Maintenance

FRAME
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]

PART NO. 524154890 100 YRM 1015

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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
remove parts.

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

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

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

WARNING
Indicates a 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

This section is for the following models:

MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]

©2009 Yale Materials Handling Corp. i

100 YRM 1015 General

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. FORKS 6. COUNTERSUNK CAPSCREW

2. FRAME 7. LOWER COVER
3. UPPER COVER 8. WASHER
4. MOTOR COVER (LH) 9. BUTTON HEAD CAPSCREW
5. MOTOR COVER (RH)

Figure 1. Frame Weldment and Covers MPB040-E, MPW045-E, and MPW050-E

1
Frame Separation and Assembly
Frame Repair
WARNING
Forklift truck frames and components may have
polyurethane paint. Welding, burning, or other heat
sufficient to cause thermal decomposition of the
paint may release isocyanates. These chemicals
are allergic sensitizers to the skin and respiratory
tract and overexposure may occur without odor
warning. Always utilize good industrial hygiene
practices including removal of all paint (prime and
finish coats) to the metal around the area to be
welded, local ventilation, and/or supplied-air respi-
ratory protection when repairing the frame.
WARNING
Do not make any repairs or adjustments unless you
have proper authorization and training. Repairs and
adjustments that are not correct can cause a dan-
gerous operating condition. Do not operate a lift
truck that needs repairs. Report the need for re-
pairs to your supervisor immediately. If repair is
necessary, put a DO NOT OPERATE tag on the con-
trol handle. Remove the key from the key switch.
Frame Separation and Assembly
SEPARATION
In some cases a fork frame or a drive unit frame may be
damaged, while the rest of the truck is still usable. The
two frames may be separated from each other by using
the following steps.
1. Raise the motorized lift truck to its maximum height.
Turn the key to the OFF position. Disconnect the
battery.
2. Remove the drive unit compartment covers.
3. Position blocks under both sides of the truck in the
area of the battery compartment and under both
forks. See How to Put Lift Truck on Blocks in Pe-
riodic Maintenance 8000 YRM 1009.
4. Remove the battery.
5. Remove the top clevis pin securing the hydraulic
cylinder to the frame. See Hydraulic Cylinder in
Walkie Hydraulic Systems 1900 YRM 1018.
2
100 YRM 1015
Most lift truck repairs are performed on the individual
components that are bolted to the frame and not to the
frame itself.
FEATURES
The lift truck frames are offered in combinations of the
following options:
1. Weight Capacity
a. 1814 kg (4000 lb)
b. 2041 kg (4500 lb)
c. 2268 kg (5000 lb)
2. Fork Length
a. 900 mm (36 in.)
b. 1050 mm (42 in.)
c. 1200 mm (48 in.)
d. 1400 mm (54 in.)
e. 1500 mm (60 in.)
3. Battery Compartment Size
a. 206 mm (8 in.) × 724 mm (29 in.)
b. 206 mm (8 in.) × 804 mm (32 in.)
c. 232 mm (9 in.) × 724 mm (29 in.)
6. Remove both pivot pins securing the upper link to
the drive unit frame. See Upper Link, Remove in
Lifting Mechanism 4000 YRM 1008.
7. Remove both drive unit frame pivot pins securing
the rocker arm to the drive unit frame. See Rocker
Arm, Remove in Lifting Mechanism 4000 YRM
1008.
8. Carefully move one of the frames away from the
other.
ASSEMBLY
1. Align both frames so the pins may be installed to
assemble the frames to each other.
2. Install both drive unit frame pivot pins to secure the
rocker arms to the drive unit frame. See Rocker
Arm, Install in Lifting Mechanism 4000 YRM 1008.
3. Install both pivot pins to secure the upper link to the
drive unit frame. See Upper Link, Install in Lifting
Mechanism 4000 YRM 1008.
100 YRM 1015
4. Install the pivot pin to secure the hydraulic cylinder
to the fork frame. See Hydraulic Cylinder, Install in
Walkie Hydraulic Systems 1900 YRM 1018.
5. Install the battery.
6. Install the drive unit compartment covers.
Battery Compartment
BATTERY COMPARTMENT
SPECIFICATIONS
WARNING
Batteries are heavy. Use care to avoid injury. Al-
ways use a battery roller stand or tray when trucks
are equipped with optional battery rollers or slide.
Always wear protective clothing and eye protection
when working with or near the battery.
The battery compartment is available in two sizes:
205 mm (8 in.) or 230 mm (9 in.).
Battery rollers may be installed in the floor of the battery
compartment. Gates are installed on both sides of the
battery to prevent movement on the rollers during oper-
ation. Spacers are available to secure batteries that fit
loosely in the battery compartment.
The battery compartment must be kept clean to ensure
proper operation and safety. Any fluids on or around
the battery is an indication that electrolyte is spilling or
leaking out. Leaking batteries must be repaired or re-
placed and the battery compartment must be cleaned.
WARNING
Never place tools or other objects on top of the bat-
tery.
Contact of objects between the battery posts can result
in personal injury and severe damage to the lift truck.
Battery Compartment
7. Connect the battery and turn the key switch to the
ON position.
8. Remove the blocks and lower the lift truck to the
floor.
9. Test the operation of the truck before returning to
service.
Never allow tools or other objects to be placed on top of
the battery. Water levels in the battery must be checked
regularly and filled to specifications if the level is too low.
NOTE: Battery water levels can be maintained without
removing the battery from the truck.
See Periodic Maintenance 8000 YRM 1009 for more
information on regularly scheduled battery mainte-
nance.
CHANGING THE BATTERY
WARNING
Batteries are heavy. Use care to avoid injury. Al-
ways use a battery roller stand or tray when trucks
are equipped with optional battery rollers or slide.
WARNING
Always wear protective clothing, gloves, and gog-
gles when handling batteries and electrolyte.
Make sure the capacity of the crane and spreader bar
is greater than the weight of the battery. The weight
of the battery is normally shown on the battery case.
The maximum battery weight is shown on the lift truck
nameplate. The spreader bar must NOT be made of
metal, or it must have insulated straps. See Figure 2.
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
grease. DO NOT use solvent on new paint. Clean
the surface of old paint using a cleaning solvent.
2. Remove the paper from the back of the label. DO
NOT touch the adhesive surface.
3. Carefully hold the label in the correct position above
the surface. Put the label in the correct position
on the surface. Make sure all air is removed from
under the label and the corners and edges are tight.

