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Table 4. Battery Chart for DPI Gen III Chargers Only

Mfg

Part

Voltage

Capacity

20HR/

RC@25A

(AmpHrs)

Application

Batt Type

DPI Gen III

Mode

US - Battery

Lead Acid

Batteries

US1800

24

208

Deep Cycle

HV Flooded

2

AGM2224

24

224

Deep Cycle

Absorbent Glass

Mat

4

Changing Mode Setting (DPI Accusense Gen
III Models with Jumper Ports)

NOTE:

Mode settings can be checked by connecting

the battery charger to a 120V AC power source and
watching the LED display. The LED display will flash
once if the mode is set to Mode 1, twice if set to Mode
2, three times if set to Mode 3, and four times if the
charger is set to Mode 4. If the LEDs do not flash
when initially connected to power, refer to Trouble-
shooting (DPI Chargers) in this section.

Modes are set by the position of the jumpers on the
jumper port. Accessing the jumper port requires re-
moval of a plate on the front of the battery charger on
DPI Gen III chargers.

1.

Remove the screws used to retain the jumper port
cover to the charger and remove the cover.

2.

Locate the jumpers on the port.

3.

Arrange the jumpers in the proper configuration
for your battery type.

4.

Replace the cover on the charger and install the
mounting screws.

Accusense Gen III with Dip Switches

Battery Charger (Accusense by DPI

®

)

2200 YRM 1007

40

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Summary of Contents for MPB040-E

Page 1: ...Maintenance WALKIE HYDRAULIC SYSTEMS MPB040E B827 MPW045 E B802 MPW050 E C802 PART NO 524154894 1900 YRM 1018 ...

Page 2: ...od 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...

Page 3: ...s 4 Install 4 Hydraulic Pump 5 Remove 5 Install 5 Hydraulic Pump Reservoir 7 Remove 7 Install 7 Hydraulic Cylinder 8 Remove 8 Repacking 9 Install 9 Relief Valve Adjustment 10 Relief Valve Pressure Check 10 Relief Valve Adjust 11 Troubleshooting 12 Lift Assemblies 12 Hydraulic Cylinders 12 Hydraulic Pump 13 This section is for the following models MPB040E B827 MPW045 E B802 MPW050 E C802 2007 Yale ...

Page 4: ......

Page 5: ... 2 and Figure 3 If the breather is clogged or blocked the ability of the system to lift a load will be greatly reduced Figure 1 Hydraulic Schematic As oil is pushed out of the pump it passes through a one way check valve to the lift cylinder The check valve prevents oil from flowing back to the pump when lifting ceases holding the lift cylinder in the raised position until lowered The piston will ...

Page 6: ... make it appear that a prob lem exists with the battery or hydraulic system CLEANLINESS Adhere to the following precautionary steps to ensure that the hydraulic system remains clean 1 Flush the entire system when a failure is encoun tered to make sure all paint metal chips welding shot and debris are removed 2 Filter each change of oil to prevent the introduction of contaminants into the system 3 ...

Page 7: ...f from the fluid while in the reservoir before recycling through the system Aerated Hydraulic Oil Results in system noise that is similar to cavitation Aerated oil is caused by the in gestion of air through the pipe joints of the inlet lines and high velocity discharge lines as well as cylinder rod packing Aeration can also be caused by oil dis charging above the fluid level 1 HYDRAULIC POWER UNIT...

Page 8: ...raulic oil from the hydraulic unit into an appropriate container 5 Tag and disconnect all of the electrical wires from the hydraulic unit 6 Remove the hydraulic lines from the hydraulic unit 7 Loosen and remove the three capscrews attaching the hydraulic unit to the frame Remove the hy draulic unit and place in a clean work area SPECIAL PRECAUTIONS WARNING To avoid personal injury and prevent elec...

Page 9: ... with the adapter plate up Align the pump mounting holes with the holes in the motor Ensure that the tank is seated into the motor 4 Install the four capscrews and tighten to 13 6 to 16 3 N m 10 to 12 lbf ft 5 Install the O rings into the pump cavities Apply grease to the return tubes Insert tubes into pump cavities and O rings Grease the suction tube and insert into locking device with hole Insta...

Page 10: ...Hydraulic Pump 1900 YRM 1018 Figure 4 Hydraulic Unit 6 ...

Page 11: ...e reservoir 6 Clean the reservoir and the suction screen Inspect the screen for damage and replace if necessary NOTE On 24 volt trucks the capscrews that hold the reservoir to the subunit also hold the motor to the sub unit When the capscrews are removed the motor will be resting on the subunit When reinserting the cap screws ensure that the motor is located correctly and the coupler is seated pro...

Page 12: ...ye and face protection during removal and installation 1 Raise the motorized lift truck forks platform to one half its maximum height 2 Place blocks under the forks Block the drive wheel See the section Periodic Maintenance 8000 YRM 1009 How to Put a Lift Truck on Blocks 3 Remove the drive unit compartment cover 4 Separate the frames Refer to the section Frame 100 YRM 1015 5 Manually collapse the ...

Page 13: ...nut to 27 N m 20 lbf ft INSTALL WARNING Be careful when removing or installing snap rings The snap rings can come loose during removal or installation with enough force to cause a personal injury Always use the correct snap ring pliers and wear eye and face protection during removal and installation 1 Align the bottom of the cylinder with the frame and install the bottom clevis pin 2 Install the r...

