Yale Forklift C820 (MSW030-040E) Service Manual – PDF DOWNLOAD

Description

Yale Forklift C820 (MSW030-040E) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift C820 (MSW030-040E) Service Manual – PDF DOWNLOAD

Language : English
Pages : 620
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift C820 (MSW030-040E) 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
524158039-0620YRM0294-(09-2016)-US-EN 43
General 47
Brush and Commutator Inspection 48
Hydraulic Pump Motor and Traction Motor 48
Steering Pump Motor 51
Normal Commutator Surface 51
Commutator Problems 51
Brush Replacement 56
Stoning the Commutator 59
Motors Repair 60
Disassemble 61
Traction Motor and Hydraulic Pump Motor 61
Steering Pump Motor 62
Assemble 66
Traction Motor and Hydraulic Pump Motor 66
Steering Pump Motor 68
Brush Alignment, Traction and Hydraulic Motors 70
Tests for Damaged Field and Armature 71
Test for an Open Circuit in One Armature Winding 71
Test for Short Circuit in One Armature Winding 71
Test for Short Circuit to Armature Shaft 72
Test for Open Circuit in Field Coil 72
Test for Short Circuit in Field Coil 73
Test for Short Circuit Between Field and Motor Case 73
Brush Holder Test 73
Troubleshooting 74
524158040-2240YRM0001-(01-2023)-US-EN 79
General 85
Battery Type 85
Lead-Acid Batteries 85
Lithium-Ion Batteries 86
Specific Gravity 86
Chemical Reaction in a Cell 86
Electrical Terms 88
Battery Selection 89
Battery Voltage 90
Battery as a Counterweight 90
Battery Ratings 90
Kilowatt-Hours 90
Battery Maintenance 91
Safety Procedures 91
Maintenance Records 91
New Battery 91
Cleaning Battery 92
Adding Water to Battery 94
Hydrometer 94
Battery Temperature 95
Charging Battery 96
Types of Battery Charges 97
Methods of Charging 98
Troubleshooting Charger 99
Knowing When Battery Is Fully Charged 99
Where to Charge Batteries 99
Equipment Needed 99
Battery Connectors 100
Battery Care 100
Troubleshooting 102
524158040-2240YRM0001-(03-2020)-US-EN 107
General 111
Battery Type 111
Lead-Acid Batteries 111
Lithium-Ion Batteries 112
Specific Gravity 112
Chemical Reaction in a Cell 112
Electrical Terms 114
Battery Selection 114
Battery Voltage 115
Battery as a Counterweight 116
Battery Ratings 116
Kilowatt-Hours 116
Battery Maintenance 116
Safety Procedures 116
Maintenance Records 117
New Battery 117
Cleaning Battery 117
Adding Water to Battery 119
Hydrometer 120
Battery Temperature 121
Charging Battery 122
Types of Battery Charges 122
Methods of Charging 124
Troubleshooting Charger 124
Knowing When Battery Is Fully Charged 125
Where to Charge Batteries 125
Equipment Needed 125
Battery Connectors 126
Battery Care 126
Troubleshooting 128
524164470-4000YRM0480-(08-2016)-US-EN 133
General 137
Mast Weldments 139
Carriages 140
Two-Stage Mast 142
Description 143
Operation 148
Three-Stage Mast 149
Description 149
Operation 152
524164471-4000YRM0482-(05-2018)-US-EN 157
General 161
Safety Procedures When Working Near Mast 161
Load Backrest Extension, Carriage, Load Rollers, Side Rollers, and Forks 162
Load Backrest Extension, Remove and Install 163
Carriage Assembly, Remove and Install 163
Carriage Load Rollers, Remove and Install 166
Side Rollers, Disassemble and Assemble 166
Fork, Replace 167
Hook-Type Forks 167
Remove 167
Install 167
Forks Check 167
Two-Stage Mast Assembly 170
Remove 170
Clean and Inspect 175
Lift Cylinders, Remove and Install Dual-Lift Cylinders 176
Lift Cylinder, Remove and Install Single Main-Lift Cylinders 177
Remove 177
Install 178
Inner Mast Assembly, Remove and Install 179
Hoses, Replace 179
Hose and Cable Sheaves, Replace 179
Two-Stage Lift Chains 181
Remove and Install 181
Clean and Inspect 181
Two-Stage Chain Sheave, Remove and Install 182
Load Rollers and Wear Plugs, Remove and Install 182
Two-Stage Mast Assembly, Install 183
Three-Stage Mast Assembly 184
Three-Stage Mast Assembly, Remove 184
Clean and Inspect 185
Free-Lift Cylinder, Remove and Install 188
Main Cylinders (Standard), Remove and Install 189
Inner and Intermediate Mast Assemblies, Remove and Install 191
Hoses, Replace 191
Hose and Cable Sheaves, Replace 193
Free-Lift Hose Sheave 193
Carriage Sheaves 193
Three-Stage Lift Chains, Remove and Install 194
General 194
Free-Lift Chains 194
Main-Lift Chains 194
Three-Stage Chain Sheaves, Disassemble and Assemble 195
Free-Lift Chain Sheaves 195
Main-Lift Chain Sheaves 195
Load Rollers and Wear Plugs, Remove and Install 195
Three-Stage Mast Assemble, Install 196
Mast Operation Check 197
Hydraulic System Leaks Check 197
Lift Chains Check 198
General 198
Clean and Inspect 198
Lubrication 199
Mast Adjustments 199
General 200
Adjust Wear Plugs – Mast 200
Adjust Free-Lift Chain (Three-Stage Only) 202
Adjust Main-Lift Chains 202
Two-Stage 202
Three-Stage 204
Adjust Wear Strips 204
Carriage Adjustments 205
Adjust Wear Plug – Carriage 205
Adjust Side Rollers – Carriage 205
Adjust Thrust Rollers – Carriage 206
Troubleshooting 207
524164473-4000YRM0481-(08-2016)-US-EN 211
General 215
Description 215
Lowering Control Valve 216
Main Cylinder Repair 217
Disassemble 218
Assemble 219
Free-Lift Cylinder Repair 220
Disassemble 220
Assemble 220
Troubleshooting 222
524164715-0630YRM0961-(03-2022)-US-EN 225
General 233
Check Oil Level 234
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 235
Drive Tire 235
Remove 235
Install 235
Master Drive Unit 236
Remove 236
Disassemble 243
Remove Drive Axle Group 243
Remove Upper Housing Group 244
Remove Pinion Group 244
Install 246
Troubleshooting 248
524164715-0630YRM0961-(12-2018)-US-EN 251
General 259
Check Oil Level 260
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 261
Drive Tire 261
Remove 261
Install 261
Master Drive Unit 261
Remove 261
Disassemble 268
Remove Drive Axle Group 268
Remove Upper Housing Group 268
Remove Pinion Group 268
Install 271
Troubleshooting 273
524164716-1600YRM0962-(08-2016)-US-EN 277
General 281
Special Precautions 281
Control Handle Head 282
Control Handle (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 283
Remove 283
Install 285
Control Handle (MPE060/080-E) 286
Remove (Handle) 286
Steer Bearings and Support 287
Disassemble 287
Repair 287
Assemble 287
Install (Handle) 289
Gas Spring 290
Discharging the Gas Spring 290
Remove (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 291
Remove (MPE060/080-E) 291
Install (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 291
Install (MPE060/080-E) 291

