Yale MSW025-E Guía

Maintenance

STEERING MECHANISM

MSW020/025-E [A895];

MSW025/030-F [B895];

MPB040-E [B827];

MPW045-E [B802];

MPW050-E [C802]

PART NO. 524154892 1600 YRM 1004

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the

product. Updated technical service information may be available from your local authorized Yale® dealer.

Service Manuals provide general guidelines for maintenance and service and are intended for use by

trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-

tained in the Service Manual could result in damage to the products, personal injury, property damage or

death.

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the

load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the

weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift

trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK

ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the

specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-

move parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit

needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.

Be sure to follow the necessary safety precautions when handling these fuels and when working on these

fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.

Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this man-

ual:

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

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

This section is for the following models:

(MSW020/025-E) [A895];

(MSW025/030-F) [B895];

(MPB040-E) [B827];

(MPW045-E) [B802];

(MPW050-E) [C802]

Table of Contents

General

The control handle assembly is designed to perform

several functions. The standard control handle

includes the speed/direction control and buttons for

the horn, traction reversing, and hydraulic functions.

The control handle is connected to the Master Drive

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.

A bottom-mounted control handle assembly is used

on the MSW020/025-E, MSW025/030-F, MPB040-E,

MPW045-E, and MPW050-E. The handle is designed

to be used while the operator is walking beside the lift

truck.

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. Turn the key switch to the OFF position and dis-

connect the battery.

2. Discharge the capacitors in the controllers by con-

necting a 200-ohm, 2-watt resistor across the

controller's B+ and B− terminals. DO NOT short

across the motor controller terminals with a

screwdriver or jumper wire. See Figure 1 and Fig-

ure 2.

3. Remove the 200-ohm, 2-watt resistor before re-

connecting the battery.

1. POSITIVE CONNECTION

2. NEGATIVE CONNECTION

3. INSULATED JUMPER WIRES

4. 200-OHM, 2-WATT RESISTOR

Figure 1. Discharging Controller - MPB040-E

1600 YRM 1004 General

Figure 2. Discharging Controller - MSW020-E,

MSW025-E, MSW025-F, MSW030-F, MPW045-E,

and MPW050-E

Legend for Figure 2

1. NEGATIVE CONNECTION

2. POSITIVE CONNECTION

3. 200-OHM, 2-WATT RESISTOR

4. INSULATED JUMPER WIRES

Control Handle Head

Refer to the section Electrical System

2200YRM1007 for instructions on removing and in-

stalling the control handle head from the control han-

dle. The instructions for disassembly and assembly of

the control handle head can be located in the same

section.

Control Handle

REMOVE

WARNING

The gas springs used on the control handle are

installed under tension and can release with

enough force to cause personal injury or property

damage.

WARNING

The capacitor in the transistor controller can hold

an electrical charge after the battery is disconnec-

ted. To prevent electrical shock and personal in-

jury, discharge the capacitor before inspecting or

repairing any component in the drive unit com-

partment. Wear safety glasses. Make certain the

battery has been disconnected. Refer to Figure 1

and Figure 2 in the Special Precautions section of

this manual.

1. Move the lift truck to a safe, level area and block

the wheels to prevent movement.

2. Turn the key switch to the OFF position and dis-

connect the battery.

3. Remove the drive unit compartment covers and

MDU covers.

Special Precautions 1600 YRM 1004

4. Discharge the capacitor in the controller by con-

necting a 200-ohm, 2 watt resistor between the B

+ and B- connectors on the controller.

5. Disconnect the control handle wiring harness plug

and the control handle arm prox switch plug loca-

ted on top of the drive motor.

For the following instructions refer to Figure 3.

6. Remove the rubber bumper retaining screw and

wire clamp.

7. If necessary, remove the control handle head.

See the section Electrical System

2200YRM1007, Figure 3.

CAUTION

Discharging the gas spring is a destructive opera-

tion.

8. Discharge and remove the gas spring. Refer to

Gas Spring.

9. Remove setscrews.

10. Remove both threaded control arm pivot pins and

washers.

11. Remove the control arm from the support bracket.

12. Remove two screws from the support bracket and

remove the control handle arm prox switch.

13. If bushings are worn, remove the bushings from

the support bracket pivot pin holes.

INSTALL

1. Install the new gas spring to the control handle

arm. Refer to Gas Spring.

2. If previously removed, install the bushings into the

support bracket pivot pin holes.

NOTE: Install the switch to the bracket with wire to

bottom of the bracket.

