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Yale Pallet Truck: MCW020, MCW040 Workshop Service Manual
Original factory manuals for Yale Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text
Covered models:
MCW020
MCW040
Format: PDF,198 Pages
Language: English
Contents:
1 OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS-GENERAL
SERIAL NUMBER
MODEL CODE
TRUCK WEIGHT
CAPACITY RATING
SAFETY LABELS
OPERATOR PRE-CHECKS AND INSPECTION
OPERATING PROCEDURE-GENERAL
SHUT DOWN PROCEDURE
SAFETY AND OPERATIONAL CHECKLIST
KEY SWITCH
OPERATING CONTROLS-CONTROL HANDLE
REVERSING BUTTON
HORN BUTTON
DIRECTID SPEED CONTROL
BRAKING
STEERING
BATTERY CONNECTOR
BATTERY INDICATOR AND HOURMETER (OPTIONAL)
HYDRAULIC CONTROLS
DESIGNATED OPERATOR POSITION
OPERATING PROCEDURES
SAFE MAINTENANCE PROCEDURES
MOVING A DISABLED LIFT TRUCK
HOW TO PUTA LIFT TRUCK ON BLOCKS
HOW TO RAISE DRIVE TIRE
HOW TO RAISE LOAD WHEELS
PRECAUTIONS FOR TRUCKS IN STORAGE
PRECAUTIONS FOR BATTERIES IN STORAGE
2 GENERAL TRUCK AND LUBRICATION
GENERAL
DRIVE UNIT COMPARTMENT COVER
REMOVAL AND INSTALLATION
HYDRAULIC COMPARTMENT COVER
REMOVAL AND INSTALLATION
BATTERY-REMOVAL AND INSTALLATION
TIRES AND WHEELS
SOLID TIRES
REMOVE TIRE FROM WHEEL
INSTALL THE TIRE ON WHEEL
INSTALL THE WHEELS
DRIVE WHEEL
REMOVAL
INSTALLATION
LOAD WHEEL
REMOVAL
INSTALLATION
LOAD WHEEL BRACKET
REMOVAL
INSTALLATION
YALE WARRANTY INFORMATION
LUBRICATION INSTRUCTIONS-GENERAL
EVERY 8 HOURS
EVERY 350 HOURS
EVERY 2000 HOURS
RECOMMENDED SCHEDULE OF MAINTENANCE
HYDRAULIC OILS
GEAR OILS
GREASE
FASTENERS-INTRODUCTION
THREADS, NOMENCLATURE
STRENGTH IDENTIFICATION
3 ELECTRICAL SYSTEM
ELECTRICAL SYSTEM-GENERAL
CURTIS PMC TRANSISTOR CONTROLLER
PRINCIPLES OF OPERATION
TRANSISTOR MOTOR CONTROLLER
BASIC CONTROLLER OPERATION
FIELD EFFECT TRANSISTOR (FET)
MOTOR CIRCUIT THAT OPERATES WITH PULSES
INDUCTION CURRENT FROM THE MOTOR
PLUGGING
CONTROL CIRCUIT
STATIC-RETURN-TO-OFF (SRO) FUNCTION
THERMAL PROTECTION FUNCTION
LOW VOLTAGE PROTECTION FUNCTION
POWER CIRCUIT
SEQUENCE OF OPERATION-TRACTION CIRCUIT
ELECTRICAL SYSTEM-CHECKS
TROUBLESHOOTING
FAULT PROCEDURES
ADJUSTMENTS
PLUGGING ADJUSTMENT
ACCELERATION ADJUSTMENT
CURRENT LIMITADJUSTMENT
ACCELERATOR POTENTIOMETER ADJUSTMENT
REPAIRS
CONTROLLER REPLACEMENT
CONTACTORS
TESTING CONTACTORS
CONTACTOR REPLACEMENT
CONTACTOR COMPONENT REPLACEMENT
FUSES
RELAYS
BRAKE SWITCH
REMOVAL AND INSTALLATION
STEERING HANDLE SWITCHES
REMOVAL
INSTALLATION
MOTOR MAINTENANCE-GENERAL
BRUSHAND COMMUTATOR INSPECTION
NORMAL COMMUTATOR SERVICE
COMMUTATOR PROBLEMS
BRUSH REPLACEMENT, DRIVEAND
