Yale Forklift B891 (MPW080) Service Manual – PDF DOWNLOAD

Description

Yale Forklift B891 (MPW080) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift B891 (MPW080) Service Manual – PDF DOWNLOAD

Language : English
Pages : 350
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift B891 (MPW080) 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
524164713-0100YRM0960-(08-2016)-US-EN 43
General 47
Frame Separation and Assembly 49
Frame Separation 49
Frame Assembly 49
Painting Instructions 50
Label Replacement 50
524164716-1600YRM0962-(08-2016)-US-EN 57
General 61
Special Precautions 61
Control Handle Head 62
Control Handle (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 63
Remove 63
Install 65
Control Handle (MPE060/080-E) 66
Remove (Handle) 66
Steer Bearings and Support 67
Disassemble 67
Repair 67
Assemble 67
Install (Handle) 69
Gas Spring 70
Discharging the Gas Spring 70
Remove (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 71
Remove (MPE060/080-E) 71
Install (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 71
Install (MPE060/080-E) 71

Steering and Dash Assembly (Complete)
72
Remove 72
Install 72
Troubleshooting 74
524164717-1800YRM0963-(08-2016)-US-EN 77
General 81
Description 81
Special Precautions 84
Brake Check 85
Hold On Grade Test 85
Brake Coil Check 86
Brake Assembly Repair 86

MPW060-E and MPE060-E (Up to 10/2001)
86
Remove 86
Install 87

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
89
Remove 89
Install 91
Brake Assembly Adjustment 91
Air Gap, Adjust 91
Torque Nut, Adjust 92
Adjust 93

MPW060-E, MPW080-E, and MPE060-E Equipped With Brake Assembly Part Number 524144871 93

MPW060-E, MPW080-E, MPE060-E, and All Other Models Covered by This Section Equipped With Brake Assembly Part Number 524169212 93
Troubleshooting 94
524164718-1900YRM0964-(08-2016)-US-EN 99
General 103
Description of Operation 104
Lifting a Load 105
Lowering a Load 107
Hydraulic Lines 107
Hydraulic Oil 107
Clean 107
Sound Level 107
Special Precautions 108
Hydraulic Reservoir 110
Description 110
Drive Unit Compartment Covers 110

MPC060-E, MPC080-E, MPC060-F, and MPC080-F
110
Remove 110
Install 110

MPE060-E, MPE080-E, MPE060-F, MPE080-F, MPW060-E, MPW065-E, and MPW080-E
111
Remove 111
Install 111
Lift Pump and Motor 112
General 112
Remove 112
Lift Pump and Motor Assembly 112
Disassemble 114
Remove Reservoir 114
Remove Pump Motor 114

MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
114

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
114
Disassemble Pump 114

MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
114

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
118
Assemble 118
Assemble Pump 118

MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
118

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
118
Install Pump Motor 118
Install Reservoir to Pump 119
Install 119
Lift Pump and Motor Assembly 119
Valve Repair 121
Lowering Valve 121
Remove 121
Install 121
Relief Valve 121

MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
121
Remove 121
Install 122

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
122
Remove 122
Install 122
Check Valve 123

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
123
Remove 123
Install 123
Lift Cylinder 124
Remove 124
Disassemble 124
Assemble 124
Install 125
Relief Valve Adjustment 126
Relief Valve Pressure Check 126
Adjust Relief Valve Pressure 127

MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
127

MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
128
Troubleshooting 129
Lift Assemblies 129
Lift Cylinders 130
Lift Pump and Motor Assembly 131
524164719-2200YRM0928-(09-2016)-US-EN 137
General 141
Safety Precautions 141
Description 141
Curtis PMC 1297 Transistor Motor Controller 142
Principles of Operation 142
Install 142
Programming Controller 144
1307 Programmer Handset 147
Description/Features 147
Scroll Display Keys 147
Change Value Keys 147
More Info Key 147
Operation 147
Connecting Handset to Traction Motor Controller 148
Disconnecting Handset From Traction Motor Controller 148
Programmer Self-Test 148
Menu Selections 149
Program Menu 149
Test Menu 149
Diagnostics Menu 150
Diagnostic History 150
Special Program Menu 150
Programming Traction Motor Controller – 1307 Handset 150
1311 Programmer Handset 152
Description/Features 152
Menu Navigation Key 153
Data Increase/Decrease Key 154
Bookmark Keys 154
Operation 154
Connecting Handset to Traction Motor Controller 154
Disconnecting the Handset From the Traction Motor Controller 154
Main Menu Selections 155
Program Menu 155
Monitor Menu 155
Faults Menu 156
Functions menu 157
Information Menu 157
Programmer Setup Menu 157
Programming the Traction Motor Controller – 1311 Handset 157
Parameters 159
Adjusting Parameters 159
Top Speed 159
Acceleration 159
Neutral Braking 159
Plug Braking 159
Coast Braking(MPE060-E/MPE080-E Only) 159
Empty Volts 159
Battery Discharge Indicator (BDI)/Hourmeter 160
LED Fault Codes 160
Control Card Functional Test 183
524164720-2200YRM0929-(08-2016)-US-EN 187
General 191
Electrical System Checks 194
Safety Precautions 195
Repairs 196
Controller, Replace 197
Remove 197
Install 198
Contactor Coil, Check 199
Contactor, Replace 199
Contactor Tips, Replace 199
Remove 200
Install 200
Fuses 200

