Maintenance

ELECTRICAL SYSTEM
MPE060E [A896];
MPE080E [A890];
MPW060E [A897];
MPW065E [A894];
MPW080E [A891]

PART NO. 524164720 2200 YRM 929

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, 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 remove 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 manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Electrical System Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Electrical System Checks .................................................................................................................................... 5
Safety Precautions .......................................................................................................................................... 5
Repairs ................................................................................................................................................................ 8
Controller, Replace.......................................................................................................................................... 8
Remove....................................................................................................................................................... 9
Install .......................................................................................................................................................... 9
Contactor Coil, Check ..................................................................................................................................... 10
Contactor, Replace.......................................................................................................................................... 10
Contactor Tips, Replace.................................................................................................................................. 10
Remove....................................................................................................................................................... 10
Install .......................................................................................................................................................... 10
Fuses................................................................................................................................................................... 12
Brake Switch - MPW060-E, MPW065-E, MPW080-E, MPE060-E (→Aug 2003) and MPE080-E (→Aug
2003) ................................................................................................................................................................... 12
Remove and Install.......................................................................................................................................... 12
Brake and Interlock Switches - MPE060-E (Aug. 2003→) and MPE080-E (Aug. 2003→) ................................. 13
Disassemble.................................................................................................................................................... 13
Assemble ........................................................................................................................................................ 13
Height Limit.......................................................................................................................................................... 13
Control Handle..................................................................................................................................................... 14
Disassemble.................................................................................................................................................... 14
Control Handle Card (Old Style) ..................................................................................................................... 14
Control Handle Card (New Style) .................................................................................................................... 15
Configure .................................................................................................................................................... 15
Calibrate...................................................................................................................................................... 17
Assemble ........................................................................................................................................................ 17
Remote Control Box Switches (MPE060E and MPE080E) ................................................................................. 19
Remove ........................................................................................................................................................... 19
Install............................................................................................................................................................... 19
Motor Maintenance - General.............................................................................................................................. 19
Brush and Commutator Inspection ...................................................................................................................... 20
Commutator Problems .................................................................................................................................... 22
Brush Replacement............................................................................................................................................. 26
Drive Motor .......................................................................................................................................................... 28
Remove ........................................................................................................................................................... 28
Disassemble.................................................................................................................................................... 29
Assemble ........................................................................................................................................................ 29
Install............................................................................................................................................................... 29
Lift Pump Motor ................................................................................................................................................... 30
Remove ........................................................................................................................................................... 30
Install............................................................................................................................................................... 30
Commutator Repairs ........................................................................................................................................... 30
Testing the Drive Motor........................................................................................................................................ 31
Damaged Field and Armature ......................................................................................................................... 31
Short Circuit in an Armature Winding.............................................................................................................. 31
Short Circuit in the Armature........................................................................................................................... 32
Open Circuit in a Field Coil ............................................................................................................................. 32
Short Circuit in a Field Coil ............................................................................................................................. 32
Short Circuit Between Field and Motor Case .................................................................................................. 32
Brush Holder ................................................................................................................................................... 32

©2007 Yale Materials Handling Corp. i

Table of Contents Electrical System

TABLE OF CONTENTS (Continued)

Troubleshooting ................................................................................................................................................... 33

This section is for the following models:

MPE060E [A896];
MPE080E [A890];
MPW060E [A897];
MPW065E [A894];
MPW080E [A891]

ii
2200 YRM 929 General

General
This manual describes the electrical systems used on
WARNING the motorized hand lift trucks. Procedures are outlined
DO NOT make repairs or adjustments unless you for the maintenance, adjustment, and repair that may
have both authorization and training. Repairs and be required when servicing these lift trucks. The drive
adjustments that are not correct can create a dan- control for the Motorized Hand Trucks is a Curtis Tran-
gerous operating condition. DO NOT operate a lift sistor Motor Controller 1297 Model, also known as a
truck that needs repairs. Report the need for re- MOSFET or PMC system. See Figure 1, Figure 2, and
pairs to your supervisor immediately. If repair is Figure 3.
necessary, put a DO NOT OPERATE tag on the con-
trol handle. Remove the key from the key switch.

Figure 1. Drive Unit Compartment (MPW060E, MPW065E, and MPW080E)

1
General 2200 YRM 929

Legend for Figure 1

1. TRACTION MOTOR 10. PUMP CABLE (NEG.)
2. ELECTRIC BRAKE 11. WIRE HARNESS-MAIN
3. DRIVE UNIT 12. CABLE (POS.)
4. HYDRAULIC UNIT 13. CABLE (A1)
5. HORN 14. CABLE (A2)
6. IGNITION SWITCH 15. CABLE (F1)
7. BATTERY GAGE/SPYGLASS 16. CABLE (F2)
8. BATTERY CONNECTOR 17. PUMP CABLE (POS.)
9. CONTROLLER PANEL

Legend for Figure 2

1. TRACTION MOTOR 12. GRAB RAIL
2. ELECTRIC BRAKE 13. CONTROL BOX
3. DRIVE UNIT 14. WIRE HARNESS-HANDRAIL
4. HYDRAULIC UNIT 15. WIRE HARNESS-MAIN
5. HORN 16. CABLE (POS)
6. IGNITION SWITCH 17. CABLE (A1)
7. BATTERY GAGE/SPYGLASS 18. CABLE (A2)
8. BATTERY DISCONNECT 19. CABLE (F1)
9. CONTROL PANEL 20. CABLE (F2)
10. CAPSCREW 21. PUMP CABLE (POS.)
11. CAPSCREW 22. PUMP CABLE (NEG.)

2
2200 YRM 929 General

Figure 2. Drive Unit Compartment (MPE060E and MPE080E)

3
General 2200 YRM 929

1. WASHER 19. LOCKWASHER

2. LOCKWASHER 20. NUT
3. CAPSCREW 21. NUT
4. CAPSCREW 22. LOCKWASHER
5. WASHER 23. NUT
6. LOCKWASHER 24. SCREW
7. WASHER 25. CONVERTER - 12 V ONLY
8. SCREW 26. WASHER
9. SCREW 27. LOCKWASHER
10. SCREW 28. CAPSCREW
11. FUSE-MOTORS 29. RESISTOR
12. FUSE-CONTROLLER 30. RELAY
13. MOUNTING PLATE 31. SCREW
14. BUSS BAR 32. WASHER
15. FUSE HOLDER 33. LOCKWASHER
16. STAND-OFF 34. LABEL
17. CONTROLLER 35. LABEL
18. CONTACTOR

Figure 3. Controller Panel Assembly

4
2200 YRM 929 Electrical System Checks

Electrical System Checks

1. Block lift truck so the drive tire is raised slightly off
WARNING the floor to prevent unexpected movement when
Disconnect the battery and separate the connec- making checks.
tor before opening the compartment cover or in-
specting or repairing the electrical system. If a tool 2. Turn the key switch to the OFF position and discon-
causes a short circuit, the high current flow from nect the battery.
the battery can cause personal injury or property
damage. 3. Discharge capacitors in controllers by connecting a
200-ohm, 2-watt resistor across the controller’s B+
The capacitor in the transistor controller can hold and B terminals. See Figure 4. DO NOT short
an electrical charge after the battery is discon- across the motor controller terminals with a screw-
nected. To prevent electrical shock and personal driver or jumper wire. Remove the 200-ohm, 2-watt
injury, discharge the capacitor before inspecting resistor before reconnecting the battery.
or repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected.

