Yale Forklift MPB040E [B827] MPW045E [B802] Maintenance Manual PDF

Description

Yale Forklift MPB040E [B827] MPW045E [B802] Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift MPB040E [B827] MPW045E [B802] Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 288
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift MPB040E [B827] MPW045E [B802] Maintenance Manual – PDF DOWNLOAD

toc 1
Capacities and Specifications 1
Safety Precautions Maintenance and Repair 2
Gear Oils 5
Grease 5
Hydraulic System 6
Weight 6
Basic Truck Without Battery 6
Tires 7
Torque Specifications 7
Caster Assembly 7
Master Drive Unit 7
Steering 7
Brake 7
Lift Mechanism 7
Battery Specifications and Adjustments 8
4000 LB – 24 Volt 8
4500 LB – 24 Volt 9
4500 LB – 12 Volt 9
toc 13
DC Motor Maintenance 13
Safety Precautions Maintenance and Repair 14
General 17
Brush and Commutator Inspection 17
Hydraulic Pump Motor and Traction Motor 17
Steering Pump Motor 20
Normal Commutator Surface 20
Commutator Problems 20
Brush Replacement 24
Stoning the Commutator 26
Motors Repair 28
Disassemble 28
Traction Motor and Hydraulic Pump Motor 28
Steering Pump Motor 32
Assemble 32
Traction Motor and Hydraulic Pump Motor 32
Steering Pump Motor 33
Brush Alignment, Traction and Hydraulic Motors 36
Tests for Damaged Field and Armature 36
Test for an Open Circuit in Armature 36
Test for Short Circuit in One Armature Winding 37
Test for Short Circuit to Armature Shaft 37
Test for Open Circuit in Field Coil 37
Test for Short Circuit in Field Coil 37
Test for Short Circuit between Field and Motor Case 38
Brush Holder Test 38
Troubleshooting 38
tables 13
Table 1 Normal Commutator Surfaces 19
Table 2 Commutator Problems 20
Table 3 Brush Wear Replacement Guide 24
toc 43
Diagrams 43
Safety Precautions Maintenance and Repair 44
General Notes 47
B802 and B827 47
toc 63
Electrical System 63
Safety Precautions Maintenance and Repair 64
General 67
Description of Operation 68
Special Precautions 70
Moving a Disabled Lift Truck 71
Electrical System Checks 72
Safety Precautions 72
Repairs 73
Controller, Replace 73
Remove 73
Install 76
Contactor Coil, Check 76
Contactor, Replace 76
Remove 76
Install 77
Key Switch Removal and Installation 77
Remove 77
Install 77
Battery Indicator/Hourmeter Display 77
Remove 77
Install 78
Fuses 78
MPB040-E 78
MPW045-E 78
MSW020/025-E 78
Control Handle Arm Proximity Switch 78
Repair 78
Check and Adjust 78
Remove 79
Install 80
Control Handle 80
Disassemble 80
Calibrate New Control Handle Card 82
Assemble 83
Switches (ON/OFF and Proportional) 83
Remove 83
Install 84
Traction Motor 84
Disassemble 84
Assemble 85
Lift Pump Motor 86
Repair ( MSW020/025-E ) 86
Battery Charger 87
Description 87
Operation 87
Charging 87
Equalize 87
Signals 87
Protections 87
Troubleshooting 87
Troubleshooting 89
tables 63
Table 1 Contactor Coil Resistance Values 76
toc 93
Frame 93
Safety Precautions Maintenance and Repair 94
General 97
Description 97
MPB040-E and MPW045-E 97
Frame 98
Repairs 98
Features MPB040-E and MPW045-E 98
Frame Separation and Assembly 98
Frame Separation – MPB040-E and MPW045-E 98
Frame Assembly – MPB040-E and MPW045-E 99
Battery Compartment 99
Battery Compartment Specifications 99
Changing the Battery 99
Remove 100
Install 100
Battery Spacer Adjustment 100
Label Replacement 102
Painting Instructions 103
Load Wheels 103
MPB040-E and MPW045-E 103
Remove 103
Install 104
toc 107
Walkie Hydraulic Systems 107
Safety Precautions Maintenance and Repair 108
General 111
Operation 111
Lifting a Load 111
Lowering a Load 111
Hydraulic Lines 112
Hydraulic Oil 112
Cleanliness 113
Sound Level 114
Hydraulic Unit 114
Remove 114
Special Precautions 115
Install 115
Hydraulic Pump 116
Remove 116
Install 116
