Yale Forklift A287 (MPE080VG) Service Manual – PDF DOWNLOAD

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Yale Forklift A287 (MPE080VG) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A287 (MPE080VG) Service Manual – PDF DOWNLOAD

Language : English
Pages : 624
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift A287 (MPE080VG) Service Manual – PDF DOWNLOAD

General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
General 27
Battery Type 27
Lead-Acid Batteries 27
Lithium-Ion Batteries 28
Specific Gravity 28
Chemical Reaction in a Cell 28
Electrical Terms 30
Battery Selection 31
Battery Voltage 32
Battery as a Counterweight 32
Battery Ratings 32
Kilowatt-Hours 32
Battery Maintenance 33
Safety Procedures 33
Maintenance Records 33
New Battery 33
Cleaning Battery 34
Adding Water to Battery 36
Hydrometer 36
Battery Temperature 37
Charging Battery 38
Types of Battery Charges 39
Methods of Charging 40
Troubleshooting Charger 41
Knowing When Battery Is Fully Charged 41
Where to Charge Batteries 41
Equipment Needed 41
Battery Connectors 42
Battery Care 42
Troubleshooting 44
General 53
Battery Type 53
Lead-Acid Batteries 53
Lithium-Ion Batteries 54
Specific Gravity 54
Chemical Reaction in a Cell 54
Electrical Terms 56
Battery Selection 56
Battery Voltage 57
Battery as a Counterweight 58
Battery Ratings 58
Kilowatt-Hours 58
Battery Maintenance 58
Safety Procedures 58
Maintenance Records 59
New Battery 59
Cleaning Battery 59
Adding Water to Battery 61
Hydrometer 62
Battery Temperature 63
Charging Battery 64
Types of Battery Charges 64
Methods of Charging 66
Troubleshooting Charger 66
Knowing When Battery Is Fully Charged 67
Where to Charge Batteries 67
Equipment Needed 67
Battery Connectors 68
Battery Care 68
Troubleshooting 70
General 83
Check Oil Level 84
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 85
Drive Tire 85
Remove 85
Install 85
Master Drive Unit 86
Remove 86
Disassemble 93
Remove Drive Axle Group 93
Remove Upper Housing Group 94
Remove Pinion Group 94
Install 96
Troubleshooting 98
General 109
Check Oil Level 110
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 111
Drive Tire 111
Remove 111
Install 111
Master Drive Unit 111
Remove 111
Disassemble 118
Remove Drive Axle Group 118
Remove Upper Housing Group 118
Remove Pinion Group 118
Install 121
Troubleshooting 123
toc 127
Troubleshooting and Adjustments Using the AC Controls Program (E 127
Safety Precautions Maintenance and Repair 128
General 131
Computer Requirements 131
Software, Install 131
Language Selection 131
Demo Mode 132
Connect PC to Lift Truck 136
Starting AC Controls Program 138
Lift Truck Control Setup 143
Change Lift Truck Serial Number or Hourmeter 143
Setting Factory Default Values or Changing Lift Truck Parameters 144
Create New Custom Lift Truck Configuration 150
Lift Truck Configuration Properties 153
Import New Lift Truck Configuration From Disk 156
Delete Custom Lift Truck Configuration or Password File 158
Dash Display 161
Custom Display Languages 161
Download Display Language 163
Clear Operator Log 163
Password Functions 166
Enable/Disable Password and Lift Truck Inspection Functions 166
Truck Inspection Checklist 166
Password 166
Password Properties 166
Create New Password File 171
Download Passwords 172
Upload Passwords 174
Reports Menu 176
Devices Report 176
Custom Report 176
Password Report 176
Operator Report 183
Current Settings Report 186
Status Code Report 190
Status Codes Log 193
Troubleshooting 195
Diagnostics 195
Help Menu 198
General 198
Contents 198
Technical Support 198
About Electric Truck AC Controls Program 198
toc 205
Diagrams 205
Safety Precautions Maintenance and Repair 206
General 229
Accessing the Drive Unit Compartment 229
MPE060VG and MPE080VGMPE060VH and MPE080VH 229
