Yale Forklift B802 (MPW045E) Service Manual – PDF DOWNLOAD

Description

Yale Forklift B802 (MPW045E) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift B802 (MPW045E) Service Manual – PDF DOWNLOAD

Language : English
Pages : 410
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift B802 (MPW045E) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524154890-0100YRM1015-(08-2009)-US-EN 43
toc 43
Frame 43
Safety Precautions Maintenance and Repair 44
General 47
Description 47
Frame Repair 48
Features 48
Frame Separation and Assembly 48
Separation 48
Assembly 48
Battery Compartment 49
Battery Compartment Specifications 49
Changing the Battery 49
Remove 50
Install 50
Battery Spacer Adjustment 50
Label Replacement 50
Painting Instructions 52
Load Wheels 52
Remove 52
Install 53
524154891-0630YRM1003-(03-2008)-US-EN 57
toc 57
Master Drive Unit 57
Safety Precautions Maintenance and Repair 58
General 61
Description 61
Special Precautions 61
Master Drive Unit Repair 63
Remove 63
Disassemble 65
Repair 66
Assemble 66
Install 66
Troubleshooting 67
524154892-1600YRM1004-(10-2015)-US-EN 71
General 75
Special Precautions 75
Control Handle Head 76
Control Handle 76
Remove 76
Install 77
Gas Spring 79
Discharging the Gas Spring 79
Troubleshooting 80
524154893-1800YRM1005-(03-2008)-US-EN 83
toc 83
Brakes 83
Safety Precautions Maintenance and Repair 84
General 87
Description 87
Special Precautions 88
Brake Assembly Repair 89
Brake Override 89
Remove 90
Repair 92
Install 93
Troubleshooting 94
524154894-1900YRM1018-(04-2007)-US-EN 97
toc 97
Walkie Hydraulic Systems 97
Safety Precautions Maintenance and Repair 98
General 101
Operation 101
Lifting a Load 101
Lowering a Load 101
Hydraulic Lines 101
Hydraulic Oil 102
Cleanliness 102
Sound Level 103
Hydraulic Unit 104
Remove 104
Special Precautions 104
Install 104
Hydraulic Pump 105
Remove 105
Install 105
Hydraulic Pump Reservoir 107
Remove 107
Install 107
Hydraulic Cylinder 108
Remove 108
Repacking 109
Install 109
Relief Valve Adjustment 110
Relief Valve Pressure Check 110
Relief Valve Adjust 111
Troubleshooting 112
Lift Assemblies 112
Hydraulic Cylinders 112
Hydraulic Pump 113
tables 97
Table 1 Relief Valve Settings 110
524154896-2200YRM1007-(10-2016)-US-EN 117
General 121
Description of Operation 123
Special Precautions 125
Moving a Disabled Lift Truck 127
Electrical System Checks 127
Safety Precautions 128
Repairs 129
Controller, Replace 129
Remove 129
Install 132
Contactor Coil, Check 132
Contactor, Replace 133
Remove 133
Install 133
Key Switch Removal and Installation 133
Remove 133
Install 133
Battery Indicator/Hourmeter Display 134
Remove 134
Install 134
Fuses 135
MPB040-E 135

