Yale Forklift B905 (MPC080-F) Service Manual – PDF DOWNLOAD

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Yale Forklift B905 (MPC080-F) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift B905 (MPC080-F) Service Manual – PDF DOWNLOAD

Language : English
Pages : 482
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift B905 (MPC080-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
524167323-0100YRM1030-(01-2008)-US-EN 97
toc 97
Frame 97
Safety Precautions Maintenance and Repair 98
General 101
Description 101
Features 103
MPC060-E, MPC060-F, MPC080-E, and MPC080-F 103
MTR005-E, MTR005-F, MTR007-E, and MTR007-F 104
Covers 104
Special Precautions 106
Frame Separation and Assembly 108
MPC060-E, MPC060-F, MPC080-E, and MPC080-F 108
Frame Separation 108
Painting Instructions 108
Label Replacement 109
Battery Compartment 109
tables 97
Table 1 Wheel Base and Fork Length 103
Table 2 Wheel Base and Fork Length 103
Table 3 Wheel Base and Fork Length 103
Table 4 Wheel Base and Fork Length 104
524167325-1600YRM1031-(01-2008)-US-EN 117
toc 117
Steering Mechanism 117
Safety Precautions Maintenance and Repair 118
Introduction 121
General 121
Description of Operation 121
Special Precautions 121
Control Handle 123
Remove 123
Install 123
Support Assembly 125
Remove 125
Disassemble 125
Repair 125
Assemble 126
Install 126
Control Handle and Support Assembly (Complete) 126
Remove 126
Install 127
Troubleshooting 129
524167327-8000YRM1033-(01-2008)-US-EN 133
toc 133
Capacities and Specifications 133
Safety Precautions Maintenance and Repair 134
Hydraulic System (MPC060/080-E and MPC060/080-F) 137
Hydraulic Oils 137
Master Drive Unit Specifications 138
Gear Oils 138
Grease 139
Tire Specifications 139
Torque Specifications 140
Master Drive Unit 140
Brake 140
Steering 140
Electrical 140
Coupler ( MTR005-E, MTR005-E AC, MTR007-E, and MTR007-E ) 140
Lift Pump ( MPC060-E, MPC060-E AC, MPC080-E, and MPC080-E AC ) 140
Travel Speeds 141
MTR005-E, MTR005-E AC, MTR007-E, and MTR007-E 141
MPC060-E, MPC060-E AC, MPC080-E, and MPC080-E AC 141
Truck Weight 141
Battery Specifications and Adjustments 142
524167328-8000YRM1034-(01-2008)-US-EN 145
toc 145
Diagrams 145
Safety Precautions Maintenance and Repair 146
524183085-2200YRM1058-(04-2011)-US-EN 177
toc 177
Troubleshooting and Adjustments Using the AC Controls Program (E 177
Safety Precautions Maintenance and Repair 178
General 181
Computer Requirements 181
Software, Install 181
Language Selection 181
Demo Mode 182
Connect PC to Lift Truck 186
Starting AC Controls Program 188
Lift Truck Control Setup 193
Change Lift Truck Serial Number or Hourmeter 193
Setting Factory Default Values or Changing Lift Truck Parameters 194
Create New Custom Lift Truck Configuration 200
Lift Truck Configuration Properties 203
Import New Lift Truck Configuration From Disk 206
Delete Custom Lift Truck Configuration or Password File 208
Dash Display 211
Custom Display Languages 211
Download Display Language 213
Clear Operator Log 213
Password Functions 216
Enable/Disable Password and Lift Truck Inspection Functions 216
Truck Inspection Checklist 216
Password 216
Password Properties 216
Create New Password File 221
Download Passwords 222
Upload Passwords 224
Reports Menu 226
Devices Report 226
Custom Report 226
Password Report 226
Operator Report 233
Current Settings Report 236
Status Code Report 240
Status Codes Log 243
Troubleshooting 245
Diagnostics 245
Help Menu 248
General 248
Contents 248
Technical Support 248
About Electric Truck AC Controls Program 248
524274699-0620YRM1283-(12-2018)-US-EN 255
General 259
Accessing the Drive Unit Compartment 259
MPE060VG and MPE080VGMPE060VH and MPE080VH 259
MPC060/080-F and MTR005/007-F 260
Special Precautions 262
Discharging the Capacitors 262
Description 264
AC Motor Repair 264
Remove 264
Disassemble 265
Inspect 267
Assemble 267
Install 267
Troubleshooting 268
524274701-1800YRM1285-(04-2011)-US-EN 273
toc 273
Brakes 273
Safety Precautions Maintenance and Repair 274
General 277
Accessing the Drive Unit Compartment 277
MPE060/080-F, MPE060-VG, and MPE080-VG 277
MPC060/080-F and MTR005/007-F 278
Description 279
Special Precautions 281
Brake Check 282
Brake Release 282
Brake Apply 282
Air Gap 282
Hold On Grade Test 284
Brake Assembly Repair 284
MPE060-F, MPC060-F, MTR005-F, and MPE060-VG 284
Remove 284
Repair 285
Install 285
MPE080-F, MPC080-F, MTR007-F, and MPE080-VG 286
Remove 286
Repair 286
Install 287
Troubleshooting 288
tables 273
Table 1 Stator Resistance 282
Table 2 Adjustment Specifications 283
524309189-2200YRM1353-(07-2008)-US-EN 293
toc 293
User Interface 293
Safety Precautions Maintenance and Repair 294
General 297
Description 297
Dash Display Menu Access 297