All checks, adjustments, and repairs in the drive unit

compartment are done with the compartment cover re-
moved. Remove the drive unit compartment cover for
access to the electrical components.

SAFETY PRECAUTIONS

WARNING
Some checks require the battery to be reconnected.
DO NOT connect the battery until the procedure
tells you to do so. Make sure the drive wheel is
raised to prevent truck movement and possible
injury. Raise the drive wheel. The blocks must pre-
vent the lift truck from falling and causing personal
injury or property damage.

CAUTION
To avoid controller damage, always disconnect the
battery before disconnecting any cables from the 1. POSITIVE CONNECTION
controller. Discharge the capacitor, and never put 2. NEGATIVE CONNECTION
power to the controller with any power wire discon- 3. INSULATED JUMPER WIRES
nected. Never short any controller terminal or mo- 4. 200-OHM, 2-WATT RESISTOR
tor terminal to the battery. Make sure to use proper
Figure 4. Discharging the Capacitors
procedure when servicing the controller.

5
Electrical System Checks 2200 YRM 929

NOTE: These checks require a volt-ohmmeter with a the frame of the lift truck, such as a dirty battery
meter movement. Most digital meters will not operate case. Carbon dust in a motor or other parts can
correctly for some of these checks. Specific checks re- cause a circuit path. Check for additional equip-
quire additional equipment. ment that may cause a circuit path to the frame.

NOTE: The correct meter polarity is necessary for the 6. Check for voltage between each terminal of the
checks. The voltage checks are made between the connector that fastens to the battery and a clean
point indicated in Table 1 and battery negative. Con- connection on the frame. Normally, there is small
nect the meter negative to battery negative. voltage (less than 30 percent of the battery voltage)
between the battery and the frame, even though the
NOTE: The battery does not have to be removed to resistance is very high. A higher voltage can indi-
check the specific gravity. cate a dirty battery or a damaged battery. Clean the
battery and battery compartment as necessary.
4. Using a hydrometer, check the specific gravity of
the battery. If the specific gravity is less than 1.260, 7. Visually check for parts or wires that are loose or
the battery is not fully charged or is damaged. A damaged.
fully-charged battery has a specific gravity of 1.270
to 1.290. A discharged battery has a specific gravity NOTE: Make an identification of any wires before you
of approximately 1.165. disconnect them. The wires must be reconnected cor-
rectly after checks or repairs.
5. The electric lift truck has a two-wire system. The
frame must not be a common electrical path. Check
for 50,000 ohms or more between each battery ter-
minal and a clean connection on the frame. Re-
move any circuit paths between the controller and

6
2200 YRM 929 Electrical System Checks

Table 1. Voltage Checks

LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION.

NO FAULT IS DISPLAYED ON THE CONTROLLER.

Possible Causes:
1. Battery not connected.
2. Control fuse is damaged.
3. Key switch or brake switch is damaged.
4. Transistor controller connector unplugged.
5. Transistor controller is damaged.

1.0 Check for battery voltage on the 1.0.1 Battery voltage at control fuse.
battery side of control fuse. Check for open control fuse.

1.0.2 No battery voltage at control fuse.

Connect battery or check wiring
between battery and fuse.

1.1 Check for battery voltage at control 1.1.1 Battery voltage at key switch.
fuse terminal of key switch. Check for damaged key switch.
Check connector.

1.1.2 No voltage at key switch. Wire to key switch

or connections is damaged.

1.3 Key switch closed. Brake switch closed. 1.3.1 Battery voltage at B+ terminal.
Check for battery voltage at B+ terminal of Check fault code. If no fault code,
transistor controller. possible damaged control handle card.

1.3.2 No voltage at B+ terminal.

Check B terminal.
Check fault code.

7
Repairs 2200 YRM 929

Repairs
TRUCK ON BLOCKS. The blocks must prevent the
WARNING lift truck from falling and causing personal injury
DO NOT make repairs or adjustments unless you or property damage.
have both authorization and training. Repairs and
adjustments that are not correct can create danger- NOTE: Although the controller is factory programmed,
ous operating conditions. DO NOT operate a lift any custom parameters must be uploaded or re-entered
truck that needs repairs. Report the need for repairs into the controller when replacing. See the section Cur-
to your supervisor immediately. If repair is neces- tis 1297 Transistor Motor Controller 2200 YRM 928.
sary, attach a DO NOT OPERATE tag to the control
handle. DO NOT replace the controller until you have thoroughly
checked all other electrical components and are sure
Disconnect the battery and separate the connector the controller is malfunctioning. For the following pro-
before opening the drive unit compartment cover cedures, refer to Figure 6.
or inspecting or repairing the electrical system. If
a tool causes a short circuit, the high current flow
from the battery can cause personal injury or prop-
erty damage.

The capacitor in the transistor controller can hold

an electrical charge after the battery is discon-
nected. To prevent electrical shock and personal
injury, discharge the capacitor before inspecting or
repairing any component in the drive unit compart-
ment. Connect a 200-ohm, 2-watt resistor across
the B+ (positive) and B (negative) connectors of
the controller. See Figure 5.

All checks, adjustments, and repairs in the drive unit

compartment are done with the compartment cover re-
moved. Remove the drive unit compartment cover for
access to the electrical components and discharge the
capacitor.

CONTROLLER, REPLACE

WARNING
Some checks require the battery to be connected. 1. POSITIVE CONNECTION
DO NOT connect the battery until the procedure 2. NEGATIVE CONNECTION
tells you to do so. Make sure the drive wheel is 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
raised to prevent movement and possible injury.
Raise the drive wheel. See the section Periodic Figure 5. Discharging Controller
Maintenance 8000 YRM 919, HOW TO PUT A LIFT

8
2200 YRM 929 Repairs

Remove Install
1. Move the truck to a safe, level location. Turn the 1. Install replacement controller on lift truck using
key switch to the OFF position, disconnect the bat- mounting hardware.
tery, and block the drive tire to prevent unexpected
movement. 2. Connect wires and cables to the proper terminals
as identified during the removal procedure.
2. Remove the drive unit compartment covers.
3. Connect battery, turn the key switch to the ON po-
3. Discharge the capacitor. See Special Precautions sition, and turn parking brake to the OFF position.
in this section.
4. Test for proper operation.
4. Tag and disconnect wires from the controller.
5. Install the drive unit compartment covers.
5. Remove mounting screws and remove controller.