Page 14: ...vel as required See Hydraulic Pump Reservoir 1 Operate lift truck until hydraulic oil reaches operat ing temperature 43 to 49 C 110 to 120 F 2 Lower the forks completely to relieve pressure from hydraulic circuit 3 Turn key to the OFF position and disconnect the battery 4 Block load wheels to prevent lift truck from moving 5 Remove the drive unit compartment covers 6 Discharge the capacitor See Sp...

Page 15: ...rtment covers RELIEF VALVE ADJUST Refer to Relief Valve Pressure Check to determine if adjustment is necessary 1 Verify the key switch is in the OFF position and the battery is disconnected 2 Remove the hydraulic reservoir See Hydraulic Pump Reservoir 3 Loosen the locking nut on the relief valve See Fig ure 6 4 Adjust the relief valve screw in small increments Turn the adjustment screw clockwise t...

Page 16: ... or replace Deformed lifting components Disassemble repair or replace Bent hydraulic cylinder piston rod See Hydraulic Cylinders below HYDRAULIC CYLINDERS PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Oil leaks from cylinder gland around piston rod An oil ring appears on the piston rod Foreign matter on packing Replace packing Score on piston rod Remove any foreign matter Smooth rod surface with an o...

Page 17: ... between cylinder tube and wear ring Replace wear ring included in packing kit HYDRAULIC PUMP PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Pump not delivering oil Pump does not draw oil Check pump piping and valves for leaks Low oil level in reservoir Check fluid level Clogged screen at pump inlet Change oil and clean screen Pump pressure fails to rise Improperly adjusted relief valve Increase to sp...

Page 18: ...mp and replace oil seals Breather clogged Clean or replace breather Cavitation caused by high oil viscosity Change to recommended oil and op erate pump in recommended temper ature ranges Abnormal temperature rise of hydraulic oil Overwork Adjust workload to fall within pump s operating range Improper viscosity or contaminated oil Drain and replace oil with recom mended oil Pump case or drive gear ...

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Page 20: ...Yale Materials Handling Corp 1400 Sullivan Dr Greenville NC 27834 2011 1900 YRM 1018 4 07 8 05 9 03 1 02 Printed in U S A ...

Page 21: ...Maintenance ELECTRICAL SYSTEM MSW020 025 E A895 MPB040 E B827 MPW045 E B802 MSW025 030 F B895 MPW050 E C802 PART NO 524154896 2200 YRM 1007 ...

Page 22: ...odic 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 for...

Page 23: ...rmeter Display 14 Remove 14 Install 14 Fuses 15 MPB040 E 15 MPW045 050 E 15 MSW020 025 E 15 MSW025 030 F 15 Control Handle Arm Proximity Switch 16 Repair 16 Check and Adjust 16 Remove 16 Install 17 Control Handle 18 Disassemble 18 Control Handle Card Old Style 18 Control Handle Card New Style 19 Configure 20 Calibrate 21 Assemble 23 Switches ON OFF and Proportional 25 Remove 25 Install 25 Traction...

Page 24: ... DPI Accusense Gen III Models with Jumper Ports 40 Accusense Gen III with Dip Switches 40 Changing Mode Setting 42 Troubleshooting DPI Chargers 42 General 42 Error Modes 43 Battery Pack Troubleshooting 44 Battery Charger Accusense 20A 45 Description 45 Operation 45 LED Display 45 Charging 46 Charger Mode Battery Type Selection Accusense 20A 47 Changing Mode Setting Accusense 20A 50 Troubleshooting...

Page 25: ...r models MPW045 E B802 and MPW050 E C802 for additional information on the ZAPI display and for information on troubleshooting fault codes adjusting parameters and testing the ZAPI motor controller See the section DC Motor Maintenance 0620YRM0294 for general information on DC motors See the section Periodic Maintenance 8000YRM1048 for models MSW020 025 E A895 Periodic Maintenance 8000YRM1009 for m...

Page 26: ...E BATTERY CABLE 5 LIFT PUMP MOTOR 6 WIRING HARNESS 7 CONTROL HANDLE ARM PROXIMITY SWITCH 8 DRIVE MOTOR 9 MAIN CONTACTOR 10 CONTROL FUSE 11 HORN 12 ZAPI MOTOR CONTROLLER 13 POWER FUSE 14 NEGATIVE BATTERY CABLE 15 LOWERING VALVE Figure 1 Electrical Components General 2200 YRM 1007 2 ...

Page 27: ...signals to the control handle card The control handle card uses serial communication to send these signals to the ZAPI motor controller The ZAPI motor controller contains the system logic The motor controller receives the inputs pro cesses the commands and provides outputs to the appropriate component to activate them The traction motor armature and separately excited field are powered directly by...

Page 28: ...attery pack consisting of 4 6 volt deep cycle automotive style batteries and an onboard 25 amp charger The battery pack uses a 175 amp X type connector This connector provides two auxiliary contacts for the truck inhibit circuit al lowing the batteries to remain connected to the truck while the charger is operating The MSW020 E MSW025 F and MPB040 E can be configured with a standard 175 amp batter...

Page 29: ...riodic Mainte nance 8000YRM1379 for your lift truck Refer to How to Put a Lift Truck on Blocks WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is disconnec ted To prevent an electrical shock and personal injury discharge the capacitor before inspecting or repairing any component in the drive unit com partment Wear safety glasses Make certain that ...

Page 30: ...NSULATED JUMPER WIRES Figure 3 Discharging the Capacitor MSW020 025 E MPW045 050 E and MSW025 030 F 1 POSITIVE CONNECTION 2 NEGATIVE CONNECTION 3 INSULATED JUMPER WIRES 4 200 OHM 2 WATT RESISTOR Figure 4 Discharging the Capacitor MPB040 E Special Precautions 2200 YRM 1007 6 ...

