Yale Forklift A902 (MTR005-E) Service Manual – PDF DOWNLOAD

Description

Yale Forklift A902 (MTR005-E) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A902 (MTR005-E) Service Manual – PDF DOWNLOAD

Language : English
Pages : 370
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A902 (MTR005-E) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524158040-2240YRM0001-(01-2023)-US-EN 43
General 49
Battery Type 49
Lead-Acid Batteries 49
Lithium-Ion Batteries 50
Specific Gravity 50
Chemical Reaction in a Cell 50
Electrical Terms 52
Battery Selection 53
Battery Voltage 54
Battery as a Counterweight 54
Battery Ratings 54
Kilowatt-Hours 54
Battery Maintenance 55
Safety Procedures 55
Maintenance Records 55
New Battery 55
Cleaning Battery 56
Adding Water to Battery 58
Hydrometer 58
Battery Temperature 59
Charging Battery 60
Types of Battery Charges 61
Methods of Charging 62
Troubleshooting Charger 63
Knowing When Battery Is Fully Charged 63
Where to Charge Batteries 63
Equipment Needed 63
Battery Connectors 64
Battery Care 64
Troubleshooting 66
524158040-2240YRM0001-(03-2020)-US-EN 71
General 75
Battery Type 75
Lead-Acid Batteries 75
Lithium-Ion Batteries 76
Specific Gravity 76
Chemical Reaction in a Cell 76
Electrical Terms 78
Battery Selection 78
Battery Voltage 79
Battery as a Counterweight 80
Battery Ratings 80
Kilowatt-Hours 80
Battery Maintenance 80
Safety Procedures 80
Maintenance Records 81
New Battery 81
Cleaning Battery 81
Adding Water to Battery 83
Hydrometer 84
Battery Temperature 85
Charging Battery 86
Types of Battery Charges 86
Methods of Charging 88
Troubleshooting Charger 88
Knowing When Battery Is Fully Charged 89
Where to Charge Batteries 89
Equipment Needed 89
Battery Connectors 90
Battery Care 90
Troubleshooting 92
524164715-0630YRM0961-(03-2022)-US-EN 97
General 105
Check Oil Level 106
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 107
Drive Tire 107
Remove 107
Install 107
Master Drive Unit 108
Remove 108
Disassemble 115
Remove Drive Axle Group 115
Remove Upper Housing Group 116
Remove Pinion Group 116
Install 118
Troubleshooting 120
524164715-0630YRM0961-(12-2018)-US-EN 123
General 131
Check Oil Level 132
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 133
Drive Tire 133
Remove 133
Install 133
Master Drive Unit 133
Remove 133
Disassemble 140
Remove Drive Axle Group 140
Remove Upper Housing Group 140
Remove Pinion Group 140
Install 143
Troubleshooting 145
524164717-1800YRM0963-(08-2016)-US-EN 149
General 153
Description 153
Special Precautions 156
Brake Check 157
Hold On Grade Test 157
Brake Coil Check 158
Brake Assembly Repair 158

MPW060-E and MPE060-E (Up to 10/2001)
158
Remove 158
Install 159

MPW060-E and MPE060-E (10/2001 and Up), MPE080-E, MTR005-E, MTR007-E, MPC060-E, MPC080-E, MPW065-E, MPW080-E, MSW030-040-E, MRW020-030-E, and MCW025-030-040-E
161
Remove 161
Install 163
Brake Assembly Adjustment 163
Air Gap, Adjust 163
Torque Nut, Adjust 164
Adjust 165

MPW060-E, MPW080-E, and MPE060-E Equipped With Brake Assembly Part Number 524144871 165