MPW045/050-E
135

MSW020/025-E
135

MSW025/030-F
135

Control Handle Arm Proximity Switch
136
Repair 136
Check and Adjust 136
Remove 136
Install 137
Control Handle 138
Disassemble 138
Control Handle Card (Old Style) 138
Control Handle Card (New Style) 139
Configure 140
Calibrate 141
Assemble 143
Switches (ON/OFF and Proportional) 145
Remove 145
Install 145
Traction Motor 145
Disassemble 146
Assemble 148
Lift Pump Motor 148
Repair (MSW020/025-E and MSW025/030-F) 148
Lift Link Proximity Sensor (MPW050-E) 150
Check 150
Repair 150
Remove 150
Test 150
Install 151
Adjust 151
Battery Charger (Moran®) 151
Description 152
Operation 152
Charging 152
Equalize 152
Signals 152
Protections 152
Troubleshooting 152
Battery Charger (Accusense by DPI®) 156
Description 156
Operation 156
LED Display 156
Charging 157
Charger Mode/Battery Type Selection (DPI Gen II Models) 158
Changing Mode Setting (DPI Gen II Models) 158
Charger Mode/Battery Type Selection (DPI Gen III Models) 159
Changing Mode Setting (DPI Accusense Gen III Models with Jumper Ports) 160
Accusense Gen III with Dip Switches 160
Changing Mode Setting 162
Troubleshooting (DPI Chargers) 162
General 162
Error Modes 163
Battery Pack Troubleshooting 164
Battery Charger (Accusense® 20A) 165
Description 165
Operation 165
LED Display 165
Charging 166
Charger Mode/Battery Type Selection (Accusense 20A) 167
Changing Mode Setting (Accusense 20A) 170
Troubleshooting (Accusense 20A Chargers) 170
General 170
Error Modes 171
Battery Pack Troubleshooting 173
Troubleshooting 174
524154897-4000YRM1008-(08-2009)-US-EN 177
toc 177
Lifting Mechanism 177
Safety Precautions Maintenance and Repair 178
General 181
Lift Linkage 181
Load Wheel 182
Remove 182
Install 183
Rear Link and Load Wheel 183
Remove 183
Install 183
Compression Rod 184
Remove 184
Install 184
Lower Link 185
Remove 185
Install 186
Upper Link 186
Remove 186
Install 187
Caster Wheels (Optional) 187
Remove 187
Install 188
Replace 188
524154898-8000YRM1009-(02-2007)-US-EN 191
toc 191
Periodic Maintenance 191
Safety Precautions Maintenance and Repair 192
General 195
How to Move a Disabled Truck 195
How to Tow the Lift Truck 195
How to Put a Lift Truck on Blocks 196
How to Raise Drive/Steer Tire 197
How to Raise Load Wheels 197
Welding Repairs 197
Battery Maintenance 198
How to Charge the Battery 198
Equalizing Charge 198
Normal Charge 198
Maintenance-Free Battery Charger 199
Battery Charger ( MPB040E Only) 199
How to Change the Battery 199
Maintenance Schedule 200
Checks and Inspection Procedures 200
Hydraulic System 200
Lifting Mechanism 202
Controls 202
Electrical and Battery 203
Wheels and Tires 203
Casters 204
Recommended Schedule of Maintenance 204
Lubrication Instructions 209
Every 8 Hours or Daily 209
Every 350 Hours or 6 Months 209
Check Hydraulic Oil Level 209
Every 2000 Hours or 2 Years 210
To Fill Hydraulic Reservoir 210
tables 191
Table 1 Specific Gravity Corrections 198
524154899-8000YRM1010-(10-2015)-US-EN 215
Hydraulic Oils 219
Gear Oils 220
Grease 220
Hydraulic System 222
Weight 222
Basic Truck Without Battery 222
Tires 222
Torque Specifications 223
Caster Assembly 223
Master Drive Unit 223
Steering 223
Brake 223
Lift Mechanism 223
Battery Specifications and Adjustments 224
4000 LB – 24 Volt 224
4500 – 12 Volt 225
4500 and 5000 LB – 24 Volt 225
524154900-8000YRM1011-(03-2018)-US-EN 229
General Notes 233
Schematics 234
524158039-0620YRM0294-(09-2016)-US-EN 253
General 257
Brush and Commutator Inspection 258
Hydraulic Pump Motor and Traction Motor 258
Steering Pump Motor 261
Normal Commutator Surface 261
Commutator Problems 261
Brush Replacement 266
Stoning the Commutator 269
Motors Repair 270
Disassemble 271
Traction Motor and Hydraulic Pump Motor 271
Steering Pump Motor 272
Assemble 276
Traction Motor and Hydraulic Pump Motor 276
Steering Pump Motor 278
Brush Alignment, Traction and Hydraulic Motors 280
Tests for Damaged Field and Armature 281
Test for an Open Circuit in One Armature Winding 281
Test for Short Circuit in One Armature Winding 281
Test for Short Circuit to Armature Shaft 282
Test for Open Circuit in Field Coil 282
Test for Short Circuit in Field Coil 283
Test for Short Circuit Between Field and Motor Case 283
Brush Holder Test 283
Troubleshooting 284
524158040-2240YRM0001-(01-2023)-US-EN 289
General 295
Battery Type 295
Lead-Acid Batteries 295
Lithium-Ion Batteries 296
Specific Gravity 296
Chemical Reaction in a Cell 296
Electrical Terms 298
Battery Selection 299
Battery Voltage 300
Battery as a Counterweight 300
Battery Ratings 300
Kilowatt-Hours 300
Battery Maintenance 301
Safety Procedures 301
Maintenance Records 301
New Battery 301
Cleaning Battery 302
Adding Water to Battery 304
Hydrometer 304
Battery Temperature 305
Charging Battery 306
Types of Battery Charges 307
Methods of Charging 308
Troubleshooting Charger 309
Knowing When Battery Is Fully Charged 309
Where to Charge Batteries 309
Equipment Needed 309
Battery Connectors 310
Battery Care 310
Troubleshooting 312
524158040-2240YRM0001-(03-2020)-US-EN 317
General 321
Battery Type 321
Lead-Acid Batteries 321
Lithium-Ion Batteries 322
Specific Gravity 322
Chemical Reaction in a Cell 322
Electrical Terms 324
Battery Selection 324
Battery Voltage 325
Battery as a Counterweight 326
Battery Ratings 326
Kilowatt-Hours 326
Battery Maintenance 326
Safety Procedures 326
Maintenance Records 327
New Battery 327
Cleaning Battery 327
Adding Water to Battery 329
Hydrometer 330
Battery Temperature 331
Charging Battery 332
Types of Battery Charges 332
Methods of Charging 334
Troubleshooting Charger 334
Knowing When Battery Is Fully Charged 335
Where to Charge Batteries 335
Equipment Needed 335
Battery Connectors 336
Battery Care 336
Troubleshooting 338
524188546-2200YRM1067-(08-2010)-US-EN 343
toc 343
ZAPI™ Controllers 343
Safety Precautions Maintenance and Repair 344
General 347
Description 347
ZAPI™ Transistor Motor Controller 347
Principles of Operation 348
Controller Safety 348
Controller Adjustments 349
Modes of Operation 349
User-Selectable Operating Modes 349
Programming 350
Custom Performance Mode 350
Controller Parameters 350
Tester Menu 351
Set Option Menu 352
ZAPI™ Handset 352
Troubleshooting 356
Control Card Functional Test 380
ZAPI™ PC Interface 382
Connecting PC to ZAPI™ Controller 382
File Menu 385
Open File 385
TX From File 386
Save File 388
Print Settings 390
Exit 391
Connection Menu 392
Function Menu 392
Parameter 393
Memory Menu 397
Set Options 398
Tester 400
Data Logger 402
Alarm Logbook 405
Alarms 406
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) 407
Repair 408
Remove 408
Brass Stud Replacement 408
Remove 408
Install 408
Install 408
Repair 408
tables 343
Table 1 Parameters 351

S.V 06/24