MPC060/080-F and MTR005/007-F 230
Special Precautions 232
Discharging the Capacitors 232
Description 234
AC Motor Repair 234
Remove 234
Disassemble 235
Inspect 237
Assemble 237
Install 237
Troubleshooting 238
toc 243
Brakes 243
Safety Precautions Maintenance and Repair 244
General 247
Accessing the Drive Unit Compartment 247
MPE060/080-F, MPE060-VG, and MPE080-VG 247
MPC060/080-F and MTR005/007-F 248
Description 249
Special Precautions 251
Brake Check 252
Brake Release 252
Brake Apply 252
Air Gap 252
Hold On Grade Test 254
Brake Assembly Repair 254
MPE060-F, MPC060-F, MTR005-F, and MPE060-VG 254
Remove 254
Repair 255
Install 255
MPE080-F, MPC080-F, MTR007-F, and MPE080-VG 256
Remove 256
Repair 256
Install 257
Troubleshooting 258
tables 243
Table 1 Stator Resistance 252
Table 2 Adjustment Specifications 253
toc 263
AC Motor Controller 263
Safety Precautions Maintenance and Repair 264
General 267
Discharging the Capacitors 267
Description 268
Electrical System 268
AC Traction Motor 269
Controller 269
Service PC Connection 269
Parameters 269
General 269
Parameter Description 271
Parameters 271
Extended Shift 271
Walk Speed (Both Directions) 271
Hi Speed (FWD) 271
Hi Speed (REV) 271
Minimum Acceleration 271
Maximum Acceleration 271
Plugging 271
ADS-Neutral 271
ADS-Throttle 271
Pick Acceleration 271
Pick Deceleration 272
Battery Full Voltage 272
Lift Interrupt 272
Troubleshooting 272
General 272
Non-Status Code Errors 273
Powered Black Screen 273
Tiller Oscillation and Bias (EPAS Option) 274
Status Codes 274
Electrical Checks 367
General Electrical System Checks 367
Static Checks on Power and Ground Connections 367
Static Checks on CAN Connections 368
Tiller Harness Shorts and Continuity Checks 369
Control Card Functional Test 370
Dash Display 372
General 372
Startup 373
Status LED 373
Performance Mode Indicator 373
Hourmeter 373
Battery Charge Indicator 374
Fault Log 374
Connector Pin-Outs 375
System Logic Diagram 377
tables 263
Table 1 Parameter Default Values 270
Table 2 Fault Codes 275
toc 381
User Interface 381
Safety Precautions Maintenance and Repair 382
General 385
Description 385
Dash Display Menu Access (Standard Handle) 385
Dash Display Menu Access (Metal Handle Option) 386
Menu Navigation 387
Standard Handle 387
Metal Handle Option 389
Dash Display Versions 390
Supervisor Menu 391
View Versions 392
Hourmeters 392
Diagnostics 392
Fault Log 393
Controller Inputs 394
Control Handle Inputs 394
Run Diagnostics 395
Traction Motor 396
Pump Motor and Valve 396
Control Handle 396
Temperatures 397
Power Steering 397
Service Reminder 398
Change Supervisor Password 398
Operator Modes 399
Exit to Run Mode 399
tables 381
Table 1 Corresponding Buttons 389
Table 2 Supervisor Menu 391
Table 3 Diagnostics Menu 393
Table 4 Controller Inputs 394
Table 5 Control Handle Inputs 394
Table 6 Run Diagnostics Menu 395
toc 403
User Interface 403
Safety Precautions Maintenance and Repair 404
General 407
Description 407
Dash Display Menu Access (Standard Handle) 407
Dash Display Menu Access (Metal Handle Option) 408
Menu Navigation 409
Standard Handle 409
Metal Handle Option 411
Dash Display Versions 412
Technician Menu 413
View Versions 414
Hourmeters 414
Diagnostics 415
Fault Log 415
Controller Inputs 416
Control Handle Inputs 416
Run Diagnostics 417
Traction Motor 418
Pump Motor and Valve 419
Control Handle 419
Traction Temps 419
Power Steering 420
Service Reminder 420
Change Supervisor Password 421
Operator Modes 421
Set Performance 422
Extended Shift 423
Walk Speed 424
High Speed (FWD) 424
High Speed (REV) 424
Minimum Acceleration 425
Maximum Acceleration 425
Plugging 425
ADS-Neutral 426
ADS-Throttle 426
Pick Acceleration 426
Pick Deceleration 427
Battery Full 427
Lift Interrupt 427
