Yale Forklift C802 (MPW050E) Service Manual – PDF DOWNLOAD

Description

Yale Forklift C802 (MPW050E) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift C802 (MPW050E) Service Manual – PDF DOWNLOAD

Language : English
Pages : 398
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift C802 (MPW050E) 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
524158039-0620YRM0294-(09-2016)-US-EN 229
General 233
Brush and Commutator Inspection 234
Hydraulic Pump Motor and Traction Motor 234
Steering Pump Motor 237
Normal Commutator Surface 237
Commutator Problems 237
Brush Replacement 242
Stoning the Commutator 245
Motors Repair 246
Disassemble 247
Traction Motor and Hydraulic Pump Motor 247
Steering Pump Motor 248
Assemble 252
Traction Motor and Hydraulic Pump Motor 252
Steering Pump Motor 254
Brush Alignment, Traction and Hydraulic Motors 256
Tests for Damaged Field and Armature 257
Test for an Open Circuit in One Armature Winding 257
Test for Short Circuit in One Armature Winding 257
Test for Short Circuit to Armature Shaft 258
Test for Open Circuit in Field Coil 258
Test for Short Circuit in Field Coil 259
Test for Short Circuit Between Field and Motor Case 259
Brush Holder Test 259
Troubleshooting 260
524158040-2240YRM0001-(01-2023)-US-EN 265
General 271
Battery Type 271
Lead-Acid Batteries 271
Lithium-Ion Batteries 272
Specific Gravity 272
Chemical Reaction in a Cell 272
Electrical Terms 274
Battery Selection 275
Battery Voltage 276
Battery as a Counterweight 276
Battery Ratings 276
Kilowatt-Hours 276
Battery Maintenance 277
Safety Procedures 277
Maintenance Records 277
New Battery 277
Cleaning Battery 278
Adding Water to Battery 280
Hydrometer 280
Battery Temperature 281
Charging Battery 282
Types of Battery Charges 283
Methods of Charging 284
Troubleshooting Charger 285
Knowing When Battery Is Fully Charged 285
Where to Charge Batteries 285
Equipment Needed 285
Battery Connectors 286
Battery Care 286
Troubleshooting 288
524158040-2240YRM0001-(03-2020)-US-EN 293
General 297
Battery Type 297
Lead-Acid Batteries 297
Lithium-Ion Batteries 298
Specific Gravity 298
Chemical Reaction in a Cell 298
Electrical Terms 300
Battery Selection 300
Battery Voltage 301
Battery as a Counterweight 302
Battery Ratings 302
Kilowatt-Hours 302
Battery Maintenance 302
Safety Procedures 302
Maintenance Records 303
New Battery 303
Cleaning Battery 303
Adding Water to Battery 305
Hydrometer 306
Battery Temperature 307
Charging Battery 308
Types of Battery Charges 308
Methods of Charging 310
Troubleshooting Charger 310
Knowing When Battery Is Fully Charged 311
Where to Charge Batteries 311
Equipment Needed 311
Battery Connectors 312
Battery Care 312
Troubleshooting 314
524188546-2200YRM1067-(08-2010)-US-EN 319
toc 319
ZAPI™ Controllers 319
Safety Precautions Maintenance and Repair 320
General 323
Description 323
ZAPI™ Transistor Motor Controller 323
Principles of Operation 324
Controller Safety 324
Controller Adjustments 325
Modes of Operation 325
User-Selectable Operating Modes 325
Programming 326
Custom Performance Mode 326
Controller Parameters 326
Tester Menu 327
Set Option Menu 328
ZAPI™ Handset 328
Troubleshooting 332
Control Card Functional Test 356
ZAPI™ PC Interface 358
Connecting PC to ZAPI™ Controller 358
File Menu 361
Open File 361
TX From File 362
Save File 364
Print Settings 366
Exit 367
Connection Menu 368
Function Menu 368
Parameter 369
Memory Menu 373
Set Options 374
Tester 376
Data Logger 378
Alarm Logbook 381
Alarms 382
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) 383
Repair 384
Remove 384
Brass Stud Replacement 384
Remove 384
Install 384
Install 384
Repair 384
tables 319
Table 1 Parameters 327
524255609-8000YRM1228-(09-2005)-US-EN 387
toc 387
Diagrams 387
Safety Precautions Maintenance and Repair 388
General Notes 391

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