NOTE: The label cannot be moved after it touches the

surface.

1. LABEL (YALE) 6. LABEL (PATENTS AND TRADEMARKS)

2. NAMEPLATE 7. LABEL (PINCH WARNING)
3. LABEL (WARNING) 8. OPERATING MANUAL
4. DECAL 9. NAMEPLATE LABEL
5. RIVET 10. LABEL (BATTERY DISCHARGE NOTICE)

Figure 3. Label and Decal Location

5
Load Wheels
Painting Instructions
WARNING
Always use solvents and paints in an area with ven-
tilation. DO NOT use solvents or paints near heat or
fire.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. Wear protection for eyes
and skin. When using cleaning solvents, always
follow the recommendations of the manufacturer.
1. Remove all dirt from the surface to be painted.
Clean the area to be painted using a solvent for
painted surfaces. Remove all oil and grease.
Load Wheels
REMOVE
WARNING
Put blocks under both forks and on both sides of
the drive tire. The blocks must prevent the lift truck
from falling and causing personal injury or property
damage.
1. Use the lift button to raise the lift truck to its maxi-
mum height.
2. Put blocks under both forks and on both sides of the
drive tire. See the section How to Put a Lift Truck
on Blocks in the Periodic Maintenance manual.
6
100 YRM 1015
2. Remove the top surface of paint and all rust from
the metal using sandpaper. Paint all metal sur-
faces where the paint is completely removed using
primer. Apply the primer before applying the color
paint.
3. Protect all surfaces that will not be painted. DO
NOT paint cylinder rods, cables, labels, plates, or
controls.
4. Paint all the surfaces the original color, using Yale®
paint. Follow the directions on the container.
3. Drive the roll pin retaining the axle shaft to the rear
axle link out of the link and axle.
4. Lower the hoist cylinder using the lower button.
This will raise the load wheels off the floor.
5. Move the key to the OFF position. Disconnect the
battery. Remove the battery.
6. Remove the axle shaft. Remove bearings and load
wheel from the link. It may be necessary to drive
the bearing out of the wheel. Drive the bearing out
from the opposite sides. See Figure 4.
100 YRM 1015 Load Wheels

1. LOAD WHEEL 5. BUSHING

2. FITTING 6. AXLE
3. ROLLER 7. FITTING
4. BEARING 8. PIN

Figure 4. Load Wheel and Link Assembly

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
1. Prelubricate the bearings with the recommended
grease. Install the bearings in the load wheel.
2. Align the load wheel and bearings inside the link
and insert the axle shaft.
3. Install the roll pin in the link and through the axle
shaft.
4. Raise the load wheels. Lubricate the load wheel.
6. Remove the blocks from under the forks and from
each side of the drive tire. Turn the key to the ON
position and use the lower button to lower the lift
truck to its minimum height. The truck should lift
and lower evenly.
7. Test the operation of the motorized hand truck be-
fore returning the truck to service.
The function of the load wheels is further explained in
Lifting Mechanism 4000 YRM 1008.

