Yale Forklift C819 (MCW025_030_040E) Service Manual – PDF DOWNLOAD

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FILE DETAILS:

Yale Forklift C819 (MCW025_030_040E) Service Manual – PDF DOWNLOAD

Language : English
Pages : 634
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift C819 (MCW025_030_040E) 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
524153636-2100YRM0999-(09-2016)-US-EN 43
General 47
Description 47
Tilt Cylinder Repair 47
Remove 47
Disassemble 47
Clean 47
Assemble 51
Install 51
Tilt Cylinder Leak Check 52
Mast Tilt Angle Adjustment 52
Troubleshooting 52
524158039-0620YRM0294-(09-2016)-US-EN 57
General 61
Brush and Commutator Inspection 62
Hydraulic Pump Motor and Traction Motor 62
Steering Pump Motor 65
Normal Commutator Surface 65
Commutator Problems 65
Brush Replacement 70
Stoning the Commutator 73
Motors Repair 74
Disassemble 75
Traction Motor and Hydraulic Pump Motor 75
Steering Pump Motor 76
Assemble 80
Traction Motor and Hydraulic Pump Motor 80
Steering Pump Motor 82
Brush Alignment, Traction and Hydraulic Motors 84
Tests for Damaged Field and Armature 85
Test for an Open Circuit in One Armature Winding 85
Test for Short Circuit in One Armature Winding 85
Test for Short Circuit to Armature Shaft 86
Test for Open Circuit in Field Coil 86
Test for Short Circuit in Field Coil 87
Test for Short Circuit Between Field and Motor Case 87
Brush Holder Test 87
Troubleshooting 88
524158040-2240YRM0001-(01-2023)-US-EN 93
General 99
Battery Type 99
Lead-Acid Batteries 99
Lithium-Ion Batteries 100
Specific Gravity 100
Chemical Reaction in a Cell 100
Electrical Terms 102
Battery Selection 103
Battery Voltage 104
Battery as a Counterweight 104
Battery Ratings 104
Kilowatt-Hours 104
Battery Maintenance 105
Safety Procedures 105
Maintenance Records 105
New Battery 105
Cleaning Battery 106
Adding Water to Battery 108
Hydrometer 108
Battery Temperature 109
Charging Battery 110
Types of Battery Charges 111
Methods of Charging 112
Troubleshooting Charger 113
Knowing When Battery Is Fully Charged 113
Where to Charge Batteries 113
Equipment Needed 113
Battery Connectors 114
Battery Care 114
Troubleshooting 116
524158040-2240YRM0001-(03-2020)-US-EN 121
General 125
Battery Type 125
Lead-Acid Batteries 125
Lithium-Ion Batteries 126
Specific Gravity 126
Chemical Reaction in a Cell 126
Electrical Terms 128
Battery Selection 128
Battery Voltage 129
Battery as a Counterweight 130
Battery Ratings 130
Kilowatt-Hours 130
Battery Maintenance 130
Safety Procedures 130
Maintenance Records 131
New Battery 131
Cleaning Battery 131
Adding Water to Battery 133
Hydrometer 134
Battery Temperature 135
Charging Battery 136
Types of Battery Charges 136
Methods of Charging 138
Troubleshooting Charger 138
Knowing When Battery Is Fully Charged 139
Where to Charge Batteries 139
Equipment Needed 139
Battery Connectors 140
Battery Care 140
Troubleshooting 142
524164470-4000YRM0480-(08-2016)-US-EN 147
General 151
Mast Weldments 153
Carriages 154
Two-Stage Mast 156
Description 157
Operation 162
Three-Stage Mast 163
Description 163
Operation 166
524164471-4000YRM0482-(05-2018)-US-EN 171
General 175
Safety Procedures When Working Near Mast 175
Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks 176
Load Backrest Extension, Remove and Install 177
Carriage Assembly, Remove and Install 177
Carriage Load Rollers, Remove and Install 180
Side Rollers, Disassemble and Assemble 180
Fork, Replace 181