1. WASHER 10. SCREW 19. LOCKWASHER

2. LOCKWASHER 11. FUSE-MOTORS 20. NUT
3. CAPSCREW 12. FUSE-CONTROLLER 21. NUT
4. CAPSCREW 13. MOUNTING PLATE 22. LOCKWASHER
5. WASHER 14. BUSS BAR 23. NUT
6. LOCKWASHER 15. FUSE HOLDER 24. SCREW
7. WASHER 16. STAND-OFF 25. LABEL
8. SCREW 17. CONTROLLER 26. LABEL
9. SCREW 18. CONTACTOR

Figure 6. Controller Panel Assembly

9
Repairs 2200 YRM 929

CONTACTOR COIL, CHECK operation of the lift truck. Cleaning is not necessary.
DO NOT USE A FILE ON THE CONTACTS. DO NOT
Disconnect coil wires. Test contactor coil using an ohm- LUBRICATE THE CONTACTS. Replace contacts when
meter to measure the resistance. Use the highest resis- the silver alloy is worn away to the base support metal.
tance indication. The coil should read 52 ohms ±10%
(14 ohms ±10% on models MPW065E). Remove and Remove
replace contactor if resistance readings indicate a short
circuit in both directions or if there is an open circuit in Refer to Figure 7 for the following procedures.
both directions. Make sure coil wires are connected to
the proper terminals. 1. Remove contactor as described in Contactor, Re-
place.
NOTE: The contactor contains no serviceable parts and
must be replaced as a complete assembly. 2. Remove screws (4) that fasten the top cover to the
coil and frame.
CONTACTOR, REPLACE
3. Remove cover, moving contact (2), and return
NOTE: Make an identification of any wires before dis- spring.
connecting them. The wires must be connected cor-
4. Remove capscrews, washers, and nuts that make
rectly after checks or repairs.
up the fixed contactor tips (1) from the top cover.
Make sure battery is disconnected and capacitor in con-
5. If a coil will be replaced, remove coil frame and
troller is discharged. For the correct procedure to dis-
remove end cap from frame.
charge the controller, refer to Figure 5. If the lift truck
has an EE rating, remove cover of the contactor box for 6. Remove coil from frame.
access to the contactor terminals. Make an identifica-
tion of the wires and cables, and disconnect them from Install
the contactor assembly. Remove mounting screws and
replace contactor assembly. Install wires and cables as 1. Install new coil on frame and install end cap.
removed. Install cover of contactor box on EE units.
2. Install moving contact (2) and return spring.
CONTACTOR TIPS, REPLACE
3. Install capscrews, washers, and nuts that make up
the fixed contactor tips (1) to the top cover.
CAUTION
NOTE: Check that the moving contactor and springs
All contactor tips must be replaced at the same time
move freely without binding.
if any need replacing.
4. Install cover to coil and frame using screws (4).
NOTE: If both the contactor tips and the coil will be
replaced, replace complete contactor as described in 5. Install contactor assemblies on the lift truck as de-
Contactor, Replace. Perform only the procedures nec- scribed in Contactor, Replace.
essary to complete the repairs.

The contactor tips are made of special silver alloy. The

contacts will look black and rough from normal opera-
tion. This condition does not cause problems with the

10
2200 YRM 929 Repairs

Legend for Figure 7

1. FIXED CONTACTS 4. SCREW
2. MOVING 5. RETURN SPRING
CONTACTS 6. COIL AND FRAME
3. TOP COVER 7. END CAP

Figure 7. Contactor

11
Brake Switch - MPW060-E, MPW065-E, MPW080-E, MPE060-E (→Aug 2003) and MPE080-E (→Aug
2003) 2200 YRM 929

Fuses
for both the drive motor and the hydraulic pump motor.
WARNING The fuses are located on the contactor panel. Remove
The capacitor in the transistor controller can hold and replace as required.
an electrical charge after the battery is discon-
nected. To prevent electrical shock and personal If it cannot be determined visually that a fuse has failed,
injury, discharge the capacitor before inspecting check for continuity using an ohmmeter. To replace FU
or repairing any component in the drive unit com- 1, loosen capscrews retaining it. Install a new fuse and
partment. Wear safety glasses. Make certain the tighten capscrews. FU 2 is retained by a fuse holder.
battery has been disconnected. Make certain that any replacement fuse is of the right
amperage before installation.
The motorized hand trucks use a single 5-amp (FU 2)
fuse for the control circuit, and 400-amp (FU 1) fuses

Brake Switch - MPW060-E, MPW065-E, MPW080-E, MPE060-E

(→Aug 2003) and MPE080-E (→Aug 2003)
REMOVE AND INSTALL brake switch is normally open until the control handle is
moved to the operating position. Refer to Brakes 1800
WARNING YRM 963 .
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. To prevent electrical shock and personal
injury, discharge the capacitor before inspecting
or repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected.

Check the brake switch for continuity. Remove the

nut that retains the switch to the bracket. Remove the
switch.

Attach the brake switch to the bracket using the nut.

Install wires to the switch.

Connect the battery. Move the brake handle to check

that brake switch closes when the brake is released and
opens when the brake is engaged. See Figure 8. The Figure 8. Brake Operation

12
2200 YRM 929 Height Limit

Brake and Interlock Switches - MPE060-E (Aug. 2003→)

and MPE080-E (Aug. 2003→)
DISASSEMBLE
1. Position the lift truck on a level surface. Turn the
key switch to the OFF position and disconnect the
battery.

NOTE: The screws have been installed using Loctite®

290.

2. Remove the two screws and the nut plate retaining

the switches to the control handle hub. See Fig-
ure 9.

3. Remove switches from the hub and tag all wiring

connections to the switches for later use when as-
sembling the switches to the hub.

4. Remove the switch.

ASSEMBLE
1. Attach wiring to correct switch terminals.

2. Install switches into hub with two screws and nut- 1. NUTPLATE 3. REGEN SWITCH
plate. Apply Loctite® 290 to the screws, install, and 2. SCREW 4. BRAKE SWITCH
tighten.
Figure 9. Brake and Interlock Switches
3. Connect battery and turn the key switch to the ON
position.

4. Test for proper operation before returning the truck

to service.

