Yale Forklift MSW020/025-E [A895] Maintenance Manual – PDF DOWNLOAD
FILE DETAILS:
Yale Forklift MSW020/025-E [A895] Maintenance Manual – PDF DOWNLOAD
Language : English
Pages : 322
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Yale Forklift MSW020/025-E [A895] Maintenance Manual – PDF DOWNLOAD
toc 1
Capacities and Specifications 1
Safety Precautions Maintenance and Repair 2
Lift and Hydraulic System Specifications 5
Master Drive Unit Specifications 5
Tire Specifications 5
Torque Specifications 6
Master Drive Unit 6
Brake 6
Steering 6
Mast 6
Frame 6
Travel Speeds 6
Truck Weight 6
Battery Specifications 7
toc 11
DC Motor Maintenance 11
Safety Precautions Maintenance and Repair 12
General 15
Brush and Commutator Inspection 15
Hydraulic Pump Motor and Traction Motor 15
Steering Pump Motor 18
Normal Commutator Surface 18
Commutator Problems 18
Brush Replacement 22
Stoning the Commutator 24
Motors Repair 26
Disassemble 26
Traction Motor and Hydraulic Pump Motor 26
Steering Pump Motor 30
Assemble 30
Traction Motor and Hydraulic Pump Motor 30
Steering Pump Motor 31
Brush Alignment, Traction and Hydraulic Motors 34
Tests for Damaged Field and Armature 34
Test for an Open Circuit in Armature 34
Test for Short Circuit in One Armature Winding 35
Test for Short Circuit to Armature Shaft 35
Test for Open Circuit in Field Coil 35
Test for Short Circuit in Field Coil 35
Test for Short Circuit between Field and Motor Case 36
Brush Holder Test 36
Troubleshooting 36
tables 11
Table 1 Normal Commutator Surfaces 17
Table 2 Commutator Problems 18
Table 3 Brush Wear Replacement Guide 22
toc 41
Diagrams 41
Safety Precautions Maintenance and Repair 42
toc 53
Electrical System 53
Safety Precautions Maintenance and Repair 54
General 57
Description of Operation 58
Special Precautions 60
Moving a Disabled Lift Truck 61
Electrical System Checks 62
Safety Precautions 62
Repairs 63
Controller, Replace 63
Remove 63
Install 66
Contactor Coil, Check 66
Contactor, Replace 66
Remove 66
Install 67
Key Switch Removal and Installation 67
Remove 67
Install 67
Battery Indicator/Hourmeter Display 67
Remove 67
Install 68
Fuses 68
MPB040-E 68
MPW045-E 68
MSW020/025-E 68
Control Handle Arm Proximity Switch 68
Repair 68
Check and Adjust 68
Remove 69
Install 70
Control Handle 70
Disassemble 70
Calibrate New Control Handle Card 72
Assemble 73
Switches (ON/OFF and Proportional) 73
Remove 73
Install 74
Traction Motor 74
Disassemble 74
Assemble 75
Lift Pump Motor 76
Repair ( MSW020/025-E ) 76
Battery Charger 77
Description 77
Operation 77
Charging 77
Equalize 77
Signals 77
Protections 77
Troubleshooting 77
Troubleshooting 79
tables 53
Table 1 Contactor Coil Resistance Values 66
toc 83
Frame 83
Safety Precautions Maintenance and Repair 84
General 87
Description 87
Features 87
Frame Repair 88
Base Arms 88
Base Arms 88
Remove 88
Install 89
Adjust 90
Painting Instructions 90
Label Replacement 90
Battery Compartment 91
tables 83
Table 1 Base Arm Width 88
toc 95
Industrial Battery 95
Safety Precautions Maintenance and Repair 96
General 99
Lead-Acid Batteries 99
Specific Gravity 100
Chemical Reaction in a Cell 100
Electrical Terms 101
Battery Selection 102
Battery Voltage 103
Battery as a Counterweight 103
Battery Ratings 103
Kilowatt-Hours 103
Battery Maintenance 104
Safety Procedures 104
Maintenance Records 104
New Battery 104
Cleaning Battery 105
Adding Water to Battery 106
Hydrometer 106
Battery Temperature 107
Charging Battery 108
Types of Battery Charges 109
Methods of Charging 110
Troubleshooting Charger 110
Knowing When Battery Is Fully Charged 111
Where to Charge Batteries 111
Equipment Needed 111
Battery Connectors 111
Battery Care 112
tables 95
Table 1 Battery Capacity Terms 103
toc 117
Lift Cylinders 117
Safety Precautions Maintenance and Repair 118
General 121
Safety Procedures When Working Near Mast 121
Safety Chain the Mast 121
Blocking the Mast 122
Description 122
Lift Cylinders 122
Flow Control Valve 122
Lift System Check 123
Leak Test 123
Lift Cylinder Repair 124
Remove 124
Disassemble 125
Repair 125
Assemble 127
Install 127
Troubleshooting 128
toc 131
Mast Description 131
Safety Precautions Maintenance and Repair 132
General 135
Mast Weldments 135
Carriage 136
Mast Assembly 137
Mast Mounts 137
toc 143
Mast Repairs 143
Safety Precautions Maintenance and Repair 144