Hook-Type Forks 181
Remove 181
Install 181
Forks Check 181
Two-Stage Mast Assembly 184
Remove 184
Clean and Inspect 189
Lift Cylinders, Remove and Install Dual-Lift Cylinders 190
Lift Cylinder, Remove and Install Single Main-Lift Cylinders 191
Remove 191
Install 192
Inner Mast Assembly, Remove and Install 193
Hoses, Replace 193
Hose and Cable Sheaves, Replace 193
Two-Stage Lift Chains 195
Remove and Install 195
Clean and Inspect 195
Two-Stage Chain Sheave, Remove and Install 196
Load Rollers and Wear Plugs, Remove and Install 196
Two-Stage Mast Assembly, Install 197
Three-Stage Mast Assembly 198
Three-Stage Mast Assembly, Remove 198
Clean and Inspect 199
Free-Lift Cylinder, Remove and Install 202
Main Cylinders (Standard), Remove and Install 203
Inner and Intermediate Mast Assemblies, Remove and Install 205
Hoses, Replace 205
Hose and Cable Sheaves, Replace 207
Free-Lift Hose Sheave 207
Carriage Sheaves 207
Three-Stage Lift Chains, Remove and Install 208
General 208
Free-Lift Chains 208
Main-Lift Chains 208
Three-Stage Chain Sheaves, Disassemble and Assemble 209
Free-Lift Chain Sheaves 209
Main-Lift Chain Sheaves 209
Load Rollers and Wear Plugs, Remove and Install 209
Three-Stage Mast Assemble, Install 210
Mast Operation Check 211
Hydraulic System Leaks Check 211
Lift Chains Check 212
General 212
Clean and Inspect 212
Lubrication 213
Mast Adjustments 213
General 214
Adjust Wear Plugs – Mast 214
Adjust Free-Lift Chain (Three-Stage Only) 216
Adjust Main-Lift Chains 216
Two-Stage 216
Three-Stage 218
Adjust Wear Strips 218
Carriage Adjustments 219
Adjust Wear Plug – Carriage 219
Adjust Side Rollers – Carriage 219
Adjust Thrust Rollers – Carriage 220
Troubleshooting 221
524164473-4000YRM0481-(08-2016)-US-EN 225
General 229
Description 229
Lowering Control Valve 230
Main Cylinder Repair 231
Disassemble 232
Assemble 233
Free-Lift Cylinder Repair 234
Disassemble 234
Assemble 234
Troubleshooting 236
524164715-0630YRM0961-(03-2022)-US-EN 239
General 247
Check Oil Level 248
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 249
Drive Tire 249
Remove 249
Install 249
Master Drive Unit 250
Remove 250
Disassemble 257
Remove Drive Axle Group 257
Remove Upper Housing Group 258
Remove Pinion Group 258
Install 260
Troubleshooting 262
524164715-0630YRM0961-(12-2018)-US-EN 265
General 273
Check Oil Level 274
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 275
Drive Tire 275
Remove 275
Install 275
Master Drive Unit 275
Remove 275
Disassemble 282
Remove Drive Axle Group 282
Remove Upper Housing Group 282
Remove Pinion Group 282
Install 285
Troubleshooting 287
524164716-1600YRM0962-(08-2016)-US-EN 291
General 295
Special Precautions 295
Control Handle Head 296
Control Handle (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 297
Remove 297
Install 299
Control Handle (MPE060/080-E) 300
Remove (Handle) 300
Steer Bearings and Support 301
Disassemble 301
Repair 301
Assemble 301
Install (Handle) 303
Gas Spring 304
Discharging the Gas Spring 304
Remove (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 305
Remove (MPE060/080-E) 305
Install (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 305
Install (MPE060/080-E) 305

Steering and Dash Assembly (Complete)
306
Remove 306
Install 306
Troubleshooting 308
524164717-1800YRM0963-(08-2016)-US-EN 311
General 315
Description 315
Special Precautions 318
Brake Check 319
Hold On Grade Test 319
Brake Coil Check 320
Brake Assembly Repair 320