Height Limit
Height limiting is controlled by the height limit switch in will cause this current draw: The first is when the lift
the 1297 Curtis controller. When the controller senses cylinder reaches maximum height, and the second is
a high current draw from the hydraulic pump, it will shut when the load exceeds the rated capacity. In either
down the pump. There are two separate incidents that case, the controller will shut down the pump.

13
Control Handle 2200 YRM 929

Control Handle
DISASSEMBLE plugged into the control handle card. Unplug
switches from the control handle card and remove
WARNING the card.
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do so.
CONTROL HANDLE CARD (OLD STYLE)
Improper repairs and adjustments can create dan- After servicing the control handle head, it is necessary
gerous operating conditions. DO NOT operate a lift to calibrate the control handle card. If replacing with a
truck that needs repairs. Report the need for repairs new style card (usually blue in color), refer to Control
to your supervisor immediately. If repair is neces- Handle Card (New Style).
sary, attach a DO NOT OPERATE tag to the control
handle and disconnect the battery. 1. Install the control handle card in the upper half of
the control handle.
NOTE: It is not always necessary to remove and dis-
assemble all the components that make up the control NOTE: When inserting knobs make sure that flange on
section of the steering handle to replace a damaged one of the butterfly knobs inserts between the spring on
part. Perform only the steps necessary to replace the the control handle.
damaged parts. See Figure 14.
2. Slide shaft and butterfly knob into the control handle
1. Move the lift truck to a safe, level area and block the card. Be careful not to rotate the shaft inside the
drive wheel to prevent movement of the lift truck. control handle card.

2. Turn the key switch to the OFF position and discon- 3. Connect the switches and wire harness connectors.
nect the battery.
4. Install the remaining butterfly knob. Apply Loctite®
3. The handle is comprised of two molded-plastic 242 to the screw attaching the butterfly knob onto
halves and is held together by capscrews. Remove the upper half of the handle and tighten the screw
the screws. to 1 N•m (9 lbf in).

4. Disengage the hooks under the auto-reverse 5. Lubricate friction points on the butterfly knobs with
switch. Slide the upper half off of the lower half us- silicone spray lubricant.
ing a gentle rocking motion while lifting and pulling
the upper half away from lower half. 6. Connect the battery.

5. Unplug the handle wiring harness from the control 7. Move the jumper on the J1 terminal to the calibrate
handle card. mode. See Figure 10, view B.

6. Place upper half of the handle upside down on a 8. With the handle in the full upright position, turn the
secure, level work surface so the internal parts are key switch to the ON position.
facing up.
9. Slowly rotate the butterfly knobs in the forward di-
NOTE: Make note of the position of the butterfly knobs rection and hold at maximum rotation for 5 seconds.
relative to the handle BEFORE removal.
10. Slowly rotate the butterfly knobs back to the neutral
7. Remove one of the butterfly knobs by removing the position and leave for 5 seconds.
screw that holds it to handle (4).
11. Slowly rotate the butterfly knobs in the reverse di-
8. Using the remaining butterfly knob, slide the shaft rection and hold at maximum rotation for 5 seconds.
out of the handle. Be careful not to rotate the shaft
12. Slowly rotate the butterfly knobs back to the neutral
within the control handle card.
position and leave for 5 seconds.
9. Refer to the wiring diagram, or draw a sketch
of where each of the push button switches are

14
2200 YRM 929 Control Handle

20. Test the lift truck to verify correct travel, lift, and
lower speeds.

CONTROL HANDLE CARD (NEW STYLE)

NOTE: New style control handle cards will be blue in
color and should be used as replacement cards regard-
less of color of the card removed. If simply calibrating
an existing old style card (green in color), refer to Con-
trol Handle Card (Old Style).

NOTE: Verify that the magnetic holder of the thumb-

wheel switch has been installed in the proper position.
See Figure 11.

After servicing the control handle head, it may be nec-

essary to configure and/or calibrate the control handle
card.

Configure
Refer to Figure 11 for the following instructions.

1. Partially assembly the control handle head. Refer

to Assemble.

A. RUN MODE B. CALIBRATE MODE 2. Connect the control handle card wiring, verify that
the battery is connected, and turn the key switch to
Figure 10. Control Handle Card Calibration the ON position.

NOTE: If control handle includes the optional propor- 3. The LED will display the program setting for approx-
tional switches, it will be necessary to perform Step 13 imately five seconds. See Figure 11. The proper
through Step 16. If control handle includes only the full control handle card setting for this model is number
speed and half speed ON/OFF lift and lower switches, 7. If the correct number is displayed on the LED,
then go to Step 17. the control handle card is configured correctly.

13. Slowly press the proportional LIFT button and hold 4. To begin configuring the card, turn the key switch to
down five seconds. the OFF position.

14. Slowly release the proportional LIFT button and 5. Move the jumper from P (park) to C (configure).
wait for five seconds. See Figure 12.

15. Slowly press the proportional LOWER button and 6. Turn the key switch to the ON position and view the
hold down for five seconds. LED display.

16. Slowly release the proportional LOWER button and 7. Press and release the S2 (turtle) switch or S3 (horn)
wait for five seconds. switch to change the number displayed on the LED
to the correct value.
17. Move the jumper on the J1 terminal to the RUN
mode. See Figure 10, view A. 8. Press and release the S (belly) switch to save the
value. A decimal will appear on the LED display
18. Turn the key switch to the OFF position. beside the number showing it has been saved.
19. Install the upper half on the lower half. Refer to As-
semble for instructions on how to install the upper
half on the lower half.

15
Control Handle 2200 YRM 929

1. JUMPER TERMINALS (SV2) 4. LED DISPLAY SCREEN

2. HORN SWITCH (S1) 5. BELLY SWITCH (S)
3. THUMBWHEEL SWITCH (MAGNETIC HOLDER) 6. TURTLE SWITCH (S2)

Figure 11. Control Handle Card (New Style)

Legend for Figure 12
1. P (PARK/ HOME POSITION)
2. D (NOT USED)
3. T (TEACH/CALIBRATE)
4. C (CONFIGURE)
5. JUMPER TERMINAL (SV2)

9. Turn the key switch to the OFF position and move

the jumper to the park (P) position.

10. Turn the key to the ON position and view the LED to
verify the correct number has been saved. The LED
will display the program setting for approximately
five seconds.

Figure 12. Jumper Terminal (SV2)

16
2200 YRM 929 Control Handle

Calibrate 6. Rotate the thumbwheel in the "Rotation Left" direc-

tion (toward the operator) and hold to the mechan-
Refer to Figure 11 for the following instructions. ical stop. Press the left side lower button (sideshift
left button if equipped with sideshift option).
1. Verify that the key switch is in the OFF position.
7. The LED screen will change to show this segment
2. Move the jumper from P (park) to T (teach/cali-
complete. See Figure 13, view C. Release the
brate). See Figure 12.
thumbwheel so it returns to the neutral position.
3. Verify that the battery is connected and turn the key
8. Move the jumper from T (teach/calibrate) to P
switch to the ON position. The LED will display a
(park). See Figure 12.
dash symbol to signal that the card is in calibration
mode. See Figure 13, view A. 9. The LED screen will change to show a decimal be-
side the completed segments indicating they have
been saved. See Figure 13, view D.

