Yale MSW025-E Guide

Maintenance
STEERING MECHANISM
MSW020/025-E [A895];
MSW025/030-F [B895];
MPB040-E [B827];
MPW045-E [B802];
MPW050-E [C802]
PART NO. 524154892 1600 YRM 1004

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2015 Yale Materials Handling Corp.
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Special Precautions .................................................................................................................................................. 1
Control Handle Head ................................................................................................................................................ 2
Control Handle ..........................................................................................................................................................2
Remove ................................................................................................................................................................ 2
Install .................................................................................................................................................................... 3
Gas Spring ................................................................................................................................................................5
Discharging the Gas Spring ..................................................................................................................................5
Troubleshooting ........................................................................................................................................................ 6
This section is for the following models:
(MSW020/025-E) [A895];
(MSW025/030-F) [B895];
(MPB040-E) [B827];
(MPW045-E) [B802];
(MPW050-E) [C802]
Table of Contents
i

General
The control handle assembly is designed to perform
several functions. The standard control handle
includes the speed/direction control and buttons for
the horn, traction reversing, and hydraulic functions.
The control handle is connected to the Master Drive
Unit (MDU) and is used to steer the truck as it turns
the MDU. Move the control handle left or right to turn
the drive/steer tire and steer the truck. Controls
mounted in the handle are linked to the control panel
by a wiring harness that passes through the center of
the handle. The brake is applied when the handle is in
the full up or down position.
A bottom-mounted control handle assembly is used
on the MSW020/025-E, MSW025/030-F, MPB040-E,
MPW045-E, and MPW050-E. The handle is designed
to be used while the operator is walking beside the lift
truck.
Special Precautions
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before trouble-
shooting or adjusting and before connecting or
disconnecting a handset or personal computer.
CAUTION
To avoid controller damage, always disconnect
the battery, discharge the capacitor, and never
put power to the controller while any power wires
are disconnected. Never short any controller ter-
minal or motor terminal to the battery. Make sure
to use the proper procedure when servicing the
controller.
1. Turn the key switch to the OFF position and dis-
connect the battery.
2. Discharge the capacitors in the controllers by con-
necting a 200-ohm, 2-watt resistor across the
controller's B+ and B− terminals. DO NOT short
across the motor controller terminals with a
screwdriver or jumper wire. See Figure 1 and Fig-
ure 2.
3. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery.
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 1. Discharging Controller - MPB040-E
1600 YRM 1004 General
1

Figure 2. Discharging Controller - MSW020-E,
MSW025-E, MSW025-F, MSW030-F, MPW045-E,
and MPW050-E
Legend for Figure 2
1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
3. 200-OHM, 2-WATT RESISTOR
4. INSULATED JUMPER WIRES
Control Handle Head
Refer to the section Electrical System
2200YRM1007 for instructions on removing and in-
stalling the control handle head from the control han-
dle. The instructions for disassembly and assembly of
the control handle head can be located in the same
section.
Control Handle
REMOVE
WARNING
The gas springs used on the control handle are
installed under tension and can release with
enough force to cause personal injury or property
damage.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected. Refer to Figure 1
and Figure 2 in the Special Precautions section of
this manual.
1. Move the lift truck to a safe, level area and block
the wheels to prevent movement.
2. Turn the key switch to the OFF position and dis-
connect the battery.
3. Remove the drive unit compartment covers and
MDU covers.
Special Precautions 1600 YRM 1004
2

4. Discharge the capacitor in the controller by con-
necting a 200-ohm, 2 watt resistor between the B
+ and B- connectors on the controller.
5. Disconnect the control handle wiring harness plug
and the control handle arm prox switch plug loca-
ted on top of the drive motor.
For the following instructions refer to Figure 3.
6. Remove the rubber bumper retaining screw and
wire clamp.
7. If necessary, remove the control handle head.
See the section Electrical System
2200YRM1007, Figure 3.
CAUTION
Discharging the gas spring is a destructive opera-
tion.
8. Discharge and remove the gas spring. Refer to
Gas Spring.
9. Remove setscrews.
10. Remove both threaded control arm pivot pins and
washers.
11. Remove the control arm from the support bracket.
12. Remove two screws from the support bracket and
remove the control handle arm prox switch.
13. If bushings are worn, remove the bushings from
the support bracket pivot pin holes.
INSTALL
1. Install the new gas spring to the control handle
arm. Refer to Gas Spring.
2. If previously removed, install the bushings into the
support bracket pivot pin holes.
NOTE: Install the switch to the bracket with wire to
bottom of the bracket.
3. Install the control handle arm prox switch into the
mounting bracket and mount onto the support
bracket with retaining screws. Leave retaining
screws loose until the control handle arm is instal-
led.
4. Install the bumper and wire clamp with retaining
screw and tighten to 10.5 N•m (93 lbf in).
5. If removed, install the control handle head. See
the section Electrical System 2200YRM1007,
Figure 3.
6. Install the control arm into the support bracket.
Apply Loctite® 242 to the threaded portion of the
pivot pins and install pivot pins. Torque to 190
±7 N•m (140 ±5 lbf ft).
7. Install and tighten setscrews.
8. Drive the pin through lower end of gas spring to
secure to support bracket.
9. Adjust control handle arm prox switch. Refer to
the section Electrical System 2200YRM1007,
Control Handle Arm Prox Switch - Install.
10. Install the MDU covers and drive unit compart-
ment covers.
11. Connect the battery and test the operation of the
lift truck prior to returning to service.
1600 YRM 1004 Control Handle
3