MPW060-E and MPE060-E (Up to 10/2001)
320
Remove 320
Install 321

MPW060-E and MPE060-E (10/2001 and Up), MPE080-E, MTR005-E, MTR007-E, MPC060-E, MPC080-E, MPW065-E, MPW080-E, MSW030-040-E, MRW020-030-E, and MCW025-030-040-E
323
Remove 323
Install 325
Brake Assembly Adjustment 325
Air Gap, Adjust 325
Torque Nut, Adjust 326
Adjust 327

MPW060-E, MPW080-E, and MPE060-E Equipped With Brake Assembly Part Number 524144871 327

MPW060-E, MPW080-E, MPE060-E, and All Other Models Covered by This Section Equipped With Brake Assembly Part Number 524169212 327
Troubleshooting 328
524167547-0100YRM1024-(08-2016)-US-EN 333
General 337
Features (MSW030/040-E and MRW020/030-E) 337
Features (MCW025/030/040-E) 339
Frame Repair 340
Painting Instructions 341
Label Replacement 342
Battery Compartment 344
Battery Roller Option 345
Remove 345
Install 345
524167548-2000YRM1025-(02-2018)-US-EN 349
General 353
Description of Operation 353
Hydraulic Oil 354
Clean 354
Sound Level 354
Special Precautions 354
Control Valve 355
Hydraulic Reservoir 356
Description 356
Manual Lowering 356
Lift Pump and Motor Repair 358
General 358
Remove Lift Pump and Motor Assembly 359
Disassemble 365
Remove Reservoir 365
Remove Pump Motor 365
Disassemble Pump 365
Assemble 366
Assemble Pump 366
Install Pump Motor 366
Install Reservoir to Pump 366
Install Lift Pump and Motor Assembly 366
Valve Repair 367
Proportional Valve (Lowering) 367
Remove 367
Install 367
Directional Valve 368
Remove 368
Install 368
Lift Valve 369
Remove 369
Install 369
Counterbalance Valve 370
MRW020/030-E 370
Remove 370
Install 371
MCW025/030/040-E 371
Remove 371
Install 372
Relief Valve and Check Valve 372
Remove 372
Install 373
Pilot Operated Check Valve 373
MRW020/030-E 373
Remove 373
Install 373
Selector Valves: Reach, Tilt, and Sideshift 374