10. Recycle the key switch OFF and ON and test all
truck functions for proper operation.

ASSEMBLE
1. Install control handle card in the upper half of con-
trol handle. See Figure 14.

NOTE: When inserting knobs, make sure that flange

on one of the butterfly knobs inserts between spring on
handle (9).

2. Slide shaft and butterfly knob into control handle

card. Be careful not to rotate the shaft inside the
control handle card.

3. Connect the switches and wire harness connectors.

A. CALIBRATION MODE 4. Plug handle wiring harness into control handle
B. ROTATION RIGHT SEGMENT COMPLETE card.
C. ROTATION LEFT SEGMENT COMPLETE
D. ALL SEGMENTS COMPLETE AND SAVED
CAUTION
Figure 13. LED Views DO NOT force the upper half onto the lower half as
NOTE: "Rotation Right" and "Rotation Left" directions this will cause damage to the retaining hooks of the
are specified by labels printed on face of card. upper half.

4. Rotate the thumbwheel in the "Rotation Right" di- 5. To install upper half of handle onto the lower half:
rection (toward the forks) and hold to the mechani- a. Tip the upper half up and align the hooks under
cal stop. Press the left side lift button (sideshift right the auto-reverse switch.
button if equipped with sideshift option).
b. Lower the upper half onto the lower half.
5. The LED screen will change to show this segment
complete. See Figure 13, view B. Release the 6. Install capscrews to retain upper half of control han-
thumbwheel so it returns to the neutral position. dle to lower half.
NOTE: "Rotation Right" and "Rotation Left" directions 7. Connect battery cable and test control handle op-
are specified by labels printed on face of card. eration.

17
Control Handle 2200 YRM 929

1. LOWER HALF 12. SPRING

2. UPPER HALF 13. SWITCH
3. CONTROL HANDLE CARD ASSEMBLY 14. HORN SWITCH COVER
4. SHAFT 15. SWITCH ASSEMBLY
5. BUSHING 16. LABEL
6. LH BUTTERFLY KNOB 17. LABEL
7. WASHER 18. LABEL
8. SCREW 19. ACTUATOR (MPE060E AND MPE080E)
9. SPRING 20. ACTUATOR (MPE060E AND MPE080E)
10. RH BUTTERFLY KNOB 21. SPRING
11. SWITCH COVER 22. MICROSWITCH (MPE060E AND MPE080E)

Figure 14. Control Handle

18
2200 YRM 929 Motor Maintenance - General

Remote Control Box Switches (MPE060E and MPE080E)

REMOVE switches from control box by gently prying them
out with a small, flat head screwdriver.
1. Turn key to OFF position. Disconnect battery.
8. Inspect actuator springs for damage. Replace any
2. Remove drive unit compartment cover. damaged springs.
3. Unplug remote control box wiring harness and gen-
INSTALL
tly push some of the wiring up inside the tube of the
grab bar. 1. Position each switch in the correct mounting bracket
with the switch plunger aligned correctly and push
4. Remove four corner Allen head screws and wash-
it in gently until it locks into place.
ers retaining control box covers to handrail. Re-
move covers and switch assemblies from grab bar. 2. Plug switches into remote control box wiring
harness. Pay special attention to the order the
5. Gently pull wiring harness out of grab bar a couple
switches are plugged into the harness.
of inches or just enough to allow switch wiring to be
unplugged. 3. Pull remote control box wiring harness downward
through the grab rail until it is flush with the upper
6. Make certain wires to switches are identified. Pay
opening of the tube.
special attention to the order in which the switches
are plugged into the wire harness. Unplug switches 4. Install four Allen head screws to retain cover and
from wiring harness. Remove remote control box switches to handrail.
and switches and place them on a clean, level work
area. 5. Reconnect battery and test operation of lift truck
before returning truck to service.
7. Test switches for continuity. Replace any switches
found to be damaged or inoperative. Remove

Motor Maintenance - General

This portion of the electrical section describes disas- the battery to the commutator and the armature. The
sembly and assembly, brush replacement, inspection, maintenance of the commutator and the brushes is im-
and checks for malfunction of DC motors. Inspect com- portant to the good operation of a DC motor.
mutator and brushes every 200 hours of operation. The
commutator is the rotating electric connection between Drive motors and hydraulic pump motors are similar in
the armature and the electric power supplied by the bat- design. The hydraulic pump motors are smaller than the
tery. Brushes made of carbon compounds slide on the drive motors, but the disassembly and maintenance of
rotating commutator and are the path for electricity from the motors are similar.

19
Brush and Commutator Inspection 2200 YRM 929

Brush and Commutator Inspection

NOTE: Vacuum cleaning, when possible, is the recom-
WARNING mendation of manufacturers of electric motors. The use
Put blocks under each side of the truck under the of compressed air can send dirt particles into the bear-
drive unit frame. Position blocks on both sides of ings and other areas of the motor that can cause pos-
the load wheels. The blocks must prevent the lift sible damage.
truck from falling and causing personal injury or
property damage. 5. Inspect commutator surface. Refer to Table 2, Ta-
ble 3, Table 4, Table 5, Table 6, Table 7, Table 8,
1. Raise drive wheel off the floor. Block lift truck. Dis- Table 9, Table 10, Figure 15, Figure 16, Figure 17,
connect battery. and Figure 20. The commutator wears slowly in
normal service. The mica must be cut below the
2. Remove drive unit compartment covers.
surface of the commutator bars after a long service
period or after a commutator has been turned in a
WARNING lathe. Carefully rotate armature. DO NOT damage
The capacitor in the transistor controller can hold commutator if you use a tool to rotate the armature.
an electrical charge after the battery is discon-
6. Inspect white or gray insulation (mica) between
nected. To prevent electrical shock and personal
commutator bars. The mica must not touch the
injury, discharge the capacitor before inspecting
brushes or the brushes will wear very rapidly.
or repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the 7. Install brush covers, when used, and drive unit com-
battery has been disconnected. partment cover.
3. Discharge capacitor in transistor controller. 8. Connect battery. Lower truck to floor. Test opera-
tion of motorized hand truck before returning truck
4. If used, remove brush covers to motor. Wear eye
to service.
protection. Use a vacuum cleaner or compressed
air to remove dirt and brush dust from commutator
area.

