Hyster-Yale Hyster-Yale Electric Pallet Truck MSW025-F MSW025-F

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.

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

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.

Move lift truck to a safe, level area

Block drive tire to prevent movement

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

Remove the upper drive unit compartment cover

Tag, identify, and disconnect the wires and cables

Disconnect all wires and cables from the contactor

Loosen two mounting screws and lockwashers that hold contactor to plate and remove contactor

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.