Yale Forklift C821 (MRW020-030E) Service Manual – PDF DOWNLOAD

Description

Yale Forklift C821 (MRW020-030E) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift C821 (MRW020-030E) Service Manual – PDF DOWNLOAD

Language : English
Pages : 674
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift C821 (MRW020-030E) 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
524164474-4500YRM0971-(05-2018)-US-EN 225
General 229
Safety Procedures When Working Near Mast 229
Description 231
Reach Assemblies 231
Repair – General 233
Load Backrest Removal and Installation 233
Fork Replacement 234
Hook Forks 234
General 234
Remove 234
Install 235
Forks Check 235
Reach Assembly Removal and Installation 237
Carriage Load Rollers Removal and Installation 237
Side Rollers Disassembly and Assembly 239
Reach Assembly Repair 239
Reach Assembly Outer Frame 239
Remove 239
Disassemble 242
Clean and Inspect 243
Assemble 243
Install 243
Remove Without Sideshifter 243
Disassemble Without Sideshifter 244
Clean and Inspect 244
Assemble Without Sideshifter 245
Install Without Sideshifter 245
Single-Reach Scissor Arms 246
Remove and Disassemble 246
Clean and Inspect 249
Assemble and Install 249
Double-Reach Scissor Arms 250
Remove and Disassemble 250
Clean and Inspect 254
Assemble and Install 254

Frame AssemblyInner 255
Remove 257
Disassemble 258
Clean and Inspect 259
Assemble 259
Install 260
Reach Cylinders 261
Remove 261
Disassemble 262
Clean and Inspect 262
Assemble 263
Install 263
Tilt Cylinder 263
Remove 263
Clean, Inspect, and Repair 264
Install 265
Sideshift Cylinder 266
Remove 266
Clean and Inspect 266
Reach/Tilt Selector Valve 266
Remove 266
Disassemble 266
Clean and Inspect 267
Assemble 267
Install 267

Reach Assembly AdjustmentsCarriage or 267
Adjust Wear Plug 267
Adjust Side Rollers 269
Adjust Thrust Rollers 270
Adjust Reach Cylinders 270
Specifications 271
Troubleshooting 274
(NDR030GB, NR045GB, NDR030AE,NR035/040/045AE, NDR030CB, NR045CB and NS040/050AF) 274
(MRW020/030-E) 275
524164715-0630YRM0961-(03-2022)-US-EN 279
General 287
Check Oil Level 288
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 289
Drive Tire 289
Remove 289
Install 289
Master Drive Unit 290
Remove 290
Disassemble 297
Remove Drive Axle Group 297
Remove Upper Housing Group 298
Remove Pinion Group 298
Install 300
Troubleshooting 302
524164715-0630YRM0961-(12-2018)-US-EN 305
General 313
Check Oil Level 314
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 315
Drive Tire 315
Remove 315
Install 315
Master Drive Unit 315
Remove 315
Disassemble 322
Remove Drive Axle Group 322
Remove Upper Housing Group 322
Remove Pinion Group 322
Install 325
Troubleshooting 327
524164716-1600YRM0962-(08-2016)-US-EN 331
General 335
Special Precautions 335
Control Handle Head 336
Control Handle (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 337
Remove 337
Install 339
Control Handle (MPE060/080-E) 340
Remove (Handle) 340
Steer Bearings and Support 341
Disassemble 341
Repair 341
Assemble 341
Install (Handle) 343
Gas Spring 344
Discharging the Gas Spring 344
Remove (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 345
Remove (MPE060/080-E) 345
Install (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 345
Install (MPE060/080-E) 345

Steering and Dash Assembly (Complete)
346
Remove 346
Install 346
Troubleshooting 348
524164717-1800YRM0963-(08-2016)-US-EN 351
General 355
Description 355
Special Precautions 358
Brake Check 359
Hold On Grade Test 359
Brake Coil Check 360
Brake Assembly Repair 360

MPW060-E and MPE060-E (Up to 10/2001)
360
Remove 360
Install 361

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
363
Remove 363
Install 365
Brake Assembly Adjustment 365
Air Gap, Adjust 365
Torque Nut, Adjust 366
Adjust 367

MPW060-E, MPW080-E, and MPE060-E Equipped With Brake Assembly Part Number 524144871 367

MPW060-E, MPW080-E, MPE060-E, and All Other Models Covered by This Section Equipped With Brake Assembly Part Number 524169212 367
Troubleshooting 368
524167547-0100YRM1024-(08-2016)-US-EN 373
General 377
Features (MSW030/040-E and MRW020/030-E) 377
Features (MCW025/030/040-E) 379
Frame Repair 380
Painting Instructions 381
Label Replacement 382
Battery Compartment 384
Battery Roller Option 385
Remove 385
Install 385
524167548-2000YRM1025-(02-2018)-US-EN 389
General 393
Description of Operation 393
Hydraulic Oil 394
Clean 394
Sound Level 394
Special Precautions 394
Control Valve 395
Hydraulic Reservoir 396
Description 396
Manual Lowering 396
Lift Pump and Motor Repair 398
General 398
Remove Lift Pump and Motor Assembly 399
Disassemble 405
Remove Reservoir 405
Remove Pump Motor 405
Disassemble Pump 405
Assemble 406
Assemble Pump 406
Install Pump Motor 406
Install Reservoir to Pump 406
Install Lift Pump and Motor Assembly 406
Valve Repair 407
Proportional Valve (Lowering) 407
Remove 407
Install 407
Directional Valve 408
Remove 408
Install 408
Lift Valve 409
Remove 409
Install 409
Counterbalance Valve 410
MRW020/030-E 410
Remove 410
Install 411
MCW025/030/040-E 411
Remove 411
Install 412
Relief Valve and Check Valve 412
Remove 412
Install 413
Pilot Operated Check Valve 413
MRW020/030-E 413
Remove 413
Install 413
Selector Valves: Reach, Tilt, and Sideshift 414