7
 NOTES

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8
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

100 YRM 1015 8/09 (8/05)(4/05)(1/03)(1/02) Printed in U.S.A.

 Maintenance

MASTER DRIVE UNIT

MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]

PART NO. 524154891 630 YRM 1003

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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
remove parts.

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

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

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

WARNING
Indicates a 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

This section is for the following models:

MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]

©2008 Yale Materials Handling Corp. i

630 YRM 1003
General
This section has the description and repair procedures
for the master drive unit (MDU). The traction motor,
steering, and brake repair procedures are in separate
sections. The main parts of the drive unit are the hous-
ing, pinion (motor), first intermediate gear set, second
intermediate gear set, drive gear, bearings, axle, wheel,
and spindle. The spindle is bolted to the top of the drive
unit has tapered bearings installed for the mounting of
the MDU to the frame. The steering control handle fas-
tens to the MDU. The traction motor fastens to the drive
unit. The drive unit and the traction motor turn as a unit
for steering.
In some instances, it may only be necessary to remove
the drive motor and brake assembly to work on the
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
of gears do not need adjustment for wear. All the parts
that rotate have ball bearings or tapered roller bearings.
The ball bearings are lubed by gear oil and the tapered
roller bearings are packed with multipurpose #2 grease
with 2% to 4% molybdenum disulfide. A pinion gear on
the motor armature drives the first of the three reduction
gears. The second intermediate gear engages the drive
Special Precautions
WARNING
Block each side of the truck under the drive unit
frame. Position blocks on both sides of the load
wheels to prevent the truck from falling.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. Discharge the capacitor before inspecting
or repairing any component in the MDU compart-
ment to prevent personal injury and damage to
the electrical system. Make certain the battery has
been disconnected. DO NOT use a screwdriver
Special Precautions
See the section Steering Mechanism 1600 YRM 1004
for troubleshooting and repairs on the steering compo-
nents.
See the section Electrical System 2200 YRM 1007
and DC Motor Maintenance 620 YRM 294 for trou-
bleshooting and repairs on the electrical components
of the MDU.
See the section Brakes 1800 YRM 1005 for trou-
bleshooting and repairs of the brake components.
See the section Periodic Maintenance 8000 YRM
1048, Periodic Maintenance 8000 YRM 1379, or Pe-
riodic Maintenance 8000 YRM 1009 for instructions
on checking and changing the drive unit gear oil.
gear. The drive gear is mounted on the drive axle. The
drive axle is the mount for the final drive gear and the
wheel.
A spring applied/electrically released friction brake is
mounted to the drive motor between the motor and the
MDU. See the section Brakes 1800 YRM 1005 for ad-
ditional information on the electrical brake.
to make a short circuit across the B+ and B
terminals of the transistor controller. Always wear
safety glasses.
WARNING
Perform the following steps before performing any
troubleshooting or adjustments, and before con-
necting or disconnecting a handset or personal
computer to avoid personal injury and prevent
electrical shock.
1. Verify that the key switch is in the OFF position and
the battery connector is completely disconnected.
1
Special Precautions 630 YRM 1003

Legend for Figure 1

WARNING
To avoid controller damage, always disconnect 1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
the battery, discharge the capacitor, and never put 3. INSULATED JUMPER WIRES
power to the controller with any power wire dis- 4. 200-OHM, 2-WATT RESISTOR
connected. Never short any controller terminal or
motor terminal to battery. Make sure to use proper
procedure when servicing the controller.