MPW060-E, MPW080-E, MPE060-E, and All Other Models Covered by This Section Equipped With Brake Assembly Part Number 524169212 165
Troubleshooting 166
524164719-2200YRM0928-(09-2016)-US-EN 171
General 175
Safety Precautions 175
Description 175
Curtis PMC 1297 Transistor Motor Controller 176
Principles of Operation 176
Install 176
Programming Controller 178
1307 Programmer Handset 181
Description/Features 181
Scroll Display Keys 181
Change Value Keys 181
More Info Key 181
Operation 181
Connecting Handset to Traction Motor Controller 182
Disconnecting Handset From Traction Motor Controller 182
Programmer Self-Test 182
Menu Selections 183
Program Menu 183
Test Menu 183
Diagnostics Menu 184
Diagnostic History 184
Special Program Menu 184
Programming Traction Motor Controller – 1307 Handset 184
1311 Programmer Handset 186
Description/Features 186
Menu Navigation Key 187
Data Increase/Decrease Key 188
Bookmark Keys 188
Operation 188
Connecting Handset to Traction Motor Controller 188
Disconnecting the Handset From the Traction Motor Controller 188
Main Menu Selections 189
Program Menu 189
Monitor Menu 189
Faults Menu 190
Functions menu 191
Information Menu 191
Programmer Setup Menu 191
Programming the Traction Motor Controller – 1311 Handset 191
Parameters 193
Adjusting Parameters 193
Top Speed 193
Acceleration 193
Neutral Braking 193
Plug Braking 193
Coast Braking(MPE060-E/MPE080-E Only) 193
Empty Volts 193
Battery Discharge Indicator (BDI)/Hourmeter 194
LED Fault Codes 194
Control Card Functional Test 217
524167323-0100YRM1030-(01-2008)-US-EN 221
toc 221
Frame 221
Safety Precautions Maintenance and Repair 222
General 225
Description 225
Features 227
MPC060-E, MPC060-F, MPC080-E, and MPC080-F 227
MTR005-E, MTR005-F, MTR007-E, and MTR007-F 228
Covers 228
Special Precautions 230
Frame Separation and Assembly 232
MPC060-E, MPC060-F, MPC080-E, and MPC080-F 232
Frame Separation 232
Painting Instructions 232
Label Replacement 233
Battery Compartment 233
tables 221
Table 1 Wheel Base and Fork Length 227
Table 2 Wheel Base and Fork Length 227
Table 3 Wheel Base and Fork Length 227
Table 4 Wheel Base and Fork Length 228
524167325-1600YRM1031-(01-2008)-US-EN 241
toc 241
Steering Mechanism 241
Safety Precautions Maintenance and Repair 242
Introduction 245
General 245
Description of Operation 245
Special Precautions 245
Control Handle 247
Remove 247
Install 247
Support Assembly 249
Remove 249
Disassemble 249
Repair 249
Assemble 250
Install 250
Control Handle and Support Assembly (Complete) 250
Remove 250
Install 251
Troubleshooting 253
524167326-8000YRM1032-(02-2007)-US-EN 257
toc 257
Periodic Maintenance 257
Safety Precautions Maintenance and Repair 258
Introduction 261
General 261
Drive Unit Compartment Covers 261
Remove 261
Install 261
How to Move a Disabled Truck 262
How to Tow the Truck 263
How to Put the Truck on Blocks 264
How to Raise Drive/Steer Tire 264
How to Raise the Load Wheels 264
Special Precautions 265
Maintenance Schedule 266
Maintenance Procedures Every 8 Hours or Daily 269
Checks With the Key Switch OFF 269
Safety Labels 269
Battery 270
Frame 270
Load Wheels, Drive Tire, and Casters 270
Lift Linkage ( MPC060-E and MPC080-E ) 271
Coupler ( MTR005-E and MTR007-E ) 271
Steering Operation 271
Checks With the Key Switch ON 271