Steering and Dash Assembly (Complete)
292
Remove 292
Install 292
Troubleshooting 294
524164717-1800YRM0963-(08-2016)-US-EN 297
General 301
Description 301
Special Precautions 304
Brake Check 305
Hold On Grade Test 305
Brake Coil Check 306
Brake Assembly Repair 306

MPW060-E and MPE060-E (Up to 10/2001)
306
Remove 306
Install 307

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
309
Remove 309
Install 311
Brake Assembly Adjustment 311
Air Gap, Adjust 311
Torque Nut, Adjust 312
Adjust 313

MPW060-E, MPW080-E, and MPE060-E Equipped With Brake Assembly Part Number 524144871 313

MPW060-E, MPW080-E, MPE060-E, and All Other Models Covered by This Section Equipped With Brake Assembly Part Number 524169212 313
Troubleshooting 314
524167547-0100YRM1024-(08-2016)-US-EN 319
General 323
Features (MSW030/040-E and MRW020/030-E) 323
Features (MCW025/030/040-E) 325
Frame Repair 326
Painting Instructions 327
Label Replacement 328
Battery Compartment 330
Battery Roller Option 331
Remove 331
Install 331
524167548-2000YRM1025-(02-2018)-US-EN 335
General 339
Description of Operation 339
Hydraulic Oil 340
Clean 340
Sound Level 340
Special Precautions 340
Control Valve 341
Hydraulic Reservoir 342
Description 342
Manual Lowering 342
Lift Pump and Motor Repair 344
General 344
Remove Lift Pump and Motor Assembly 345
Disassemble 351
Remove Reservoir 351
Remove Pump Motor 351
Disassemble Pump 351
Assemble 352
Assemble Pump 352
Install Pump Motor 352
Install Reservoir to Pump 352
Install Lift Pump and Motor Assembly 352
Valve Repair 353
Proportional Valve (Lowering) 353
Remove 353
Install 353
Directional Valve 354
Remove 354
Install 354
Lift Valve 355
Remove 355
Install 355
Counterbalance Valve 356
MRW020/030-E 356
Remove 356
Install 357
MCW025/030/040-E 357
Remove 357
Install 358
Relief Valve and Check Valve 358
Remove 358
Install 359
Pilot Operated Check Valve 359
MRW020/030-E 359
Remove 359
Install 359
Selector Valves: Reach, Tilt, and Sideshift 360

