Maintenance

STEERING MECHANISM
MP20 [A249];
MPB045VG [A245]

PART NO. 550036881 1600 YRM 1504

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Special Precautions .................................................................................................................................................. 1
Control Handle Head ................................................................................................................................................ 2
Control Handle ..........................................................................................................................................................3
Remove ................................................................................................................................................................ 3
Install .................................................................................................................................................................... 7
Gas Spring ................................................................................................................................................................7
Discharging the Gas Spring ..................................................................................................................................8
Remove ................................................................................................................................................................ 8
Install .................................................................................................................................................................... 8
Troubleshooting ........................................................................................................................................................ 9

This section is for the following models:

(MP20) [A249];
(MPB045VG) [A245]

©2016 Yale Materials Handling Corp. i

1600 YRM 1504
General
The control handle assembly is designed to perform
several functions. The standard control handle
includes the speed/direction control and buttons for
the horn, traction reversing, and hydraulic functions.
The control handle is connected to the Master Drive
Unit (MDU) and is used to steer the truck as it turns
the MDU. Move the control handle left or right to turn
Special Precautions
WARNING
The capacitor in the controller can hold an electri-
cal charge after the battery is disconnected. To
prevent electrical shock and personal injury, dis-
charge the capacitor before inspecting or repair-
ing any component. Wear safety glasses. Make
certain the battery has been disconnected. DO
NOT use a screwdriver to discharge the traction
motor controller.
WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments, and
connecting or disconnecting a handset or PC.
CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never put
power to the controller with any power wire dis-
General
the drive/steer tire and steer the truck. Controls
mounted in the handle are linked to the control panel
by a wiring harness that passes through the center of
the handle. The brake is applied when the handle is in
the full up or down position.
connected. Never short any controller terminal or
motor terminal to battery. Make sure to use proper
procedures when servicing the controller.
1. Move the truck to a safe, level area. Turn the key
switch to the OFF position and disconnect the
battery.
2. Remove the drive unit compartment cover to ac-
cess the drive unit compartment.
CAUTION
DO NOT short across the motor controller termi-
nals with a screwdriver or jumper wire.
3. Discharge the capacitors in the controllers by con-
necting a 200-ohm, 2-watt resistor across the
controller's B+ and B− terminals using insulated
jumper wires. See Figure 1.
4. Remove the 200-ohm, 2-watt resistor before re-
connecting the battery.
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Special Precautions 1600 YRM 1504

Legend for Figure 1

1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION

Figure 1. Discharging Controller

Control Handle Head

Refer to the section Electrical System dle. The instructions for disassembly and assembly of
2200YRM1508 for instructions on removing and in- the control handle head can be located in the same
stalling the control handle head from the control han- section.

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1600 YRM 1504
Control Handle
REMOVE
WARNING
The gas springs used on the control handle are
installed under tension and can release with
enough force to cause personal injury or property
damage.
WARNING
The capacitor in the controller can hold an electri-
cal charge after the battery is disconnected. To
prevent electrical shock and personal injury, dis-
charge the capacitor before inspecting or repair-
ing any component in the drive unit compartment.
Wear safety glasses. Make certain the battery has
been disconnected. Refer to the Special Precau-
tions section of this manual.
Control Handle
1. Move the lift truck to a safe, level area and block
the wheels to prevent movement.
2. Turn the key switch to the OFF position and dis-
connect the battery.
3. Remove the drive unit compartment cover. Refer
to AC Motor Repair 0620YRM1513.
4. Discharge the capacitor in the controller by con-
necting a 200-ohm, 2 watt resistor between the B
+ and B- connectors on the controller. See Fig-
ure 1.
5. Disconnect the control handle wiring harness plug
and the control handle arm prox sensor plug loca-
ted on top of the drive motor.
For the following instructions refer to Figure 2, Fig-
ure 3, or Figure 4.
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Control Handle 1600 YRM 1504

1. CONTROL HANDLE HEAD 9. CAPSCREW

2. CAPSCREW 10. PIVOT SHAFT
3. LOCKNUT 11. STRAP CLAMP
4. LOCKNUT 12. BUSHING
5. HOLE PLUG 13. SENSOR
6. GAS SPRING 14. BALL STUD
7. SCREW 15. CONTROL HANDLE ARM
8. CAPSCREW 16. RETAINING NUT

Figure 2. Control Handle Assembly (MP20 (A249))

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1600 YRM 1504 Control Handle

Legend for Figure 3

1. CONTROL HANDLE HEAD

2. CAPSCREW
3. LOCKNUT
4. HOLE PLUG
5. GAS SPRING
6. PIVOT SHAFT
7. STRAP CLAMP
8. BUSHING
9. SENSOR
10. BALL STUD
11. CONTROL HANDLE ARM
12. RETAINING NUT

Figure 3. Control Handle Assembly (MPB045VG

(A245)

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Control Handle 1600 YRM 1504

1. CONTROL HANDLE HEAD 11. MOUNTING WELDMENT

2. CONTROL HANDLE ARM 12. GROMMET
3. GAS SPRING 13. PIVOT SHAFT
4. BALL STUD 14. CAPSCREW
5. NUT 15. NUT
6. PLUG 16. CAPSCREW
7. BUSHING 17. CAPSCREW
8. COVER 18. STRAP CLAMP
9. CAPSCREW 19. SHIM
10. WASHER

Figure 4. Delivery Handle (Optional)