Page 31: ... for the brake override feature is secured near this connection with wire ties 6 Disconnect the connectors and connect the brake wiring harness to the brake override connector See Figure 5 NOTE The brake will release when battery is con nected The brake will remain released until the bat tery is disconnected or the brake override circuit is disconnected 7 Connect the battery connectors 8 Roll the ...

Page 32: ... less than 1 260 the battery is not fully charged or is damaged A fully charged battery has a specific gravity of 1 270 to 1 290 A discharged battery has a specific gravity of ap proximately 1 165 8 The truck has an isolated electrical system nei ther battery terminal is connected to the truck frame Check for 50 000 ohms or more between each terminal one at a time of the battery con nector of the ...

Page 33: ... Periodic Maintenance 8000YRM1009 or Peri odic Maintenance 8000YRM1379 for your lift truck NOTE If removing the entire control panel assembly to include the electrical panel plate it will be neces sary to perform Step 6 If only removing the controller contactor horn fuses or wires it is not necessary to perform Step 6 See Figure 6 or Figure 7 6 Remove battery to gain access to control panel screws...

Page 34: ...TOR RED 3 CONTROLLER 4 HORN 5 WASHER 6 LOCKWASHER 7 CAPSCREW 8 CAPSCREW 9 CAPSCREW 10 NUT 11 FUSE 175 AMP 12 FUSE 5 AMP 13 BOLT 14 LOCKWASHER 15 NUT 16 DISPLAY 17 IGNITION SWITCH Figure 6 Control Panel MPB040 E Repairs 2200 YRM 1007 10 ...

Page 35: ... LOCKWASHER 8 CONVERTER 12 V TRUCKS ONLY 9 CAPSCREW 10 CAPSCREW 11 WASHER 12 WASHER 13 LOCKWASHER 14 CAPSCREW 15 NUT 16 DISPLAY 17 IGNITION SWITCH 18 CAPSCREW 19 LOCKWASHER 20 NUT 21 FUSE 250 AMP 22 HORN Figure 7 Control Panel MPW045 050 E MSW020 025 E and MSW025 030 F 2200 YRM 1007 Repairs 11 ...

Page 36: ...ire terminals on the battery selector jumper b To use a flooded cell battery connect the wire terminals on the battery selector jumper 5 Reconnect battery connectors 6 Turn the key switch to the ON position 7 If available install customer parameters and set tings 8 Test lift truck in a safe area away from other per sonnel and equipment 9 Install the lower drive unit compartment cover 10 Install th...

Page 37: ...rocedure 3 Reconnect battery connectors 4 Install the upper drive unit compartment cover 5 Turn the key switch to the ON position 6 Test lift truck in a safe area away from other per sonnel and equipment Key Switch Removal and Installation REMOVE 1 Move the lift truck to a safe level area 2 Block drive wheel to prevent truck from rolling 3 Disconnect battery connectors and turn the key switch to t...

Page 38: ...h to the OFF position and dis connect battery 2 Remove the upper drive unit compartment cover 3 Discharge the capacitor See Special Precautions in this section 4 Disconnect the wire harness plug from the back of the display Locking tab is hidden underneath rub ber boot 5 Remove nuts and washers holding retaining bracket Remove bracket and gauge from control panel INSTALL 1 Install gauge in control...

Page 39: ...s the 12 volt DC to 24 volt DC converter circuit MSW020 025 E The MSW020 025 E 24 volt lift trucks have two fuses They are 1 250 amp FU 1 protects both the lift pump mo tor and the drive motor 2 5 amp FU 2 protects the control circuits If it cannot be determined visually that any of the fuses have failed check for continuity using an ohm meter To replace FU 1 loosen retaining capscrews Install a n...

Page 40: ...nd the proximity switch LED is lit 11 Place the control handle arm in the full up or down position Verify that battery voltage is not present and the proximity switch LED is not lit If the proximity switch does not operate properly check that the gap measurement is within specifica tion and that the wiring harness and connections are good Adjust the switch gap if necessary or repair any wiring pro...

Page 41: ... proximity switch 4 Connect the switch to the wiring harness 5 Connect the battery and turn the key switch to the ON position 6 With the handle at 10 from vertical move the proximity switch until the LED turns on 7 Slowly move the proximity switch in the opposite direction until the LED just turns off 8 Torque the two capscrews to 4 17 N m 37 lbf in 9 Verify that the truck operates correctly with ...

Page 42: ...ative to the handle BEFORE removal 9 Remove one of the butterfly knobs by removing the screw that holds it on the shaft 10 Using the remaining butterfly knob slide the shaft out of the handle Be careful not to rotate the shaft within the control handle card 11 Refer to the wiring diagram or draw a sketch of where each of the push button switches are plug ged into the control handle card Unplug swi...

Page 43: ...release the proportional LIFT button and wait for five seconds 15 Slowly press the proportional LOWER button and hold down for five seconds 16 Slowly release the proportional LOWER button and wait for five seconds 17 Move the jumper on the J1 terminal to the RUN mode See Figure 12 view A 18 Turn the key switch to the OFF position 19 Install the upper half on the lower half Refer to Assemble for in...

Page 44: ...rd setting for this model is number 3 for 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 control handle card is configured correctly 4 To begin configuring the card turn the key switch to the OFF position 5 Move the jumper from P park to C configure See Figure 14 1 JUMPER TERMINALS SV2 2 HORN SWITCH S1 3 THUMBWHEEL S...

