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Yale Forklift B897 (MPW060E) Service Manual – PDF DOWNLOAD
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Yale Forklift B897 (MPW060E) Service Manual – PDF DOWNLOAD
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Description
Yale Forklift B897 (MPW060E) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Yale Forklift B897 (MPW060E) Service Manual – PDF DOWNLOAD
Language : English
Pages : 350
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Yale Forklift B897 (MPW060E) 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 25
Frame Separation and Assembly 27
Frame Separation 27
Frame Assembly 27
Painting Instructions 28
Label Replacement 28
General 39
Special Precautions 39
Control Handle Head 40
Control Handle (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 41
Remove 41
Install 43
Control Handle (MPE060/080-E) 44
Remove (Handle) 44
Steer Bearings and Support 45
Disassemble 45
Repair 45
Assemble 45
Install (Handle) 47
Gas Spring 48
Discharging the Gas Spring 48
Remove (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 49
Remove (MPE060/080-E) 49
Install (MPW060/065/080-E, MSW030/040-E, MRW020/030-E, and MCW025/030/040-E) 49
Install (MPE060/080-E) 49
Steering and Dash Assembly (Complete)
50
Remove 50
Install 50
Troubleshooting 52
General 59
Description 59
Special Precautions 62
Brake Check 63
Hold On Grade Test 63
Brake Coil Check 64
Brake Assembly Repair 64
MPW060-E and MPE060-E (Up to 10/2001)
64
Remove 64
Install 65
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
67
Remove 67
Install 69
Brake Assembly Adjustment 69
Air Gap, Adjust 69
Torque Nut, Adjust 70
Adjust 71
MPW060-E, MPW080-E, and MPE060-E Equipped With Brake Assembly Part Number 524144871 71
MPW060-E, MPW080-E, MPE060-E, and All Other Models Covered by This Section Equipped With Brake Assembly Part Number 524169212 71
Troubleshooting 72
General 81
Description of Operation 82
Lifting a Load 83
Lowering a Load 85
Hydraulic Lines 85
Hydraulic Oil 85
Clean 85
Sound Level 85
Special Precautions 86
Hydraulic Reservoir 88
Description 88
Drive Unit Compartment Covers 88
MPC060-E, MPC080-E, MPC060-F, and MPC080-F
88
Remove 88
Install 88
MPE060-E, MPE080-E, MPE060-F, MPE080-F, MPW060-E, MPW065-E, and MPW080-E
89
Remove 89
Install 89
Lift Pump and Motor 90
General 90
Remove 90
Lift Pump and Motor Assembly 90
Disassemble 92
Remove Reservoir 92
Remove Pump Motor 92
MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
92
MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
92
Disassemble Pump 92
MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
92
MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
96
Assemble 96
Assemble Pump 96
MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
96
MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
96
Install Pump Motor 96
Install Reservoir to Pump 97
Install 97
Lift Pump and Motor Assembly 97
Valve Repair 99
Lowering Valve 99
Remove 99
Install 99
Relief Valve 99
MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
99
Remove 99
Install 100
MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
100
Remove 100
Install 100
Check Valve 101
MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
101
Remove 101
Install 101
Lift Cylinder 102
Remove 102
Disassemble 102
Assemble 102
Install 103
Relief Valve Adjustment 104
Relief Valve Pressure Check 104
Adjust Relief Valve Pressure 105
MPE060-E, MPE060-F, MPC060-E, MPC060-F, and MPW060-E
105
MPE080-E, MPE080-F, MPC080-E, MPC080-F, MPW065-E, and MPW080-E
106
Troubleshooting 107
Lift Assemblies 107
Lift Cylinders 108
Lift Pump and Motor Assembly 109
General 119
Safety Precautions 119
Description 119
Curtis PMC 1297 Transistor Motor Controller 120
Principles of Operation 120
Install 120
Programming Controller 122
1307 Programmer Handset 125
Description/Features 125
Scroll Display Keys 125
Change Value Keys 125
More Info Key 125
Operation 125
Connecting Handset to Traction Motor Controller 126
Disconnecting Handset From Traction Motor Controller 126
Programmer Self-Test 126
Menu Selections 127
Program Menu 127
Test Menu 127
Diagnostics Menu 128
Diagnostic History 128
Special Program Menu 128
Programming Traction Motor Controller – 1307 Handset 128
1311 Programmer Handset 130
Description/Features 130
Menu Navigation Key 131
Data Increase/Decrease Key 132
Bookmark Keys 132
Operation 132
Connecting Handset to Traction Motor Controller 132
Disconnecting the Handset From the Traction Motor Controller 132