Table 2. Normal Commutator Surfaces

A light brown surface of the commutator, where it

rotates on the brushes, is a normal condition. The
surface of the commutator must be smooth.

20
2200 YRM 929 Brush and Commutator Inspection

Table 2. Normal Commutator Surfaces (Continued)

Variations between light brown and dark brown colors

are normal. The surface of the commutator must be
smooth.

A condition called slot bar marking is normal if the

commutator surface is smooth. The variable color
occurs in a pattern according to the number of
conductors per slot.

A very dark surface is normal and an acceptable

condition if the commutator surface is smooth.

21
Brush and Commutator Inspection 2200 YRM 929

COMMUTATOR PROBLEMS
Commutator and motor problems are shown in Table 3,
Table 4, Table 5, Table 6, Table 7, Table 8, Table 9, and
Table 10.

Table 3. Commutator Problems

Heavy streaks and fine grooves indicate the beginning

of damage to the commutator.
Possible Causes:
• Operation of the motor in dirty and abrasive condi-
tions.
• Continuous operation of a motor with a light load.
• Brush pressure is too low.
• Worn brushes.

Table 4. Commutator Problems

Grooves and lines that have followed the heavy streaks

and fine grooves shown in the armature must be
removed from the motor so that the commutator can be
repaired. A commutator with this condition will cause
the brushes to wear rapidly.
Possible Causes:
• Operation of the motor in dirty and abrasive condi-
tions.
• Continuous operation of a motor with a light load.
• Brush pressure is too low.
• Worn brushes.

22
2200 YRM 929 Brush and Commutator Inspection

Table 5. Commutator Problems

Grooves that are the width of the brushes.

Possible Causes:
• Operation of the motor in dirty and abrasive condi-
tions.
• Wrong type of brushes for this motor and operation.
• Brush pressure is too high.

Table 6. Commutator Problems

A condition called copper drag occurs when copper

from the commutator bar is pulled into the slot between
the commutator bars. This condition will cause a
short circuit between the commutator bars if it is not
corrected. The brushes will wear rapidly.
Possible Causes:
• Operation of the motor in dirty and abrasive condi-
tions.
• Brush holder is not adjusted electrically correct for the
motor.
• Wrong type of brushes for this motor and operation.
• Brush pressure is wrong (too high or too low).

23
Brush and Commutator Inspection 2200 YRM 929

Table 7. Commutator Problems

Electrical burns on commutator bars on opposite sides

of the commutator.
Possible Causes:
• Open armature winding.
• Motor has been stalled.

Table 8. Commutator Problems

Copper wears rapidly at the edge of the commutator

bars.
Possible Causes:
• Operation of the motor in dirty and abrasive condi-
tions.
• Wrong type of brushes for this motor and operation.

24
2200 YRM 929 Brush and Commutator Inspection

Table 9. Commutator Problems

1. Flashover causes burning of the ends of the com-

mutator bar.
2. Open circuit in winding causes deep burning of ad-
jacent commutator bars.
3. Overheating causes damage to varnish insulation.

Possible Causes:
• Motor has been too hot. Wrong lift truck for the appli-
cation.
• Motor has been stalled.
• Open armature winding.
• Open field coil.

Table 10. Commutator Problems

Check for loose or high commutator bars.

Possible Causes:
• Motor has been stalled.
• Motor has been too hot.

1 - High commutator bars 2 - Rapid brush wear from high Brush and commutator damage occurs when
at each brush position can commutator bars. the high commutator hits and forces the brush
occur if the motor is stalled. up. Arcing and burns occur as the brush
moves back down to the normal surface.

25
Brush Replacement 2200 YRM 929

Brush Replacement
Worn motor brushes must be replaced before they dam- injury, discharge the capacitor before inspecting
age the surface of the commutator. Move brush spring or repairing any component in the drive unit com-
and remove a brush from the brush holder. Measure partment. Wear safety glasses. Make certain the
length of brush as shown in Figure 15. Replace all battery has been disconnected.
brushes if the length of one brush is less than the min-
imum length. Brushes are made to different specifica- NOTE: When the brushes must be replaced, it is rec-
tions for motors used in different applications. Use only ommended to replace the brush springs, also.
replacement brushes approved by your dealer.
1. Move the key switch to the OFF position. Discon-
nect battery.

2. Remove drive unit compartment cover.

3. Remove drive unit compartment cover to access

motor. Remove brush covers to motor. Wear eye
protection. Use a vacuum cleaner or compressed
air to remove dirt and "brush dust" from commutator
area.

4. Make a note of the arrangement and connections

of the brush assembly. The replacement brushes
must be installed in the same positions as they were
removed.

5. Loosen the screw that fastens the brush wire to its

terminal. Remove brush springs and brushes.

6. Inspect brush holders for burns and damage. Make

sure brush holder is fastened tightly to mounts at
end of motor. Make sure new brushes will move
freely and smoothly in brush holders.

7. Connect new brush wire to its terminal mount.

8. Check brush springs for damage from heat and cor-

rosion. See Figure 16. Replace damaged brush
1. BRUSH HOLDER (4)
2. BRUSH MOUNTING PLATE springs. Check brush springs for approximately
3. BRUSH SPRING (4) equal pressure. Brush springs normally have a
4. BRUSH SET spring pressure of approximately 1.5 N per each
cm 2 (0.33 lbf per each in. 2) when measured with
Figure 15. Typical Brush Assembly a spring scale.

WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is discon-
nected. To prevent electrical shock and personal

26
2200 YRM 929 Brush Replacement

If new brushes are not fitted to the commutator by

stoning, the contact surface can be small until the
brushes wear to fit the commutator. This small surface
can cause burns and a rough surface on the com-
mutator. Stoning the commutator is most easily done
when the motor rotates slowly. When the motor rotates
at higher speeds, the centrifugal force removes the
abrasive particles from the commutator more quickly.
See Figure 21.

1. BRUSH 3. COMMUTATOR
2. BRUSH SPRING

Figure 16. Brush Removal and Inspection

Brush springs for the drive motor normally have a spring

force of approximately 10.2 ±1.1 N (2.3 ±0.25 lbf) when 1. SPRING SCALE
measured with a spring scale as shown in Figure 17. 2. BRUSH IN BRUSH HOLDER
3. COMMUTATOR
NOTE: The brush springs used in this motor has a con- 4. BRUSH SPRING
stant force design. The force of the brush spring against
the brush stays almost constant as the brush wears and Figure 17. Brush Spring Pressure Check
becomes shorter in its brush holder.

9. New brushes must be made to fit the surface of the

commutator by an abrasive procedure called ston-
ing the commutator. Use a Brush Seater and Com-
mutator Stone (No. 23-007M from the Ideal Com-
pany or an equivalent brush seater stone). Refer to
Figure 21.

