Hyster-Yale Hyster-Yale Electric Pallet Truck MSW025-E MSW025-E

Warning: This procedure requires trained personnel with PPE!

Lift truck moved to a safe, level area

Drive tire blocked to prevent movement

Key switch turned to the OFF position and battery connectors disconnected

Upper drive unit compartment cover removed

Wires and cables tagged, identified, and disconnected

All wires and cables disconnected from the contactor

Two mounting screws and lockwashers that hold contactor to plate loosened and contactor removed

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.

REPAIR: A proximity switch is used to sense the position of the control handle arm.

Move the lift truck to a safe, level area before performing any repairs.

Turn the key switch to the OFF position.

Remove the upper drive unit compartment cover.

Remove the lower drive unit compartment cover.

Remove the four capscrews from the two-piece shield over the MDU and remove the shields.

Turn the key switch to the ON position.

Verify battery voltage at the proximity switch connector between pin #1 and pin #2.

1. Move the lift truck to a safe, level area.

2. Block drive wheel to prevent truck from rolling.

3. Disconnect battery connectors and turn the key switch to the OFF position.

4. Remove the upper drive unit compartment cover.

5. Remove the lower drive unit compartment cover.

6. Discharge the capacitor. See Special Precautions.

7. Remove nut retaining the key switch to bracket.

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.

Remove the traction motor and brake assembly from the MDU

Clean outside surfaces of motor before disassembly

Make index marks on the ends of the motor and field ring to ensure proper reassembly

Measure the brush in the brush holder

Remove capscrews from commutator end of motor

Remove screws that fasten pinion end cover to field ring

Remove pinion end cover from armature