Hyster-Yale Electric Pallet Truck MSW030-F

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.

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.

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.

Warning: This procedure requires trained personnel with PPE!

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

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.

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.