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MPB040E
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Manual
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For lift trucks manufactured after May, 2013, refer to
Figure 35 to determine which mode switch setting
should be used to charge a particular battery.
Figure 35. Switch Position Mode Chart
2200 YRM 1007
Battery Charger (Accusense
®
20A)
49
72
74
Table of Contents
Main Page
Section 1
3
Table of Contents
3
Operation
5
Lifting a Load
5
Lowering a Load
5
Hydraulic Lines
5
General
5
Hydraulic Oil
6
Cleanliness
6
Sound Level
7
Install
8
Hydraulic Unit
8
Special Precautions
8
Remove
8
Hydraulic Pump
9
Remove
9
Install
9
Hydraulic Pump Reservoir
11
Remove
11
Install
11
Hydraulic Cylinder
12
Remove
12
Repacking
13
Install
13
Relief Valve Adjustment
14
Relief Valve Pressure Check
14
Relief Valve Adjust
15
Troubleshooting
16
Lift Assemblies
16
Hydraulic Cylinders
16
Hydraulic Pump
17
Section 2
23
General
25
Description of Operation
27
Special Precautions
29
Moving a Disabled Lift Truck
31
Electrical System Checks
32
Safety Precautions
32
Controller, Replace
33
Remove
33
Repairs
33
Contactor Coil, Check
36
Install
36
Contactor, Replace
37
Install
37
Key Switch Removal and Installation
37
Remove
37
Install
38
Remove
38
Fuses
39
Install
39
Mpb040-E
39
Mpw045/050-E
39
Msw020/025-E
39
Msw025/030-F
39
Check and Adjust
40
Control Handle Arm Proximity Switch
40
Remove
40
Repair
40
Install
41
Control Handle
42
Control Handle Card (Old Style)
42
Disassemble
42
Control Handle Card (New Style)
43
Configure
44
Calibrate
45
Assemble
47
Install
49
Remove
49
Switches (ON/OFF and Proportional)
49
Disassemble
50
Traction Motor
50
Assemble
52
Lift Pump Motor
52
Repair (Msw020/025-E and Msw025/030-F)
52
Check
54
Lift Link Proximity Sensor (MPW050-E)
54
Remove
54
Repair
54
Test
54
Adjust
55
Install
55
Battery Charger (Moran ® )
56
Charging
56
Description
56
Equalize
56
Operation
56
Protections
56
Signals
56
Troubleshooting
56
Battery Charger (Accusense by DPI ® )
60
Description
60
LED Display
60
Operation
60
Charging
61
Changing Mode Setting (DPI Gen II Models)
62
Charger Mode/Battery Type Selection (DPI Gen II Models)
62
Charger Mode/Battery Type Selection (DPI Gen III Models)
63
Accusense Gen III with Dip Switches
64
Changing Mode Setting
64
General
66
Troubleshooting (DPI Chargers)
66
Error Modes
67
Battery Pack Troubleshooting
68
Battery Charger (Accusense ® 20A)
69
Description
69
LED Display
69
Operation
69
Charging
70
Charger Mode/Battery Type Selection (Accusense 20A)
71
Changing Mode Setting (Accusense 20A)
74
General
74
Troubleshooting (Accusense 20A Chargers)
74
Error Modes
75
Battery Pack Troubleshooting
77
Troubleshooting
78
Section 3
83
General
85
Lift Linkage
85
Load Wheel
86
Remove
86
Install
87
Rear Link and Load Wheel
87
Remove
87
Compression Rod
88
Install
88
Remove
88
Lower Link
89
Remove
89
Install
90
Remove
90
Upper Link
90
Caster Wheels (Optional)
91
Install
91
Remove
91
Install
92
Replace
92
Section 4
97
General
99
Brush and Commutator Inspection
100
Hydraulic Pump Motor and Traction Motor
100
Commutator Problems
103
Normal Commutator Surface
103
Steering Pump Motor
103
Brush Replacement
108
Stoning the Commutator
111
Disassemble
113
Motors Repair
113
Traction Motor and Hydraulic Pump Motor
113
Steering Pump Motor
114
Assemble
118
Traction Motor and Hydraulic Pump Motor
118
Steering Pump Motor
120
Brush Alignment, Traction and Hydraulic Motors
123
Test for an Open Circuit in One Armature Winding
123
Test for Short Circuit in One Armature Winding
123
Tests for Damaged Field and Armature
123
Test for Open Circuit in Field Coil
124
Test for Short Circuit to Armature Shaft
124
Brush Holder Test
125
Test for Short Circuit between Field and Motor Case
125
Test for Short Circuit in Field Coil
125
Troubleshooting
126
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