Yale MPB040-E User manual

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
The main frame has mounts for the lifting mechanism,
the electrical system parts, the hydraulic pump assem-
bly, and the master drive unit (MDU). Repair procedures
for major systems/parts that fasten to the main frame
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
lifting mechanism. The base of the forks and the bat-
tery end of the weldment are lifted by the cylinder to
raise the load. At the same time, the fork tips are lifted
by linkage operating the load wheel assembly. There
is also a mount for the optional casters. The mounting
holes for the casters are in the main frame weldment.
1. FORKS
2. FRAME
3. UPPER COVER
4. MOTOR COVER (LH)
5. MOTOR COVER (RH)
6. COUNTERSUNK CAPSCREW
7. LOWER COVER
8. WASHER
9. BUTTON HEAD CAPSCREW
Figure 1. Frame Weldment and Covers MPB040-E, MPW045-E, and MPW050-E
1

Frame Separation and Assembly 100 YRM 1015
Frame Repair
WARNING
Forklift truckframesandcomponentsmayhave
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.Removethekeyfromthekeyswitch.
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. 206mm(8in.)×724mm(29in.)
b. 206mm(8in.)×804mm(32in.)
c. 232mm(9in.)×724mm(29in.)
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
twoframesmaybeseparatedfromeachotherbyusing
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.
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.
2

100 YRM 1015 Battery Compartment
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.
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.
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.
Neverallowtoolsorotherobjectstobeplacedontopof
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
1. CRANE
2. SPREADER BAR 3. INSULATED STRAPS
4. BATTERY
Figure 2. Changing the Battery
For the following instructions, refer to Figure 2.
Remove
1. Move lift truck under overhead crane or other suit-
able lifting device.
2. Block drive tire to prevent movement of lift truck.
3. Turn key switch OFF, disconnect battery connector,
and move it out of the way.
4. Loosen one of the battery spacers and move it out
of the way. See Figure 2.
5. Connect spreader bar to battery using insulated
straps and lift battery out of lift truck.
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. Remove any obstructions in battery compartment
(i.e., battery cables or tools).
2. Lower new battery into battery compartment.
3. Connect battery cable connector. Adjust location of
battery to allow proper connection of cables.
4. Adjust the brackets on each side of the battery and
tighten the capscrews, lockwashers, and nuts to re-
tain the battery.
5. Remove spreader bar and insulated straps from
battery.
Battery Spacer Adjustment
The battery spacers are designed to hold the battery
in place during normal operation. The spacers are ad-
justed by adding or removing spacers as required to
prevent the battery from moving.
Label Replacement
WARNING
Replace damaged Warning or Caution labels imme-
diately.
If labels or information plates are missing or damaged,
they must be replaced. See Figure 3.
NOTE: The nameplate cover is installed using rivets.
Remove old rivets before installing a new nameplate
cover. See your Yale®lift truck dealer to make sure the
nameplate cover information is correct and complete
before installing a new nameplate cover. Fasten the
nameplate cover with the rivet heads outside.
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.
NOTE: The label cannot be moved after it touches the
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.
1. LABEL(YALE)
2. NAMEPLATE
3. LABEL (WARNING)
4. DECAL
5. RIVET
6. LABEL (PATENTS AND TRADEMARKS)
7. LABEL (PINCH WARNING)
8. OPERATING MANUAL
9. NAMEPLATE LABEL
10. LABEL (BATTERY DISCHARGE NOTICE)
Figure 3. Label and Decal Location
5

Load Wheels 100 YRM 1015
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.
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.
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.
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.
6

100 YRM 1015 Load Wheels
1. LOAD WHEEL
2. FITTING
3. ROLLER
4. BEARING
5. BUSHING
6. AXLE
7. FITTING
8. PIN
Figure 4. Load Wheel and Link Assembly
7. Remove all old lubricant. Clean and inspect all
parts. Replace all defective parts.
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.
5. Install the battery in the battery compartment and
connect the battery.
6. Remove the blocks from under the forks and from
eachsideofthedrivetire. TurnthekeytotheON
positionandusethelowerbuttontolowerthelift
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 Special Precautions
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.
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.
Description
TheMDUisatriplereductiondriveunit.Thethreesets
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
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.
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
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
WARNING
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.
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
Figure 1. Discharging Controller - MPB040-E
Legend for Figure 1
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
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
2