON/OFF Switch: PROPORTIONAL) a. Separate the button from the switch by spread- ing the four tabs to allow the switch to slide out Remove of the button. NOTE: It is not always necessary to remove and dis- b.

  • Page 50: Traction Motor

    Traction Motor 2200 YRM 1007 Traction Motor brush replacement is RECOMMENDED. See DISASSEMBLE section 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.
  • Page 51 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...

  • Page 52: Assemble

    Traction Motor 2200 YRM 1007 ASSEMBLE 5. Carefully install commutator end cover to housing. Install and tighten capscrews. 1. Make sure all components are clean. If bearings 6. Install brushes and spring assemblies. Replace are worn, install new bearings in end cap. brush cover, if used.
  • Page 53 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.

  • Page 54: Lift Link Proximity Sensor (Mpw050-E)

    Lift Link Proximity Sensor (MPW050-E) 2200 YRM 1007 Lift Link Proximity Sensor (MPW050-E) The lift link proximity sensor is located near the bot- b. If the lift pump and motor does not activate, tom of the control panel. This sensor detects the lift troubleshoot the electrical system.

  • Page 55: Install

    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.

  • Page 56: Battery Charger (Moran ® )

    ® 2200 YRM 1007 Battery Charger (Moran ® Battery Charger (Moran One of the following may be the cause in the event of DESCRIPTION charger failure and the red LED is blinking: Some early model lift trucks are equipped with a •...
  • Page 57 ® 2200 YRM 1007 Battery Charger (Moran • If the AC input fuse is blown, replace and re- necessary. First remove the four Phillips head connect the charger to the AC outlet. Check screws on the side of the charger and slide the AC voltage while in operation to confirm the AC cover off to access the fuse.
  • Page 58 ® 2200 YRM 1007 Battery Charger (Moran 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...
  • Page 59 ® 2200 YRM 1007 Battery Charger (Moran If the charger begins the charge cycle, but stops be- temperature. Eventually, it will become too hot, fore it is complete and an error light comes on, this causing the charger to shut down to protect itself. usually indicates a problem with the batteries.

  • Page 60: Battery Charger (Accusense By Dpi ® )

    ® 2200 YRM 1007 Battery Charger (Accusense by DPI ® 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.

  • Page 61: Charging

    ® 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 Illuminates continuously The charger uses a 5-step charging process: when AC power is present.

  • Page 62: Charger Mode/Battery Type Selection (Dpi Gen Ii Models)

    ® 2200 YRM 1007 Battery Charger (Accusense by DPI CHARGER MODE/BATTERY TYPE CAUTION SELECTION (DPI GEN II MODELS) DO NOT use batteries types that are not approved for the charger or improper mode settings. Dam- CAUTION age to the batteries or charger may occur if the mode setting is not correct for the type of batter- DO NOT use batteries types that are not approved ies being used.

  • Page 63: Charger Mode/Battery Type Selection (Dpi Gen Iii Models)

    ® 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.

  • Page 64: Accusense Gen Iii With Dip Switches

    ® 2200 YRM 1007 Battery Charger (Accusense by DPI Table 4. Battery Chart for DPI Gen III Chargers Only Part Voltage Capacity Application Batt Type DPI Gen III 20HR/ Mode RC@25A (AmpHrs) US - Battery US1800 Deep Cycle HV Flooded Lead Acid AGM2224 Deep Cycle...
  • Page 65 ® 2200 YRM 1007 Battery Charger (Accusense by DPI Figure 30. Switch Position Mode Chart...

  • Page 66: Troubleshooting (Dpi Chargers)

    ® 2200 YRM 1007 Battery Charger (Accusense by DPI Changing Mode Setting peat Step 1. If LEDs still do not flash at least once upon connecting power, replace NOTE: Mode settings can be checked by connecting the charger. the battery charger to a 120V AC power source and 2.

  • Page 67: Error Modes

    ® 2200 YRM 1007 Battery Charger (Accusense by DPI 3. Is the Power On LED illuminated continuously a. Connect the voltmeter to the charger's positive when the charger is connected to a 120 volt AC (Red) and negative (Black) connections at the power source? battery terminals.

  • Page 68: Battery Pack Troubleshooting

    ® 2200 YRM 1007 Battery Charger (Accusense by DPI Battery Voltage High indicates the charger is sens- After a charging cycle, the SG measurement for each ing it is connected to a battery pack with a voltage rat- cell should be 1.265 or greater. ing greater than 24 volts.

  • Page 69: Battery Charger (Accusense ® 20A)

    ® 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.

  • Page 70: Charging

    ® 2200 YRM 1007 Battery Charger (Accusense 20A) 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 Illuminates continuously The charger uses a 6-step charging process:...