Main Menu Selections 133
Program Menu 133
Monitor Menu 133
Faults Menu 134
Functions menu 135
Information Menu 135
Programmer Setup Menu 135
Programming the Traction Motor Controller – 1311 Handset 135
Parameters 137
Adjusting Parameters 137
Top Speed 137
Acceleration 137
Neutral Braking 137
Plug Braking 137
Coast Braking(MPE060-E/MPE080-E Only) 137
Empty Volts 137
Battery Discharge Indicator (BDI)/Hourmeter 138
LED Fault Codes 138
Control Card Functional Test 161
General 169
Electrical System Checks 172
Safety Precautions 173
Repairs 174
Controller, Replace 175
Remove 175
Install 176
Contactor Coil, Check 177
Contactor, Replace 177
Contactor Tips, Replace 177
Remove 178
Install 178
Fuses 178
Brake Switch – MPW060-E, MPW065-E, MPW080-E, MPE060-E (→Aug 2003) and MPE080-E (→Aug 2003)
179
Remove and Install 179
Brake and Interlock Switches – MPE060-E (Aug 2003→) and MPE080-E (Aug 2003→) 179
Disassemble 180
Assemble 180
Height Limit 180
Control Handle 181
Disassemble 181
Control Handle Card (Old Style) 181
Control Handle Card (New Style) 182
Configure 182
Calibrate 184
Assemble 184
Remote Control Box Switches (MPE060E and MPE080E) 186
Remove 186
Install 186
Motor Maintenance – General 186
Brush and Commutator Inspection 187
Commutator Problems 189
Brush Replacement 193
Drive Motor 195
Remove 195
Disassemble 196
Assemble 197
Install 197
Lift Pump Motor 198
Remove 198
Install 198
Commutator Repairs 198
Testing the Drive Motor 199
Damaged Field and Armature 199
Short Circuit in an Armature Winding 199
Short Circuit in the Armature 200
Open Circuit in a Field Coil 200
Short Circuit in a Field Coil 200
Short Circuit Between Field and Motor Case 201
Brush Holder 201
Troubleshooting 201
General 209
Description of Operation 209
Load Wheel 210
Remove 210
Install 210
Caster Wheels 211
Caster Shim Adjustment 211
Caster Replacement 213
Disassemble 214
Assemble 214
Caster Lubrication 215
Rear Link and Load Wheel Assembly 216
Remove 216
Install 217
Pull Rod 221
Remove 221
End Replacement 221
Install 222
Adjust 222
Rear Fork Adjustment 223
Rocker Arm 224
Remove 224
Install 226
Upper Link 226
Remove 226
Install 227
Troubleshooting 228
Hydraulic System 237
Hydraulic Oils 237
Gear Oils 237
Grease 238
Truck Weights 238
Weight (Basic Truck Without Battery) 239
Tires 239
Drive Tire 239
Torque Specifications 240
Caster Assembly 240
Master Drive Unit 240
Steering 240
Brake 240
Electrical 240
Lift Mechanism 240
Battery Specifications and Adjustments 241
MPE060E and MPW060E – 24 Volt
241
MPW065E – 12 Volt
242
MPE080E – 24 Volt
242
MPW080E – 24 Volt
243
General 251
How to Move a Disabled Truck 252
How to Tow the Lift Truck 252
How to Raise the Lift Truck 253
Lifting Drive/Steer Tire 253
Lifting Load Wheels 254
How to Put a Lift Truck on Blocks 254
How to Raise Drive/Steer Tire 254
How to Raise Load Wheels 255
Welding Repairs 255
Maintenance Schedule 256
Checks and Inspection Procedures 256
Hydraulic System 256
Lifting Mechanism 257
Controls 257
Electrical and Battery 258
Wheels and Tires 259
Casters 259
Lubrication Instructions 260
Every 8 Hours or Daily 261
Every 50 Hours or 1 Month 261
Every 350 Hours or 2 Months 261
Check Hydraulic Oil Level 261
Every 2000 Hours or 1 Year 261
To Fill Hydraulic Reservoir 263
Recommended Schedule of Maintenance 263
Battery Maintenance 269
How to Charge the Battery 269
Equalizing Charge 269
Normal Charge 269
Maintenance-Free Battery Charger 270
How to Change the Battery 270
General Notes 279
General 299
Accessing the Drive Unit Compartment 299
Unit Codes: C896, D896, E896 299
Unit Codes: B894, B897, B891, D820, D819, D821, D902 300
Special Precautions 301
Discharging the Capacitors 301
Description 302
AC Motor Repair 302
Remove 302
Install 303
Troubleshooting 304
Safety Precautions 313
General 315
Check Oil Level 315
Drive Tire 316
Remove 316
Install 316
Master Drive Unit, Kordel® Before December, 2019 316
Remove 316
Disassemble 318
Bevel Gear Set (Ring and Pinion) 318
Remove 318
Install 320
Flange Shaft Seal 320
Remove 320
Install 321
Steering Bearing 321
Remove 321
Replace 321
Master Drive Unit, Kordel® After December, 2019 321
Remove 321
Disassemble 323
Seal Ring 323
Helical Pinion 323
Steering Bearing 324
Assemble 325
Steering Bearing 325
Helical Pinion 325
Seal Ring 325
Install 325
Troubleshooting 326
General 335
Threaded Fasteners 335
Nomenclature, Threads 335
Strength Identification 336
Cotter (Split) Pins 337
Fastener Torque Tables 342
Conversion Table 344
S.V 05/24
