Yale Material Handling Corporation Pallet Truck MPW080

WARNING: Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can create a dangerous operating condition. Do not operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, put a 'DO NOT OPERATE' tag on the control handle. Remove the key from the key switch.

WARNING: Disconnect the battery and separate the connector before opening the drive unit compartment cover or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage.

WARNING: The capacitor in the motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses. Make certain the battery has been disconnected. Use a screwdriver or jumper wire to make a short-circuit across the B+ and B- terminals of the motor controller.

Battery disconnected and connector separated?

Capacitor in the motor controller discharged?

Turn the plugging (braking) adjustment screw

Is the adjustment screw set in the one o'clock position for default or factory setting?

Sign off on the plugging adjustment

WARNING: Put blocks under each side of the truck under the drive unit frame. Position blocks on both sides of the load wheels. The blocks must prevent the lift truck from falling and causing injury or damage.

Raise the drive wheel off the floor. Block the lift truck. See Section 1-HOW TO PUT A LIFT TRUCK ON BLOCKS. Disconnect the battery.

Remove the drive unit compartment cover. Refer to Section 2-DRIVE UNIT COMPARTMENT COVER-REMOVAL AND INSTALLATION.

WARNING: The capacitor in the motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses. Make certain the battery has been disconnected.

Discharge the capacitor in the motor controller.

If used, remove the brush covers to the motor. Wear eye protection. Use a vacuum cleaner or compressed air to remove dirt and 'brush dust' from the commutator area.

Visually inspect the commutator surface. Refer to Figures 3-20 through 3-28. The commutator wears slowly in normal service. The mica must be cut below the surface of the commutator bars after a long service period or after a commutator has been turned in a lathe. Carefully rotate the armature. DO NOT damage the commutator if you use a tool to rotate the armature.

Inspect the white or gray insulation (mica) between the commutator bars. The mica must not touch the brushes or the brushes will wear very rapidly.

Install the brush covers, when used and the drive unit compartment cover. Refer to Section 2-DRIVE UNIT COMPARTMENT-REMOVAL AND INSTALLATION.

Warning: Perform the test with the wires disconnected from the relay contact terminals.

Enter the ohmmeter reading for the relay coil

Does the ohmmeter reading match the chart?

Are the relay contacts functioning correctly?

CAUTION: Do not clean the battery with steam or hot water. Do not use a high pressure hose.

Battery compartment clean and dry

Upload a photo of the battery before cleaning

Battery washed with water and dried with compressed air

Electrolyte removed from the battery compartment

Enter the amount of soda used in lb

Enter the amount of water used in qts

Solution of bicarbonate of soda applied

Solution flushed from the battery with clean water

WARNING: Do not make repairs or adjustments unless you have both authorization and training.

Report the need for repairs to your supervisor immediately.

If repair is necessary, put a 'DO NOT OPERATE' tag on the control handle. Remove the key from the key switch.

Drive unit compartment cover removed

Dirt build up around the hydraulic unit cleaned

Pressure relieved from the hydraulic cylinder

Supply line from the pump disassembled and tee installed

Relief valve adjustment screw sealant removed and valve adjusted

Pressure gauge and tee removed from the supply line and sealant applied over the adjustment screw