3. Install the control handle arm prox switch into the

mounting bracket and mount onto the support

bracket with retaining screws. Leave retaining

screws loose until the control handle arm is instal-

led.

4. Install the bumper and wire clamp with retaining

screw and tighten to 10.5 N•m (93 lbf in).

5. If removed, install the control handle head. See

the section Electrical System 2200YRM1007,

Figure 3.

6. Install the control arm into the support bracket.

Apply Loctite® 242 to the threaded portion of the

pivot pins and install pivot pins. Torque to 190

±7 N•m (140 ±5 lbf ft).

7. Install and tighten setscrews.

8. Drive the pin through lower end of gas spring to

secure to support bracket.

9. Adjust control handle arm prox switch. Refer to

the section Electrical System 2200YRM1007,

Control Handle Arm Prox Switch - Install.

10. Install the MDU covers and drive unit compart-

ment covers.

11. Connect the battery and test the operation of the

lift truck prior to returning to service.

1600 YRM 1004 Control Handle

Figure 3. Control Handle Assembly

Control Handle 1600 YRM 1004

Legend for Figure 3

1. CONTROL HANDLE ARM

2. PIVOT PIN

3. WASHER

4. BUSHING

5. PIN

6. GAS SPRING

7. SCREW

8. LOCKWASHER

9. FLAT WASHER

10. RUBBER BUMPER

11. CONTROL HANDLE ARM PROX SWITCH

12. MOUNTING BRACKET

13. SCREW

14. SCREW

15. CONTROL HANDLE HEAD

16. SCREW

17. LOCKWASHER

18. FLAT WASHER

19. SCREW

20. LOCKWASHER

21. WIRE CLAMP

22. ALLEN HEAD SCREW

23. SETSCREW

Gas Spring

WARNING

Disconnect the battery by separating the battery

connector before opening the compartment cover

and before inspecting or repairing the electrical

system. DO NOT place tool on top of the battery. If

a tool causes a short circuit, the high-current flow

from the battery can cause personal injury or

property damage.

WARNING

The capacitor in the traction motor controller can

hold an electrical charge after the battery is dis-

connected. To prevent electrical shock and per-

sonal injury, discharge the capacitor before in-

specting or repairing any component. Make cer-

tain the battery has been disconnected and al-

ways wear safety glasses. See Special Precau-

tions in this section. DO NOT attempt to discharge

the capacitors by shorting the controller.

WARNING

The gas spring used on the control handle is in-

stalled under tension and can release with

enough force to cause personal injury or property

damage.

Review the following procedures before removing the

gas spring.

DISCHARGING THE GAS SPRING

WARNING

Goggles and a face shield must be worn for per-

sonal protection as metal chips and hydraulic lu-

bricant may be ejected from the drill operation

due to the high internal pressure.

CAUTION

The control handle return spring is charged with

pressurized gas and contains a hydraulic oil lubri-

cant.

NOTE: This process is a destructive operation to the

gas spring. A new gas spring must be used during re-

assembly. This is necessary because internal dam-

age to the spring components which are not detecta-

ble could cause damage or injury when the spring is

removed.

1. Check that the handle return spring is installed

and properly secure the control handle arm in the

full upright position. Remove the plastic plugs to

increase visibility of the gas spring.

CAUTION

DO NOT damage the control handle wiring har-

ness inside the control handle arm.

1600 YRM 1004 Control Handle

2. Locate and drill a 7 mm (0.25 in.) access hole

through the center of the control handle tube, ap-

proximately 50 mm (2 in.) below the existing ac-

cess hole.

WARNING

Contents are under pressure. This process may

eject metal chips and oil.

3. Locate the gas spring inside the control handle

through the newly drilled access hole and drill a

3 mm (0.125 in.) hole into the gas spring cylinder

shell to relieve pressure.

4. Clean up any discharged oil and dispose of in ac-

cordance with local regulations.

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Steering is rough or difficult. Damaged, worn, or defective steer-

ing handle swivel bearing(s).

Replace bearings.

Steering handle swivel bearing(s)

need lubrication.

Lubricate or repack bearings.

Bearing retaining nut torque incor-

rect.

Loosen retaining nut and tighten to

correct torque. See the section

Master Drive Unit 0630YRM1003.

Drive unit housing bearing (steer)

damaged.

Replace drive unit housing bearing

(steer).

Steering handle does not return to

the vertical position.

Gas spring is weak or broken. Replace gas spring.

Gas spring ball stud broken or

loose.

Retighten or replace gas spring

ball stud.

Gas Spring 1600 YRM 1004

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