Brake Switch – MPW060-E, MPW065-E, MPW080-E, MPE060-E (→Aug 2003) and MPE080-E (→Aug 2003)
201
Remove and Install 201
Brake and Interlock Switches – MPE060-E (Aug 2003→) and MPE080-E (Aug 2003→) 201
Disassemble 202
Assemble 202
Height Limit 202
Control Handle 203
Disassemble 203
Control Handle Card (Old Style) 203
Control Handle Card (New Style) 204
Configure 204
Calibrate 206
Assemble 206
Remote Control Box Switches (MPE060E and MPE080E) 208
Remove 208
Install 208
Motor Maintenance – General 208
Brush and Commutator Inspection 209
Commutator Problems 211
Brush Replacement 215
Drive Motor 217
Remove 217
Disassemble 218
Assemble 219
Install 219
Lift Pump Motor 220
Remove 220
Install 220
Commutator Repairs 220
Testing the Drive Motor 221
Damaged Field and Armature 221
Short Circuit in an Armature Winding 221
Short Circuit in the Armature 222
Open Circuit in a Field Coil 222
Short Circuit in a Field Coil 222
Short Circuit Between Field and Motor Case 223
Brush Holder 223
Troubleshooting 223
524164721-4000YRM0965-(08-2016)-US-EN 227
General 231
Description of Operation 231
Load Wheel 232
Remove 232
Install 232
Caster Wheels 233
Caster Shim Adjustment 233
Caster Replacement 235
Disassemble 236
Assemble 236
Caster Lubrication 237
Rear Link and Load Wheel Assembly 238
Remove 238
Install 239
Pull Rod 243
Remove 243
End Replacement 243
Install 244
Adjust 244
Rear Fork Adjustment 245
Rocker Arm 246
Remove 246
Install 248
Upper Link 248
Remove 248
Install 249
Troubleshooting 250
524164722-8000YRM0918-(08-2016)-US-EN 255
Hydraulic System 259
Hydraulic Oils 259
Gear Oils 259
Grease 260
Truck Weights 260
Weight (Basic Truck Without Battery) 261
Tires 261
Drive Tire 261
Torque Specifications 262
Caster Assembly 262
Master Drive Unit 262
Steering 262
Brake 262
Electrical 262
Lift Mechanism 262
Battery Specifications and Adjustments 263
MPE060E and MPW060E – 24 Volt
263
MPW065E – 12 Volt
264
MPE080E – 24 Volt
264
MPW080E – 24 Volt
265
524164723-8000YRM0919-(09-2016)-US-EN 269
General 273
How to Move a Disabled Truck 274
How to Tow the Lift Truck 274
How to Raise the Lift Truck 275
Lifting Drive/Steer Tire 275
Lifting Load Wheels 276
How to Put a Lift Truck on Blocks 276
How to Raise Drive/Steer Tire 276
How to Raise Load Wheels 277
Welding Repairs 277
Maintenance Schedule 278
Checks and Inspection Procedures 278
Hydraulic System 278
Lifting Mechanism 279
Controls 279
Electrical and Battery 280
Wheels and Tires 281
Casters 281
Lubrication Instructions 282
Every 8 Hours or Daily 283
Every 50 Hours or 1 Month 283
Every 350 Hours or 2 Months 283
Check Hydraulic Oil Level 283
Every 2000 Hours or 1 Year 283
To Fill Hydraulic Reservoir 285
Recommended Schedule of Maintenance 285
Battery Maintenance 291
How to Charge the Battery 291
Equalizing Charge 291
Normal Charge 291
Maintenance-Free Battery Charger 292
How to Change the Battery 292
524164724-8000YRM0920-(02-2018)-US-EN 297
General Notes 301
550142686-0620YRM2005-(12-2018)-US-EN 317
General 321
Accessing the Drive Unit Compartment 321
Unit Codes: C896, D896, E896 321
Unit Codes: B894, B897, B891, D820, D819, D821, D902 322
Special Precautions 323
Discharging the Capacitors 323
Description 324
AC Motor Repair 324
Remove 324
Install 325
Troubleshooting 326
550142687-0630YRM2006-(12-2019)-US-EN 331
Safety Precautions 335
General 337
Check Oil Level 337
Drive Tire 338
Remove 338
Install 338
Master Drive Unit, Kordel® Before December, 2019 338
Remove 338
Disassemble 340
Bevel Gear Set (Ring and Pinion) 340
Remove 340
Install 342
Flange Shaft Seal 342
Remove 342
Install 343
Steering Bearing 343
Remove 343
Replace 343
Master Drive Unit, Kordel® After December, 2019 343
Remove 343
Disassemble 345
Seal Ring 345
Helical Pinion 345
Steering Bearing 346
Assemble 347
Steering Bearing 347
Helical Pinion 347
Seal Ring 347
Install 347
Troubleshooting 348

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