Control Handle 271
Gauges 271
Fuses 272
High Speed Switch 272
Hydraulic (MPC060-E and MPC080-E) 272
Hand Brake 272
Maintenance Procedures Every 350 Hours or Every 2 Months 273
Battery Equalizing Charge 273
Coupler Lubrication (MTR005-E and MTR007-E) 273
Control Handle Pivot 273
Brakes 273
Drive Tire and Wheel 274
Drive Unit Assembly 274
Check Oil Level 274
Motor Brushes 274
Maintenance Procedures Every 2000 Hours or Yearly 275
Load Wheel Bearings (MTR005-E and MTR007-E) 275
Remove 275
Inspect 276
Install 276
Contactor 276
Inspecting the Contacts 277
Hydraulic System (MPC060-E and MPC080-E) 278
Changing the Hydraulic Oil 278
Master Drive Unit 283
Drive Unit Gear Oil 283
Welding Repairs 284
Battery Maintenance 284
How to Charge Battery 284
How to Change Battery 285
Adjusting the Battery Spacers 286
Changing Battery With Rollers 286
Remove 286
Install 286
Remove Battery Using Overhead Crane 286
Install Battery Using Overhead Crane 287
Battery Specifications 288
tables 257
Table 1 Maintenance Schedule 266
Table 2 Specific Gravity Corrections 285
Table 3 Battery Specifications (MTR005-E) 288
Table 4 Battery Specifications (MTR007-E) 288
Table 5 Battery Specifications (MPC060-E) 289
Table 6 Battery Specifications (MPC080-E) 289
524167327-8000YRM1033-(01-2008)-US-EN 293
toc 293
Capacities and Specifications 293
Safety Precautions Maintenance and Repair 294
Hydraulic System (MPC060/080-E and MPC060/080-F) 297
Hydraulic Oils 297
Master Drive Unit Specifications 298
Gear Oils 298
Grease 299
Tire Specifications 299
Torque Specifications 300
Master Drive Unit 300
Brake 300
Steering 300
Electrical 300
Coupler ( MTR005-E, MTR005-E AC, MTR007-E, and MTR007-E ) 300
Lift Pump ( MPC060-E, MPC060-E AC, MPC080-E, and MPC080-E AC ) 300
Travel Speeds 301
MTR005-E, MTR005-E AC, MTR007-E, and MTR007-E 301
MPC060-E, MPC060-E AC, MPC080-E, and MPC080-E AC 301
Truck Weight 301
Battery Specifications and Adjustments 302
524167328-8000YRM1034-(01-2008)-US-EN 305
toc 305
Diagrams 305
Safety Precautions Maintenance and Repair 306
524179410-2200YRM1052-(08-2003)-US-EN 337
toc 337
Electrical System 337
Safety Precautions Maintenance and Repair 338
Introduction 341
General 341
Description of Operation 341
Special Precautions 346
Electrical System Checks 347
Repairs 347
Controller, Replace 348
Remove 348
Install 348
Control Handle Module 348
Check 348
Remove 350
Install 350
Contactor, Replace 351
Remove 351
Install 351
Contactor Coil, Check 351
Contactor Tips, Replace 352
Remove 352
Install 352
Key Switch 353
Remove 353
Install 353
Parking Brake Switch 353
Remove 353
Install 353
Battery Indicator/Hourmeter Display 354
Remove 354
Install 354
Fuses 354
High Speed Switch Assembly 355
Remove 355
Install 355
Control Handle 356
Disassemble 356
Hand-brake 356
Upper Cover 356
Handle Shaft 357
Lower Cover 357
Directional/Throttle Switch 357
Neutral Switches 357
Throttle Sensor 357
Assemble 361
Directional/Throttle Switch 361
Neutral Switches 361
Throttle Sensor 362
Lower Cover 362
Handle Shaft 362
Upper Cover 363
Hand-brake 363
Drive Motor 364
Remove 364
Disassemble 364
Assemble 364
Install 367
Lift Pump Motor (MPC060-E and MPC080-E Only) 367
Remove 367
Install 367
Troubleshooting 368
General Troubleshooting 368
tables 337
Table 1 Input Connector (J4) Voltages 351

S.V 06/24