Yale MSW025-F Guide

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

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.

©2016 Yale Materials Handling Corp.
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Description of Operation ...........................................................................................................................................3
Special Precautions ..................................................................................................................................................5
Moving a Disabled Lift Truck .................................................................................................................................... 7
Electrical System Checks .........................................................................................................................................8
Safety Precautions ............................................................................................................................................... 8
Repairs ......................................................................................................................................................................9
Controller, Replace ...............................................................................................................................................9
Remove ............................................................................................................................................................9
Install ..............................................................................................................................................................12
Contactor Coil, Check .........................................................................................................................................12
Contactor, Replace .............................................................................................................................................13
Remove ..........................................................................................................................................................13
Install ..............................................................................................................................................................13
Key Switch Removal and Installation ......................................................................................................................13
Remove ..............................................................................................................................................................13
Install ..................................................................................................................................................................13
Battery Indicator/Hourmeter 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 Motor .........................................................................................................................................................26
Disassemble .......................................................................................................................................................26
Assemble ............................................................................................................................................................28
Lift Pump Motor ...................................................................................................................................................... 28
Repair () MSW020/025-E and MSW025/030-F...................................................................................................28
Lift Link Proximity Sensor (MPW050-E).................................................................................................................. 30
Check ................................................................................................................................................................. 30
Repair .................................................................................................................................................................30
Remove ..........................................................................................................................................................30
Test ................................................................................................................................................................30
Table of Contents
i

TABLE OF CONTENTS (Continued)
Install ..............................................................................................................................................................31
Adjust .............................................................................................................................................................31
Battery Charger (Moran®) .......................................................................................................................................32
Description ..........................................................................................................................................................32
Operation ............................................................................................................................................................32
Charging .........................................................................................................................................................32
Equalize ......................................................................................................................................................... 32
Signals ........................................................................................................................................................... 32
Protections .....................................................................................................................................................32
Troubleshooting ..................................................................................................................................................32
Battery Charger (Accusense by DPI®) ....................................................................................................................36
Description ..........................................................................................................................................................36
Operation ............................................................................................................................................................36
LED Display ................................................................................................................................................... 36
Charging .........................................................................................................................................................37
Charger Mode/Battery Type Selection (DPI Gen II Models) ...............................................................................38
Changing Mode Setting (DPI Gen II Models) .................................................................................................38
Charger Mode/Battery Type Selection (DPI Gen III Models) ..............................................................................39
Changing Mode Setting (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 (Accusense 20A Chargers) ......................................................................................................50
General .......................................................................................................................................................... 50
Error Modes ................................................................................................................................................... 51
Battery Pack Troubleshooting ........................................................................................................................53
Troubleshooting ......................................................................................................................................................54
This section is for the following models:
(MSW020/025-E) [A895];
(MPB040-E) [B827];
(MPW045-E) [B802];
(MSW025/030-F) [B895];
(MPW050-E) [C802]
Table of Contents
ii

General
This section includes removal, disassembly, checks,
adjustments, assembly, and installation procedures
for the electrical system components on the
MSW020/025-E [A895], MSW025/030-F [B895],
MPB040-E [B827], MPW045-E [B802], and MPW050-
E [C802] truck models. This section does NOT
include the electrical components covered in other
sections such as motors and industrial batteries. See
Figure 1.
See the section ZAPI™ Controllers 2200YRM1064
for models MSW020/025-E [A895] and MSW025/030-
F [B895]; ZAPI™ Controllers 2200YRM1006 for
models MPB040-E [B827]; ZAPI™ Controllers
2200YRM1067 for 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 models MPB040-E [B827],
MPW045-E [B802], and MPW050-E [C802]; Periodic
Maintenance 8000YRM1379 for models
MSW025/030-F [B895]. See the section Diagrams
8000YRM1050 for models MSW020/025-E [A895];
Diagrams 8000YRM1011 for models MPB040-E
[B827] and MPW045-E [B802]; Diagrams
8000YRM1228 for models MPW050-E [C802];
Diagrams 8000YRM1381 for models MSW025/030-F
[B895].
2200 YRM 1007 General
1

1. BATTERY CONNECTOR
2. BATTERY INDICATOR/HOURMETER DISPLAY
3. KEY SWITCH
4. POSITIVE 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

