Maintenance

STEERING MECHANISM
MSW020/025-E [A895];
MPB040-E [B827];
MPW045-E [B802]

PART NO. 524154892 1600 YRM 1004

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Steering Mechanism Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Special Precautions............................................................................................................................................. 1
Control Handle Head ........................................................................................................................................... 2
Control Handle..................................................................................................................................................... 2
Remove ........................................................................................................................................................... 2
Install............................................................................................................................................................... 3
Troubleshooting ................................................................................................................................................... 5

This section is for the following models:

MSW020/025-E [A895];
MPB040-E [B827];
MPW045-E [B802]

©2003 Yale Materials Handling Corp. i

1600 YRM 1004 Special Precautions

General
The control handle assembly is designed to perform in the handle are linked to the control panel by a wiring
several functions. The standard control handle includes harness that passes through the center of the handle.
the speed/direction control and buttons for the horn, The brake is applied when the handle is in the full up or
traction reversing, and hydraulic functions. The con- down position.
trol handle is connected to the master drive unit (MDU)
and is used to steer the truck as it turns the MDU. The The bottom-mounted control handle assembly is used
MDU is supported by a bearing that is mounted to the on the MSW020/025-E, MPB040-E, and MPW045-E.
frame. Move the control handle left or right to turn the The handle is designed to be used while the operator is
drive/steer tire and steer the truck. Controls mounted walking beside the lift truck.

Special Precautions
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before trou-
bleshooting 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 terminal
or motor terminal to the battery. Make sure to use
proper procedure when servicing the controller.

1. Turn key switch to OFF position and disconnect the

battery.

2. Discharge the capacitors in the controllers by

connecting a 200-ohm, 2-watt resistor across the
controller’s B+ and B terminals. DO NOT short
across the motor controller terminals with a screw-
driver or jumper wire. Remove the 200-ohm, 2-watt
resistor before reconnecting the battery. See Fig- BM080062
ure 1 and Figure 2.
1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR

Figure 1. Discharging Controller - MPB040-E

1
Control Handle 1600 YRM 1004

Legend for Figure 2

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

+B
£>

BM080063

Figure 2. Discharging Controller - MSW020-E,

MSW025-E, and MPW045-E

Control Handle Head

Refer to Electrical System for your lift truck, 2200 instructions for disassembly and assembly of the con-
YRM 1007, for instructions on removing and installing trol handle head can be located in the same manual.
the control handle head from the control handle. The

Control Handle
REMOVE battery has been disconnected. Refer to Figure 1
and Figure 2 in the Special Precautions section of
WARNING this manual.
The gas springs used on the control handle have 1. Move lift truck to a safe, level area and block the
tension and can release with enough force to cause wheels to prevent movement.
personal injury or property damage.
2. Turn key switch to the OFF position and disconnect
A WARNING battery.
The capacitor in the transistor controller can hold 3. Remove the drive unit compartment covers and
an electrical charge after the battery is discon- MDU covers.
nected. To prevent electrical shock and personal
injury, discharge the capacitor before inspecting 4. Discharge capacitor in the controller by connecting
or repairing any component in the drive unit com- a 200-ohm, 2 watt resistor between the B+ and B
partment. Wear safety glasses. Make certain the connectors on the controller.

2
1600 YRM 1004 Control Handle

5. Disconnect the control handle wiring harness plug 2. If previously removed, install the bushings into sup-
and the control handle arm prox switch plug located port bracket pivot pin holes.
on top of the drive motor.
NOTE: Install switch to bracket with wire to bottom of
For the following instructions refer to Figure 3. bracket.

6. Remove the rubber bumper retaining screw and 3. Install control handle arm prox switch into mounting
wire clamp. bracket and mount onto support bracket with retain-
ing screws. Leave retaining screws loose until con-
7. If necessary, remove the control handle head. See trol handle arm is installed.
Electrical System 2200 YRM 1007, Control Han-
dle. 4. Install bumper and wire clamp with retaining screw
and tighten to 10.5 N•m (93 lbf in).
8. Use a hammer and pin punch to drive pin clear of
the lower end of gas spring. 5. If removed, install the control handle head. See
Electrical System 2200 YRM 1007, Control Han-
9. Remove both threaded control arm pivot pins and dle.
washers.
6. Install control arm into support bracket. Apply Loc-
10. Remove the control arm from the support bracket. tite 242™ to the threaded portion of the pivot pins
and install pivot pins. Torque to 96 N•m (71 lbf ft).
11. Remove Allen-head screw from upper arm to re-
move gas spring. 7. Drive the pin through lower end of gas spring to
secure to support bracket.
12. Remove two screws from support bracket and re-
move control handle arm prox switch. 8. Adjust control handle arm prox switch. Refer to
Electrical 2200 YRM 1007, Control Handle Arm
13. If bushings are worn, remove the bushings from the
Prox Switch, Install.
support bracket pivot pin holes.
9. Install the MDU covers and drive unit compartment
INSTALL covers.
1. Install the upper end of gas spring to control han- 10. Connect the battery and test the operation of the lift
dle arm using Allen-head screw. Torque to 27 N•m truck prior to returning to service.
(20 lbf ft).

3
Control Handle 1600 YRM 1004

BM220011

Figure 3. Control Handle Assembly

4
1600 YRM 1004 Troubleshooting

Legend for Figure 3

1. CONTROL HANDLE ARM 12. MOUNTING BRACKET
2. PIVOT PIN 13. SCREW
3. WASHER 14. SCREW
4. BUSHING 15. CONTROL HANDLE HEAD
5. PIN 16. SCREW
6. GAS SPRING 17. LOCKWASHER
7. SCREW 18. FLAT WASHER
8. LOCKWASHER 19. SCREW
9. FLAT WASHER 20. LOCKWASHER
10. RUBBER BUMPER 21. WIRE CLAMP
11. CONTROL HANDLE ARM PROX SWITCH 22. ALLEN-HEAD SCREW

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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

handle swivel bearing(s).

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

need lubrication.

Bearing retaining nut torque incorrect. Loosen retaining nut and tighten to cor-
rect torque. See Master Drive Unit
630 YRM 1003.

Drive unit housing bearing (steer) Replace drive unit housing bearing
damaged. (steer).

Steering handle does not re- Gas spring is weak or broken. Replace gas spring.
turn to the vertical position.

Gas spring ball stud broken or loose. Retighten or replace gas spring ball
stud.

5
 NOTES

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

1600 YRM 1004 5/03 (1/02) Printed in U.S.A.