and MRW020/030-EMCW025/030/040-E 414
Remove 414
Install 415
Relief Valve Adjustment 415
Bleed Hydraulic System 417
Troubleshooting 417
Hydraulic Diagrams and Schematics 419
524167549-2200YRM1026-(09-2016)-US-EN 441
General 445
Description of Operation 446
Special Precautions 449
Moving a Disabled Lift Truck 450
Electrical System Checks 451
Safety Precautions 451
Repairs 453
Controller, Replace 453
Remove 453
Install 453
Contactor Coil, Check 455
Contactor, Replace 455
Remove 455
Install 455
Key Switch 456
Remove 456
Install 456
Battery Indicator/Hourmeter Display 456
Remove 457
Install 457
Fuses 458
Brake Switch 458
Description 458
Remove 458
Install 459
Control Handle 460
Disassemble 460
Control Handle Card (Old Style) 463
Control Handle Card (New Style) 464
Configure 464
Calibrate 465
Assemble 466
Drive Motor 467
Remove 467
Disassemble 467
Assemble 467
Install 469
Lift Pump Motor 469
Remove 469
Install 469
Troubleshooting 471
General Troubleshooting 471
Hydraulic Troubleshooting 471
Sideshift and Tilt Function Setup (MRW020/030-E and MCW025/030/040E) 482
524167551-8000YRM1027-(12-2018)-US-EN 487
General 491
How to Move a Disabled Lift Truck 491
How to Tow a Lift Truck 491
How to Put The Lift Truck on Blocks 493
How to Raise the Drive/Steer Tire 493
How to Raise the Load Wheels (MSW030/040-E and MRW020/030-E) 494
How to Raise the Load Wheels (MCW025/030/040-E) 495
Attachments 495
Safety Procedures When Working Near Mast 495
Maintenance Schedule 497
Maintenance Procedures Every 8 Hours or Daily 503
Checks Before Operation 503
How to Make Checks With Key Switch OFF 504
Safety Labels 504
Battery 504
Brake 505
Tires and Wheels 505
Mast, Forks, and Lift Chains 505
Reach Mechanism (MRW020/030-E) 508
Control Handle 508
Hydraulic System 508
How to Make Checks With Key Switch ON 509
Check for Leaks in Lift System 509
Control Buttons 509
Direction/Speed Control and Switches 509
Gauges, Horn, Fuses 509
Maintenance Procedures Every 350 Hours or Every 2 Months 510
Fittings Lubrication 510
Lift Chain Adjustments 511
Drive Wheel 512
Brake 513
Hydraulic System 513
Hydraulic Hoses and Fittings 513
Fluid Level 513
Hydraulic Reservoir Breather 513
Master Drive Unit 513
Check Oil Level 513
Traction and Pump Motor Brushes 514
Contactor 516
Maintenance Procedures Every 2000 Hours or Yearly 516
Forks Check 516
Hydraulic Oil Change 518
Load Wheel Bearings ()MCW025/030/040-E 519
Remove 519
Install 522
Master Drive Unit 522
Drive Unit Gear Oil 522
Welding Repairs 522
General Repairs 523
Load Wheels (MSW040-E and MRW020-030-E) 523
Remove 523
Install 524
Lift Cylinder Leak Test 525
Battery Maintenance 525
How to Charge the Battery 525
Normal Charge 526
Equalizing Charge 527
How to Change the Battery 527
Standard Battery Spacer Adjustment 527
Changing the Battery With an Overhead Crane 527
Remove 528
Install 528
Changing Battery With Rollers 529
Remove 529
Install 530
524167552-8000YRM1028-(09-2016)-US-EN 533
Lift and Hydraulic System Specifications 537
Hydraulic Tank Capacity 537
Hydraulic Oils 537
Master Drive Unit Specifications 538
Gear Oils 538
Grease 539
Tire Specifications 539
Torque Specifications 539
Master Drive Unit 539
Brake 539
Steering 539
Mast 540
Truck Weight 540
Travel Speeds 540
Battery Specifications 542
524167553-8000YRM1029-(02-2018)-US-EN 545
524185045-2200YRM1064-(08-2016)-US-EN 593
General 597
Description 598
ZAPI™ Transistor Motor Controller 598
Principles of Operation 598
Controller Safety 599
Controller Adjustments 599
Modes of Operation 600
User-Selectable Operating Modes 600
Programming 601
Custom Performance Mode 601
Controller Parameters 601
Setting Drive Modes 601
Tester Menu 603
Set Option Menu 603
ZAPI™ Handset 604
Alarm Code Diagnostics 607
Alarm Code Diagnostic Procedure 608
Troubleshooting 610
Auxiliary Hydraulics (MSW030/040-E, MRW020/030-E, MCW025/030/040-E) 634
Control Card Functional Test 639
Traction Motor Test 640
ZAPI™ PC Interface 642
Connecting PC to ZAPI™ Controller 642
File Menu 646
Open File 646
TX From File 648
Save File 650
Print Settings 652
Exit 653
Connection Menu 654
Function Menu 654
Parameter 654
Memory Menu 659
Set Options 660
Tester 662
Data Logger 664
Alarm Logbook 667
Alarms 669
Programming Tilt and Sideshift on the ZAPI Controller (Laptop) 669
Repair 670
Remove 670
Brass Stud Replacement 670
Remove 670
Install 670
Install 670
Repair 671
Sideshift Setup With Auxiliary (MRW020/030-E) 671

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