and MRW020/030-EMCW025/030/040-E 374
Remove 374
Install 375
Relief Valve Adjustment 375
Bleed Hydraulic System 377
Troubleshooting 377
Hydraulic Diagrams and Schematics 379
524167549-2200YRM1026-(09-2016)-US-EN 401
General 405
Description of Operation 406
Special Precautions 409
Moving a Disabled Lift Truck 410
Electrical System Checks 411
Safety Precautions 411
Repairs 413
Controller, Replace 413
Remove 413
Install 413
Contactor Coil, Check 415
Contactor, Replace 415
Remove 415
Install 415
Key Switch 416
Remove 416
Install 416
Battery Indicator/Hourmeter Display 416
Remove 417
Install 417
Fuses 418
Brake Switch 418
Description 418
Remove 418
Install 419
Control Handle 420
Disassemble 420
Control Handle Card (Old Style) 423
Control Handle Card (New Style) 424
Configure 424
Calibrate 425
Assemble 426
Drive Motor 427
Remove 427
Disassemble 427
Assemble 427
Install 429
Lift Pump Motor 429
Remove 429
Install 429
Troubleshooting 431
General Troubleshooting 431
Hydraulic Troubleshooting 431
Sideshift and Tilt Function Setup (MRW020/030-E and MCW025/030/040E) 442
524167551-8000YRM1027-(12-2018)-US-EN 447
General 451
How to Move a Disabled Lift Truck 451
How to Tow a Lift Truck 451
How to Put The Lift Truck on Blocks 453
How to Raise the Drive/Steer Tire 453
How to Raise the Load Wheels (MSW030/040-E and MRW020/030-E) 454
How to Raise the Load Wheels (MCW025/030/040-E) 455
Attachments 455
Safety Procedures When Working Near Mast 455
Maintenance Schedule 457
Maintenance Procedures Every 8 Hours or Daily 463
Checks Before Operation 463
How to Make Checks With Key Switch OFF 464
Safety Labels 464
Battery 464
Brake 465
Tires and Wheels 465
Mast, Forks, and Lift Chains 465
Reach Mechanism (MRW020/030-E) 468
Control Handle 468
Hydraulic System 468
How to Make Checks With Key Switch ON 469
Check for Leaks in Lift System 469
Control Buttons 469
Direction/Speed Control and Switches 469
Gauges, Horn, Fuses 469
Maintenance Procedures Every 350 Hours or Every 2 Months 470
Fittings Lubrication 470
Lift Chain Adjustments 471
Drive Wheel 472
Brake 473
Hydraulic System 473
Hydraulic Hoses and Fittings 473
Fluid Level 473
Hydraulic Reservoir Breather 473
Master Drive Unit 473
Check Oil Level 473
Traction and Pump Motor Brushes 474
Contactor 476
Maintenance Procedures Every 2000 Hours or Yearly 476
Forks Check 476
Hydraulic Oil Change 478
Load Wheel Bearings ()MCW025/030/040-E 479
Remove 479
Install 482
Master Drive Unit 482
Drive Unit Gear Oil 482
Welding Repairs 482
General Repairs 483
Load Wheels (MSW040-E and MRW020-030-E) 483
Remove 483
Install 484
Lift Cylinder Leak Test 485
Battery Maintenance 485
How to Charge the Battery 485
Normal Charge 486
Equalizing Charge 487
How to Change the Battery 487
Standard Battery Spacer Adjustment 487
Changing the Battery With an Overhead Crane 487
Remove 488
Install 488
Changing Battery With Rollers 489
Remove 489
Install 490
524167552-8000YRM1028-(09-2016)-US-EN 493
Lift and Hydraulic System Specifications 497
Hydraulic Tank Capacity 497
Hydraulic Oils 497
Master Drive Unit Specifications 498
Gear Oils 498
Grease 499
Tire Specifications 499
Torque Specifications 499
Master Drive Unit 499
Brake 499
Steering 499
Mast 500
Truck Weight 500
Travel Speeds 500
Battery Specifications 502
524167553-8000YRM1029-(02-2018)-US-EN 505
524185045-2200YRM1064-(08-2016)-US-EN 553
General 557
Description 558
ZAPI™ Transistor Motor Controller 558
Principles of Operation 558
Controller Safety 559
Controller Adjustments 559
Modes of Operation 560
User-Selectable Operating Modes 560
Programming 561
Custom Performance Mode 561
Controller Parameters 561
Setting Drive Modes 561
Tester Menu 563
Set Option Menu 563
ZAPI™ Handset 564
Alarm Code Diagnostics 567
Alarm Code Diagnostic Procedure 568
Troubleshooting 570
Auxiliary Hydraulics (MSW030/040-E, MRW020/030-E, MCW025/030/040-E) 594
Control Card Functional Test 599
Traction Motor Test 600
ZAPI™ PC Interface 602
Connecting PC to ZAPI™ Controller 602
File Menu 606
Open File 606
TX From File 608
Save File 610
Print Settings 612
Exit 613
Connection Menu 614
Function Menu 614
Parameter 614
Memory Menu 619
Set Options 620
Tester 622
Data Logger 624
Alarm Logbook 627
Alarms 629
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) 629
Repair 630
Remove 630
Brass Stud Replacement 630
Remove 630
Install 630
Install 630
Repair 631
Sideshift Setup With Auxiliary (MRW020/030-E) 631

S.V 06/24