Hyster-Yale Electric Pallet Truck MSW025-F

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, activating the switch and sending a signal to the ZAPITM Controller. A red LED on the switch illuminates when the target is sensed. Refer to Brakes 1800YRM1005.

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 performing 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.

Warning: Always troubleshoot to verify the component(s) at fault before replacing the controller.

Lift truck moved to a safe, level area

Note: Some new controllers may have software upgrades which will not allow previous controller parameters and settings to be transferred.

Note all special customer parameters and settings

Key switch turned to the OFF position

Battery connectors disconnected and separated

Drive tire blocked to prevent movement

Battery removed to gain access to control panel screws

Upper drive unit compartment cover removed

1. Remove the traction motor and brake assembly from the MDU. See Brakes 1800YRM1005.

CAUTION: The pinion end cover and the armature are heavy components. Work carefully so the field coils, pole pieces, and armature are not damaged during disassembly and assembly.

2. Clean outside surfaces of motor before disassembly. Make index marks on the ends of the motor and field ring to ensure proper reassembly.

3. Remove brush cover, if used. Measure the brush in the brush holder, use a tire tread depth gauge or small scale to measure from the top of the brush holder to the back of the brush. a. Brush replacement is REQUIRED when the height of the brush measures 11 mm (0.44 in.) below the brush box. If the brush is worn 8 mm (0.31 in.) below the brush box, then brush replacement is RECOMMENDED. See the section DC Motor Maintenance 0620YRM0294 for the replacement of brushes and spring assemblies.

4. Remove capscrews from commutator end of motor. Carefully slide end cover from motor and armature shaft. DO NOT damage parts. A puller is often necessary to separate the end cover from the field ring.

5. Remove screws that fasten pinion end cover to field ring. Remove end cover and armature. Use a plastic or rubber hammer, as necessary, to loosenend cover.

6. Remove pinion end cover from armature.

7. Remove screws that fasten brush holder assembly to commutator end cover.

8. Disassemble components of motor, as necessary, to make repairs. See Figure 17 and the section DC Motor Maintenance 0620YRM0294.

1. Turn the key switch to the OFF position and disconnect 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 rubber boot.

5. Remove nuts and washers holding retaining bracket. Remove bracket and gauge from control panel.

1. Install gauge in control panel.

2. Install retaining bracket, washers, and nuts. Tighten nuts.

NOTE: On some models, the dash indicator will display 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. Specific 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 Precautions.