Yale Pallet Truck: MCW020, MCW040 Workshop Service Manual

MAINTENANCE MANUAL For Models MCW 020-040 2000-4000 Lb. Capacity For Service & Parts Contact Yale Materials Handling Corp. 1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011 Authorized Dealer 1619 © September 1995

Yale Industrial Trucks user information EXPLANATION OF MODEL CODE MODEL M-Motorized Hand - TYPE C-Counterbalanced OPERATOR POSITION W-Walk Control RATED CAPACITY 020-2,000 lbs. 040-4,000 lbs. - BATTERY COMPARTMENT S-Small L-Large M C W 040 L C N 24 T V 083 - MAST OVERALL HEIGHT Measured in Inches - MAST TYPE V-Simplex E-Triplex F-Duplex - CONTROL TYPE T-Transistor - VOLTAGE 12-12 Volt 24-24 Volt - MANUFACTURING SOURCE N-North America DESIGN SERIES A-B-C etc. To verify that this manual is correct for this truck compare the model code, as explained above, with the nameplate on the truck. Refer to Table of Contents for nameplate location and information. If the model code in this manual does not agree with the information on the nameplate contact your Yale industrial truck dealer. B

Yale Industrial Trucks This Maintenance Manual is divided into major sections which are listed on this page. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab. SECTIONS 1 OPERATING INSTRUCTIONS 2 GENERAL TRUCK AND LUBRICATION 3 ELECTRICAL SYSTEM 4 DRIVE UNIT ASSEMBLY 5 BRAKE SYSTEM 6 CONTROL HANDLE 7 HYDRAULIC SYSTEM 8 MAST 9 BATTERY AND CHARGING SYSTEMS 10 USER SUPPORT INFORMATION 11 ALPHABETICAL INDEX

Yale SECTION 1 Industrial Trucks OPERATING INSTRUCTIONS 1

Yale Industrial Trucks SECTION 1 - CONTENTS OPERATING INSTRUCTIONS DESCRIPTION PAGE NUMBER OPERATING INSTRUCTIONS-GENERAL 1-1 SERIAL NUMBER 1-1 MODEL CODE 1-1 TRUCK WEIGHT 1-1 CAPACITY RATING 1-1 SAFETY LABELS 1-3 OPERATOR PRE-CHECKS AND INSPECTION 1-3 OPERATING PROCEDURE-GENERAL 1-4 SHUT DOWN PROCEDURE 1-5 SAFETY AND OPERATIONAL CHECKLIST 1-5 KEY SWITCH 1-7 OPERATING CONTROLS-CONTROL HANDLE 1-8 REVERSING BUTTON 1-8 HORN BUTTON 1-8 DIRECTIONAND SPEED CONTROL 1-8 BRAKING 1-8 STEERING 1-9 BATTERY CONNECTOR 1-9 BATTERY INDICATOR AND HOURMETER (OPTIONAL) 1-9 HYDRAULIC CONTROLS 1-9 DESIGNATED OPERATOR POSITION 1-10 OPERATING PROCEDURES 1-10 SAFE MAINTENANCE PROCEDURES 1-11 MOVING A DISABLED LIFT TRUCK 1-12 HOW TO PUT A LIFT TRUCK ON BLOCKS 1-12 HOW TO RAISE DRIVE TIRE 1-12 HOW TO RAISE LOAD WHEELS 1-12 PRECAUTIONS FOR TRUCKS IN STORAGE 1-12 PRECAUTIONS FOR BATTERIES IN STORAGE 1-13