Page 45: ...y five seconds Calibrate Refer to Figure 13 for the following instructions 1 Verify that the key switch is in the OFF position 2 Move the jumper from P park to T teach See Figure 14 a Ensure the leads from the Right Lift switch con nects to the JP10 socket and the leads from the Right Lower switch connects to the JP12 socket See Figure 13 b Ensure the leads from the Left Lift switch or shift right...

Page 46: ...mplete See Figure 15 view C Release the thumbwheel so it returns to the neutral position NOTE Rotation Right and Rotation Left directions are specified by labels printed on face of card 6 Rotate the thumbwheel in the Rotation Left di rection toward the operator and hold to the me chanical stop Press the left side lower button sideshift left button if equipped with sideshift op tion 7 The LED scree...

Page 47: ...ray lubricant NOTE It may not have been necessary to remove the lower half of the control handle cover If the cover lower half is already installed to the control handle shaft skip to Step 7 6 Install lower half of control handle cover to control handle shaft and secure with two capscrews Tor que to 27 N m 20 lbf ft 7 Plug handle wiring harness into control handle card CAUTION DO NOT force the upp...

Page 48: ...NG 6 BUTTERFLY KNOB LH 7 WASHER 8 SCREW 9 SPRING 10 BUTTERFLY KNOB RH 11 SWITCH COVER 12 SPRING 13 SWITCH COVER 14 BUTTONS 15 SWITCH ON OFF 16 HORN SWITCH COVER 17 LABEL 18 LABEL 19 LABEL 20 SWITCH 21 PROPORTIONAL SWITCH OPTIONAL Figure 16 Control Handle Control Handle 2200 YRM 1007 24 ...

Page 49: ...d switch from control handle card NOTE Both ON OFF and proportional switches use three tabs to keep the switches attached to the upper half of the control handle 9 Remove the switch by pressing the three tabs to ward the switch and pushing the switch through upper half of cover 10 Replace ON OFF Switch a Separate the button from the switch by spread ing the four tabs to allow the switch to slide o...

Page 50: ...h measures 11 mm 0 44 in below the brush box If the brush is worn 8 mm 0 31 in below the brush box then brush replacement is RECOMMENDED See the section DC Motor Maintenance 0620YRM0294 for the replacement of brushes and spring assemblies 4 Remove capscrews from commutator end of mo tor Carefully slide end cover from motor and ar mature shaft DO NOT damage parts A puller is often necessary to sepa...

Page 51: ...1 END COVER 2 ARMATURE 3 BEARING 4 MOUNTING STUD 5 HOUSING AND WINDINGS 6 BRUSH AND SPRING 7 COMMUTATOR END CAP 8 COVER BAND Figure 17 Disassembled Traction Motor 2200 YRM 1007 Traction Motor 27 ...

Page 52: ... disassembled The motors are serv iced as an assembly REPAIR MSW020 025 E AND MSW025 030 F The lift pump motor is an electric motor mounted on top of the lift pump and hydraulic tank The motor drives the lift pump supplying oil pressure to the hy draulic system When repairing the lift pump motor ALWAYS check that the battery is charged and check all electrical connections BEFORE removing the mo to...

Page 53: ...e 0620YRM0294 for replacement of the brushes If other components of the motor are damaged then the entire motor must be replaced The lift pump mo tor for the MPB040 E is a 24 VDC motor where the MPW045 050 E offers both a 12 VDC and 24 VDC motor These motors are not serviceable and must be replaced when not functioning properly Repair or re place the lift pump motor and install See Walkie Hy draul...

Page 54: ...ical system c If the forks raise properly but the lift pump and motor does not shut off when the forks reach maximum lift height unplug and clean the proximity sensor connector Reconnect the sensor with the wiring harness and check oper ation again If the problem remains proceed to the next step CAUTION Keep hands and fingers clear of lift linkage to avoid injury from pinch points 3 Cover the face...

Page 55: ...rrectly it must be replaced Install 1 Position the rear jam nut onto the position sensor threads 2 Install the position sensor into the bracket on the frame of the lift truck as removed 3 Install the front jam nut onto the position sensor threads Snug jam nut to secure sensor in place 1 PIN 1 BROWN WIRE 2 PIN 2 BLUE WIRE 3 PIN 3 BLACK WIRE Figure 21 Sensor Connector Front View 4 Connect the sensor...

Page 56: ...a malfunction of the charger or bat tery occurs One of the following may be the cause in the event of charger failure and the red LED is blinking AC mains failure DC fuse blown Power circuit break down One of the following may be the cause in the event of battery failure and the red LED is ON The total security time 14 or 15 hours has ex pired The security time before the battery gassing voltage 1...

Page 57: ...voltage indicates need for charging and the unit will not charge check the internal 50 amp DC output fuse and replace if necessary First remove the four Phillips head screws on the side of the charger and slide the cover off to access the fuse See Figure 24 If the DC output fuse requires replacement this could be an indication of an improperly wired battery pack Verify that all battery connections...

Page 58: ...Figure 24 50 Amp DC Output Fuse Figure 25 Battery Charger Legend for Figure 25 1 TRANSFORMER 2 RECTIFIER BRIDGE 3 CIRCUIT BOARD 4 DC OUTPUT FUSE 5 AC INPUT FUSE Battery Charger Moran 2200 YRM 1007 34 ...

Page 59: ...battery voltage does not rise as it should the charger output cur rent will increase which raises the transformer temperature Eventually it will become too hot causing the charger to shut down to protect itself The charger will restart itself and begin charging again after the transformer has cooled down but the same situation may occur again If this hap pens within one hour after start up the one...

