Yale Forklift B827 (MPB040E) Service Manual – PDF DOWNLOAD

Description

Yale Forklift B827 (MPB040E) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift B827 (MPB040E) Service Manual – PDF DOWNLOAD

Language : English
Pages : 504
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift B827 (MPB040E) 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
524154895-2200YRM1006-(03-2014)-US-EN 117
524154896-2200YRM1007-(10-2016)-US-EN 191
General 195
Description of Operation 197
Special Precautions 199
Moving a Disabled Lift Truck 201
Electrical System Checks 201
Safety Precautions 202
Repairs 203
Controller, Replace 203
Remove 203
Install 206
Contactor Coil, Check 206
Contactor, Replace 207
Remove 207
Install 207
Key Switch Removal and Installation 207
Remove 207
Install 207
Battery Indicator/Hourmeter Display 208
Remove 208
Install 208
Fuses 209
MPB040-E 209

MPW045/050-E
209

MSW020/025-E
209

MSW025/030-F
209

Control Handle Arm Proximity Switch
210
Repair 210
Check and Adjust 210
Remove 210
Install 211
Control Handle 212
Disassemble 212
Control Handle Card (Old Style) 212
Control Handle Card (New Style) 213
Configure 214
Calibrate 215
Assemble 217
Switches (ON/OFF and Proportional) 219
Remove 219
Install 219
Traction Motor 219
Disassemble 220
Assemble 222
Lift Pump Motor 222
Repair (MSW020/025-E and MSW025/030-F) 222
Lift Link Proximity Sensor (MPW050-E) 224
Check 224
Repair 224
Remove 224
Test 224
Install 225
Adjust 225
Battery Charger (Moran®) 225
Description 226
Operation 226
Charging 226
Equalize 226
Signals 226
Protections 226
Troubleshooting 226
Battery Charger (Accusense by DPI®) 230
Description 230
Operation 230
LED Display 230
Charging 231
Charger Mode/Battery Type Selection (DPI Gen II Models) 232
Changing Mode Setting (DPI Gen II Models) 232
Charger Mode/Battery Type Selection (DPI Gen III Models) 233
Changing Mode Setting (DPI Accusense Gen III Models with Jumper Ports) 234
Accusense Gen III with Dip Switches 234
Changing Mode Setting 236
Troubleshooting (DPI Chargers) 236
General 236
Error Modes 237
Battery Pack Troubleshooting 238
Battery Charger (Accusense® 20A) 239
Description 239
Operation 239
LED Display 239
Charging 240
Charger Mode/Battery Type Selection (Accusense 20A) 241
Changing Mode Setting (Accusense 20A) 244
Troubleshooting (Accusense 20A Chargers) 244
General 244
Error Modes 245
Battery Pack Troubleshooting 247
Troubleshooting 248
524154897-4000YRM1008-(08-2009)-US-EN 251
toc 251
Lifting Mechanism 251
Safety Precautions Maintenance and Repair 252
General 255
Lift Linkage 255
Load Wheel 256
Remove 256
Install 257
Rear Link and Load Wheel 257
Remove 257
Install 257
Compression Rod 258
Remove 258
Install 258
Lower Link 259
Remove 259
Install 260
Upper Link 260
Remove 260
Install 261
Caster Wheels (Optional) 261
Remove 261
Install 262
Replace 262
524154898-8000YRM1009-(02-2007)-US-EN 265
toc 265
Periodic Maintenance 265
Safety Precautions Maintenance and Repair 266
General 269
How to Move a Disabled Truck 269
How to Tow the Lift Truck 269
How to Put a Lift Truck on Blocks 270
How to Raise Drive/Steer Tire 271
How to Raise Load Wheels 271
Welding Repairs 271
Battery Maintenance 272
How to Charge the Battery 272
Equalizing Charge 272
Normal Charge 272
Maintenance-Free Battery Charger 273
Battery Charger ( MPB040E Only) 273
How to Change the Battery 273
Maintenance Schedule 274
Checks and Inspection Procedures 274
Hydraulic System 274
Lifting Mechanism 276
Controls 276
Electrical and Battery 277
Wheels and Tires 277
Casters 278
Recommended Schedule of Maintenance 278
Lubrication Instructions 283
Every 8 Hours or Daily 283
Every 350 Hours or 6 Months 283
Check Hydraulic Oil Level 283
Every 2000 Hours or 2 Years 284
To Fill Hydraulic Reservoir 284
tables 265
Table 1 Specific Gravity Corrections 272
524154899-8000YRM1010-(10-2015)-US-EN 289
Hydraulic Oils 293
Gear Oils 294
Grease 294
Hydraulic System 296
Weight 296
Basic Truck Without Battery 296
Tires 296
Torque Specifications 297
Caster Assembly 297
Master Drive Unit 297