Min Steer Assist FWD (Power Steering Assist Only) 428
Min Steer Assist REV (Power Steering Assist Only) 428
Max Steer Assist (Power Steering Assist Only) 428
Defaults 429
Save and Exit 429
Exit Without Saving 429
Set General Items 430
A/V Alarm (Audible/Visual) 430
Clear Fault Log 431
Calibrations 431
Throttle 432
MPE060-80F and MPE060-80VG Composite Handle ( ⇒ S/N B890N02938 432
MPE060-80F and MPE060-80VG Composite Handle ( S/N B890N02939J, B 432
MPE060-80F and MPE060-80VG Metal Handle 433
Steer Handle (Power Steering Assist Only) 434
Change Service Technician Password 434
Exit to Run Mode 435
tables 403
Table 1 Corresponding Buttons 411
Table 2 Technician Menu 413
Table 3 Diagnostics Menu 415
Table 4 Controller Inputs 416
Table 5 Control Handle Inputs 416
Table 6 Run Diagnostics Menu 418
Table 7 Performance Parameters 422
Table 8 Set Performance Menu 422
Table 9 Set General Items Menu 430
Table 10 Calibrations Menu 431
toc 439
Periodic Maintenance 439
Safety Precautions Maintenance and Repair 440
General 443
How to Move a Disabled Truck 443
How to Tow the Lift Truck 444
How to Put a Lift Truck on Blocks 444
How to Raise Drive/Steer Tire 444
How to Raise Load Wheels 445
Accessing the Drive Unit Compartment 445
Special Precautions 446
Discharging the Capacitors 446
Welding Repairs 448
Maintenance Schedule 448
Maintenance Procedures Every 8 Hours or Daily 452
Checks With Key Switch Turned OFF 452
Battery 452
Hydraulic Leaks 453
Drive Tire, Load Wheels, Casters, and Frame 453
Checks With Key Switch Turned ON 454
Operation 454
Maintenance Procedures Every 250 Hours or Every 6 Weeks 455
Caster Lubrication 455
Maintenance Procedures Every 500 Hours or Every 3 Months 456
Hydraulic System 456
Hydraulic Oil 456
Hydraulic Reservoir Breather 456
Steering System 456
Power Assist Steering 456
Lift Linkage and Load Wheels 457
Casters 457
Caster Adjustment Check 457
Caster Adjust Heavy-Duty 457
Master Drive Unit 458
Change Gear Oil 458
Check Oil Level 458
Drive Tire Check 459
Maintenance Procedures Every 2000 Hours or Yearly 459
Lubrication 459
Repack Load Wheel Bearings 459
Repack Steer Bearings (Manual Steer Only) 459
Hydraulic System 459
Oil Change 459
Brake 460
Electrical 460
MDU 460
Oil Change 460
Battery Maintenance 461
How to Charge the Battery 461
Equalizing Charge 461
Normal Charge 462
How to Change the Battery 462
Transporting 463
Loading 463
Unloading 463
Preparation for Storage 464
Short-Term Storage (1 to 6 months) 464
Long-Term Storage (6 months or longer) 464
Preparation for Use 464
Preparation After Shipment 464
Preparation After Storage 464
tables 439
Table 1 Maintenance Schedule 449
Table 2 Specific Gravity Corrections 461
toc 467
Frame 467
Safety Precautions Maintenance and Repair 468
General 471
Frame Separation and Assembly 472
Disassemble 472
Assemble 472
Painting Instructions 473
Label Replacement 473
toc 477
Steering Mechanism 477
Safety Precautions Maintenance and Repair 478
General 481
Accessing the Drive Unit Compartment 481
Special Precautions 482
Electromagnetic Shield 483
Calibration 483
Power Assist Steering 483
Control Handle 484
Control Handle Head 484
Control Handle 484
Standard Steering 484
Remove 484
Install 485
Power Assist Steering 486
Remove 486
Install 487
Gas Spring 489
Discharging the Gas Spring 489
Remove 489
Install 490
Articulating Shaft and Pinions (Power Assist Models) 491
Remove 491
Pinion Repair 491
Upper Pinion 491
Remove 492
Install 492
Lower Pinion 493
Install 494
Steer Motor Assembly 494
Repair 494
Steer Motor, Replace 494
Steer Motor Gear, Replace 495
Gearbox/Complete Assembly, Replace 496
Steer Support Assembly 497
Standard Steering 497
Remove (Complete Unit) 497
Disassemble 497
Assemble 499
Install (Complete Unit) 499