Yale Industrial Trucks OPERATING INSTRUCTIONS-GENERAL Before attempting to operate this truck, carefully read and understand these operating procedures. Make sure the truck is in proper operating condition. Visually inspect the entire truck for any damage that may have occurred during shipment. NOTE: Throughout this manual the terms right, left, front and rear relate to the viewpoint of an operator walking with with the forks trailing. Familiarize yourself with the information contained on the nameplate which is located on the drive frame top plate. Information on this nameplate is as follows: Serial Number This is an identification number assigned to this particular truck and should be used when ordering service parts or when requesting any information from your Yale industrial truck OPERATING INSTRUCTIONS dealer. The serial number is a six digit number preceded by a letter and is stamped on the truck frame and on the nameplate. This truck meets all applicable mandatory requirements of ANSI B56.1 -Safety Standard for Powered Industrial Trucks at the time of manufacture. In addition, these trucks are classified by Underwriters' Laboratories, Inc. and/or approved by Factory Mutual Engineering Corporation for the type designation shown on the nameplate. Consult UL Index of Classified Products and FM Approval Guide. Model Code The model number and the serial number should be used when requesting information. An explanation of the model code is located on Page B of this manual. Truck Weight This is the approximate weight of the truck without a load on the forks. This weight plus the weight of the load to be moved must be considered when operating on elevated floors, elevators, etc. MCW MAlii.l.L'1 DO NOT OVERLOAD ralhfi kr ÿ Truck Serial no Type BatteryType Volts Max. A.H. (6H our Rate) Truck Weight LessBattery lb TruckWeight With BatI lb Allowable Batt.Wt. Range to lb Width Over LoadTires Inches Back Tilt deg. Pressure. PS.I. LoadTires Steer Tires SEE FIGURE 1-2 FOR A DESCRIPTION OF THE LABELS AND PLATES Battery Type Volt Max. A.M. (6 Hour Flaie) Battery Size nx inx in + Vi-0in Truck Weight Less Battery lb Truck Weight With lb 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. SERIAL NUMBER, NAMEPLATE SERIAL NUMBER, FRAME OPERATOR WARNING ANSI-PLATE OPERATOR CAUTION BATTERY HYDRAULIC FUNCTION NO RIDING FORK WARNING MAST WARNING U.L. PLATE PINCH POINT WARNING Figure 1-1 - Serial Number, Nameplate Capacity Rating This rating shows the maximum load capacity of this truck. Personal injury and damage to the truck can occur if the capacity is exceeded. and Warning Label Locations-MCW No additions, omissions or modifications should be made that will affect compliance to the previously stated requirements or in any way minimize the effectiveness of the safety devices. 1-1

Yalo Industrial Trucks Safety and informational labels are located in conspicuous locations on this truck and should be strictly followed. Check the nameplate of each truck before operation. These safety and informational labels must be replaced immediately if missing or OPERATING INSTRUCTIONS defaced. Labels will vary with type of truck and equipment installed. Refer to the Parts Manual for part number and location for all labels. ÿWARNING * 12 A MOVING MAST SECTIONS. KEEP HANDS CLEAR OF THIS AREA 10 Yale Classified by Underwriters Laboratories Inc. As to Fire and Electric Shock Hazard Only Typei i Industrial Truck. d No. i i Yale Materials Handling Corporation ÿ 15 Junction Rd. Remington, NJ 08822 7 A WARNING DO NOT OPERATE THIS TRUCK UNTIL YOU HAVE ... • Been trained and qualified • Readthe operators manual attached to truck • Read all caution rules attached to truck • Checked the nameplate for capacity • Checked the truck daily for proper operation and had all defects corrected FAILURE TO COMPLY WITH THESE REQUIREMENTS WILL CREATE AND UNREASONABLE RISK OF INJURY TO YOURSELF AND OTHERS THIS TRUCK IS TO BE EQUIPPED WITH A BATTERY MEASURING +1/2 in - 0 in +1/2 in -0 in L / NO RIDING 11 THIS TRUCK AS MANUFACTURED, MEETS ALL THE APPLICABLE MANDATORY REQUIREMENTS OF ANSI B56.1-XXXX Safety Standard for Powered Indus¬ trial Trucks, Part III. 7 THE REFERENCE NUMBERS IN THIS FIGURE CORRESPOND WITH THOSE LISTED IN FIGURE 1-1. Figure 1-2 - Safety and Informational Labels 1-2