27
Drive Motor 2200 YRM 929

Drive Motor
REMOVE
1. Raise drive wheel off floor and block lift truck. Dis-
connect battery.

2. Remove drive unit compartment cover to access

drive unit.

3. Discharge the capacitors in the controllers by con-

necting a 200-ohm, 2-watt resistor across the B+
and B controller terminals. DO NOT short across
the motor controller terminals with a screwdriver or
jumper wire. Remove the 200-ohm, 2-watt resistor
before reconnecting the battery. See Figure 18 and
Figure 19.

1. B+ TERMINAL
2. B TERMINAL
3. 200-OHM, 2-WATT RESISTOR
4. JUMPER WIRES

Figure 19. Discharging the Capacitors

5. Remove electric brake by following the instructions

in Brakes 1800 YRM 963.

6. Tag and disconnect motor wires and harness

clamps on motor.

7. Remove capscrews that retain motor to drive unit

housing.
1. B+ TERMINAL
2. B TERMINAL
3. JUMPER WIRES WARNING
4. 200-OHM, 2-WATT RESISTOR
Make certain that the overhead lifting device and
Figure 18. Discharging the Capacitors sling are suitable for the amount of weight being
lifted.
4. Remove control handle. Refer to Steering Mech-
anism 1600 YRM 962 for the correct removal pro- 8. Using an overhead lifting device and a sling, lift mo-
cedures for the type of motorized hand truck being tor off the drive unit housing and place on a clean
serviced. work bench.

NOTE: The electric brake can be removed from the 9. Inspect components for damage and replace as
drive motor prior to or after removing the drive motor necessary.
from the lift truck.

28
2200 YRM 929 Drive Motor

DISASSEMBLE 6. Install brushes and spring assemblies. Replace

brush cover, if used. See Figure 20.
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 dis-
assembly and assembly.

For the following instructions, see Figure 20.

1. Clean outside surfaces of motor before disassem-

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

2. Remove brush cover, if used. Remove brushes and

spring assemblies.

3. Remove capscrews from commutator end of motor.

Carefully slide end cover from motor and armature
shaft. DO NOT damage parts. A puller is often
necessary to separate the end cover from the motor
field ring.

4. Remove screws that fasten pinion end cover to mo-

tor field ring. Remove end cover and armature. Use
a plastic or rubber hammer, as necessary, to loosen
end cover.

5. Remove pinion end cover from armature.

6. Remove screws that fasten brush holder assembly

to commutator end cover.

7. Disassemble components of motor, as necessary,

Figure 20. Typical Drive Motor
to make repairs. For further instructions on repair-
ing the motor, refer to the section DC Motor Main-
INSTALL
tenance 620 YRM 294.
1. Position motor on housing.
ASSEMBLE
1. Make sure all components are clean. If bearings CAUTION
are worn, install new bearings in end covers. To prevent damage to the drive motor, be sure
to tighten all motor mounting nuts to the correct
2. Make sure field coils and pole pieces are installed torque.
correctly in motor field ring.
2. Install nuts, lockwashers, and, if necessary, the
3. Install brush holder assembly in commutator end studs to attach motor to housing. Tighten lower
cover. nuts to 26 N•m (19 lbf ft). Tighten upper nuts to
4. Carefully install armature in motor field ring. Install 20 N•m (15 lbf ft).
and tighten screws. 3. Install motor wires and harness clamps.
5. Carefully install commutator end cover on armature
and fasten it to motor field ring. Install and tighten
capscrews.

29
Commutator Repairs 2200 YRM 929

5. Install control handle. Refer to Steering Mecha-

CAUTION nism 1600 YRM 962 for the correct installation pro-
To prevent damage to the brake assembly, always cedures for the type of motorized hand truck being
follow the special procedure for brake adjustment serviced.
when adjusting the brake.
6. Install drive unit compartment covers.
4. Install electric brake by following the instructions in
Brakes 1800 YRM 963. 7. Connect battery. Lower truck to floor. Test opera-
tion before returning truck to service.

Lift Pump Motor

REMOVE INSTALL
1. Move key to OFF position and disconnect battery. 1. Install motor onto lift pump.

2. Remove drive unit compartment covers. 2. Install lift pump and motor assembly to frame. See
Walkie Hydraulic Systems 1900 YRM 964.
3. To remove lift pump motor, the complete lift pump
and motor assembly must be removed. See Walkie 3. Connect the battery and turn key switch to the ON
Hydraulic Systems 1900 YRM 964. position.

4. Separate motor from pump by removing the cap- 4. Test operation of motorized hand truck before re-
screws that secure them together. See Walkie Hy- turning truck to service.
draulic Systems 1900 YRM 964.

Commutator Repairs
with light pressure. Move brush seater stone back-
WARNING ward and forward across the surface of the com-
Wear eye protection. Raise the drive wheel. Oper- mutator until the marks on the commutator are re-
ate the motor at low speed. Protect your fingers. moved. Apply the brush seater stone to the com-
DO NOT use a brush seater stone less than 60 mm mutator before each set of brushes so the brush
(2.5 in.) in length. seater particles have an even distribution.

3. Turn the key switch to the OFF position and discon-

CAUTION nect battery. Check all brush contact surfaces. The
DO NOT permit the brush seater stone to stay in brushes fit correctly when 85% of the brush contact
contact with the commutator too long and cause surface touches the commutator. This procedure
more wear than necessary. See Figure 21. normally requires approximately 15 to 45 minutes.
1. If the commutator has grooves or other damage, the 4. When the brushes have the correct contact surface
armature must be removed so the commutator can with the commutator, use compressed air to remove
be repaired. Motors are normally repaired by ser- the abrasive dust from the commutator area and the
vice personnel that have the special equipment re- motor.
quired for the repair. Connect battery so the motor
can be operated. The drive unit compartment cover 5. When the installation and checks are complete, in-
must be removed for access to the motor. Raise stall brush cover. Make sure the wires to brushes
drive wheel. do not touch any part of motor case and cause a
short circuit.
2. Operate motor so the commutator rotates in the
same direction as the long tips of the brushes. Ap-
ply brush seater stone to the moving commutator

30
2200 YRM 929 Testing the Drive Motor

NOTE: A BRUSH SEATER STONE CAN ALSO BE FASTENED TO A WOOD STICK WITH GLUE AS SHOWN IN
THE ILLUSTRATION. THIS ARRANGEMENT MAKES IT EASIER TO APPLY A BRUSH SEATER STONE IN SMALL
PLACES.
1. BRUSH SEATER STONE