Hydraulic Pump Reservoir 118
Remove 118
Install 118
Hydraulic Cylinder 119
Remove 119
Repacking 120
Install 120
Relief Valve Adjustment 121
Troubleshooting 123
Lift Assemblies 123
Hydraulic Cylinders 123
Hydraulic Pump 124
toc 129
Industrial Battery 129
Safety Precautions Maintenance and Repair 130
General 133
Lead-Acid Batteries 133
Specific Gravity 134
Chemical Reaction in a Cell 134
Electrical Terms 135
Battery Selection 136
Battery Voltage 137
Battery as a Counterweight 137
Battery Ratings 137
Kilowatt-Hours 137
Battery Maintenance 138
Safety Procedures 138
Maintenance Records 138
New Battery 138
Cleaning Battery 139
Adding Water to Battery 140
Hydrometer 140
Battery Temperature 141
Charging Battery 142
Types of Battery Charges 143
Methods of Charging 144
Troubleshooting Charger 144
Knowing When Battery Is Fully Charged 145
Where to Charge Batteries 145
Equipment Needed 145
Battery Connectors 145
Battery Care 146
tables 129
Table 1 Battery Capacity Terms 137
toc 151
Lifting Mechanism 151
Safety Precautions Maintenance and Repair 152
General 155
Lift Linkage 155
Load Wheel 156
Remove 156
Install 157
Rear Link and Load Wheel 157
Remove 157
Install 157
Compression Rod 158
Remove 158
Install 158
Lower Link 158
Remove 158
Install 159
Upper Link 160
Remove 160
Install 160
Caster Wheels (Optional) 161
Remove 161
Install 161
Replace 161
toc 165
Master Drive Unit 165
Safety Precautions Maintenance and Repair 166
General 169
Description 169
Special Precautions 169
Master Drive Unit Repair 171
Remove 171
Disassemble 173
Repair 174
Assemble 174
Install 174
Troubleshooting 175
toc 179
Periodic Maintenance 179
Safety Precautions Maintenance and Repair 180
General 183
How to Move a Disabled Truck 183
How to Tow the Lift Truck 184
How to Put a Lift Truck on Blocks 184
How to Raise Drive/Steer Tire 184
How to Raise Load Wheels 185
Welding Repairs 185
Battery Maintenance 186
How to Charge the Battery 186
Equalizing Charge 186
Normal Charge 186
Maintenance Free Battery Charger 187
Battery Charger ( MPB040E only) 187
How to Change the Battery 187
Maintenance Schedule 188
Checks and Inspection Procedures 188
Hydraulic System 188
Lifting Mechanism 189
Controls 190
Electrical and Battery 190
Wheels and Tires 191
Recommended Schedule of Maintenance 191
Lubrication Instructions 197
Every 8 Hours or Daily 197
Every 350 Hours or 6 Months 197
Check Hydraulic Oil Level 197
Every 2000 Hours or 2 Years 197
To Fill Hydraulic Tank 197
tables 179
Table 1 Specific Gravity Corrections 186
toc 203
Steering Mechanism 203
Safety Precautions Maintenance and Repair 204
General 207
Special Precautions 207
Control Handle Head 208
Control Handle 208
Remove 208
Install 209
Troubleshooting 211
toc 215
ZAPI™ Controllers 215
Safety Precautions Maintenance and Repair 216
General 219
Description 219
ZAPI™ Transistor Motor Controller 219
Principles of Operation 220
Controller Safety 220
Controller Adjustments 221
Modes of Operation 221
User-Selectable Operating Modes 221
Programming 222
Custom Performance Mode 222
Controller Parameters 222
Tester Menu 223
Set Option Menu 223
ZAPI™ Handset 224
Troubleshooting 228
ZAPI™ PC Interface 246
Connecting PC to ZAPI™ Controller 246
File Menu 249
Open File 249
TX From File 250
Save File 252
Print Settings 254
Exit 255
Connection Menu 256
Function Menu 256
Parameter 256
Memory Menu 261
Set Options 262
Tester 264
Data Logger 266
Alarm Logbook 268
Alarms 269
Repair 269
Remove 269
Install 270
Repair 270
tables 215
Table 1 Parameters 222
toc 273
Brakes 273
Safety Precautions Maintenance and Repair 274
General 277
Description 278
Special Precautions 279
Brake Assembly Repair 280
Brake Override 280
Remove 281
Repair 283
Install 283
Troubleshooting 285

S.V 07/24