Yale Industrial Trucks SAFETY LABELS A definition of the safety labels used on the motorized lift trucks is listed below. /j\ DANGER DANGER: Identified by a Red Label, immediate hazards which WILL result in severe personal injury or death. /j\ WARNING WARNING: Identified by a Orange Label, hazards or unsafe practices which MAY result in personal injury or death. A CAUTION CAUTION: Identified by a Yellow Label, hazards or unsafe practices which may result in minor personal injury, product or property damage. THE READER MAYFINDANY ORALL OF THE FOLLOWING LABELS USED IN THIS PUBLICATION. AN UNDERSTANDING OF THEIR USE, AS GIVENBELOW WILL AID THE READER. NOTE An advisory procedure, practice, condition, etc., which is essential to emphasize. CAUTION Directs attention to hazards or unsafe practices which may result in minor personal injury, product or property damage if the proper precautions are not taken. /j\ WARNING Directs attention to unsafe practices which could result in personal injury or death if proper precautions are not taken. /j\ DANGER Directs attention to unsafe practices and/or existing hazards which WILL result in severe personal injury or death if proper precautions are not taken. OPERATING INSTRUCTIONS OPERATOR PRE-CHECKS AND INSPECTION Before each shift, every 8 hours, it is the operator's responsibility to carry out the following checks and inspections before beginning truck operation. Do not operate truck if it is in need of repair, if it is in an unsafe condition, or might contribute to an unsafe condition. Remove the key and report the condition to the proper authority. If the truck becomes unsafe in any way while you are operating it, STOP operating the truck and report the matter immediately to the proper authority. Basic maintenance information and the Recommended Schedule of Maintenance are in the Operational Maintenance Manual, Part Number 5192938-05, located in the document holder on the compartment cover. Also refer to Section 2 of this manual. 1. Make sure all capacity, safety and informational plates or labels are attached. This truck is not considered safe to use without a legible, properly filled out nameplate. Contact Yale Materials Handling Corporation or your local dealer for Yale industrial trucks if the nameplate is not present and legible. See the Operating Manual or the Parts Manual for label and plate locations. 2. Make sure the load backrest extension and all other safety devices are attached. 3. Inspect truck for any damage that might have occurred during the previous shift. 4. Inspecttruckfor any signs of external leaking of the battery and hydraulic system. 5. Check hydraulic hoses for leaking, chafing, cuts or reinforcement showing through the outside of the hose. 6. Operate brakes, all hydraulic controls, lift, tilt, reversing switch, direction and speed control and steering. Make sure they operate freely and return to their proper positions. 7. Inspect condition of wheels and tires. 8. Inspect forks for any damage. Make sure they are correctly attached and locked into position. 9. Make sure the chains are not damaged or kinked. Check for excess slack or mistracking on the sheaves. 10. Test horn and any other accessories. Make sure they are properly mounted and in good working order. 11. Operate the lift truck and make sure all gauges and meters (when equipped) are functioning properly. 12. Make sure any unusual noises are investigated immediately. 1-3