Steering 297
Brake 297
Lift Mechanism 297
Battery Specifications and Adjustments 298
4000 LB – 24 Volt 298
4500 – 12 Volt 299
4500 and 5000 LB – 24 Volt 299
524154900-8000YRM1011-(03-2018)-US-EN 303
General Notes 307
Schematics 308
524158039-0620YRM0294-(09-2016)-US-EN 327
General 331
Brush and Commutator Inspection 332
Hydraulic Pump Motor and Traction Motor 332
Steering Pump Motor 335
Normal Commutator Surface 335
Commutator Problems 335
Brush Replacement 340
Stoning the Commutator 343
Motors Repair 344
Disassemble 345
Traction Motor and Hydraulic Pump Motor 345
Steering Pump Motor 346
Assemble 350
Traction Motor and Hydraulic Pump Motor 350
Steering Pump Motor 352
Brush Alignment, Traction and Hydraulic Motors 354
Tests for Damaged Field and Armature 355
Test for an Open Circuit in One Armature Winding 355
Test for Short Circuit in One Armature Winding 355
Test for Short Circuit to Armature Shaft 356
Test for Open Circuit in Field Coil 356
Test for Short Circuit in Field Coil 357
Test for Short Circuit Between Field and Motor Case 357
Brush Holder Test 357
Troubleshooting 358
524158040-2240YRM0001-(01-2023)-US-EN 363
General 369
Battery Type 369
Lead-Acid Batteries 369
Lithium-Ion Batteries 370
Specific Gravity 370
Chemical Reaction in a Cell 370
Electrical Terms 372
Battery Selection 373
Battery Voltage 374
Battery as a Counterweight 374
Battery Ratings 374
Kilowatt-Hours 374
Battery Maintenance 375
Safety Procedures 375
Maintenance Records 375
New Battery 375
Cleaning Battery 376
Adding Water to Battery 378
Hydrometer 378
Battery Temperature 379
Charging Battery 380
Types of Battery Charges 381
Methods of Charging 382
Troubleshooting Charger 383
Knowing When Battery Is Fully Charged 383
Where to Charge Batteries 383
Equipment Needed 383
Battery Connectors 384
Battery Care 384
Troubleshooting 386
524158040-2240YRM0001-(03-2020)-US-EN 391
General 395
Battery Type 395
Lead-Acid Batteries 395
Lithium-Ion Batteries 396
Specific Gravity 396
Chemical Reaction in a Cell 396
Electrical Terms 398
Battery Selection 398
Battery Voltage 399
Battery as a Counterweight 400
Battery Ratings 400
Kilowatt-Hours 400
Battery Maintenance 400
Safety Procedures 400
Maintenance Records 401
New Battery 401
Cleaning Battery 401
Adding Water to Battery 403
Hydrometer 404
Battery Temperature 405
Charging Battery 406
Types of Battery Charges 406
Methods of Charging 408
Troubleshooting Charger 408
Knowing When Battery Is Fully Charged 409
Where to Charge Batteries 409
Equipment Needed 409
Battery Connectors 410
Battery Care 410
Troubleshooting 412
524188546-2200YRM1067-(08-2010)-US-EN 417
toc 417
ZAPI™ Controllers 417
Safety Precautions Maintenance and Repair 418
General 421
Description 421
ZAPI™ Transistor Motor Controller 421
Principles of Operation 422
Controller Safety 422
Controller Adjustments 423
Modes of Operation 423
User-Selectable Operating Modes 423
Programming 424
Custom Performance Mode 424
Controller Parameters 424
Tester Menu 425
Set Option Menu 426
ZAPI™ Handset 426
Troubleshooting 430
Control Card Functional Test 454
ZAPI™ PC Interface 456
Connecting PC to ZAPI™ Controller 456
File Menu 459
Open File 459
TX From File 460
Save File 462
Print Settings 464
Exit 465
Connection Menu 466
Function Menu 466
Parameter 467
Memory Menu 471
Set Options 472
Tester 474
Data Logger 476
Alarm Logbook 479
Alarms 480
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) 481
Repair 482
Remove 482
Brass Stud Replacement 482
Remove 482
Install 482
Install 482
Repair 482
tables 417
Table 1 Parameters 425
550149026-2200YRM2030-(06-2017)-US-EN 485
General 489
AccuSense® Q-Series Charger 489
Charger Mode/Battery Type Selection 490
Mode Setting Check 491
Convenience Port 492
Multi-Stage Charging 493
LED Display, Multi-Stage Charge 495
Cell, Battery, and Battery Pack Voltage 496
Voltages 496
Troubleshooting 497
Charger Troubleshooting 497
Error Code Description 497
Diagnostics and Troubleshooting 499
Output Connector Circuit 500
Vehicle Lockout Control Option 501

S.V 06/24