  • Page 71: Charger Mode/Battery Type Selection (Accusense 20A)

    ® 2200 YRM 1007 Battery Charger (Accusense 20A) 6. Equalization Stage mode setting is not correct for the type of batter- Equalization stage will happen only when ies being used. If the battery manufacturer of the Mode 2 is selected. During this stage, the battery you are using is not listed, contact Service Power LED flashes.
  • Page 72 ® 2200 YRM 1007 Battery Charger (Accusense 20A) 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...
  • Page 73 ® 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...

  • Page 74: Changing Mode Setting (Accusense 20A)

    ® 2200 YRM 1007 Battery Charger (Accusense 20A) Changing Mode Setting (Accusense 20A) b. Do all 5 LEDs simultaneously flash at least once upon connection? (LEDs should flash be- NOTE: Mode settings can be checked by connecting tween one to four times depending on battery the battery charger to a 120V AC power source and type/mode configuration.) watching the LED display.

  • Page 75: Error Modes

    ® 2200 YRM 1007 Battery Charger (Accusense 20A) 3. Is the Power On LED illuminated continuously a. Connect the voltmeter to the charger's positive when the charger is connected to a 120 volt AC (Red) and negative (Black) connections at the power source? battery terminals.
  • Page 76 ® 2200 YRM 1007 Battery Charger (Accusense 20A) LEDs Frozen (no activity) or Charger seems inop- Internal Over Temperature: Charger shut down due erable: Battery may have been subjected to an Over- to an internal over temperature condition. Check fan Discharge condition.

  • Page 77: Battery Pack Troubleshooting

    ® 2200 YRM 1007 Battery Charger (Accusense 20A) Battery Pack Troubleshooting 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 Disconnect the charger from the AC power source WARNING...

  • Page 78: Troubleshooting

    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.
  • Page 80 2200 YRM 1007 10/16 (8/16)(1/14)(9/13)(12/12)(7/11)
  • Page 81 Maintenance LIFTING MECHANISM MPB040E [B827]; MPW045-E [B802]; MPW050-E [C802] PART NO. 524154897 4000 YRM 1008...
  • Page 82 • 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.
  • Page 83 Install................................Lower Link ................................Remove ................................Install................................Upper Link ................................Remove ................................Install................................Caster Wheels (Optional) ............................ Remove ................................Install................................Replace ................................This section is for the following models: MPB040E [B827]; MPW045-E [B802]; MPW050-E [C802] ©2009 Yale Materials Handling Corp.

  • Page 85: General

    4000 YRM 1008 General General LIFT LINKAGE high pressure hydraulic fluid to the lift cylinder. This action extends the cylinder, operates the lift linkage, and This section has the description and repair procedures raises the forks. At the same time, the rocker arms for the MPB040-E, MPW045-E, MPW050-E units.

  • Page 86: Load Wheel

    Load Wheel 4000 YRM 1008 Load Wheel REMOVE 3. Put blocks under both forks and under the drive end of truck. See the section How to Put a Lift Truck on Blocks. WARNING Put blocks under both forks and on both sides of 4.

  • Page 87: Install

    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.

  • Page 88: Compression Rod

    Compression Rod 4000 YRM 1008 NOTE: Some models are equipped with bushings in b. Align the compression rod yoke and the load the load roller link where the compression rod yoke at- wheel link. taches. Install new bushings if removed as required. c.

  • Page 89: Lower Link

    4000 YRM 1008 Lower Link 7. Test the operation of the motorized hand truck be- fore returning the truck to service. Lower Link REMOVE from falling and causing personal injury or property damage. WARNING 1. Use the lift button to raise the lift truck to its maxi- Batteries are heavy and can cause a personal injury.

  • Page 90: Install

    Upper Link 4000 YRM 1008 5. PIN Figure 3. Lower Link 6. Remove the roll pin retaining the lower link pin to 4. Align the pull rod and the lower link and install the the fork frame. Drive the pin out of the frame using pivot pin.

  • Page 91: Install

    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.

  • Page 92: Install

    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...
  • Page 94 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.
  • Page 95 Maintenance DC MOTOR MAINTENANCE ALL ELECTRIC LIFT TRUCKS PART NO. 524158039 0620 YRM 0294...
  • Page 96 • 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.
  • Page 97 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.

  • Page 99: General

    0620 YRM 0294 General General This section describes disassembly and assembly, cooling fan in the traction motors is fastened to the brush installation, inspection, and checks for armature and can be removed from the armature. The malfunctions of DC motors. Inspect the commutator cooling fan can be removed during disassembly of the and brushes every 350 hours of operation.