Description of Operation
See Figure 2 for the logic diagram.
This section includes information on the following
components:
•Control handle switches (ON/OFF and propor-
tional)
• Hall effect directional/speed control
• Control handle card
• ZAPI™ motor controller
• Traction motor
• Main contactor
• Brake coil
• Lift pump motor
• Lift time-out
• Batteries
ON/OFF switches are used for:
• Single speed lift and lower functions
• Half speed lift and lower functions
• Horn
• Traction reversing
• Creep (Turtle) speed
• Throttle neutral signal
MSW020/025-E and MSW025/030-F : Standard lift
switches are ON/OFF type. Standard left-side lift
switches are at half speed. The right-side lift switches
are at full speed. Optional proportional lifting switches
are available on the right side. Proportional switches
provide a variable output to regulate the speed of the
lift and lower functions.
All lower switches are proportional type switches
which allow the operator to maintain maximum control
of the load when lowering.
MPB040/45/50-E : Use only full speed lift and lower
switches.
A Hall effect throttle control is used to provide a direc-
tional/speed signal. The neutral switch verifies the
neutral position during the self check at startup. The
Hall effect throttle control, neutral switch, traction re-
versing switch, horn switch, and creep (turtle) speed
switch are an integral part of the control handle card
and not serviced separately. The switches that control
the hydraulic functions mount into the control handle
and are serviced separately.
The Hall effect throttle control, the proportional
switches and all the ON/OFF switches provide input
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 the motor controller. No
contactors are involved in the traction circuit.
The main contactor opens to remove power from the
truck to disable all traction and lift functions in the
event of an electric failure.
Energizing the brake coil pulls the brake pressure
plate away from the friction disc to disengage the
brake. The controller powers the brake coil based on
signals from the control handle arm proximity switch
and the Directional/Speed Control. The controller also
contains logic to engage the brake regardless of han-
dle position if the truck is stationary.
MSW020/025-E and MSW025/030-F : The motor
controller energizes the series wound lift pump motor
when either lift function switch is depressed. The ap-
plied voltage to the motor varies to adjust motor RPM
and pump output to the lift function.
MPB040/045/050-E : The motor controller energizes
the series wound lift pump motor when either lift func-
tion switch is depressed.
MSW020/025-E and MSW025/030-F : All trucks have
a solenoid operated lowering valve at the pump. The
motor controller activates the solenoid coil to open the
lowering valve. The motor controller varies the voltage
to the lowering solenoid to provide proportional lower-
ing.
MPB040/045/050-E : All trucks have a solenoid oper-
ated lowering valve at the pump. The motor controller
activates the solenoid coil to open the lowering valve.
2200 YRM 1007 Description of Operation
3

The lift time-out protects the lift pump and motor as-
sembly, eliminating the need for a height limit switch.
Lift is disabled after the pump runs for a programmed
amount of time. Lift is disabled on the MSW020/025-E
and MSW025/030-F trucks after operating continu-
ously for approximately 45 seconds. Lift is disabled on
the MPB040/045/050-E trucks after operating continu-
ously for approximately six seconds. The lift time-out
feature is reset once lower is selected.
The standard MSW020-E, MSW025-F, and MPB040-
Etrucks are equipped with a battery 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 battery connector to accept the op-
tional GNB PalletPro.
The MSW025-E, MSW030-F, and MPW045/050-E
are shipped without batteries. Standard trucks have a
175-amp battery connector and will accept industrial
flooded cell batteries or maintenance free batteries,
such as the GNB PalletPro.
Figure 2. Logic Diagram
Description of Operation 2200 YRM 1007
4

Special Precautions
WARNING
DO NOT make repairs or adjustments unless you
have both authorization and training. Repairs and
adjustments that are not correct can create dan-
gerous operating conditions. DO NOT operate a
lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag to the
control handle.
WARNING
Disconnect the battery and separate the connec-
tor before opening the drive unit compartment
cover or inspecting or repairing the electrical sys-
tem. If a tool causes a short circuit, the high cur-
rent flow from the battery can cause personal in-
jury or property damage.
WARNING
Some checks and adjustments are done with the
battery connected. DO NOT connect the battery
until the procedure tells you to do so. Never have
any metal on your fingers, arms, or neck. Metal
items can accidentally make an electrical connec-
tion and cause injury.
WARNING
Before doing any tests or adjustments, raise the
vehicle off the ground and block the lift truck to
prevent unexpected movement. See the section
Periodic Maintenance 8000YRM1048, Periodic
Maintenance 8000YRM1009, or Periodic 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
the battery has been disconnected.
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 proper procedure when servicing the con-
troller.
1. Block load wheels to prevent lift truck from mov-
ing. See the section Periodic Maintenance
8000YRM1048, Periodic Maintenance
8000YRM1009, or Periodic Maintenance
8000YRM1379 for your lift truck.
2. Turn the key switch to the OFF position and dis-
connect the battery.
3. 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 3 or Fig-
ure 4.
4. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery.
2200 YRM 1007 Special Precautions
5