Figure 3. Control Handle Assembly
Control Handle 1600 YRM 1004
4

Legend for Figure 3
1. CONTROL HANDLE ARM
2. PIVOT PIN
3. WASHER
4. BUSHING
5. PIN
6. GAS SPRING
7. SCREW
8. LOCKWASHER
9. FLAT WASHER
10. RUBBER BUMPER
11. CONTROL HANDLE ARM PROX SWITCH
12. MOUNTING BRACKET
13. SCREW
14. SCREW
15. CONTROL HANDLE HEAD
16. SCREW
17. LOCKWASHER
18. FLAT WASHER
19. SCREW
20. LOCKWASHER
21. WIRE CLAMP
22. ALLEN HEAD SCREW
23. SETSCREW
Gas Spring
WARNING
Disconnect the battery by separating the battery
connector before opening the compartment cover
and before inspecting or repairing the electrical
system. DO NOT place tool on top of the battery. If
a tool causes a short circuit, the high-current flow
from the battery can cause personal injury or
property damage.
WARNING
The capacitor in the traction motor controller can
hold an electrical charge after the battery is dis-
connected. To prevent electrical shock and per-
sonal injury, discharge the capacitor before in-
specting or repairing any component. Make cer-
tain the battery has been disconnected and al-
ways wear safety glasses. See Special Precau-
tions in this section. DO NOT attempt to discharge
the capacitors by shorting the controller.
WARNING
The gas spring used on the control handle is in-
stalled under tension and can release with
enough force to cause personal injury or property
damage.
Review the following procedures before removing the
gas spring.
DISCHARGING THE GAS SPRING
WARNING
Goggles and a face shield must be worn for per-
sonal protection as metal chips and hydraulic lu-
bricant may be ejected from the drill operation
due to the high internal pressure.
CAUTION
The control handle return spring is charged with
pressurized gas and contains a hydraulic oil lubri-
cant.
NOTE: This process is a destructive operation to the
gas spring. A new gas spring must be used during re-
assembly. This is necessary because internal dam-
age to the spring components which are not detecta-
ble could cause damage or injury when the spring is
removed.
1. Check that the handle return spring is installed
and properly secure the control handle arm in the
full upright position. Remove the plastic plugs to
increase visibility of the gas spring.
CAUTION
DO NOT damage the control handle wiring har-
ness inside the control handle arm.
1600 YRM 1004 Control Handle
5

2. Locate and drill a 7 mm (0.25 in.) access hole
through the center of the control handle tube, ap-
proximately 50 mm (2 in.) below the existing ac-
cess hole.
WARNING
Contents are under pressure. This process may
eject metal chips and oil.
3. Locate the gas spring inside the control handle
through the newly drilled access hole and drill a
3 mm (0.125 in.) hole into the gas spring cylinder
shell to relieve pressure.
4. Clean up any discharged oil and dispose of in ac-
cordance with local regulations.
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Steering is rough or difficult. Damaged, worn, or defective steer-
ing handle swivel bearing(s).
Replace bearings.
Steering handle swivel bearing(s)
need lubrication.
Lubricate or repack bearings.
Bearing retaining nut torque incor-
rect.
Loosen retaining nut and tighten to
correct torque. See the section
Master Drive Unit 0630YRM1003.
Drive unit housing bearing (steer)
damaged.
Replace drive unit housing bearing
(steer).
Steering handle does not return to
the vertical position.
Gas spring is weak or broken. Replace gas spring.
Gas spring ball stud broken or
loose.
Retighten or replace gas spring
ball stud.
Gas Spring 1600 YRM 1004
6

1600 YRM 1004 10/15 (3/08)(10/06)(9/05)(8/05)(7/05)