Page 60: ...s AC protected by a 20 amp circuit breaker Figure 26 DPI Gen II Chargers 1 USB PORT FACTORY USE ONLY 2 MODE PORT DIP SWITCHES Figure 27 DPI Gen III Chargers NOTE Some markets use a special 230 volt AC charger which require connection to a 230 volt AC outlet Users with 230 volt AC chargers should substi tute 230 volts AC in the place of 120 volts AC when instructed to connect the charger to a power...

Page 61: ...d will begin the charging cycle The charger uses a 5 step charging process 1 Pre Qualification Test During this step the yel low CHARGING LED will flash on and off every two seconds The charger is checking for faults prior to the start of charging Depending on the condition and state of charge of the batteries this step can take from 45 seconds up to 5 hours 2 Regulating Current During this step t...

Page 62: ...an Battery T 605 CAUTION DO NOT use batteries types that are not approved for the charger or improper mode settings Dam age to the batteries or charger may occur if the mode setting is not correct for the type of batter ies being used The charger is set to a default Mode 2 at the factory Any batteries other than U1800 type will require the mode setting to be changed Changing Mode Setting DPI Gen I...

Page 63: ...fferent procedures for changing charger modes for charging different battery types Newer versions of DPI Accusense Gen III use dip switches to change charge modes while older version use four jumper ports Use the proper procedure for your lift truck See Charger Mode Battery Type Selection DPI Gen II Models or Charger Mode Battery Type Selection DPI Gen III Models NOTE On older versions of the char...

Page 64: ...ode 2 three times if set to Mode 3 and four times if the charger is set to Mode 4 If the LEDs do not flash when initially connected to power refer to Trouble shooting DPI Chargers in this section Modes are set by the position of the jumpers on the jumper port Accessing the jumper port requires re moval of a plate on the front of the battery charger on DPI Gen III chargers 1 Remove the screws used ...

Page 65: ...Figure 30 Switch Position Mode Chart 2200 YRM 1007 Battery Charger Accusense by DPI 41 ...

Page 66: ...nspect all cabling for proper connections check for loose or corroded connectors or broken wires Repair as necessary and re peat Step 1 If LEDs still do not flash at least once upon connecting power replace the charger 2 Check that the charger is configured for the proper battery mode type a What is the proper charger mode for the type batteries being used 1 Refer to Charger Mode Battery Type Se l...

Page 67: ...attery terminals Record the voltage and then monitor it for approximately 3 minutes Did the voltage INCREASE while monitoring 1 YES The charger is functioning correctly Proceed to Step 7 2 NO Replace the charger 7 Was the voltage reading in Step 6 higher than 16VDC a YES Proceed to Battery Pack Troubleshoot ing b NO It is recommended that all batteries in the battery pack be replaced Error Modes T...

Page 68: ...vity SG level for each battery cell after a charging cycle After a charging cycle the SG measurement for each cell should be 1 265 or greater From cell to cell within one battery The SG measure ments should not vary more than 0 020 If variance is greater than 0 020 it is recommended that the battery be replaced with the same type of battery as the other three batteries in that pack From battery to...

Page 69: ...two digits of the MFR MOD number read 1Q or 2Q the equipment is a Gen IV Q Series charger For the Gen IV chargers refer to Accusense Gen IV Charger 2200YRM2030 For other charger models use this manual Figure 31 Accusense 20A Chargers Manufactured Before May 2013 Figure 32 Accusense 20A Chargers Manufactured After May 2013 NOTE Some markets use a special 230 volt AC charger which require connection...

Page 70: ...o indicate AC power is ap plied to the charger and will begin the charging cycle The charger uses a 6 step charging process 1 Pre Qualification Test During this step the yellow CHARGING LED will flash on and off every two seconds The charger is checking for faults prior to the start of charging Depending on the condition and state of charge of the batteries this step can take from 5 seconds up to ...

Page 71: ...not correct for the type of batter ies being used If the battery manufacturer of the battery you are using is not listed contact Service Engineering through the Contact Management System NOTE Mode settings can be checked by connecting the battery charger to a 120V AC power source and watching the LED display The LED display will flash once if the mode is set to Mode 1 twice if set to Mode 2 three ...

Page 72: ...RT FACTORY USE ONLY 2 DIP SWITCHES IN MODE PORT Figure 34 Mode Port Lift Trucks Manufactured After May 2013 A USB port located to the left of the mode port is for factory use only For lift trucks manufactured before May 2013 refer to Table 8 to determine which mode should be used to charge a particular battery Table 8 Battery Chart for Accusense 20A Chargers Only Mfg Part Voltage Capacity 20HR RC ...

Page 73: ... 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 2200 YRM 1007 Battery Charger Accusense 20A 49 ...

Page 74: ...rocedures in Er ror Modes in this section 1 Check AC power supply to charger a Connect the charger plug to a 120 volt AC power source using a 20 amp rated extension cord b Do all 5 LEDs simultaneously flash at least once upon connection LEDs should flash be tween one to four times depending on battery type mode configuration 1 YES Proceed to Step 2 2 NO Check AC power supply to charger Inspect all...

Page 75: ...arger is functioning correctly Proceed to Step 7 2 NO Replace the charger 7 Was the voltage reading in Step 6 higher than 16VDC a YES Proceed to Battery Pack Troubleshoot ing b NO It is recommended that all batteries in the battery pack be replaced Error Modes The three red LEDs are used to troubleshoot the charger Observe the operation of the Power On Ab normal Shutdown and the Detection Error LE...

