Yale MCW020, MCW040 Pallet Truck Workshop Service Maintenance Manual

Original Illustrated Factory Workshop Service Manual for Yale Pallet Trucks Models MCW020, MCW040

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
    DIRECTIONAND 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 PINIONAND 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