HYDRAULIC MOTORS
DRIVE MOTOR-BRUSH REPLACEMENT
HYDRAULIC PUMP MOTOR-BRUSH REPLACEMENT
DRIVE MOTOR
REMOVAL
INSTALLATION
HYDRAULIC PUMP MOTOR
REMOVAL
INSTALLATION
DRIVEAND HYDRAULIC MOTORS
DISASSEMBLY
ASSEMBLY
COMMUTATOR REPAIRS
TESTS
DAMAGED FIELD AND ARMATURE
SHORT-CIRCUIT INAN ARMATURE WINDING
SHORT-CIRCUIT IN THE ARMATURE
OPEN CIRCUIT INA FIELD COIL
SHORT-CIRCUIT INA FIELD COIL
SHORT-CIRCUIT BETWEEN FIELD AND MOTOR CASE
BRUSH HOLDER
SCHEMATIC 7524777-00 - TYPE "£" - MCW
WIRING DIAGRAM 7524777-00 - TYPE "E" - MCW
OPTIONS DIAGRAM 7524777-00 - TYPE "E" - MCW
4 DRIVE UNIT ASSEMBLY
DRIVE UNIT-GENERAL
DRIVE MOTOR ASSEMBLY
UPPER HOUSING
LOWER HOUSING
DRIVE WHEEL
REMOVAL
INSTALLATION
UPPER HOUSING
REMOVAL
INSTALLATION
LOWER HOUSING
DISASSEMBLY
ASSEMBLY
DRIVE UNIT
REMOVAL
INSTALLATION
BEVEL PINID GEAR ADJUSTMENT
5 BRAKE SYSTEM
BRAKE SYSTEM-GENERAL
BRAKE SHOE AND LINING ASSEMBLY
REMOVAL
INSTALLATION
BRAKE RELEASEARM
REMOVAL
INSTALLATION
BRAKE ADJUSTMENT
6 CONTROL HANDLE
CONTROL HANDLE-GENERAL
REMOVAL
INSTALLATION
CONTROL HANDLE HEAD
REMOVAL
INSTALLATION
7 HYDRAULIC SYSTEM
HYDRAULIC SYSTEM-GENERAL
SYSTEM OPERATION
HYDRAULIC OIL
CLEANLINESS
SOUND LEVEL
HYDRAULIC PUMP AND MOTOR
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CONTROL VALVE
REMOVAL
INSTALLATION .
DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY
RELIEF VALVE ADJUSTMENT
HYDRAULIC TANK
REMOVAL
INSTALLATION
INSPECTION
REPAIRS, SMALL LEAKS
REPAIRS, LARGE LEAKS
CLEANING
STEAM METHOD OF CLEANING
ADDITIONAL PREPARATIONS FOR REPAIR
HYDRAULIC CYLINDERS
DISASSEMBLY-FREE LIFT CYLINDER
CLEANING AND INSPECTION
ASSEMBLY-FREE LIFT CYLINDER
DISASSEMBLY-DUPLEX MASTLIFT CYLINDER
CLEANING AND INSPECTION
ASSEMBLY-DUPLEX MAST LIFT CYLINDER
DISASSEMBLY-TRIPLEX MAST LIFT CYLINDER
CLEANING AND INSPECTION
ASSEMBLY-TRIPLEX MAST LIFT CYLINDER
DISASSEMBLY-TILT CYLINDER
CLEANING AND INSPECTION
ASSEMBLY-TILT CYLINDER
DISASSEMBLY-SIDESHIFTER CYLINDER
CLEANING AND INSPECTION
ASSEMBLY-SIDESHIFTER CYLINDER
TROUBLESHOOTING-LIFT ASSEMBLIES
TROUBLESHOOTING-HYDRAULIC CYLINDERS
TROUBLESHOOTING-HYDRAULIC PUMP
TROUBLESHOOTING-HYDRAULIC CONTROL VALVE
8 MAST
MAST-GENERAL
DESCRIPTION AND OPERATION
CARRIAGE
MAST MOUNTS
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
LOAD BACKREST EXTENSION
REMOVAL AND INSTALLATION
FORK REPLACEMENT
HOOK FORKS
CARRIAGE ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLYAND ASSEMBLY
SIMPLEX MASTASSEMBLY
REMOVAL
CLEANING AND INSPECTION
LIFT CYLINDER-REMOVAL AND INSTALLATION
INNER MASTASSEMBLY-REMOVAL AND INSTALLATION
HOSES-REPLACEMENT