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

Moving a Disabled Lift Truck
In order to move a disabled lift truck, the electric
brake must be released by powering the brake coil
with battery voltage. A jumper is provided in the wiring
harness to supply battery voltage directly to the elec-
tric brake to release it. The truck will roll freely, but the
drive motor will not activate while the jumper is instal-
led.
WARNING
Prior to releasing the electric brake, make sure
the lift truck is blocked correctly to prevent move-
ment, causing personal injury or damage to
equipment.
1. Turn the key switch to the OFF position.
2. Disconnect and separate the battery connectors.
3. Remove the upper drive unit compartment cover.
4. Remove the lower drive unit compartment cover.
5. 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.
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 lift truck to a safe, level area prior to per-
forming any repairs on it.
CAUTION
Always unplug the Brake Override Circuit and
connect the Brake Harness prior to operating the
lift truck.
9. Make sure the brake override circuit is disconnec-
ted from the brake harness. The brake will remain
released until the battery or the brake override cir-
cuit is disconnected. Restore the harness connec-
tor to the normal operation connector correctly be-
fore attempting to operate the lift truck.
1. BRAKE HARNESS CONNECTOR
2. BRAKE OVERRIDE CIRCUIT CONNECTOR
3. NORMAL OPERATION CONNECTOR
Figure 5. Brake Override Connector
2200 YRM 1007 Moving a Disabled Lift Truck
7

Electrical System Checks
SAFETY PRECAUTIONS
NOTE: On some models, the dash indicator will dis-
play the code: EP 107 (or a higher number) for 1 to 2
seconds every time the key switch is turned to the ON
position. This code represents the EEPROM software
version and DOES NOT INDICATE A FAULT CODE.
NOTE: These checks require a volt-ohmmeter. Spe-
cific checks require additional equipment.
NOTE: The correct meter polarity is necessary for
the checks. The voltage checks are made between
the individual points and battery negative. Connect
the meter negative to battery negative.
1. Block lift truck so the drive wheels are off the
floor. See the section Periodic Maintenance
8000YRM1048, Periodic Maintenance
8000YRM1009, or Periodic Maintenance
8000YRM1379 lift trucks. Refer to How to Put a
Lift Truck on Blocks.
2. Turn the key switch to the OFF position.
3. Disconnect and separate the battery connectors.
4. Remove the upper drive unit compartment cover.
5. Remove the lower drive unit compartment cover.
6. Discharge the capacitor. See Special Precau-
tions.
7. Check the specific gravity of the battery. If the
specific gravity is 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 lift truck and a clean connection on
the frame. Remove any circuit paths between the
controller and the frame of the lift truck, such as a
dirty battery case. Carbon dust in a motor or other
parts can cause a circuit path. Check for addi-
tional equipment that may cause a circuit path to
the frame.
9. Check for voltage between each terminal of the
connector that fastens to the battery and a clean
connection on the frame. Normally there is small
voltage (less than 30% of the battery voltage) be-
tween the battery and the frame, even though the
resistance is very high. A higher voltage can indi-
cate a dirty or damaged battery. Clean battery
and battery compartment as necessary.
10. Visually check for parts or wires that are loose or
damaged.
NOTE: Make an identification of any wires before you
disconnect them. The wires must be connected cor-
rectly after checks or repairs.
Electrical System Checks 2200 YRM 1007
8

Repairs
CONTROLLER, REPLACE
When experiencing problems with the hydraulic func-
tions, the controller may not be at fault. ALWAYS
troubleshoot to verify the component(s) at fault before
replacing the controller. Refer to the section ZAPI™
Controllers 2200YRM1064, ZAPI™ Controllers
2200YRM1006, or ZAPI™ Controllers
2200YRM1067 for your lift truck for additional infor-
mation on the ZAPI™ display and for information on
troubleshooting fault codes, adjusting parameters,
and testing the ZAPI™ motor controller.
Remove
1. Move lift truck to a safe, level area.
NOTE: Some new controllers may have software up-
grades which will not allow previous controller param-
eters and settings to be transferred.
2. If possible, prior to replacing the controller, note
all special customer parameters and settings.
3. Turn the key switch to the OFF position.
4. Disconnect and separate the battery connectors.
5. Block drive tire to prevent movement. See the
section Periodic Maintenance 8000YRM1048,
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. Refer to the section Periodic Mainte-
nance 8000YRM1048, Periodic Maintenance
8000YRM1009, or Periodic Maintenance
8000YRM1379 for your lift truck, for instructions
on how to remove the battery.
7. Remove the upper drive unit compartment cover.
8. Remove the lower drive unit compartment cover.
9. Discharge the capacitor. See Special Precau-
tions.
10. Remove the jumper assembly connector from the
"E" terminal of the motor controller. If equipped,
remove the LED assembly connector from the "D"
terminal of the motor controller.
11. Tag and remove the control wiring from the motor
controller.
12. Tag and disconnect the power wires from the mo-
tor controller.
13. Remove four capscrews and lockwashers that
hold controller to plate and remove controller.
2200 YRM 1007 Repairs
9

