Yale Forklift B896 (MPE060-F) Service Manual – PDF DOWNLOAD

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Yale Forklift B896 (MPE060-F) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift B896 (MPE060-F) Service Manual – PDF DOWNLOAD

Language : English
Pages : 614
Downloadable : Yes
File Type : PDF

PART NO. 524150797

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift B896 (MPE060-F) 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
524164713-0100YRM0960-(08-2016)-US-EN 97
General 101
Frame Separation and Assembly 103
Frame Separation 103
Frame Assembly 103
Painting Instructions 104
Label Replacement 104
524164715-0630YRM0961-(03-2022)-US-EN 111
General 119
Check Oil Level 120
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 121
Drive Tire 121
Remove 121
Install 121
Master Drive Unit 122
Remove 122
Disassemble 129
Remove Drive Axle Group 129
Remove Upper Housing Group 130
Remove Pinion Group 130
Install 132
Troubleshooting 134
524164715-0630YRM0961-(12-2018)-US-EN 137
General 145
Check Oil Level 146
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 147
Drive Tire 147
Remove 147
Install 147
Master Drive Unit 147
Remove 147
Disassemble 154
Remove Drive Axle Group 154
Remove Upper Housing Group 154
Remove Pinion Group 154
Install 157
Troubleshooting 159
524164721-4000YRM0965-(08-2016)-US-EN 163
General 167
Description of Operation 167
Load Wheel 168
Remove 168
Install 168
Caster Wheels 169
Caster Shim Adjustment 169
Caster Replacement 171
Disassemble 172
Assemble 172
Caster Lubrication 173
Rear Link and Load Wheel Assembly 174
Remove 174
Install 175
Pull Rod 179
Remove 179
End Replacement 179
Install 180
Adjust 180
Rear Fork Adjustment 181
Rocker Arm 182
Remove 182
Install 184
Upper Link 184
Remove 184
Install 185
Troubleshooting 186
524183085-2200YRM1058-(04-2011)-US-EN 191
toc 191
Troubleshooting and Adjustments Using the AC Controls Program (E 191
Safety Precautions Maintenance and Repair 192
General 195
Computer Requirements 195
Software, Install 195
Language Selection 195
Demo Mode 196
Connect PC to Lift Truck 200
Starting AC Controls Program 202
Lift Truck Control Setup 207
Change Lift Truck Serial Number or Hourmeter 207
Setting Factory Default Values or Changing Lift Truck Parameters 208
Create New Custom Lift Truck Configuration 214
Lift Truck Configuration Properties 217
Import New Lift Truck Configuration From Disk 220
Delete Custom Lift Truck Configuration or Password File 222
Dash Display 225
Custom Display Languages 225
Download Display Language 227
Clear Operator Log 227
Password Functions 230
Enable/Disable Password and Lift Truck Inspection Functions 230
Truck Inspection Checklist 230
Password 230
Password Properties 230
Create New Password File 235
Download Passwords 236
Upload Passwords 238
Reports Menu 240
Devices Report 240
Custom Report 240
Password Report 240
Operator Report 247
Current Settings Report 250
Status Code Report 254
Status Codes Log 257
Troubleshooting 259
Diagnostics 259
Help Menu 262
General 262
Contents 262
Technical Support 262
About Electric Truck AC Controls Program 262
524274698-8000YRM1288-(08-2012)-US-EN 269
toc 269
Diagrams 269
Safety Precautions Maintenance and Repair 270
524274699-0620YRM1283-(12-2018)-US-EN 289
General 293
Accessing the Drive Unit Compartment 293
MPE060VG and MPE080VGMPE060VH and MPE080VH 293
MPC060/080-F and MTR005/007-F 294
Special Precautions 296
Discharging the Capacitors 296
Description 298
AC Motor Repair 298
Remove 298
Disassemble 299
Inspect 301
Assemble 301
Install 301
Troubleshooting 302
524274700-1600YRM1284-(09-2012)-US-EN 307
toc 307
Steering Mechanism 307
Safety Precautions Maintenance and Repair 308
General 311
Accessing the Drive Unit Compartment 311
Special Precautions 312
Electromagnetic Shield (Power Assist 6/2009⇒) 313
Calibration 313
Power Assist Steering 313
Control Handle 314
Control Handle Head 314
Control Handle 314
Standard Steering 314
Remove 314
Install 315
Power Assist Steering (⇒ 5/2009) 316
Remove 316
Install 317
Power Assist Steering (6/2009 ⇒) 321
Remove 321
Install 322
Gas Spring 324
Discharging the Gas Spring 324
Remove 324
Install 325
Articulating Shaft and Pinions (Power Assist Models) 326
Remove 326
Pinion Repair 326
Upper Pinion 326
Lower Pinion 328
Install 329
Steer Motor Assembly 329
Repair 329
Steer Motor, Replace 329