2. Discharge capacitors. Carefully connect a 200-

ohm, 2-watt resistor between B+ and B on con-
troller using insulated jumper wires and hold for 5
seconds. Remove the 200-ohm, 2-watt resistor be-
fore reconnecting the battery. See Figure 1 or Fig-
ure 2

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

Figure 2. Discharging Controller - MSW020-E,

MSW025-E, MSW025-F, MSW030-F, MPW045-E, and
MPW050-E

Figure 1. Discharging Controller - MPB040-E

2
630 YRM 1003
Master Drive Unit Repair
REMOVE
Separate parts of the MDU can be removed without re-
moving the complete MDU. It is not necessary to per-
form each step of the entire procedure to remove some
parts of the MDU. This procedure has steps to remove
the complete MDU. Read the entire procedure first and
do only the steps necessary to make the required re-
pairs.
WARNING
Block each side of the truck under the drive unit
frame. Position blocks on both sides of the load
wheels to prevent the truck from falling.
WARNING
Keep the MDU supported at all times using a sling
and an overhead hoist to avoid personal injury
when removing the MDU from the lift truck.
WARNING
Always disconnect the battery connector so that
the connector is completely free before performing
repairs. If the connector is not completely free, it
can reconnect the battery. Tag the connector - DO
NOT CONNECT.
1. Block lift truck. Raise drive wheel off floor. Refer to
the proper section for your lift truck: Periodic Main-
tenance 8000 YRM 1009, Periodic Maintenance
8000 YRM 1379, or Periodic Maintenance 8000
YRM 1048 - How to Put a Lift Truck on Blocks.
2. Turn key switch to OFF position and disconnect bat-
tery.
3. Remove the upper drive unit compartment cover.
4. Use the following procedure that applies to your lift
truck:
a. Remove the lower drive unit compartment
cover.
Master Drive Unit Repair
b. Remove the two screws securing the lower
drive unit compartment cover to the frame. Re-
move the lower drive unit compartment cover.
5. Remove the four Allen-head screws from the two
piece shield over the MDU and remove the shield.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. Discharge the capacitor before inspecting
or repairing any component in the MDU compart-
ment to prevent personal injury and damage to the
electrical system. Always wear safety glasses.
6. Discharge capacitors. Refer to Special Precau-
tions.
7. Remove control handle. Refer to the section Steer-
ing Mechanism 1600 YRM 1004.
8. Remove drive wheel and tire assembly by removing
capscrews (23) and washers (22).
CAUTION
Be careful not to damage the wiring when discon-
necting from the motor and the brake or when re-
moving the motor and the brake from the housing.
9. Remove drive motor and brake assembly and pull
the wires out of the top of the spindle (12). See the
section Brakes 1800 YRM 1005.
10. Support drive unit with sling ran through the center
of the spindle and a hoist or overhead crane.
11. Loosen bearing lockwasher by bending tab and
then remove lock nut.
12. Lower MDU from frame.
3
Master Drive Unit Repair 630 YRM 1003

Figure 3. Drive Unit and Brake Assembly

4
630 YRM 1003 Master Drive Unit Repair

Legend for Figure 3

1. WIRE HARNESS 16. BRAKE ASSEMBLY 31. NUT
2. SLEEVE 17. BRAKE HUB 32. BALL BEARING
3. NUT 18. KEY 33. GEAR AND PINION ASSEMBLY
4. LOCKWASHER 19. KEY 34. GEAR AND PINION ASSEMBLY
5. FLAT WASHER 20. DRIVE MOTOR 35. NUT
6. BEARING CONE AND CUP 21. PIVOT BUSHING 36. GEAR
ASSEMBLY 22. WASHER 37. OIL SLINGER
7. BEARING CONE 23. CAPSCREW 38. CASTING
8. BEARING CUP 24. DRIVE TIRE AND WHEEL 39. LOCKWASHER
9. BEARING CUP 25. MDU 40. CAPSCREW
10. BEARING CONE 26. DRIVE AXLE 41. FILL PLUG
11. ALLEN-HEAD SCREW 27. BEARING CONE AND SEAL 42. ALLEN-HEAD SCREW
12. SPINDLE ASSEMBLY 43. LOCKWASHER
13. O-RING 28. BEARING CUP 44. COVER
14. BALL BEARING 29. PIN 45. ALLEN-HEAD SCREW
15. SPACER 30. DRIVE GEAR 46. LOCKWASHER