Page 76: ...ntrol Defective If an Equipment Lockout Cable Inhibit is installed and supposed to be active but it is not Check Inhibit vehicle wiring If correct internal inhibit switch may have been over load Contact factory Internal Over Temperature Charger shut down due to an internal over temperature condition Check fan operation and remove blockages if any Mode Selected Empty The selected Charge Algo rithm ...

Page 77: ...tteries and the voltage is less than 6 3VDC after allowing the batteries to set four hours 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 DO NOT overfill battery cells 2 Verify water level in each cell of each battery Before Charging Only add minimal amount of distilled water to cover top o...

Page 78: ... the forks Dead battery Recharge or replace battery Failed Open fuse Replace Failed Open fuse Lift pump motor wiring loose or dis connected Reconnect or tighten loose wiring connections Lift pump motor not operating Repair or replace lift pump motor Operator controls do not work Dead battery Recharge or replace battery Failed Open fuse Replace Failed Open fuse Control handle wiring loose or dis co...

Page 79: ......

Page 80: ...2200 YRM 1007 10 16 8 16 1 14 9 13 12 12 7 11 ...

Page 81: ...Maintenance LIFTING MECHANISM MPB040E B827 MPW045 E B802 MPW050 E C802 PART NO 524154897 4000 YRM 1008 ...

Page 82: ...ecifications 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 ...

Page 83: ...r Link and Load Wheel 3 Remove 3 Install 3 Compression Rod 4 Remove 4 Install 4 Lower Link 5 Remove 5 Install 6 Upper Link 6 Remove 6 Install 7 Caster Wheels Optional 7 Remove 7 Install 8 Replace 8 This section is for the following models MPB040E B827 MPW045 E B802 MPW050 E C802 2009 Yale Materials Handling Corp i ...

Page 84: ......

Page 85: ...is depressed the hydraulic pump sends high pressure hydraulic fluid to the lift cylinder This action extends the cylinder operates the lift linkage and raises the forks At the same time the rocker arms and the rear links mounted under the drive unit platform are pulled upward This causes the push rod assembly to be pushed toward the load wheel end of the truck The movement of the push rods in this...

Page 86: ...xi mum height 3 Put blocks under both forks and under the drive end of truck See the section How to Put a Lift Truck on Blocks 4 Press the lower button just enough to relieve pres sure from the load wheels 5 Move the key to the OFF position Disconnect the battery 6 Drive out the roll pin retaining the load wheel axle shaft to the link Repeat for other side 7 Remove the axle shaft and bushings from...

Page 87: ...tery in the battery compartment 8 Test the operation of the motorized hand truck be fore returning the truck to service Rear Link and Load Wheel 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 Remove the battery from the lift truck Position the battery close enough to...

Page 88: ...e capacity of the lifting device and spreader bar is greater than the weight of the bat tery 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 in sulated straps 1 Use the lift button to raise the lift truck to its maxi mum height 2 Put blocks under both forks and...

Page 89: ...te The spreader bar must NOT be made of metal or it must have in sulated straps 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 Move the key to the OFF position Disconnect and remove the battery 3 Put block...

Page 90: ...nd the lower link and install the pivot pin Install the roll pin to retain the pivot pin 5 Lubricate the grease fittings 6 Remove the blocks from under the forks and from each side of the drive tire 7 Install the battery in the battery compartment Con nect the battery 8 Turn the key to the ON position and use the lower button to lower the lift truck to its minimum height 9 Test the operation of th...

Page 91: ...site side 2 Align the pivot pin with the drive unit frame and the upper link and install the pivot pin Install a roll pin to retain the pivot pin 3 Install the drive unit compartment cover 4 Remove the blocks from under the forks and from each side of the drive tire Connect the battery 5 Test for proper operation before returning the truck to service Caster Wheels Optional REMOVE WARNING Put block...

Page 92: ...The blocks must prevent the lift truck from falling and causing personal injury or property damage NOTE The caster wheel does not have to be removed from the lift truck frame to replace the wheel or the wheel axle To replace the wheel or wheel axle follow these steps 1 Raise the drive wheel off the floor Block the lift truck See How to Put a Lift Truck on Blocks 2 Remove the lock nut retaining the...

Page 93: ......

Page 94: ...Yale Materials Handling Corp 1400 Sullivan Dr Greenville NC 27834 2011 4000 YRM 1008 8 09 9 05 1 02 Printed in U S A ...

Page 95: ...Maintenance DC MOTOR MAINTENANCE ALL ELECTRIC LIFT TRUCKS PART NO 524158039 0620 YRM 0294 ...

Page 96: ...odic 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 for...

Page 97: ...r 16 Assemble 20 Traction Motor and Hydraulic Pump Motor 20 Steering Pump Motor 22 Brush Alignment Traction and Hydraulic Motors 25 Tests for Damaged Field and Armature 25 Test for an Open Circuit in One Armature Winding 25 Test for Short Circuit in One Armature Winding 25 Test for Short Circuit to Armature Shaft 26 Test for Open Circuit in Field Coil 26 Test for Short Circuit in Field Coil 27 Tes...

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Page 99: ...rs and hydraulic pump motors are similar in design The hydraulic pump motors are smaller than the traction motors but the disassembly and maintenance of these motors are similar The cooling fan in the traction motors is fastened to the armature and can be removed from the armature The cooling fan can be removed during disassembly of the traction motor The cooling fan in the hydraulic pump motors c...