Yale Industrial Trucks OPERATING PROCEDURE-GENERAL Before attempting to operate this lift truck, read and understand these operating procedures. Apply power to the lift truck by connecting the battery plug to the lift truck receptacle. Be sure the plug is fully inserted. 1. Turn the ON/OFF key switch to the ON position. 2. Move the steering/braking handle downward away from the upright position. This will energize the electrical system. The brakes are automatically applied when the steering handle is in the extreme upper or lower position. 3. Depress the butterfly switch in the desired direction of travel and rotate further until the desired speed is reached. The operator can change the direction of travel while the lift truck is moving, by moving the direction/speed control for travel in the opposite direction. The lift truck will come to a stop and then accelerate in the opposite direction. This is called plugging. When traveling facing the load place both hands on the steering handle. When traveling with the load to the rear of the operator, use one hand and walk to one side of the lift truck. Should the lift truck fail to stop for any reason, you (the operator) will not be in the path of the lift truck. Keep your arm straight. If the lift truck moves away from you, your stiff arm will force the handle down into a braking position. If the lift truck moves toward you, a stiff arm forces the handle up into the braking position. Practice with an empty lift truck until you, (the operator) have achieved satisfactory smoothness in all operations, traveling, hoisting, etc. ÿ Observe and comply with instructions concerning floor loadings. Know the weight of your lift truck and load combined. Lift truck weight information is located on the nameplate. only. Never ride a lift truck that is designed for walk operation Do not permit passengers to ride on the lift truck. ÿ Yield the right of way to pedestrians. Use extra care at cross-aisles, doorways and other locations where pedestrians can step into the path of travel of the lift truck. OPERATING INSTRUCTIONS ÿ Look in the direction of travel and keep a clear view of the path of travel. ÿ If visibility is impaired by the load, operate lift truck with the forks trailing and look in the direction of travel. ÿ Stop, start, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause lift truck to overturn or slide. ÿ Travel with the load lowered and where possible, tilted back. Do not elevate the load except during stacking. ÿ Before entering trucks or trailers, be certain the brakes on the truck or trailer are applied and wheel chock(s) are in place. If trailers are not coupled to a tractor, supports may be needed to prevent upending or corner dipping. Check the flooring of trucks, trailers and railroad cars for breaks and weakness before driving onto them. ÿ Before driving over a dockboard or bridge plate, be certain that it is properly secured. Drive carefully and slowly across the dockboard or bridge plate and never exceed its rated capacity. ÿ Watch clearances, especially around forks. Watch tailswing. The driver must be aware that the forks can sometimes extend beyond the load. This may cause the operator to hit an object or lift another load. ÿ Watch out for obstructions, especially overhead. Check clearances. ÿ Do not run over objects on the roadway surface as lift truck stability and steering could be adversely affected. ÿ Do not push loads with the lift truck or reach mechanism. ÿ When approaching cross-aisles, slow down, sound horn and keep to the right side of aisle. ÿ Operate lift truck under all conditions at a speed that will permit it to be brought to a stop in a safe manner. ÿ On inclines, travel with the load or forks downhill. If the operator should lose footing or control of the lift truck, the operator will not be in the path of travel. ÿ Do not turn on an incline. For stability reasons, a lift truck must not be driven across an incline. Motorized Hand lift trucks are not intended for operation on grades greater than 10% (a grade that changes 1 foot in elevation for every 10 feet of horizontal travel). ÿ Observe all traffic regulations, including authorized plant speed limits. Under normal traffic conditions, keep to the right. Maintain a safe distance from the lift truck ahead (approximately three lift truck lengths), and keep the lift truck under control at all times. 1-4

Yale Industrial Trucks ÿ Report all accidents involving personnel, building structures and equipment to the proper authority. ÿ Yale lift trucks are not intended for use on public roads. ÿ Avoid any abrupt moves. Be a professional. "HANDLE WITH CARE." SHUT DOWN PROCEDURE When leaving truck unattended, fully lower forks, shut off power, set brake, neutralize controls and remove key. If you park the truck on an incline, chock the wheels. OPERATING INSTRUCTIONS SAFETY AND OPERATIONAL CHECK LIST A "Daily Check List" similar to the one shown on the next page should be used every day before operating the truck. The check lists are available in tablet form with 50 sheets per tablet and can be obtained from your local Yale industrial truck dealer for a nominal fee. Both this manual and the Operating Manual contain the Recommended Schedules of Maintenance which should be used as a guide along with the Lubrication Instructions. A professional operator should also be familiar with the information contained in the American National Safety Standard for Powered Trucks-ANSI B56.1. 1-5

Yale Pallet Truck: MCW020, MCW040 Workshop Service Manual

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