DISASSEMBLE a. Remove eight capscrews (40) and lockwashers

Refer to Figure 3 for the following instructions.
NOTE: Total disassembly may not be necessary to re-
pair the MDU. Do only the steps necessary to complete
repairs.
The MDU can be removed from the lift truck to be com-
pletely disassembled. See Remove. However, certain
components may be removed with the MDU installed
in the truck. The drive motor, brake, drive wheel and
tire assembly, and pivot bushing (21) may be removed
with the MDU installed on the truck. The gear oil may
also be changed with the MDU installed. Where partial
disassembly of the MDU while installed is possible, as-
sembly, cleaning, and inspection of the MDU is much
easier when completely removed. The following steps
refer to the disassembly of an MDU which has been re-
moved from the drive unit compartment. See Figure 3.
1. Remove MDU from lift truck. Refer to Remove.
2. Place the MDU on a clean workbench.
3. Detach steering spindle by removing Allen-head
screws (11) if necessary.
4. Remove pivot bushings (21) if necessary.
(39).
b. Remove two Allen-head screws (42) and wash-
ers (43).
c. Using the slots provided, gently pry the top and
bottom sides of cover alternately from the MDU.
d. Remove cover and place on a clean work-
bench.
e. Remove two pins (29) from MDU housing if
necessary.
CAUTION
Use a hammer and a soft punch when removing
bearings to avoid damage to bearings and/or cast-
ing.
6. Remove drive axle and bearings:
a. Remove nut (31) and gear (30).
b. Remove drive axle.
c. Remove bearing cone and seal assembly (27).
7. Remove gear and pinion assemblies and bearings:

a. Remove gear and pinion assemblies (33, 34)

CAUTION by hand.
Disposal of lubricants and fluids must meet local
environmental regulations. b. Remove bearings (32) from casting and cover.

5. Remove cover and drain oil:

5
Master Drive Unit Repair
REPAIR
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. Wear protection when
handling solvents and always follow the recom-
mendations of the manufacturer.
Clean all of the parts of the MDU assembly thoroughly
with solvent. Inspect each part for damage and replace
any damaged or excessively worn parts. Bearings
should fit snug where they ride on the shaft. If there is
excessive play, replace the bearing and/or shaft. Check
the bearings for smooth operation. If a clean bearing
does not roll smoothly, it must be replaced. Check the
teeth on the gears and on the gear and pinion assem-
blies; see Figure 3, above. If the teeth are chipped or
show wear, they must be replaced. Inspect keys and
keyway grooves for damage. Never reuse a damaged
key. Always check the used gear oil for metallic chips
and shavings. If there are chips or shavings in the oil,
there is wear or damage in the MDU.
ASSEMBLE
Assembly of the MDU is basically the opposite of disas-
sembly. The major difference is installation of the bear-
ing assemblies. Use a bearing driver and hammer to
drive the bearings into place. Be careful not to damage
the casting with the bearing driver and make sure the
bearing is completely seated. The following instructions
refer to the assembly of new or undamaged parts in a
clean work environment.
CAUTION
Use a hammer and proper size driver when in-
stalling bearings to avoid damage to bearings
and/or casting.
1. Install drive axle and bearings:
a. Clean and inspect the tapered roller bearings
for wear or damage. Replace as needed.
b. Grease the tapered roller bearings, using a
standard bearing packing device, with multipur-
pose #2 grease with 2% to 4% molybdenum
disulfide.
c. Install bearing cone and seal assembly (27)
into casting and properly position seals.
6
630 YRM 1003
d. Install drive axle.
e. Install gear (30) with the flat side facing out
toward the cover. Install nut (31) and torque to
175 N•m (129 lbf ft).
2. Install gear and pinion assemblies and cover:
a. Clean and inspect the ball bearings for wear or
damage. Replace as needed.
b. Lubricate the ball bearings with gear oil.
c. Install bearings (32) into casting and cover.
d. Install gear and pinion assemblies (33, 34) by
hand.
e. Install gear case cover:
(1) Clean mounting surface of cover and
housing thoroughly to remove oil, old
sealant, and dirt.
(2) Apply Loctite 510™ around mounting
flange of cover.
(3) Install cover to housing using eight cap-
screws (40) and washers (39).
(4) Torque capscrews to 23 N•m (17 lbf ft).
3. Install steering spindle to MDU using the
Allen-head screws (11). Apply Loctite 242™ to
the Allen-head screws and torque to 23 N•m
(17 lbf ft).
INSTALL
The following steps refer to the installation of clean parts
that are new or that have been inspected and meet
specifications.
1. Support MDU with sling and hoist or overhead
crane and raise to a vertical position.
2. Clean and inspect the steer bearings for wear or
damage. Replace as needed.
3. Grease the steer bearings, using a standard bear-
ing packing device, with multipurpose #2 grease
with 2% to 4% molybdenum disulfide.
4. Install lower steer bearing on spindle.
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,
lock nut, and wire guard sleeve.
7. Torque steer bearing lock nut to 54 N•m (40 lbf ft).
Loosen nut and retorque to 34 N•m (25 lbf ft).
8. Bend locking tab into slot on bearing lockwasher.
9. Feed main wire harness through the spindle.
13. Remove fill plug (41) and fill MDU to correct level
with gear oil. Install fill plug and torque to 40 N•m
(30 lbf ft).
14. Install two piece shield on the MDU using the four
Allen-head screws to secure.
15. Use the following procedure that applies to your lift
truck:

a. Install the lower drive unit compartment cover.