  • Page 100: Brush And Commutator Inspection

    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.
  • Page 101 0620 YRM 0294 Brush and Commutator Inspection 4. Remove and inspect brushes for damage or un- springs away from holders, and install new even wear. Replace all brushes if any brush is brushes so brush commutator surface fully worn or damaged. The brushes must be at least touches commutator.
  • Page 102 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.

  • Page 103: Steering Pump Motor

    0620 YRM 0294 Brush and Commutator Inspection STEERING PUMP MOTOR NORMAL COMMUTATOR SURFACE NOTE: Some electrical trucks use a steering pump A commutator that has been in service will have a motor. Refer to your truck model's service manual for smooth and polished surface with a darker brown instructions on removal and installation of steering color where it rotates under the brushes.
  • Page 104 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. •...
  • Page 105 0620 YRM 0294 Brush and Commutator Inspection Table 2. Commutator Problems (Continued) Problem Possible Cause Illustration Grooves that are the • Operation of the width of the brushes. motor in dirty and abrasive condi- tions. • Wrong type of brushes for this motor and opera- tion.
  • Page 106 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 •...
  • Page 107 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.

  • Page 108: Brush Replacement

    Use only new brushes if it is worn to within 3 mm (0.118 in.) of brushes approved by Yale Company for that motor. the rivet. If a brush does not move easily in its holder, a new set of brushes must be installed.
  • Page 109 0620 YRM 0294 Brush Replacement Brush springs normally have a spring pressure of approximately: 1.0 to 2.0 Newtons per each cm (1.5 to 3.0 lbf per each in ) when measured with a spring scale. A brush for a traction motor has an area of approxi- mately: 5.33 ×...
  • Page 110 NOTE: The brush springs used in motors made by NOTE: To rotate the commutator of the traction mo- Yale have a constant force design. The force of the tor without moving the truck, the drive wheels must be brush spring against the brush stays almost constant raised.

  • Page 111: Stoning The Commutator

    0620 YRM 0294 Stoning the Commutator Stoning the Commutator 1. If the commutator has grooves or other damage, CAUTION the armature must be removed so the commuta- tor can be repaired. Motors are normally repaired Do not permit the brush seater stone to stay in by service persons that have the special equip- contact with the commutator too long and cause ment required.
  • Page 112 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...

  • Page 113: Motors Repair

    0620 YRM 0294 Motors Repair Motors Repair DISASSEMBLE mark on armature shaft at the position of the cou- pler hub for correct assembly. Remove coupler hub from armature shaft by loosening setscrew See the Master Drive Unit section or the Frame sec- and sliding hub off shaft and key.

  • Page 114: Steering Pump Motor

    Motors Repair 0620 YRM 0294 6. Remove drive end frame from armature. 7. Remove screws that fasten brush holder assem- bly to commutator end frame. If the brush holder (1) must be loosened or re- moved from the end frame for repairs, the brush 8.
  • Page 115 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.
  • Page 116 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.
  • Page 117 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.

  • Page 118: Assemble

    Motors Repair 0620 YRM 0294 3. Make alignment marks on commutator end frame 2. If cooling fan was removed, install it on armature. and field frame. Remove four long screws that Make sure field coils and pole pieces are installed hold commutator end frame to drive end frame.
  • Page 119 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.

  • Page 120: Steering Pump Motor

    Motors Repair 0620 YRM 0294 Steering Pump Motor 4. Align index marks and install brush holder assem- bly in commutator end frame. Install and tighten NOTE: Some lift trucks could be equipped with a two screws. Brushless DC Power Steering motor, which is non-re- 5.
  • Page 121 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.
  • Page 122 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.

  • Page 123: Brush Alignment, Traction And Hydraulic Motors

    0620 YRM 0294 Brush Alignment, Traction and Hydraulic Motors Brush Alignment, Traction and Hydraulic Motors NOTE: The brush holder in these motors can be rota- Make alignment marks between brush holder and end ted for timing of the brush alignment with the commu- frame before brush mounting plate is released.

  • Page 124: Test For Short Circuit To Armature Shaft

    Tests for Damaged Field and Armature 0620 YRM 0294 Another indication of a short circuit will be a higher shaft and the other probe on a commutator bar. See than normal current draw by the motor. A higher than Figure 16. A resistance of less than 1 megohm indi- normal current draw can also indicate other problems cates a problem between a winding and the armature or needed adjustments and does not always indicate...

  • Page 125: Test For Short Circuit In Field Coil

    0620 YRM 0294 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.

  • Page 126: Troubleshooting

    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.
  • Page 127 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...
  • Page 128 NOTES...
  • Page 130 0620 YRM 0294 9/16 (3/08)(6/15)(3/06)(8/03)

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