Yale MSW025-F Maintenance Manual
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Yale MSW025-F Maintenance Manual

Electrical system
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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

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Summary of Contents for Yale MSW025-F

  • Page 1 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 2 • 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 3: Table Of Contents

    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 4 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 5: 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 6 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 7: 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 8 Lift is disabled on the MSW020/025-E while the charger is operating. The MSW020-E, and MSW025/030-F trucks after operating continu- MSW025-F, and MPB040-E can be configured with a ously for approximately 45 seconds. Lift is disabled on standard 175-amp battery connector to accept the op- the MPB040/045/050-E trucks after operating continu- tional GNB PalletPro.

  • Page 9: 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 10 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 11: 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 12: 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 13: 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 14 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 15 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 16: 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 17: 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 18: Battery Indicator/Hourmeter Display

    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 19: Fuses

    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 20: 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 21: 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 22: 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 23: 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 24: 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 25: 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 26 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 27: 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 28 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 29: 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 30: 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 31 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 32: 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 33 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 34: 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 35: 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 36: 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 37 ® 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 38 ® 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 39 ® 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 40: 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 41: 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 42: 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 43: 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 44: Changing Mode Setting (Dpi Accusense Gen Iii Models With Jumper Ports)

    ® 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 45 ® 2200 YRM 1007 Battery Charger (Accusense by DPI Figure 30. Switch Position Mode Chart...

  • Page 46: Changing Mode Setting

    ® 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 47: 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 48: 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 49: 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 50: 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 51: 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 52 ® 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 53 ® 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 54: 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 55: 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 56 ® 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 57: 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 58: 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 60 2200 YRM 1007 10/16 (8/16)(1/14)(9/13)(12/12)(7/11)

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