CAUTION
Be careful not to damage the wiring when installing
the drive motor and brake assembly to the MDU.
10. Install drive motor and brake assembly to MDU. See
the section Brakes 1800 YRM 1005.
b. Install the lower drive unit compartment cover
and install the two screws to secure the cover
to the frame.
16. Install the upper drive unit compartment cover.

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

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Lift truck will not move. Battery not properly connected. Check electrical connections.

Battery is dead. Recharge or replace battery.

Motor not operating. Check wiring or repair motor.

Damaged gears or bearings. Replace gears or bearings.

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.

Dry or damaged bearings. Replace bearings.

Worn or damaged gears. Replace gears.

7
Troubleshooting 630 YRM 1003

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Oil leaks. Loose case cover. Tighten case cover.

Loose fill plug. Tighten fill plug.

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

630 YRM 1003 3/08 (8/05)(5/03)(1/02) Printed in U.S.A.

 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

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]

©2015 Yale Materials Handling Corp. i

1600 YRM 1004 General

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. 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.
1. POSITIVE CONNECTION
3. Remove the 200-ohm, 2-watt resistor before re- 2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
connecting the battery. 4. 200-OHM, 2-WATT RESISTOR

Figure 1. Discharging Controller - MPB040-E

1
Special Precautions 1600 YRM 1004

Legend for Figure 2

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

Figure 2. Discharging Controller - MSW020-E,

MSW025-E, MSW025-F, MSW030-F, MPW045-E,
and MPW050-E

Control Handle Head

Refer to the section Electrical System dle. The instructions for disassembly and assembly of
2200YRM1007 for instructions on removing and in- the control handle head can be located in the same
stalling the control handle head from the control han- section.

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

WARNING connect the battery.
The capacitor in the transistor controller can hold
3. Remove the drive unit compartment covers and
an electrical charge after the battery is disconnec-
MDU covers.
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or

2
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.
Control Handle
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.
3
Control Handle 1600 YRM 1004

Figure 3. Control Handle Assembly

4
1600 YRM 1004 Control Handle

Legend for Figure 3

1. CONTROL HANDLE ARM 13. SCREW

2. PIVOT PIN 14. SCREW
3. WASHER 15. CONTROL HANDLE HEAD
4. BUSHING 16. SCREW
5. PIN 17. LOCKWASHER
6. GAS SPRING 18. FLAT WASHER
7. SCREW 19. SCREW
8. LOCKWASHER 20. LOCKWASHER
9. FLAT WASHER 21. WIRE CLAMP
10. RUBBER BUMPER 22. ALLEN HEAD SCREW
11. CONTROL HANDLE ARM PROX SWITCH 23. SETSCREW
12. MOUNTING BRACKET

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.
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

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.
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.

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.

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

WARNING cordance with local regulations.
Contents are under pressure. This process may
eject metal chips and oil.

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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

ing handle swivel bearing(s).

Steering handle swivel bearing(s) Lubricate or repack bearings.

need lubrication.

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.

Gas spring ball stud broken or Retighten or replace gas spring

loose. ball stud.

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]

PART NO. 524154893 1800 YRM 1005

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly 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
remove parts.

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

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

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

WARNING
Indicates a 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

This section is for the following models:

MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]