1. MOUNTING PLATE
2. BATTERY CONNECTOR (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

1. MOUNTING PLATE
2. CONTROLLER
3. CAPSCREW
4. CONTACTOR
5. BATTERY CONNECTOR MOUNT
6. WIRE CLAMP
7. 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

Install
NOTE: If installing the entire control panel assembly
to include the electrical panel plate, it will be neces-
sary to perform Step 1. If only installing the controller,
contactor, horn, fuses, or wires, it is not necessary to
perform Step 1.
1. Install control panel assembly to lift truck by align-
ing four holes of electrical panel plate with four
holes in frame and inserting countersunk cap-
screws into holes from the battery box side. Install
washer, lockwasher, and nut on countersunk cap-
screws. Replace battery. See the section Peri-
odic Maintenance 8000YRM1048, Periodic
Maintenance 8000YRM1009, or Periodic Main-
tenance 8000YRM1379 for your lift truck, for in-
structions on how to install the battery.
2. Install replacement controller on electrical panel
plate by aligning four holes of controller with four
holes in electrical panel plate. Install four cap-
screws and lockwashers.
3. Connect wires and cables to the same terminals
as identified during the removal procedure.
4. Connect the jumper assembly to the "E" terminal,
located on the bottom of the controller. See Spe-
cial Precautions for location. Use procedure that
applies to your lift truck:
a. To use a maintenance free battery, disconnect
the wire 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 the upper drive unit compartment cover.
CONTACTOR COIL, CHECK
1. Move lift truck to a safe, level area.
2. Turn the key switch to the OFF position and dis-
connect battery connectors.
3. Block drive tire to prevent movement. See the
section Periodic Maintenance 8000YRM1048,
Periodic Maintenance 8000YRM1009, or Peri-
odic Maintenance 8000YRM1379 for your lift
truck.
4. Remove the upper drive unit compartment cover.
5. Discharge the capacitor. See Special Precau-
tions.
6. Tag, identify, and disconnect the contactor coil
wires.
7. Test contactor coil using an ohmmeter.
8. Touch the probes of the ohmmeter to the coil ter-
minals and measure the resistance between the
terminals.
9. Replace contactor if coil resistance readings
measure outside of specifications. For contactor
coil resistance values, refer to Table 1.
10. Connect contactor wires to the correct terminals.
Table 1. Contactor Coil Resistance Values
Model Resistance
MSW020/025-E and
MSW025/030-F 21 ±2.1 ?
MPB040-E 52 ±5.2 ?
MPW045/050-E 21 ±2.1 ?
Repairs 2200 YRM 1007
12

CONTACTOR, REPLACE
Remove
1. Move lift truck to a safe, level area.
2. Block drive tire to prevent movement. See the
section Periodic Maintenance 8000YRM1048,
Periodic Maintenance 8000YRM1009, or Peri-
odic Maintenance 8000YRM1379 for your lift
truck.
3. Turn the key switch to the OFF position and dis-
connect battery connectors.
4. Remove the upper drive unit compartment cover.
5. Discharge the capacitor. See Special Precau-
tions.
6. Tag, identify, and disconnect the wires and ca-
bles.
7. Disconnect all wires and cables from the contac-
tor.
8. Loosen two mounting screws and lockwashers
that hold contactor to plate and remove contactor.
Install
1. Install contactor by aligning it with mounting
screws on electrical plate and sliding into place.
Tighten mounting screws.
2. Connect wires and cables to the same terminals
as identified during the removal procedure.
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 the OFF position.
4. Remove the upper drive unit compartment cover.
5. Remove the lower drive unit compartment cover.
6. Discharge the capacitor. See Special Precau-
tions.
7. Remove nut retaining the key switch to bracket.
8. Remove the key switch.
9. Identify and disconnect electrical wires to switch.
INSTALL
1. Connect wires to proper terminals.
2. Mount the key switch in bracket.
3. Install nut to retain the key switch. Make certain
switch is properly aligned before tightening retain-
ing nut.
4. Connect battery connectors.
5. Test the key switch by turning it ON and OFF.
6. Install the drive unit compartment covers as re-
moved.
2200 YRM 1007 Repairs
13

