Hyster-Yale Hyster-Yale Electric Pallet Truck MPW050-E MPW050-E

When experiencing problems with the hydraulic functions, the controller may not be at fault. ALWAYS troubleshoot to verify the component(s) at fault before replacing the controller. Refer to the section ZAPITM Controllers 2200YRM1064, ZAPITM Controllers 2200YRM1006, or ZAPITM Controllers 2200YRM1067 for your lift truck for additional information on the ZAPITM display and for information on troubleshooting fault codes, adjusting parameters, and testing the ZAPITM motor controller.

1. Move lift truck 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.

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 Periodic Maintenance 8000YRM1379 for your lift truck.

NOTE: If removing the entire control panel assembly to include the electrical panel plate, it will be necessary 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.

WARNING: DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so.

Always wear the proper protective equipment including eye protection and petroleum resistant gloves when servicing hydraulic components.

Completely lower all lift components and relieve pressure before disassembling any part of the lift pump or disconnecting any hydraulic hoses.

The hydraulic oil is hot at normal operating temperatures. Be careful when draining the oil.

Never put your hands on pressurized hydraulic components. Pressurized hydraulic oil escaping through pin-hole leaks can be injected into the skin.

CAUTION: DO NOT OVERFILL. Oil will leak from the breather/ filler cap if too full.

NOTE: Check the hydraulic oil level in the reservoir when oil is at room temperature.

Forks completely lowered to relieve pressure from hydraulic circuit?

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.

NOTE: The caster wheel does not have to be removed from the lift truck frame to replace the wheel or the wheel axle.

Raise the drive wheel off the floor. Block the lift truck. See How to Put a Lift Truck on Blocks.

Remove the lock nut retaining the wheel on the wheel axle. Drive the wheel axle out of the arms and remove the wheel.

Align the wheel between both arms and install the wheel axle. Install the nut on the wheel axle. Tighten the nuts to 34 to 47 N•m (25 to 35 lbf ft).

Remove the blocks from under the lift truck and lower the truck to the floor. Test the operation of the truck prior to returning the truck to service.

Sign off on the caster wheels replacement

Hydraulic unit removed from the lift truck

Reservoir and pump area cleaned

Capscrews retaining the reservoir removed

Spring retaining screw from the suction tube removed

Suction tube and strainer removed

Capscrews retaining the pump to the drive motor removed

Pump assembly and coupling disassembled from the adapter

Move lift truck to a safe, level area.

Turn the key switch to the OFF position and disconnect battery connectors.

Block drive tire to prevent movement. See the section Periodic Maintenance 8000YRM1048, Periodic Maintenance 8000YRM1009, or Periodic Maintenance 8000YRM1379 for your lift truck.

Remove the upper drive unit compartment cover.

Discharge the capacitor. See Special Precautions.

Tag, identify, and disconnect the contactor coil wires.

Test contactor coil using an ohmmeter.

Touch the probes of the ohmmeter to the coil terminals and measure the resistance between the terminals.

Replace contactor if coil resistance readings measure outside of specifications. For contactor coil resistance values, refer to Table 1.