Steer Motor Gear, Replace 330
Gearbox/Complete Assembly, Replace 331
Steer Support Assembly 332
Standard Steering 332
Remove (Complete Unit) 332
Disassemble 332
Assemble 334
Install (Complete Unit) 334
Power Assist Steering (Option) 334
Remove (Complete Unit) 334
Disassemble 336
Support Base 336
Steer Swivel 337
Assemble 337
Steer Swivel 337
Support Base 338
Install (Complete Unit) 340
Electronic Coast Control (Option) 341
Disassemble 341
Assemble 343
Checks 343
Troubleshooting 344
524274701-1800YRM1285-(04-2011)-US-EN 347
toc 347
Brakes 347
Safety Precautions Maintenance and Repair 348
General 351
Accessing the Drive Unit Compartment 351
MPE060/080-F, MPE060-VG, and MPE080-VG 351
MPC060/080-F and MTR005/007-F 352
Description 353
Special Precautions 355
Brake Check 356
Brake Release 356
Brake Apply 356
Air Gap 356
Hold On Grade Test 358
Brake Assembly Repair 358
MPE060-F, MPC060-F, MTR005-F, and MPE060-VG 358
Remove 358
Repair 359
Install 359
MPE080-F, MPC080-F, MTR007-F, and MPE080-VG 360
Remove 360
Repair 360
Install 361
Troubleshooting 362
tables 347
Table 1 Stator Resistance 356
Table 2 Adjustment Specifications 357
524274702-2200YRM1286-(04-2011)-US-EN 367
toc 367
AC Motor Controller 367
Safety Precautions Maintenance and Repair 368
General 371
Discharging the Capacitors 371
Description 372
Electrical System 372
AC Traction Motor 373
Controller 373
Service PC Connection 373
Parameters 373
General 373
Parameter Description 375
Parameters 375
Extended Shift 375
Walk Speed (Both Directions) 375
Hi Speed (FWD) 375
Hi Speed (REV) 375
Minimum Acceleration 375
Maximum Acceleration 375
Plugging 375
ADS-Neutral 375
ADS-Throttle 375
Pick Acceleration 375
Pick Deceleration 376
Battery Full Voltage 376
Lift Interrupt 376
Troubleshooting 376
General 376
Non-Status Code Errors 377
Powered Black Screen 377
Tiller Oscillation and Bias (EPAS Option) 378
Status Codes 378
Electrical Checks 471
General Electrical System Checks 471
Static Checks on Power and Ground Connections 471
Static Checks on CAN Connections 472
Tiller Harness Shorts and Continuity Checks 473
Control Card Functional Test 474
Dash Display 476
General 476
Startup 477
Status LED 477
Performance Mode Indicator 477
Hourmeter 477
Battery Charge Indicator 478
Fault Log 478
Connector Pin-Outs 479
System Logic Diagram 481
tables 367
Table 1 Parameter Default Values 374
Table 2 Fault Codes 379
524274703-2200YRM1287-(07-2009)-US-EN 485
toc 485
Electrical System 485
Safety Precautions Maintenance and Repair 486
General 489
Accessing the Drive Unit Compartment 490
Special Precautions 491
Discharging the Capacitors 491
Electromagnetic Shield (Power Assist Steering 6/2009⇒) 492
Electrical System Checks 492
Safety Precautions 492
Calibration 495
Calibration Mode 495
Power Assist Steering Sensor 495
Repairs 496
Controller, Replace 496
Remove 496
Install 497
Contactor Coil, Check 497
Contactor, Replace 498
Fuses 498
Horn 498
Replace 498
Brake Switch Operation 499
Brake and Interlock Switches – (Manual Steering) 499
Disassemble 499
Assemble 499
Brake Switch and Handle Position Sensor – (Power Assist Steering 500
Brake Switch(es) 500
Handle Potentiometer Sensor (Power Assist Steering ⇒5/2009) 501
Disassemble 501
Assemble 502
Height Limit 505
Control Handle (Standard) 506
Disassemble 506
Assemble 506
Proximity Switch (Power Assist Steering 6/2009⇒) 508
Remove 508
Install 508
Remote Control Box Switches 508
Remove 508
Install 509
Motor Tests 510
Excessive Current Draw 510
Measuring Current Draw 511
Excessive Resistance 511
Troubleshooting 511
tables 485
Table 1 Voltage Checks 494
524279135-8000YRM1299-(11-2006)-US-EN 515
toc 515
Capacities and Specifications 515
Safety Precautions Maintenance and Repair 516
Hydraulic System 519
Hydraulic Oils 519
Gear Oils 520
Grease 520
Truck Weight 520
Tire Sizes 521
Torque Specifications 521
Caster Assembly 521
Drive Wheel Assembly 521
Master Drive Unit 521
Standard Steering 521
Power Assist Steering 522
Brake 522
Electrical 522
Lift Mechanism 522
Hydraulics 522
Battery Specifications 523
tables 515
Table 1 MPE060-F 523
Table 2 MPE080-F 524
524279136-8000YRM1298-(11-2006)-US-EN 527
toc 527
Periodic Maintenance 527
Safety Precautions Maintenance and Repair 528
General 531
How to Move a Disabled Truck 531
How to Tow the Lift Truck 532
How to Put a Lift Truck on Blocks 532
