Yale Forklift A283 (MPC060VG, MPC080VG) Service Manual – PDF DOWNLOAD

Description

Yale Forklift A283 (MPC060VG, MPC080VG) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A283 (MPC060VG, MPC080VG) Service Manual – PDF DOWNLOAD

Language : English
Pages : 402
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A283 (MPC060VG, MPC080VG) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(03-2020)-US-EN 1
General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
524158040-2240YRM0001-(03-2020)-US-EN 21
General 25
Battery Type 25
Lead-Acid Batteries 25
Lithium-Ion Batteries 26
Specific Gravity 26
Chemical Reaction in a Cell 26
Electrical Terms 28
Battery Selection 28
Battery Voltage 29
Battery as a Counterweight 30
Battery Ratings 30
Kilowatt-Hours 30
Battery Maintenance 30
Safety Procedures 30
Maintenance Records 31
New Battery 31
Cleaning Battery 31
Adding Water to Battery 33
Hydrometer 34
Battery Temperature 35
Charging Battery 36
Types of Battery Charges 36
Methods of Charging 38
Troubleshooting Charger 38
Knowing When Battery Is Fully Charged 39
Where to Charge Batteries 39
Equipment Needed 39
Battery Connectors 40
Battery Care 40
Troubleshooting 42
550073166-0620YRM1621-(12-2018)-US-EN 47
General 51
Special Precautions 51
Discharging the Capacitors 51
Traction Motor Repair 51
Remove 52
Disassemble 54
Clean/Inspect 58
Assemble 59
Install 60
Hydraulic Motor Repair 61
Disassemble 61
Inspect 63
Assemble 64
Special Tools 65
Tool Chart 65
Troubleshooting 66
550073167-0630YRM1609-(03-2021)-US-EN 71
Master Drive Unit 75
General 75
Description 75
Maintenance 76
Changing the Oil 76
Remove 76
Clean and Inspect 81
Install 84
Troubleshooting 85
550090222-8000YRM1634-(03-2018)-US-EN 89
550090223-8000YRM1635-(10-2013)-US-EN 107
550090441-2200YRM1631-(07-2017)-US-EN 137
General 143
Introduction 143
Description 143
Button Keypad 143
LED Indicator Lights 143
LCD Screen 144
Dash Display Menu Access 144
Menu Navigation 144
Dash Display Menu Operation 144
Nodes 144
Menu Structure 145
Service-Level Menu 146
Hour Meters 147
H1 Truck Hours 147
H2 Traction Hours 147
H3 Pump Hours 147
H5 Odometer Hours 147
H10 Display Hours 147
H32 Combinatin Node Hours 147
Performance 148
Performance Level 1 148
P1 1 Forward 149
P1 2 Reverse 149
P1 3 Acceleration 149
P1 4 Plug 149
P1 5 Coast 149
P1 6 Lift Speed 149
P1 7 Lower Speed 149
Operator Passwords 150
Add Password 150
Delete Password 150
Edit Password 150
Operator Password 150
Clear Log 151
Operator Logs 151
Operator 1-150 151
Information 152
I1 Model 152
I3 Serial Number 152
I5 Truck Voltage 152
Settings 153
S1 Metric 153
S2 User Performance 153
S3 Timeout 153
S4 Battery Type 153
S5 BDI Startup Full 153
S6 BDI Full 153
S7 BDI Empty 153
S8 BDI Reset 153
S9 Lift Interrupt 154
S10 Audible Warning 154
S11 Visual Warning 154
S12 Checklist 154
S13 Maint Reminder 154
S14 Restore Default 154
S15 Truck Lockout 154
S61 Extended Shift 155
S63 Walk Speed Accel 155
S64 Walk Speed Decel 155
S65 Pick Accel 155
S66 Pick Decel 155
S67 Min Steer Assist F 155
S68 Min Steer Assist R 155
Software Versions 155
Error Log 156
(E1) Error Log 1 157
Error 1 1 (E1 1) 157
Error 1 2 (E1 2) 157
Error 1 3 (E1 3) 157
Error 1 4 (E1 4) 157
Diagnostics 158
Diagnostics 158
D1 Status 158
D2 Input 158
D3 Output 158
D1 Status 158
D1 1 CAN 159
D1 2 Contactor 159
D1 3 Full Traction 159
D1 4 Limp Traction 159
D1 6 Lift 159
D1 7 Lower 159
D2 Inputs 160
D2 10 Display 160
D2 10 1 Bus Error 160
D2 10 2 Bus Max Error 160
D2 10 32 Combination Controller 160
D2 10 60 CTRL Hand 160
D2 32 Combination Controller 161
D2 32 1 Target Speed 163
D2 32 2 Motor Speed 163
D2 32 3 Motor Encoder 163
D2 32 4 Controller Temperature 163
D2 32 5 Motor Temperature 163
D2 32 6 Motor Current 163
D2 32 7 Cap Voltage 164
D2 32 8 Cap Maximum Voltage 164
D2 32 9 Cap Minimum Voltage 164
D2 32 10 Key Voltage 164
D2 32 11 Key Max Voltage 164
D2 32 12 Key Minimum Voltage 164
D2 32 16 MC Connct 164
D2 32 17 MC Current 164
D2 32 18 Horn Switch 164
D2 32 19 Brake Switch 164
D2 32 20 Horn Connect 164
D2 32 22 Pump Current 164
D2 32 22 Rabbit Switch 164
D2 32 26 Regen Switch 164
D2 32 27 Lift Switch 164
D2 32 28 Lower Switch 164
D2 32 31 Load Hold Connect 164
D2 32 32 Load Hold Current 165
D2 32 33 SOC 165
D2 60 Control Handle 165
D2 60 1 Horn Switch 165
D2 60 2 Lift Switch 165
D2 60 4 Lower Switch 165
D2 60 10 Tilt Up SW 165
D2 60 11 Tilt Down SW 165
D2 50 14 4th Aux IN SW 165
D2 50 15 4th Aux OUT SW 166
D2 60 19 Trac Input 166
D3 Output 166
D3 10 Display 166
D3 10 10 Display Com 166
D3 10 32 Combination Com 166
D3 10 60 Handle Com 166
D3 32 Traction 167
D3 32 1 U-V Line DC Curr 168
D3 32 2 U-W Line DC Curr 168
D3 32 3 V-W Line DC Curr 168
D3 32 6 Pump DC Current 168
D3 32 7 Pump Motor Short 168
D3 32 9 Load Hold 168
D3 32 10 Backup Alarm 168
D3 32 11 Strobe 168
D3 32 12 Horn 168
Calibration 169
169
C4 Throttle 169
550090934-0100YRM1580-(01-2016)-US-EN 173
General 177
Description 177
Features 180