©2008 Yale Materials Handling Corp. i

1800 YRM 1005
General
WARNING
DO NOT operate a lift truck that needs repairs. If a
repair is necessary, put a DO NOT OPERATE tag on
the control handle. Remove the key from the key
switch.
WARNING
Before performing repairs or adjustments on the
brake system, blocks must be placed under each
side of the frame to raise the drive tire off the
ground. The blocks must prevent the lift truck from
falling and causing personal injury or property
damage. See Periodic Maintenance 8000 YRM
1009, Periodic Maintenance 8000 YRM 1379, or
Periodic Maintenance 8000 YRM 1048, How to Put
a Lift Truck on Blocks.
Description
Motorized hand trucks have three methods of braking:
1. Regenerative (Neutral) braking
2. Controlled plugging
3. Application of the spring-applied/electrically re-
leased friction brake
NOTE: The preferred method of stopping the truck is:
Regenerative (Neutral) braking
or
Controlled plugging
Regenerative (Neutral) braking applies a retarding force
to the drive wheel through the traction motor, allowing
the unit to slow to a gradual stop. It is applied by re-
turning the speed/direction control to the NEUTRAL po-
sition or by placing the hand brake lever(s) in the first
stage position.
Controlled plugging is reversing the speed/direction
control while traveling, causing the unit to slow to a stop.
Return the speed/direction control to the NEUTRAL
position to remain stopped. If the speed/direction
control is not returned to the NEUTRAL position after
Description
WARNING
Always disconnect and separate the battery con-
nector so that the connector is completely free be-
fore performing any service or repairs. If the con-
nector is not completely free, it can reconnect. Tag
the connector: DO NOT CONNECT.
This section has the description and repair procedures
for the electric brake on the MSW020-E, MSW025-E,
MSW025-F, MSW030-F, MPB040-E, MPW045-E, and
MPW050-E lift trucks. Brake assemblies may vary in
appearance. Although some assemblies may APPEAR
to be adjustable, brake assemblies used on these trucks
ARE NOT ADJUSTABLE. Friction between parts inside
the brake will produce brake dust, squeaking, and ex-
treme heat under normal operating conditions. Brake
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.
the truck is stopped, the lift truck will accelerate in the
direction the handle is being turned. Controlled plug-
ging should stop the truck within a few feet, depending
on speed and load.
The parking brake is a spring-applied, electrically re-
leased friction brake mounted to the drive motor. When
the parking brake is applied, springs inside the brake
assembly compress a rotating friction disk against two
stationary plates.
To release the brake:
1. Connect the battery.
2. Turn the key switch to the ON position.
3. Lower the control handle arm to the operating or
BRAKE OFF position. Refer to Figure 1.
4. Rotate direction/speed control (butterfly knobs) in
the direction of travel.
1
Special Precautions
Figure 1. Brake Operation
Special Precautions
WARNING
Block each side of the truck under the drive unit
frame. Position blocks on both sides of the load
wheels. The blocks must prevent the lift truck from
falling and causing personal injury or property
damage.
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. To prevent electrical shock and personal
injury, discharge the capacitor before inspecting
or repairing any component. Wear safety glasses.
Make certain the battery has been disconnected.
Discharge the capacitors in the controller by con-
necting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals with insulated
jumper wires. DO NOT use a screwdriver to dis-
charge the traction motor controller. See Figure 2
or Figure 3.
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments, and
before connecting or disconnecting a handset or
computer.
2
1800 YRM 1005
The parking brake is applied when the control han-
dle arm is moved to the BRAKE ON position (full
up or full down position) or if a traction fault occurs.
The lift truck must meet the applicable HOLD ON
GRADE requirements; the parking brake should be
capable of holding the lift truck on a 10 percent
grade with the maximum rated load.
CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never put
power to the controller with any power wire dis-
connected. Never short any controller terminal or
motor terminal to battery. Make sure to use proper
procedure when servicing the controller.
1. Block the lift truck so that the drive wheel is off the
floor. Refer to the proper section for your truck:
Periodic Maintenance 8000 YRM 1009, Periodic
Maintenance 8000 YRM 1379, or Periodic Main-
tenance 8000 YRM 1048 - How to Put a Lift Truck
on Blocks.
2. Turn the key switch to the OFF position and discon-
nect the battery.
3. Discharge the capacitors in the controllers by con-
necting a 200-ohm, 2-watt resistor across the con-
troller’s B+ and B terminals. See Figure 2 or Fig-
ure 3 for your truck. DO NOT short across the mo-
tor controller terminals with a screwdriver or jumper
wire. Remove the 200-ohm, 2-watt resistor before
reconnecting the battery.
1800 YRM 1005 Brake Assembly Repair

1. POSITIVE CONNECTION 1. NEGATIVE CONNECTION

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

Figure 2. Discharging Controller MPB040-E Figure 3. Discharging Controller MSW020/025-E,