Page 100: ...your lift truck NOTE For some models of lift trucks the battery does not need to be removed to access the electric motors Other models will require the removal of the battery before gaining access to the electric motors To remove the battery either raise the hood panels or unfasten the floor plate depending on which motor needs to be accessed 2 Remove battery See How to Remove Battery in the Opera...

Page 101: ... the commutator surface between light brown and darker brown is normal The sur face condition is the lubrication between the com mutator and the brushes The brushes will wear rapidly if this surface condition does not develop during the first 6 to 10 hours of operation after a commutator with a new surface is installed If the commutator has deep grooves rough edges of the bars or a few bars that a...

Page 102: ... and dark brown colors are also normal The surface of the commutator must be smooth A condition called slot bar marking is also normal if the commutator surface is smooth The variable color oc curs in a pattern according to the number of conductors per slot A very dark surface is also a normal and an acceptable condition if the commutator surface is smooth Brush and Commutator Inspection 0620 YRM ...

Page 103: ...he steering pump motor See Ta ble 3 3 Install brush covers and screws Install floor plate or close hood and connect battery connector NORMAL COMMUTATOR SURFACE A commutator that has been in service will have a smooth and polished surface with a darker brown color where it rotates under the brushes See Table 1 A variation of color on the commutator surface be tween light brown and darker brown is n...

Page 104: ...pressure is too low Worn brushes Grooves and lines that have followed the heavy streaks and fine grooves shown above The arma ture must be removed from the motor so the commutator can be re paired A commutator with this condition will cause the brushes to wear rapidly Operation of the motor in dirty and abrasive condi tions Continuous opera tion of a motor with a light load Brush pressure is too l...

Page 105: ...occurs when copper from the commutator bar is pulled into the slot be tween the commutator bars This condition will cause a short circuit be tween the commutator bars if it is not corrected The brushes will wear rapidly Operation of the motor in dirty and abrasive condi tions Brush holder is not adjusted electri cally correct for the motor Wrong type of brushes for this motor and opera tion Brush ...

Page 106: ...tor bars on opposite sides of the commutator Open armature winding Motor has been stalled Copper wears rapidly at the edge of the commuta tor bars Operation of the motor in dirty and abrasive condi tions Wrong type of brushes for this motor and opera tion Brush and Commutator Inspection 0620 YRM 0294 8 ...

Page 107: ...ed Open armature winding Open field coil Brush and commutator damage occurs when the high commutator hits and forces the brush up Arc ing and burns occur as the brush moves back down to the normal sur face Check for loose or high commutator bars Motor has been stalled High com mutator bars at each brush posi tion can occur if the motor is stal led Motor has been too hot 1 High commutator bars at e...

Page 108: ... 15 mm 0 59 in 16 mm 0 63 in 20 mm 0 79 in NOTE For some models of lift trucks the battery does not need to be removed to access the electric motors Other models will require the removal of the battery before gaining access to the electric motors 2 Remove battery as necessary for your lift truck See How To Remove Battery in the Operating Manual or the YRM section Periodic Mainte nance for your lif...

Page 109: ...e Brush springs normally have a spring pressure of approximately 1 0 to 2 0 Newtons per each cm2 1 5 to 3 0 lbf per each in2 when measured with a spring scale A brush for a traction motor has an area of approxi mately 5 33 1 27 cm 6 8 cm2 2 1 0 5 in 1 05 in2 Brush springs for the traction motor normally have a spring force of approximately 9 1 to 11 3 Newtons 36 to 44 ozf when measured with a spri...

Page 110: ...ed This contact surface must be checked when new brushes are installed The contact surface MUST be approximately 85 percent of the brush surface where it touches the commutator A small contact surface can cause burns and a rough surface on the commutator If the contact surface is less than approximately 86 percent the new brushes must be made to fit the commutator better 9 If new brushes must be m...

Page 111: ...eater stone to moving commutator with light pressure Move brush seater stone backward and forward across surface of commutator until marks on commutator are removed Apply brush seater stone to commutator before each set of brushes so the brush seater particles have an even distribution CAUTION Do not permit the brush seater stone to stay in contact with the commutator too long and cause more wear ...

Page 112: ...Figure 6 Stoning the Commutator Legend for Figure 6 1 RAISE DRIVE WHEELS 2 JUMPER 3 BATTERY 4 BRUSH SEATER STONE Stoning the Commutator 0620 YRM 0294 14 ...

Page 113: ...f motor and field frame so correct as sembly is possible 2 On hydraulic motor assemblies remove two cap screws that fasten pump to pump motor See Fig ure 11 or Figure 12 Remove pump Put an index mark on armature shaft at the position of the cou pler hub for correct assembly Remove coupler hub from armature shaft by loosening setscrew and sliding hub off shaft and key Do not lose key 3 Remove brush...

Page 114: ...MOUNTING PLATE Figure 7 Brush Holder and Mounting Plate 7 Remove screws that fasten brush holder assem bly to commutator end frame 8 Disassemble components of motor as necessary to make repairs Steering Pump Motor NOTE Some lift trucks could be equipped with a Brushless DC Power Steering motor which is non re pairable NOTE Some electrical trucks use a steering pump motor Refer to the service manua...

Page 115: ... FRAME 9 SCREW 4 10 SCREW 4 11 WASHER 8 12 WASHER 13 FAN COVER 14 BRUSH COVER 15 SCREW 4 16 WASHER 4 17 FAN HUB 18 FAN 19 SCREW 2 20 SNAP RING 21 OIL SEAL 22 BRUSH HOLDER 23 SCREW 4 24 WASHER 4 25 BRUSH MOUNTING PLATE 26 MOUNT PLATE 27 SCREW 4 Figure 8 Typical Traction Motor Example 1 0620 YRM 0294 Motors Repair 17 ...