Power Assist Steering (Option) 500
Remove (Complete Unit) 501
Disassemble 501
Support Base 501
Steer Swivel 502
Assemble 502
Steer Swivel 502
Support Base 502
Install (Complete Unit) 506
Electronic Coast Control (Option) 507
Disassemble 507
Assemble 509
Checks 509
Troubleshooting 510
toc 513
Lifting Mechanism 513
Safety Precautions Maintenance and Repair 514
General 517
Description of Operation 517
Load Wheel 517
Remove 517
Install 518
Casters 519
Caster Adjustment Check 519
Caster Adjust Heavy-Duty 519
Caster Replacement 519
Disassemble 520
Heavy-Duty 520
Assemble 521
Heavy-Duty 521
Rear Link and Load Wheel 521
Remove 521
Install 521
Pull Rod 525
Remove 525
End Replacement 525
Install 525
Fork Height Adjustment 526
Rocker Arm 527
Remove 527
Install 528
Upper Link 529
Remove 529
Install 529
Entry Rollers 530
Replacement 530
Troubleshooting 531
toc 535
Capacities and Specifications 535
Safety Precautions Maintenance and Repair 536
Hydraulic System 539
Hydraulic Oils 539
Gear Oils 540
Grease 540
Truck Weight 540
Tire Sizes 541
Torque Specifications 541
Caster Assembly 541
Drive Wheel Assembly 541
Master Drive Unit 541
Standard Steering 541
Power Assist Steering 542
Brake 542
Electrical 542
Lift Mechanism 542
Hydraulics 542
Battery Specifications 542
tables 535
Table 1 MPE060-VG 543
Table 2 MPE080-VG 543
toc 547
Hydraulic System 547
Safety Precautions Maintenance and Repair 548
General 551
Description of Operation 551
Lifting a Load 552
Lowering a Load 552
Hydraulic Lines 552
Hydraulic Oil 552
Clean 552
Sound Level 553
Special Precautions 554
Hydraulic Reservoir 554
Drive Unit Compartment Covers 555
Lift Pump and Motor 556
General 556
Remove 556
Lift Pump and Motor Assembly 556
Disassemble 557
Remove Reservoir 557
Remove Pump Motor 557
Disassemble Pump 557
Assemble 559
Assemble Pump 559
Install Pump Motor 559
Install Reservoir to Pump 559
Install 560
Lift Pump and Motor Assembly 560
Valve Repair 561
Lowering Valve 561
Remove 561
Install 561
Relief Valve 561
Remove 561
Install 562
Check Valve 562
Remove 562
Install 562
Lift Cylinder 563
Remove 563
Disassemble 564
Assemble 564
Install 564
Relief Valve Pressure Check 565
Relief Valve Adjust 566
Troubleshooting 567
Lift Assemblies 567
Lift Cylinders 568
Lift Pump and Motor Assembly 569
toc 575
Electrical System 575
Safety Precautions Maintenance and Repair 576
General 579
Accessing the Drive Unit Compartment 580
Special Precautions 581
Discharging the Capacitors 581
Electromagnetic Shield 582
Electrical System Checks 582
Safety Precautions 582
Calibration 584
Power Assist Steering Sensor 584
Repairs 585
Controller, Replace 585
Remove 585
Install 586
Contactor Coil, Check 587
Fuses 587
Horn 588
Replace 588
Brake Switch Operation 588
Brake and Interlock Switches 589
Standard Steering 589
Power Assist Steering 589
Height Limit 590
Control Handle (Standard) 591
Disassemble 591
Assemble 591
Control Handle (HD Option) 592
Disassemble 592
Remove Top Cover 592
Remove Function Switches 593
Remove Throttle Sensor Assembly 593
Remove Handle Shaft Assembly 594
Remove Quick Pick Switches 594
Remove the Coast Control Switches 594
Assemble 595
Install the Coast Control Switches 595
Install Quick Pick Switches 595
Install Handle Shaft Assembly 595
Install Throttle Sensor Assembly 595
Install Function Switches 596
Install Top Cover 596
Control Module 597
Check 597
Remove 598
Install 598
Proximity Switch (Power Assist Steering) 599
Remove 599
Install 599
Remote Control Box Switches 600
Remove 600
Install 600
Troubleshooting 600
tables 575
Table 1 Voltage Checks 584
Table 2 Input Connector Voltages 598
General 609
Threaded Fasteners 609
Nomenclature, Threads 609
Strength Identification 610
Cotter (Split) Pins 611
Fastener Torque Tables 616
Conversion Table 618

S.V 05/24