MSW025/030-F, and MPW045/050-E

Brake Assembly Repair

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

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

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

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

Figure 5. Brake Assembly

5
Brake Assembly Repair 1800 YRM 1005

REPAIR
If a brake assembly is malfunctioning, the cause may
be electrical, mechanical, or a combination of both. If
the brake electrical system is functioning correctly, the
brake should release with one solid "click" when ener-
gized. The brake coil is a large 24 V coil that acts as an
electromagnet to pull the armature plate away from the
friction disk. If the brake coil is too weak to compress
the brake springs and release the friction disk, the brake
must be replaced.
1. Disconnect the brake wiring harness (if brake is in-
stalled to truck).
If removing the drive motor assembly from the lift truck,
visually inspect the brake. Use a feeler gauge to check
the gap between the brake coil and armature plate in
several places around the brake to determine if the
brake is near the end of normal service life. Proper air
gap measurements range from 0.2 to 0.6 mm (0.0078
to 0.024 in.). See Figure 6. The brake must be replaced
if it no longer meets the proper air gap specifications
or if otherwise malfunctioning. The brake hub and the
brake assembly can be replaced separately. However,
if there is damage to the brake hub, there is most likely
damage to the brake assembly.

2. Check voltage to the brake using a voltmeter.

a. Turn the key switch to the ON position.

b. Place the control handle arm in the BRAKE

OFF position.

c. Lightly rotate the directional controls to activate

the brake coil circuit.

d. Touch each lead of a voltmeter to each side

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

e. Voltage to the brake should read approximately

24 V.

3. Check the resistance of the brake coil using an

ohmmeter.

a. Touch each lead of the ohmmeter to each side

of the brake wiring harness connector.

b. If the brake coil resistance reads between

30.24 and 27.36 (ohms), the brake coil is
functioning properly.

c. If the resistance reading falls outside the spec-

ified range, the entire brake assembly must be
replaced. 1. BRAKE COIL
2. AIR GAP
If the brake mechanical functions are not operating 3. ARMATURE PLATE
correctly, the brake will not hold a fully loaded lift truck 4. FEELER GAUGE
on a 10% grade. The brake is NOT ADJUSTABLE and
must be replaced when it will not hold to specification. Figure 6. Brake Assembly

6
1800 YRM 1005 Brake Assembly Repair

INSTALL 8. Place motor shaft assembly into housing. Position

For the following instructions, refer to Figure 5.
1. Install woodruff key (17) to drive motor shaft and
slide hub onto shaft and key. Make sure groove and
key are aligned properly.
2. Install spacer (10) and brake assembly on to motor
shaft and slide down on to hub. Make sure brake
spline align with teeth on the hub.
CAUTION
Brake assemblies may vary in appearance. Some
assemblies have three Allen-head screws on top
of the brake coil. DO NOT TURN the Allen-head
screws on TOP of the brake coil. This can change
the factory preset adjustment, rendering the brake
inoperable. These brakes are preset from the fac-
tory and are NOT ADJUSTABLE.
motor and brake correctly to align brake wiring har-
ness in notch. See Figure 7. Hold the motor in
place until next step is complete.
9. Install Allen-head screw (2) and washer (3).
10. Install Allen-head screws (7) and washers (8).
Torque all three Allen-head screws to 10 N•m
(7 lbf ft).
11. Install MDU covers and drive unit compartment cov-
ers.
12. Reconnect battery, and remove blocks from wheels.
13. Brake should hold parked lift truck loaded to capac-
ity on a 10% grade. Test for proper operation before
returning to service.

3. Using a 3 mm Allen-head insert at least 55 mm long

with a square socket adaptor, install three Allen-
head capscrews securing bottom plate of brake as-
sembly to motor. Torque to 2.8 N•m (25 lbf in)

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

on to shaft using a standard press.

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

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

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

grease to ensure proper installation of drive motor
shaft assembly.

7. Reconnect wiring as removed.

CAUTION 1. MDU HOUSING

The brake wiring harness must be aligned with the 2. BRAKE WIRE NOTCH
notch in the MDU housing. If the motor and brake
assembly is secured to the MDU incorrectly, the Figure 7. MDU Brake Wire Notch
brake wiring harness may be damaged.

7
Troubleshooting 1800 YRM 1005

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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

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

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

Coil is open. Measure coil resistance. If resistance

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

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

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

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

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

Air gap is too large. Replace the brake assembly.

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

Friction disk is too worn. Replace the brake assembly.

Brake hub damaged. Replace brake and hub assembly.

8
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

1800 YRM 1005 3/08 (8/05)(5/03 )(1/02) Printed in U.S.A.