Page 116: ...RING 7 FAN 8 KEY 9 ARMATURE 10 BEARING 11 BRUSH COVER 12 COMMUTATOR END FRAME 13 TERMINAL 14 BRUSH MOUNTING PLATE 15 BUS CONNECTOR 16 WIRE 17 BRUSH SPRING 18 BRUSH 19 BRUSH HOLDER 20 FIELD FRAME Figure 9 Typical Traction Motor Example 2 Motors Repair 0620 YRM 0294 18 ...

Page 117: ...TUBE 13 HEX HEAD BOLT 14 SCREW 15 LOCKWASHER 16 DISC 17 BRUSH SPRING 18 BRUSH 19 SCREW 20 DISC SPRING 21 BRUSH HOLDER 22 CIRCLIP 23 BALL BEARING 24 END PLATE CPL 25 END FRAME COMMUTATOR 26 HEX HEAD BOLT 27 LOCKWASHER 28 RING 29 SPRING 30 BRUSH COVER Figure 10 Typical Traction Motor Example 3 0620 YRM 0294 Motors Repair 19 ...

Page 118: ...all components are clean If bearings were worn install new bearings in end frames See Figure 8 or Figure 9 2 If cooling fan was removed install it on armature Make sure field coils and pole pieces are installed correctly in field frame 3 Install brush holder assembly in commutator end frame Make sure alignment marks are aligned 4 Install drive end frame on armature 5 Carefully install armature and...

Page 119: ...RUSH 5 BRUSH HOLDER 6 BRUSH SPRING 8 7 BUSH CONNECTOR 2 8 FIELD COILS 9 BEARING 10 ARMATURE 11 FAN 12 BEARING 13 DRIVE END FRAME 14 FAN COVER 15 WOODRUFF KEY 16 FIELD FRAME Figure 11 Typical Hydraulic Pump Motor Example 1 0620 YRM 0294 Motors Repair 21 ...

Page 120: ... frame on ar mature and field frame assembly 4 Align index marks and install brush holder assem bly in commutator end frame Install and tighten two screws 5 Make sure special spring is in position in commu tator end frame Align index marks and install commutator end frame Carefully install four long screws through field frame into drive end frame Tighten screws 6 Install brush springs and brushes ...

Page 121: ...N 6 WOODRUFF KEY 7 ARMATURE 8 BEARING 9 TERMINAL ASSEMBLY 10 BRUSH COVER 11 COMMUTATOR END FRAME 12 BRUSHES 13 BRUSH HOLDER ASSEMBLY 14 BRUSH SPRING 15 BUS CONNECTOR 16 FIELD FRAME Figure 12 Typical Hydraulic Pump Motor Example 2 0620 YRM 0294 Motors Repair 23 ...

Page 122: ...USING 7 HEX HEAD BOLT 8 8 BRUSH COVER 9 BRUSH PLATE 10 BRUSH HOLDER 4 11 BRUSH SPRING 4 12 BRUSH 4 13 SCREW 4 14 WASHER 15 BRUSH TERMINAL 16 END PLATE COMMUTATOR CPL 17 END PLATE 18 FAN 19 SHROUD FAN Figure 13 Typical Hydraulic Pump Motor Example 3 Motors Repair 0620 YRM 0294 24 ...

Page 123: ...s can indicate a dam aged winding The motor must be removed from the lift truck and disassembled as shown in the illustra tions before the tests can be done TEST FOR AN OPEN CIRCUIT IN ONE ARMATURE WINDING The armature windings in large electric motors nor mally have less than 1 ohm of resistance The two commutator bars for a winding are found 180 degrees apart on the commutator If an ohmmeter R 1...

Page 124: ...or a short circuit between an armature winding and the armature shaft Put one probe on the armature shaft and the other probe on a commutator bar See Figure 16 A resistance of less than 1 megohm indi cates a problem between a winding and the armature shaft 1 ARMATURE SHAFT 2 COMMUTATOR 3 PROBES TO OHMMETER 4 RESISTANCE SHOULD BE GREATER THAN 1 MEGOHM Figure 16 Test for Short Circuit to Armature Sh...

Page 125: ... the motor A higher than normal current draw can also indicate other problems or needed adjustments and does not always indicate a short circuit in a motor winding TEST FOR SHORT CIRCUIT BETWEEN FIELD AND MOTOR CASE Make sure that carbon dust has been cleaned from the motor before making this test An ohmmeter R 10 000 scale can be used to test for a short circuit between the field and the motor ca...

Page 126: ...oo low Increase brush pressure Worn brushes Replace brushes Grooves the width of the brushes see Table 2 Operation in a dirty or abrasive en vironment Clean commutator more fre quently Wrong type of brushes for this mo tor and operation Replace brushes with correct type Brush pressure is too high Adjust brush pressure Copper drag occurs when copper from the commutator is pulled into the slot betwe...

Page 127: ...urning of the commutator bar 2 Open circuit in winding cau ses deep burning of adjacent commutator bars 3 Overheating causes damage to varnish insulation see Ta ble 2 Motor has been too hot Wrong lift truck for the application Motor has been stalled Open armature wind ing Open field coil Use correct lift truck for the appli cation Use correct operating tech niques Replace armature or resur face co...

Page 128: ...NOTES 30 ...

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Page 130: ...0620 YRM 0294 9 16 3 08 6 15 3 06 8 03 ...

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