MPC060-VG and MPC080-VG
180

MTR005-F and MTR007-F
180
Covers 180
Special Precautions 180
Frame Separation and Assembly 180

MPC060-VG and MPC080-VG
180
Frame Separation 180
Painting Instructions 181
Label Replacement 181
Battery Compartment 183
550090937-1600YRM1627-(01-2016)-US-EN 187
Introduction 191
General 191
Description of Operation 191
Special Precautions 192
Control Handle 193
Remove 193
Install 196
Support Assembly 196
Remove 196
Disassemble 196
Repair 197
Assemble 197
Install 197
Control Handle and Support Assembly (Complete) 198
Remove 198
Install 198
Troubleshooting 200
550090938-1800YRM1628-(01-2016)-US-EN 203
General 207
Accessing the Drive Unit Compartment 207
Description 208
Special Precautions 209
Brake Check 210
Brake Release 210
Brake Apply 210
Air Gap 211
Hold On Grade Test 212
Brake Assembly Repair 212

MPC060-VG and MTR005-F
213
Remove 213
Repair 214
Install 214

MPC080-VG and MTR007-F
215
Remove 215
Repair 216
Install 216
Troubleshooting 216
550090939-1900YRM1629-(10-2013)-US-EN 221
550090940-2200YRM1630-(01-2016)-US-EN 249
General 253
Introduction 253
Description 253
Button Keypad 253
LED Indicator Lights 253
LCD Screen 254
Dash Display Menu Access 254
Menu Navigation 254
Dash Display Menu Operation 255
Nodes 255
Menu Structure 255
Supervisor-Level Menu 256
Hour Meters 256
H1 Truck Hours 258
H2 Traction Hours 258
H3 Pump Hours 258
H5 Odometer Hours 258
H10 Display Hours 258
H32 Combination Node Hours 258
Performance 258
Performance Level 1 259
P1 1 Forward 260
P1 2 Reverse 260
P1 3 Acceleration 260
P1 4 Plug 260
P1 5 Coast 260
P1 6 Lift Speed 260
P1 7 Lower Speed 260
Operator Passwords 260
Add Password 261
Delete Password 261
Edit Password 261
Operator Password 261
Clear Log 261
Operator Logs 261
Operator 1-150 262
Information 262
I1 Model 263
I3 Serial Number 263
I5 Truck Voltage 263
Software Versions 263
550090942-2200YRM1632-(01-2016)-US-EN 267
General 271
Description of Operation 272
Special Precautions 276
Discharging the Capacitors 276
Electrical System Checks 277
Repairs 279
Calibration Mode 279
Controller, Replace 279
Remove 279
Install 280
Control Module 281
Check 281
Remove 283
Install 284
Contactor 284
Check 284
Remove 284
Install 285
Key Switch 285
Remove 285
Install 286
Parking Brake Switch 286
Remove 286
Install 287
Fuses 287
Horn 287
Replace 287
High Speed Switch Assembly 288
Remove 288
Install 289
Control Handle 289
Disassemble 289
Hand-brake 289
Upper Cover 290
Handle Shaft 291
Lower Cover 291
Directional/Throttle Switch 291
Neutral Switches 291
Throttle Sensor 291
Assemble 295
Directional/Throttle Switch 295
Neutral Switches 295
Throttle Sensor 296
Lower Cover 296
Handle Shaft 296
Upper Cover 297
Hand-brake 297
Lift Pump Motor (MPC060-VG and MPC080-VG Only) 297
Remove 298
Install 298
Troubleshooting 298
General Troubleshooting 298
550090943-4000YRM1589-(10-2013)-US-EN 303
550090944-8000YRM1633-(10-2013)-US-EN 325
550090945-9000YRM1657-(01-2016)-US-EN 339
SECTION 9030 ELECTRICAL SYSTEM 343
Group 03 – General Maintenance and Diagnostic Data 345
Group 20 – Diagnostic Trouble Codes 355

S.V 05/24