Yale Forklift A905 (MPC080-E) Service Manual – PDF DOWNLOAD

Description

Yale Forklift A905 (MPC080-E) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A905 (MPC080-E) Service Manual – PDF DOWNLOAD

Language : English
Pages : 436
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A905 (MPC080-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
524164718-1900YRM0964-(08-2016)-US-EN 171
General 175
Description of Operation 176
Lifting a Load 177
Lowering a Load 179
Hydraulic Lines 179
Hydraulic Oil 179
Clean 179
Sound Level 179
Special Precautions 180
Hydraulic Reservoir 182
Description 182
Drive Unit Compartment Covers 182

MPC060-E, MPC080-E, MPC060-F, and MPC080-F
182
Remove 182
Install 182

MPE060-E, MPE080-E, MPE060-F, MPE080-F, MPW060-E, MPW065-E, and MPW080-E
183
Remove 183
Install 183
Lift Pump and Motor 184
General 184
Remove 184
Lift Pump and Motor Assembly 184
Disassemble 186
Remove Reservoir 186
Remove Pump Motor 186

MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
186

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
186
Disassemble Pump 186

MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
186

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
190
Assemble 190
Assemble Pump 190

MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
190

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
190
Install Pump Motor 190
Install Reservoir to Pump 191
Install 191
Lift Pump and Motor Assembly 191
Valve Repair 193
Lowering Valve 193
Remove 193
Install 193
Relief Valve 193

MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
193
Remove 193
Install 194

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
194
Remove 194
Install 194
Check Valve 195

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
195
Remove 195
Install 195
Lift Cylinder 196
Remove 196
Disassemble 196
Assemble 196
Install 197
Relief Valve Adjustment 198
Relief Valve Pressure Check 198
Adjust Relief Valve Pressure 199

MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
199

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
200
Troubleshooting 201
Lift Assemblies 201
Lift Cylinders 202
Lift Pump and Motor Assembly 203
524164719-2200YRM0928-(09-2016)-US-EN 209
General 213
Safety Precautions 213
Description 213
Curtis PMC 1297 Transistor Motor Controller 214
Principles of Operation 214
Install 214
Programming Controller 216
1307 Programmer Handset 219
Description/Features 219
Scroll Display Keys 219
Change Value Keys 219
More Info Key 219
Operation 219
Connecting Handset to Traction Motor Controller 220
Disconnecting Handset From Traction Motor Controller 220
Programmer Self-Test 220
Menu Selections 221
Program Menu 221
Test Menu 221
Diagnostics Menu 222
Diagnostic History 222
Special Program Menu 222
Programming Traction Motor Controller – 1307 Handset 222
1311 Programmer Handset 224
Description/Features 224
Menu Navigation Key 225
Data Increase/Decrease Key 226
Bookmark Keys 226
Operation 226
Connecting Handset to Traction Motor Controller 226
Disconnecting the Handset From the Traction Motor Controller 226
Main Menu Selections 227
Program Menu 227
Monitor Menu 227
Faults Menu 228
Functions menu 229
Information Menu 229
Programmer Setup Menu 229
Programming the Traction Motor Controller – 1311 Handset 229
Parameters 231
Adjusting Parameters 231
Top Speed 231
Acceleration 231
Neutral Braking 231
Plug Braking 231
Coast Braking(MPE060-E/MPE080-E Only) 231
Empty Volts 231
Battery Discharge Indicator (BDI)/Hourmeter 232
LED Fault Codes 232
Control Card Functional Test 255
524164721-4000YRM0965-(08-2016)-US-EN 259
General 263
Description of Operation 263
Load Wheel 264
Remove 264
Install 264
Caster Wheels 265
Caster Shim Adjustment 265
Caster Replacement 267
Disassemble 268
Assemble 268
Caster Lubrication 269
Rear Link and Load Wheel Assembly 270
Remove 270
Install 271
Pull Rod 275
Remove 275
End Replacement 275
Install 276
Adjust 276
Rear Fork Adjustment 277
Rocker Arm 278
Remove 278
Install 280
Upper Link 280
Remove 280
Install 281
Troubleshooting 282
524167323-0100YRM1030-(01-2008)-US-EN 287
toc 287
Frame 287
Safety Precautions Maintenance and Repair 288
General 291
Description 291
Features 293
MPC060-E, MPC060-F, MPC080-E, and MPC080-F 293
MTR005-E, MTR005-F, MTR007-E, and MTR007-F 294
Covers 294
Special Precautions 296
Frame Separation and Assembly 298
MPC060-E, MPC060-F, MPC080-E, and MPC080-F 298
Frame Separation 298
Painting Instructions 298
Label Replacement 299
Battery Compartment 299
tables 287
Table 1 Wheel Base and Fork Length 293
Table 2 Wheel Base and Fork Length 293
Table 3 Wheel Base and Fork Length 293
Table 4 Wheel Base and Fork Length 294
524167325-1600YRM1031-(01-2008)-US-EN 307
toc 307
Steering Mechanism 307
Safety Precautions Maintenance and Repair 308
Introduction 311
General 311
Description of Operation 311
Special Precautions 311
Control Handle 313
Remove 313
Install 313
Support Assembly 315
Remove 315
Disassemble 315
Repair 315
Assemble 316
Install 316
Control Handle and Support Assembly (Complete) 316
Remove 316
Install 317
Troubleshooting 319
524167326-8000YRM1032-(02-2007)-US-EN 323
toc 323
Periodic Maintenance 323
Safety Precautions Maintenance and Repair 324
Introduction 327
General 327
Drive Unit Compartment Covers 327
Remove 327
Install 327
How to Move a Disabled Truck 328
How to Tow the Truck 329
How to Put the Truck on Blocks 330
How to Raise Drive/Steer Tire 330
How to Raise the Load Wheels 330
Special Precautions 331
Maintenance Schedule 332
Maintenance Procedures Every 8 Hours or Daily 335
Checks With the Key Switch OFF 335
Safety Labels 335
Battery 336
Frame 336
Load Wheels, Drive Tire, and Casters 336
Lift Linkage ( MPC060-E and MPC080-E ) 337
Coupler ( MTR005-E and MTR007-E ) 337
Steering Operation 337
Checks With the Key Switch ON 337
Control Handle 337
Gauges 337
Fuses 338
High Speed Switch 338
Hydraulic (MPC060-E and MPC080-E) 338
Hand Brake 338
Maintenance Procedures Every 350 Hours or Every 2 Months 339
Battery Equalizing Charge 339
Coupler Lubrication (MTR005-E and MTR007-E) 339
Control Handle Pivot 339
Brakes 339
Drive Tire and Wheel 340
Drive Unit Assembly 340
Check Oil Level 340
Motor Brushes 340
Maintenance Procedures Every 2000 Hours or Yearly 341
Load Wheel Bearings (MTR005-E and MTR007-E) 341
Remove 341
Inspect 342
Install 342
Contactor 342
Inspecting the Contacts 343
Hydraulic System (MPC060-E and MPC080-E) 344
Changing the Hydraulic Oil 344
Master Drive Unit 349
Drive Unit Gear Oil 349
Welding Repairs 350
Battery Maintenance 350
How to Charge Battery 350
How to Change Battery 351
Adjusting the Battery Spacers 352
Changing Battery With Rollers 352
Remove 352
Install 352
Remove Battery Using Overhead Crane 352
Install Battery Using Overhead Crane 353
Battery Specifications 354
tables 323
Table 1 Maintenance Schedule 332
Table 2 Specific Gravity Corrections 351
Table 3 Battery Specifications (MTR005-E) 354
Table 4 Battery Specifications (MTR007-E) 354
Table 5 Battery Specifications (MPC060-E) 355
Table 6 Battery Specifications (MPC080-E) 355
524167327-8000YRM1033-(01-2008)-US-EN 359
toc 359
Capacities and Specifications 359
Safety Precautions Maintenance and Repair 360
Hydraulic System (MPC060/080-E and MPC060/080-F) 363
Hydraulic Oils 363
Master Drive Unit Specifications 364
Gear Oils 364
Grease 365
Tire Specifications 365
Torque Specifications 366
Master Drive Unit 366
Brake 366
Steering 366
Electrical 366
Coupler ( MTR005-E, MTR005-E AC, MTR007-E, and MTR007-E ) 366
Lift Pump ( MPC060-E, MPC060-E AC, MPC080-E, and MPC080-E AC ) 366
Travel Speeds 367
MTR005-E, MTR005-E AC, MTR007-E, and MTR007-E 367
MPC060-E, MPC060-E AC, MPC080-E, and MPC080-E AC 367
Truck Weight 367
Battery Specifications and Adjustments 368
524167328-8000YRM1034-(01-2008)-US-EN 371
toc 371
Diagrams 371
Safety Precautions Maintenance and Repair 372
524179410-2200YRM1052-(08-2003)-US-EN 403
toc 403
Electrical System 403
Safety Precautions Maintenance and Repair 404
Introduction 407
General 407
Description of Operation 407
Special Precautions 412
Electrical System Checks 413
Repairs 413
Controller, Replace 414
Remove 414
Install 414
Control Handle Module 414
Check 414
Remove 416
Install 416
Contactor, Replace 417
Remove 417
Install 417
Contactor Coil, Check 417
Contactor Tips, Replace 418
Remove 418
Install 418
Key Switch 419
Remove 419
Install 419
Parking Brake Switch 419
Remove 419
Install 419
Battery Indicator/Hourmeter Display 420
Remove 420
Install 420
Fuses 420
High Speed Switch Assembly 421
Remove 421
Install 421
Control Handle 422
Disassemble 422
Hand-brake 422
Upper Cover 422
Handle Shaft 423
Lower Cover 423
Directional/Throttle Switch 423
Neutral Switches 423
Throttle Sensor 423
Assemble 427
Directional/Throttle Switch 427
Neutral Switches 427
Throttle Sensor 428
Lower Cover 428
Handle Shaft 428
Upper Cover 429
Hand-brake 429
Drive Motor 430
Remove 430
Disassemble 430
Assemble 430
Install 433
Lift Pump Motor (MPC060-E and MPC080-E Only) 433
Remove 433
Install 433
Troubleshooting 434
General Troubleshooting 434
tables 403
Table 1 Input Connector (J4) Voltages 417

S.V 06/24