General 147
Safety Procedures When Working Near Mast 147
Mast Repair 148
Remove 148
Disassemble 149
Assemble 151
Install 153
Carriage Repair 154
Remove 154
Disassemble 155
Assemble 155
Install 155
Fork Repair 156
Check 156
Remove 157
Install 157
Lift Chain Adjustment 158
Inspect 158
Adjust 158
Wear Strips Adjustment 159
toc 163
Master Drive Unit 163
Safety Precautions Maintenance and Repair 164
General 167
Description 167
Special Precautions 167
Master Drive Unit Repair 169
Remove 169
Disassemble 171
Repair 172
Assemble 172
Install 172
Troubleshooting 173
toc 177
Periodic Maintenance 177
Safety Precautions Maintenance and Repair 178
General 181
How to Move a Disabled Lift Truck 181
How to Tow Lift Truck 181
How to Put The Lift Truck on Blocks 183
How to Raise Drive/Steer Tire 183
How to Raise Load Wheels 183
Special Precautions 184
Discharging the Capacitor 184
Maintenance Schedule 185
Safety Procedures When Working Near Mast 188
Maintenance Procedures Every 8 Hours or Daily 189
Checks Before Operation 189
How to Make Checks With Key Switch OFF 189
Safety Labels 189
Battery 189
Brake 190
Tires and Wheels 190
Mast, Forks, and Lift Chains 191
Control Handle 193
Hydraulic System 193
How to Make Checks With Key Switch ON 193
Check for Leaks in Lift System 193
Control Buttons 194
Direction/Speed Control and Switches 194
Gauges, Horn, Fuses 194
Maintenance Procedures Every 350 Hours or Every 2 Months 195
Fittings Lubrication 195
Other Lubrication 195
Base Arm Capscrews 195
Battery 195
Brake 195
Lift Chain Adjustments 195
Drive Wheel 197
Master Drive Unit 197
Traction and Pump Motor Brushes 197
Contactor 199
Maintenance Procedures Every 2000 Hours or Yearly 199
Load Wheels 199
Hydraulic Oil Change 199
How to Change Drive Unit Oil 201
Welding Repairs 201
General Repairs 202
Load Wheels 202
Remove 202
Install 202
Lift Cylinder Leak Test 203
Battery Maintenance 203
How to Charge Battery 203
Normal Charge 204
Equalizing Charge 204
Industrial Battery Charging 204
Battery Pack Charging 204
Battery Spacer Adjustment 204
How to Change Battery 206
Changing Battery With Overhead Crane 206
Remove 206
Install 206
tables 177
Table 1 Maintenance Schedule 186
Table 2 Fuse Ratings 194
toc 211
Steering Mechanism 211
Safety Precautions Maintenance and Repair 212
General 215
Special Precautions 215
Control Handle Head 216
Control Handle 216
Remove 216
Install 217
Troubleshooting 219
toc 223
Walkie High Lift Hydraulic System 223
Safety Precautions Maintenance and Repair 224
General 227
Description of Operation 227
Hydraulic Oil 227
Clean 227
Sound Level 227
Special Precautions 228
Control Valve 228
Hydraulic Reservoir 228
Description 228
Manual Lowering 229
Lift Pump and Motor 230
General 230
Remove Lift Pump and Motor Assembly 230
Disassemble 230
Remove Reservoir 230
Remove Pump Motor 231
Disassemble Pump 231
Assemble 231
Assemble Pump 231
Install Pump Motor 231
Install Reservoir to Pump 233
Install Lift Pump and Motor Assembly 233
Valve Repair 235
Proportional Valve (Lowering) 235
Remove 235
Install 235
Relief Valve and Check Valve 236
Remove 236
Install 236
Relief Valve Adjustment 237
Bleed Hydraulic System 238
Troubleshooting 238
Hydraulic Schematic 240
toc 243
ZAPI™ Controllers 243
Safety Precautions Maintenance and Repair 244
General 247
Description 247
ZAPI™ Transistor Motor Controller 247
Principles of Operation 248
Controller Safety 248
Controller Adjustments 249
Modes of Operation 249
User-Selectable Operating Modes 249
Programming 250
Custom Performance Mode 250
Controller Parameters 250
Tester Menu 250
Set Option Menu 252
ZAPI™ Handset 252
Troubleshooting 256
Auxiliary Hydraulics (MSW030/040-E, MRW020/030-E, MCW025/030/040 275
ZAPI™ PC Interface 276
Connecting PC to ZAPI™ Controller 276
File Menu 279
Open File 279
TX From File 280
Save File 282
Print Settings 284
Exit 285
Connection Menu 286
Function Menu 286
Parameter 286
Memory Menu 291
Set Options 292
Tester 294
Data Logger 296
Alarm Logbook 300
Alarms 301
Repair 302
Remove 302
Install 302
Repair 302
Sideshift Setup With Auxiliary (MRW020/030-E) 302
tables 243
Table 1 Parameters 251
toc 307
Brakes 307
Safety Precautions Maintenance and Repair 308
General 311
Description 312
Special Precautions 313
Brake Assembly Repair 314
Brake Override 314
Remove 315
Repair 317
Install 317
Troubleshooting 319
S.V 07/24