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1600 YRM 1504
6. If necessary, remove the control handle head.
See the section Electrical System
2200YRM1508.
CAUTION
Discharging the gas spring is a destructive opera-
tion.
7. Discharge and remove the gas spring. Refer to
Gas Spring in this section.
8. Remove the capscrew securing the pivot shaft to
the support bracket and remove the pivot shaft.
9. Remove the control arm from the support bracket.
10. Remove the retaining nuts securing the prox sen-
sor to the control handle arm and remove the prox
sensor.
11. If bushings are worn, remove the bushings from
the control handle arm.
INSTALL
1. If previously removed, install the bushings into the
control handle arm.
2. Install the new gas spring into the control handle
arm. Refer to Gas Spring in the section.
Gas Spring
WARNING
Disconnect the battery by separating the battery
connector before opening the compartment cover
and before inspecting or repairing the electrical
system. DO NOT place tool on top of the battery. If
a tool causes a short circuit, the high-current flow
from the battery can cause personal injury or
property damage.
WARNING
The capacitor in the traction motor controller can
hold an electrical charge after the battery is dis-
connected. To prevent electrical shock and per-
sonal injury, discharge the capacitor before in-
specting or repairing any component.
Control Handle
3. Install the prox sensor onto the control handle
arm and secure with the retaining nuts. Leave re-
taining nuts loose until the control handle arm is
installed.
4. If removed, install the control handle head. See
the section Electrical System 2200YRM1508.
5. Position the control handle arm onto the support
bracket and install the pivot shaft.
6. Install the capscrew as removed. Torque to 35
N•m (26 lbf ft).
7. Secure the lower end of the gas spring to the sup-
port bracket with the capscrew and nut as re-
moved.
8. Adjust the prox sensor so the end of the sensor is
no more than 4 mm (0.16 in.) from the support
bracket. Tighten the retaining nuts.
9. Reconnect the control handle wiring harness and
prox sensor.
10. Install the drive unit compartment cover.
11. Connect the battery and test the operation of the
lift truck prior to returning to service.
Make certain the battery has been disconnected
and always wear safety glasses. See Special Pre-
cautions in this section. DO NOT attempt to dis-
charge the capacitors by shorting the controller.
WARNING
The gas spring used on the control handle is in-
stalled under tension and can release with
enough force to cause personal injury or property
damage.
Review the following procedures before removing the
gas spring.
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Gas Spring
DISCHARGING THE GAS SPRING
WARNING
Goggles and a face shield must be worn for per-
sonal protection as metal chips and hydraulic lu-
bricant may be ejected from the drill operation
due to the high internal pressure.
CAUTION
The control handle return spring is charged with
pressurized gas and contains a hydraulic oil lubri-
cant.
NOTE: This process is a destructive operation to the
gas spring. A new gas spring must be used during re-
assembly. This is necessary because internal dam-
age to the spring components which are not detecta-
ble could cause damage or injury when the spring is
removed.
1. Check that the handle return spring is installed
and properly secure the control handle arm in the
full upright position. Remove the plastic plugs to
increase visibility of the gas spring.
WARNING
Contents are under pressure. This process may
eject metal chips and oil.
2. Locate the gas spring inside the control handle
through the access hole on the front of the control
handle and drill a 3 mm (0.125 in.) hole into the
gas spring cylinder shell to relieve pressure.
3. Clean up any discharged oil and dispose of in ac-
cordance with local regulations.
REMOVE
To remove the gas spring from the control handle:
1. Remove the plastic plugs to access the gas
spring.
CAUTION
DO NOT damage the control handle wiring har-
ness inside the control handle arm.
8
1600 YRM 1504
2. Discharge the pressure from the gas spring. See
Discharging the Gas Spring.
3. Remove the retention clip from the gas spring ball
socket. Disconnect the gas spring from the ball
stud.
4. Remove the ball stud from inside the control arm
as necessary.
5. Remove the capscrew and locknut securing the
rod end of the gas spring to the tiller swivel.
INSTALL
1. Install ball stud and nut into control arm if re-
moved. Tighten to 35 N•m (26 lbf ft).
2. Lubricate both connection points with multipur-
pose lithium complex grease with 2 to 4% molyb-
denum.
CAUTION
DO NOT damage the control handle wiring har-
ness inside the control handle arm.
3. Make certain the control handle arm is secured in
the full upright position and position the new gas
spring into the control handle arm. Connect the
upper end of the gas spring to the ball stud inside
the control handle arm. Install the retention clip to
the gas spring ball socket as removed.
NOTE: Apply Loctite® 242 to the capscrew threads
before installing the nut.
4. Align the lower end of the gas spring into position
using a screwdriver and hold in position. Install
the capscrew and locknut securing the rod end of
the gas spring to the steer swivel. Tighten to
35 N•m (26 lbf ft).
5. Install the plastic plugs to the access holes on the
control handle shaft as removed.
6. Test for proper operation. Install covers as re-
moved.
1600 YRM 1504 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Steering is rough or difficult. Damaged, worn, or defective steer- Replace bearings.

ing handle swivel bearing(s).

Steering handle swivel bearing(s) Lubricate or repack bearings.

need lubrication.

Bearing retaining nut torque incor- Loosen retaining nut and tighten to
rect. correct torque. See the section
Master Drive Unit 0630YRM1503.

Drive unit housing bearing (steer) Replace drive unit housing bearing
damaged. (steer).

Steering handle does not return to Gas spring is weak or broken. Replace gas spring.
the vertical position.

Gas spring ball stud broken or Retighten or replace gas spring

loose. ball stud.

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 NOTES

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1600 YRM 1504 7/16 (3/15)(12/13)(4/12)