How to Raise Drive/Steer Tire 532
How to Raise Load Wheels 533
Accessing the Drive Unit Compartment 533
Special Precautions 534
Discharging the Capacitors 534
Welding Repairs 536
Maintenance Schedule 536
Maintenance Procedures Every 8 Hours or Daily 540
Checks With Key Switch Turned OFF 540
Battery 540
Hydraulic Leaks 541
Drive Tire, Load Wheels, Casters, and Frame 541
Checks With Key Switch Turned ON 542
Operation 542
Maintenance Procedures Every 250 Hours or Every 6 Weeks 544
Caster Lubrication 544
Maintenance Procedures Every 500 Hours or Every 3 Months 545
Hydraulic System 545
Hydraulic Oil 545
Hydraulic Reservoir Breather 545
Steering System 545
Power Assist Steering 545
Lift Linkage and Load Wheels 546
Casters 546
Caster Shim Check 546
Caster Shim Adjust 547
Master Drive Unit 548
Change Gear Oil 548
Check Oil Level 548
Drive Tire Check 549
Maintenance Procedures Every 2000 Hours or Yearly 549
Lubrication 549
Repack Load Wheel Bearings 549
Repack Steer Bearings (Manual Steer Only) 549
Hydraulic System 549
Oil Change 549
Brake 550
Electrical 550
MDU 550
Oil Change 550
Battery Maintenance 551
How to Charge the Battery 551
Equalizing Charge 551
Normal Charge 551
How to Change the Battery 552
Transporting 553
Loading 553
Unloading 553
Preparation for Storage 554
Short-Term Storage (1 to 6 months) 554
Long-Term Storage (6 months or longer) 554
Preparation for Use 554
Preparation After Shipment 554
Preparation After Storage 554
tables 527
Table 1 Maintenance Schedule 537
Table 2 Specific Gravity Corrections 551
524290090-2200YRM1323-(04-2011)-US-EN 557
toc 557
User Interface 557
Safety Precautions Maintenance and Repair 558
General 561
Description 561
Dash Display Menu Access (Standard Handle) 561
Dash Display Menu Access (Metal Handle Option) 562
Menu Navigation 563
Standard Handle 563
Metal Handle Option 565
Dash Display Versions 566
Supervisor Menu 567
View Versions 568
Hourmeters 568
Diagnostics 568
Fault Log 569
Controller Inputs 570
Control Handle Inputs 570
Run Diagnostics 571
Traction Motor 572
Pump Motor and Valve 572
Control Handle 572
Temperatures 573
Power Steering 573
Service Reminder 574
Change Supervisor Password 574
Operator Modes 575
Exit to Run Mode 575
tables 557
Table 1 Corresponding Buttons 565
Table 2 Supervisor Menu 567
Table 3 Diagnostics Menu 569
Table 4 Controller Inputs 570
Table 5 Control Handle Inputs 570
Table 6 Run Diagnostics Menu 571
524290091-2200YRM1324-(10-2012)-US-EN 579
toc 579
User Interface 579
Safety Precautions Maintenance and Repair 580
General 583
Description 583
Dash Display Menu Access (Standard Handle) 583
Dash Display Menu Access (Metal Handle Option) 584
Menu Navigation 585
Standard Handle 585
Metal Handle Option 587
Dash Display Versions 588
Technician Menu 589
View Versions 590
Hourmeters 590
Diagnostics 591
Fault Log 591
Controller Inputs 592
Control Handle Inputs 592
Run Diagnostics 593
Traction Motor 594
Pump Motor and Valve 595
Control Handle 595
Traction Temps 595
Power Steering 596
Service Reminder 596
Change Supervisor Password 597
Operator Modes 597
Set Performance 598
Extended Shift 599
Walk Speed 600
High Speed (FWD) 600
High Speed (REV) 600
Minimum Acceleration 601
Maximum Acceleration 601
Plugging 601
ADS-Neutral 602
ADS-Throttle 602
Pick Acceleration 602
Pick Deceleration 603
Battery Full 603
Lift Interrupt 603
Min Steer Assist FWD (Power Steering Assist Only) 604
Min Steer Assist REV (Power Steering Assist Only) 604
Max Steer Assist (Power Steering Assist Only) 604
Defaults 605
Save and Exit 605
Exit Without Saving 605
Set General Items 606
A/V Alarm (Audible/Visual) 606
Clear Fault Log 607
Calibrations 607
Throttle 608
MPE060-80F and MPE060-80VG Composite Handle ( ⇒ S/N B890N02938 608
MPE060-80F and MPE060-80VG Composite Handle ( S/N B890N02939J, B 608
MPE060-80F and MPE060-80VG Metal Handle 609
Steer Handle (Power Steering Assist Only) 610
Change Service Technician Password 610
Exit to Run Mode 611
tables 579
Table 1 Corresponding Buttons 587
Table 2 Technician Menu 589
Table 3 Diagnostics Menu 591
Table 4 Controller Inputs 592
Table 5 Control Handle Inputs 592
Table 6 Run Diagnostics Menu 594
Table 7 Performance Parameters 598
Table 8 Set Performance Menu 598
Table 9 Set General Items Menu 606
Table 10 Calibrations Menu 607

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