and MRW020/030-EMCW025/030/040-E 360
Remove 360
Install 361
Relief Valve Adjustment 361
Bleed Hydraulic System 363
Troubleshooting 363
Hydraulic Diagrams and Schematics 365
524167549-2200YRM1026-(09-2016)-US-EN 387
General 391
Description of Operation 392
Special Precautions 395
Moving a Disabled Lift Truck 396
Electrical System Checks 397
Safety Precautions 397
Repairs 399
Controller, Replace 399
Remove 399
Install 399
Contactor Coil, Check 401
Contactor, Replace 401
Remove 401
Install 401
Key Switch 402
Remove 402
Install 402
Battery Indicator/Hourmeter Display 402
Remove 403
Install 403
Fuses 404
Brake Switch 404
Description 404
Remove 404
Install 405
Control Handle 406
Disassemble 406
Control Handle Card (Old Style) 409
Control Handle Card (New Style) 410
Configure 410
Calibrate 411
Assemble 412
Drive Motor 413
Remove 413
Disassemble 413
Assemble 413
Install 415
Lift Pump Motor 415
Remove 415
Install 415
Troubleshooting 417
General Troubleshooting 417
Hydraulic Troubleshooting 417
Sideshift and Tilt Function Setup (MRW020/030-E and MCW025/030/040E) 428
524167551-8000YRM1027-(12-2018)-US-EN 433
General 437
How to Move a Disabled Lift Truck 437
How to Tow a Lift Truck 437
How to Put The Lift Truck on Blocks 439
How to Raise the Drive/Steer Tire 439
How to Raise the Load Wheels (MSW030/040-E and MRW020/030-E) 440
How to Raise the Load Wheels (MCW025/030/040-E) 441
Attachments 441
Safety Procedures When Working Near Mast 441
Maintenance Schedule 443
Maintenance Procedures Every 8 Hours or Daily 449
Checks Before Operation 449
How to Make Checks With Key Switch OFF 450
Safety Labels 450
Battery 450
Brake 451
Tires and Wheels 451
Mast, Forks, and Lift Chains 451
Reach Mechanism (MRW020/030-E) 454
Control Handle 454
Hydraulic System 454
How to Make Checks With Key Switch ON 455
Check for Leaks in Lift System 455
Control Buttons 455
Direction/Speed Control and Switches 455
Gauges, Horn, Fuses 455
Maintenance Procedures Every 350 Hours or Every 2 Months 456
Fittings Lubrication 456
Lift Chain Adjustments 457
Drive Wheel 458
Brake 459
Hydraulic System 459
Hydraulic Hoses and Fittings 459
Fluid Level 459
Hydraulic Reservoir Breather 459
Master Drive Unit 459
Check Oil Level 459
Traction and Pump Motor Brushes 460
Contactor 462
Maintenance Procedures Every 2000 Hours or Yearly 462
Forks Check 462
Hydraulic Oil Change 464
Load Wheel Bearings ()MCW025/030/040-E 465
Remove 465
Install 468
Master Drive Unit 468
Drive Unit Gear Oil 468
Welding Repairs 468
General Repairs 469
Load Wheels (MSW040-E and MRW020-030-E) 469
Remove 469
Install 470
Lift Cylinder Leak Test 471
Battery Maintenance 471
How to Charge the Battery 471
Normal Charge 472
Equalizing Charge 473
How to Change the Battery 473
Standard Battery Spacer Adjustment 473
Changing the Battery With an Overhead Crane 473
Remove 474
Install 474
Changing Battery With Rollers 475
Remove 475
Install 476
524167552-8000YRM1028-(09-2016)-US-EN 479
Lift and Hydraulic System Specifications 483
Hydraulic Tank Capacity 483
Hydraulic Oils 483
Master Drive Unit Specifications 484
Gear Oils 484
Grease 485
Tire Specifications 485
Torque Specifications 485
Master Drive Unit 485
Brake 485
Steering 485
Mast 486
Truck Weight 486
Travel Speeds 486
Battery Specifications 488
524167553-8000YRM1029-(02-2018)-US-EN 491
524185045-2200YRM1064-(08-2016)-US-EN 539
General 543
Description 544
ZAPI™ Transistor Motor Controller 544
Principles of Operation 544
Controller Safety 545
Controller Adjustments 545
Modes of Operation 546
User-Selectable Operating Modes 546
Programming 547
Custom Performance Mode 547
Controller Parameters 547
Setting Drive Modes 547
Tester Menu 549
Set Option Menu 549
ZAPI™ Handset 550
Alarm Code Diagnostics 553
Alarm Code Diagnostic Procedure 554
Troubleshooting 556
Auxiliary Hydraulics (MSW030/040-E, MRW020/030-E, MCW025/030/040-E) 580
Control Card Functional Test 585
Traction Motor Test 586
ZAPI™ PC Interface 588
Connecting PC to ZAPI™ Controller 588
File Menu 592
Open File 592
TX From File 594
Save File 596
Print Settings 598
Exit 599
Connection Menu 600
Function Menu 600
Parameter 600
Memory Menu 605
Set Options 606
Tester 608
Data Logger 610
Alarm Logbook 613
Alarms 615
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) 615
Repair 616
Remove 616
Brass Stud Replacement 616
Remove 616
Install 616
Install 616
Repair 617
Sideshift Setup With Auxiliary (MRW020/030-E) 617

S.V 06/24