Battery Indicator/Hourmeter Display
NOTE: On some models, the dash indicator will dis-
play the code: EP 107 (or a higher number) for 1 to 2
seconds every time the key switch is turned to the ON
position. This code represents the EEPROM software
version and DOES NOT INDICATE A FAULT CODE.
The Battery Indicator/Hourmeter Display shows bat-
tery charge status, truck hours, and fault codes. See
Figure 8.
Figure 8. Battery Indicator/Hourmeter Display
Figure 9. Battery Indicator/Hourmeter Display
REMOVE
1. Turn the key switch 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 panel.
2. Install retaining bracket, washers, and nuts.
Tighten nuts.
3. Reconnect display wire harness plug.
4. Connect battery and turn the key switch to the ON
position.
5. Test operation of lift truck in a safe area.
6. Install the upper drive unit compartment cover.
Battery Indicator/Hourmeter Display 2200 YRM 1007
14

Fuses
WARNING
Before checking or changing any fuses, make cer-
tain the battery has been disconnected.
Always wear safety glasses. Block the tires, remove
the key from the key switch, disconnect battery, and
discharge the capacitors before making checks or re-
pairs in the drive unit compartment. See Special Pre-
cautions.
MPB040-E
The MPB040-E 24-volt motorized hand trucks have
two fuses. They are:
1. 175-amp (FU 1) protects both the lift pump mo-
tor and the drive motor
2. 5-amp (FU 2) protects the control circuits
MPW045/050-E
The MPW045-E and MPW050-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.
The MPW045-E and MPW050-E 12-volt lift trucks
have three 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.
3. 5-amp (FU 3) protects 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 new fuse and tighten capscrews. FU 2 is re-
tained by a fuse holder. Make certain that any re-
placement fuse is of the right amperage before instal-
lation.
MSW025/030-F
The MSW025/030-F 24-volt lift trucks have three
fuses. They are:
1. FU 1 protects both the lift pump motor and the
drive motor.
2. FU 2 protects the control circuits.
3. FU 3 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 new fuse and tighten capscrews. FU 2 or FU
3 are retained by a fuse holder. Make certain that any
replacement fuse is of the right amperage before in-
stallation.
2200 YRM 1007 Fuses
15

Control Handle Arm Proximity Switch
REPAIR
A proximity switch is used to sense the position of the
control handle arm. A target, cast into the base of the
control handle arm moves in front of the proximity
switch when the handle is in the RUN position, acti-
vating the switch and sending a signal to the ZAPI™
Controller. A red LED on the switch illuminates when
the target is sensed. Refer to Brakes 1800YRM1005.
Check and Adjust
Check the proximity switch for proper operation. All
connections must be attached. Take voltage readings
from the back of the connector.
1. Move the lift truck to a safe, level area before per-
forming any repairs.
2. Turn the key switch to the OFF position.
3. Remove the upper drive unit compartment cover.
4. Remove the lower drive unit compartment cover.
5. Remove the four capscrews from the two-piece
shield over the MDU and remove the shields.
6. Turn the key switch to the ON position.
7. Verify battery voltage at the proximity switch con-
nector between pin #1 and pin #2.
8. Place negative lead on the battery (-).
9. Place positive lead on the black wire pin #3 of the
proximity switch connector.
10. Place the control handle arm in the operating po-
sition. Verify that battery voltage is present and
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 problems. If the proximity switch continues not
to function properly, it must be replaced.
Remove
1. Move the lift truck to a safe, level area before per-
forming any repairs.
2. Turn the key switch to the OFF position and dis-
connect the battery.
3. Remove the upper drive unit compartment cover.
4. Remove the lower drive unit compartment cover.
5. Remove the four capscrews from the two-piece
shield over the MDU and remove the shields.
6. Discharge the capacitor. See Special Precau-
tions.
7. Cut the tie wrap located at the end of the proxim-
ity switch harness.
8. Remove the proximity switch harness clamp, lo-
cated beneath the drive unit housing.
9. Disconnect the proximity switch from the wiring
harness.
10. Fully lower the control handle arm. Remove the
two capscrews that mount the proximity switch
assembly to the control handle arm. See Fig-
ure 10. Remove the proximity switch assembly.
1. PROXIMITY SWITCH
2. CAPSCREW
3. SWITCH BRACKET
Figure 10. Proximity Switch Assembly
Control Handle Arm Proximity Switch 2200 YRM 1007
16