Figure 21. Stoning the Commutator

Testing the Drive Motor

DAMAGED FIELD AND ARMATURE large electric sparks and arcs occur as the damaged
commutator bars rotate under each brush.
The tests described in the following paragraphs are to
help a service person check a motor for damage and SHORT CIRCUIT IN AN ARMATURE
to determine if it must be sent to a repair service for WINDING
rebuilt motors. The resistance checks will not normally
indicate a short circuit in a motor winding. A resistance A short circuit in a motor winding is difficult to test be-
greater than 1 to 2 ohms can indicate a damaged wind- cause of the normal low resistance (less than 1 ohm)
ing. The motor must be removed from the lift truck and of a good armature. Use a Meggar to check for a short
disassembled as shown in the illustrations before the circuit in a motor winding. A motor with a short circuit in
tests can be done. an armature winding will have a different sound when it
begins to operate, but a service person must have expe-
The armature windings in large electric motors normally rience to hear and understand the difference in sound.
have less than 1 ohm of resistance. The two commu- A winding with a short circuit will also run hotter than
tator bars for a winding are found 180 degrees apart a good winding and can have indications of heat dam-
on the commutator. If a volt-ohmmeter (R × 1 scale) age. A winding that shows heat damage when the other
is used to check the resistance between the two com- windings are normal can have a short circuit.
mutator bars of the winding, a resistance of more than
1 ohm indicates a problem in that winding. A resistance Another indication of a short circuit will be a higher-than-
of infinity (∞) indicates an open (damaged) winding. normal current draw by the motor. A higher-than-nor-
mal current draw can also indicate other problems or
If the armature has an open circuit, there will normally needed adjustments and does not always indicate a
be two burned commutator bars on opposite sides of short circuit in a motor winding.
the commutator. These burned areas will cause the
brushes to wear rapidly. When the motor operates,

31
Testing the Drive Motor 2200 YRM 929

SHORT CIRCUIT IN THE ARMATURE A winding with a short circuit will also run hotter than a
good winding and can have indications of heat damage.
A volt-ohmmeter (R × 10,000 scale) can be used to test
for a short circuit between an armature winding and the Another indication of a short circuit will be a higher-than-
armature shaft. Put one probe on the armature shaft normal current draw by the motor. A higher-than-nor-
and the other probe on a commutator bar. See Fig- mal current draw can also indicate other problems or
ure 22. A resistance of less than 1 megaohm indicates needed adjustments and does not always indicate a
a problem between a winding and the armature shaft. short circuit in a motor winding.

NOTE: Clean the dirt and "brush dust" from the com- SHORT CIRCUIT BETWEEN FIELD AND
mutator area before making a test for a short circuit. MOTOR CASE
A volt-ohmmeter (R × 10,000 scale) can be used to
test for a short circuit between the field and the motor
case. Put one probe on the motor case and the other
probe on a field terminal. Check resistance between
field terminal and motor case. A resistance of less than
1 megaohm indicates a problem between the field ter-
minal and the motor case. Make sure carbon dust has
been cleaned from motor before making this test.

BRUSH HOLDER
Make sure the carbon dust has been removed from the
brush holders. Use a volt-ohmmeter (R × 10,000 scale)
to measure the resistance between the brush holder
and the motor case. The correct resistance should be
1. ARMATURE SHAFT 3. PROBES TO infinity (∞).
2. COMMUTATOR OHMMETER

Figure 22. Test for an Armature Short Circuit

OPEN CIRCUIT IN A FIELD COIL

The field windings in large electric motors normally have
less than 1 ohm of resistance. If a volt-ohmmeter (R ×
1 scale) is used to check the resistance between the
two terminals of the winding, a resistance greater than
1 ohm indicates a problem in that winding or corrosion
in the terminal connection. See Figure 23.

SHORT CIRCUIT IN A FIELD COIL

A short circuit in a motor field winding is difficult to test
because of the normal low resistance (less than 1 ohm)
of a good field. A Meggar can be used to check for a
short circuit in a motor winding. A motor with a short cir- 1. FIELD COIL TERMINAL
cuit in a field winding will have a different sound when it 2. OHMMETER
begins to operate, but a service person must have expe-
Figure 23. Test for an Open Field Circuit
rience to hear and understand the difference in sound.

32
2200 YRM 929 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Heavy streaks and fine Operation in a dirty or abrasive envi- Clean commutator more frequently.
grooves (see Table 3). ronment.

Continuous operation of motor with a Increase load on motor from time to

light load. time.

Brush pressure is too low. Increase brush pressure.

Worn brushes. Replace brushes.

Grooves and lines following Operation in a dirty or abrasive envi- Clean commutator more frequently.
heavy streaks. The arma- ronment.
ture must be replaced, or the
brushes will wear rapidly (see
Table 4).

Continuous operation of motor with a Increase load on motor from time to

light load. time.

Brush pressure is too low. Increase brush pressure.

Worn brushes. Replace brushes.

Grooves the width of the Operation in a dirty or abrasive envi- Clean the commutator more frequently.
brushes (see Table 5). ronment.

Wrong type of brushes for this motor Replace brushes with correct type.
and operation.

Brush pressure is too high. Adjust brush pressure.

Copper drag occurs when Operation in a dirty or abrasive envi- Clean commutator more frequently.
copper from the commutator ronment.
is pulled into the slot between
the commutator bars. This
problem will cause a short cir-
cuit between the commutator
bars (see Table 6).

Brush holder is not correctly adjusted Adjust brush holder.

electrically for the motor.

Wrong type of brushes for this motor Replace brushes with correct type.
and operation.

Brush pressure is incorrect (too high or Adjust brush pressure.

too low).

33
Troubleshooting 2200 YRM 929

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Electrical burns on commuta- Open armature winding. Replace armature.

tor bars on opposite sides of
the commutator (see Table 7).

Motor has been stalled. Use correct operating techniques.

Copper wears rapidly at the Operation in a dirty or abrasive envi- Clean commutator more frequently.
edge of the commutator bars ronment.
(see Table 8).

Wrong type of brushes for this motor Replace brushes with correct type.
and operation.

Burning/Overheating (see Ta- Motor has been too hot. Wrong lift Use correct lift truck for the application.
ble 9). truck for the application.

1. Flashover causes burning 1. Motor has been stalled. 1. Use correct operating techniques.
of the commutator bar.
2. Open circuit in winding 2. Open armature winding. 2. Replace armature or resurface
causes deep burning commutator in a lathe.
of adjacent commutator
bars.
3. Overheating causes dam- 3. Open field coil. 3. Replace field coil.
age to varnish insulation.

Commutator bars are either Motor has been stalled. Use correct operating techniques.
too high or too loose, both of
which can cause damage to
brushes (see Table 10).

Motor has been too hot. Use correct lift truck for the operation.

34
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 929 11/07 (1/07)(3/06)(10/04)(2/04)(4/02) Printed in U.S.A.