HOSEAND CABLE SHEAVES-REPLACEMENT
LIFT CHAINS-REMOVAL AND INSTALLATION
CLEANING AND INSPECTION
CHAIN SHEAVE-REMOVAL AND INSTALLATION
LOAD ROLLERS AND WEAR PLUGS
REMOVAL AND INSTALLATION
INSTALLATION
DUPLEX MASTASSEMBLY
REMOVAL
CLEANING AND INSPECTION
LIFT CYLINDERS-REMOVAL AND INSTALLATION
INNER MASTASSEMBLY-REMOVAL AND INSTALLATION
HOSES-REPLACEMENT
HOSE AND CABLE SHEAVES-REPLACEMENT
LIFT CHAINS-REMOVAL AND INSTALLATION
CLEANING AND INSPECTION
CHAIN SHEAVE-REMOVAL AND INSTALLATION
LOAD ROLLERS AND WEAR PLUGS
REMOVAL AND INSTALLATION
INSTALLATION
TRIPLEX MASTASSEMBLY
REMOVAL
CLEANING AND INSPECTION
FREE LIFT CYLINDER-REMOVAL AND INSTALLATION
MAIN CYLINDERS-REMOVAL AND INSTALLATION
INNER AND INTERMEDIATE MASTASSEMBLIES
REMOVAL AND INSTALLATION
HOSES-REPLACEMENT
HOSEAND CABLE SHEAVE-REPLACEMENT
FREE LIFT HOSE SHEAVE-REPLACEMENT
CARRIAGE SHEAVES-REPLACEMENT
LIFT CHAIN-REMOVAL AND INSTALLATION
FREE LIFT CHAINS-REMOVAL AND INSTALLATION
MAINLIFT CHAINS-REPLACEMENT
CHAIN SHEAVES-DISASSEMBLY AND ASSEMBLY
FREE LIFT CHAIN SHEAVES
MAIN LIFT CHAIN SHEAVES
LOAD ROLLERS AND WEAR PLUGS
REMOVAL AND INSTALLATION
INSTALLATION
TILT CYLINDER
REMOVAL
INSTALLATION
SIDESHIFTER CARRIAGE
REMOVAL
INSTALLATION
CHECKS AND ADJUSTMENTS
CHECK MAST OPERATION
REMOVEAIR FROM HYDRAULIC SYSTEM
CHECK FOR LEAKS IN THE HYDRAULIC SYSTEM
CHECK LIFT CHAINS
CLEANING AND INSPECTION
LUBRICATION
MAST ADJUSTMENTS
WEAR PLUGS-MAST
WEAR STRIPS
FREE LIFT CHAIN (TRIPLEX ONLY)
MAIN LIFT CHAINS
SIMPLEX
DUPLEX
TRIPLEX
TILT CYLINDER
CARRIAGE ASSEMBLY ADJUSTMENTS
WEAR PLUG
SIDE ROLLERS
THRUST ROLLERS
TROUBLESHOOTING-LIFT ASSEMBLIES
9 BATTERY AND CHARGING SYSTEMS
BATTERYAND CHARGING SYSTEM-GENERAL
SAFETY TIPS FOR HANDLING
INDUSTRIAL TRUCK BATTERIES
LEAD-ACID BATTERIES
SPECIFIC GRAVITY
CHEMICAL REACTION
HOW TO SELECT THE BATTERY
VOLTAGE OFA BATTERY
BATTERY RATINGS
KILOWATT HOURS
THE BATTERYAS A COUNTERWEIGHT
BATTERY MAINTENANCE
MAINTENANCE RECORDS
CLEANING THE BATTERY
ADDING WATER
HYDROMETER
BATTERY TEMPERATURE
CHARGING THE BATTERY
TYPES OF BATTERY CHARGES
METHODS OF CHARGING
TROUBLESHOOTING THE CHARGER
HOW TO KNOW WHEN THE BATTERY IS FULLY CHARGED
BATTERY CHARGING AREA
EQUIPMENT NEEDED
TROUBLESHOOTING-BATTERY
TROUBLESHOOTING-BATTERY
10 USER SUPPORT INFORMATION
SERVICE PARTS ORDERING INSTRUCTIONS
TECHNICAL PUBLICATIONS
PARTS MANUAL-MCW-1 602
OPERATING MANUAL-MRW, MSW, MCW-1601 (5192838-05)
OPERATOR TRAINING
SERVICE TRAINING COURSES
SERVICE TRAINING MATERIALS
USER SUPPORT INFORMATION
11 ALPHABETICAL INDEX
File Data
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