Dash Display 298
Menu Navigation 299
Supervisor Menu 301
View Versions 302
Hourmeters 302
Diagnostics 302
Fault Log 303
Controller Inputs 304
Control Handle Inputs 304
Run Diagnostics 305
Traction Motor 306
Pump Motor and Valve 306
Control Handle 306
Temperatures 307
Service Reminder 307
Change Supervisor Password 308
Operator Modes 308
Exit to Run Mode 309
tables 293
Table 1 Supervisor Menu 301
Table 2 Diagnostics Menu 303
Table 3 Controller Inputs 304
Table 4 Control Handle Inputs 304
Table 5 Run Diagnostics Menu 305
524309190-2200YRM1354-(07-2008)-US-EN 313
toc 313
User Interface 313
Safety Precautions Maintenance and Repair 314
General 317
Description 317
Dash Display Menu Access 317
Menu Navigation 318
Dash Display 320
Technician Menu 320
View Versions 322
Hourmeters 322
Diagnostics 322
Fault Log 323
Controller Inputs 324
Control Handle Inputs 325
Run Diagnostics 326
Traction Motor 327
Pump Motor and Valve 327
Control Handle 327
Traction Temps 328
Service Reminder 328
Change Supervisor Password 328
Operator Modes 329
Set Performance 329
Extended Shift 331
Walk Speed 331
High Speed (FWD) 332
High Speed (REV) 332
Minimum Acceleration 332
Maximum Acceleration 332
Plugging 333
ADS-Neutral 333
ADS-Throttle 333
Battery Full 334
Lift Interrupt 334
Defaults 334
Save and Exit 335
Exit Without Saving 335
Set General Items 335
A/V Alarm (Audible/Visual) 336
Clear Fault Log 336
Calibrations 336
Throttle 337
Change Service Technician Password 337
Exit to Run Mode 338
tables 313
Table 1 Technician Menu 321
Table 2 Diagnostics Menu 323
Table 3 Controller Inputs 324
Table 4 Control Handle Inputs 325
Table 5 Run Diagnostics Menu 326
Table 6 Performance Parameters 329
Table 7 Set Performance Menu 330
Table 8 Set General Items Menu 335
Table 9 Calibrations Menu 336
524313735-8000YRM1368-(05-2008)-US-EN 343
toc 343
Periodic Maintenance 343
Safety Precautions Maintenance and Repair 344
Introduction 347
General 347
Drive Unit Compartment Covers 349
Remove 349
Install 349
How to Move a Disabled Truck 350
How to Tow the Truck 350
How to Put the Truck on Blocks 351
How to Raise Drive/Steer Tire 351
How to Raise the Load Wheels 351
Special Precautions 352
Maintenance Schedule 353
Maintenance Procedures Every 8 Hours or Daily 357
Checks With the Key Switch OFF 357
Safety Labels 357
Battery 357
Frame 358
Drive Tire, Casters (Optional), and Trail Wheels or Load Wheels 358
Lift Linkage ( MPC060/080-F ) 358
Coupler ( MTR005/007-F ) 358
Steering Operation 358
Checks With the Key Switch ON 359
Control Handle 359
Gauges 359
Fuses 359
High Speed Switch 359
Hydraulic ( MPC060/080-F ) 360
Hand Brake 360
Maintenance Procedures Every 250 Hours or Every 6 Weeks 361
Caster Lubrication 361
Maintenance Procedures Every 500 Hours or Every 3 Months 362
Hydraulic System 362
Hydraulic Oil 362
Hydraulic Reservoir Breather 362
Steering System 362
Steer Column and Tilt Mechanism 362
Lift Linkage and Load Wheels (MPC060/080-F) 362
Casters 362
Caster Shim Check 362
Caster Shim Adjust 364
Master Drive Unit 364
Change Gear Oil 364
Check Oil Level 364
Drive Tire Check 365
Maintenance Procedures Every 2000 Hours or Yearly 365
Trail Wheel Bearings (MTR005/007-F) 365
Remove 365
Inspect 365
Install 366
Hydraulic System (MPC060/080-F) 367
Changing the Hydraulic Oil 367
Master Drive Unit 371
Drive Unit Gear Oil 371
Brakes 371
Welding Repairs 372
Battery Maintenance 372
How to Charge Battery 372
How to Change Battery 373
Adjusting the Battery Spacers 373
Changing Battery With Rollers 374
Remove 374
Install 374
Remove Battery Using Overhead Crane 374
Install Battery Using Overhead Crane 375
Battery Specifications 375
tables 343
Table 1 Maintenance Schedule 354
Table 2 Specific Gravity Corrections 373
Table 3 Battery Specifications (MPC060-F) 375
Table 4 Battery Specifications (MPC080-F) 376
Table 5 Battery Specifications (MTR005-F) 376
Table 6 Battery Specifications (MTR007-F) 377
524318491-2200YRM1357-(01-2008)-US-EN 381
toc 381
Electrical System 381
Safety Precautions Maintenance and Repair 382
General 385
Description of Operation 387
Special Precautions 390
Discharging the Capacitors 390
Electrical System Checks 391
Repairs 393
Calibration Mode 393
Controller, Replace 393
Remove 393
Install 394
Control Module 394
Check 394
Remove 396
Install 396
Contactor 396
Check 396
Remove 396
Install 397
Key Switch 397
Remove 397
Install 398
Parking Brake Switch 399
Remove 399
Install 399
Fuses 399
Horn 400
Replace 400
High Speed Switch Assembly 400
Remove 400
Install 400
Control Handle 401
Disassemble 401
Hand-brake 402
Upper Cover 402
Handle Shaft 402
Lower Cover 403
Directional/Throttle Switch 403
Neutral Switches 403
Throttle Sensor 403
Assemble 407
Directional/Throttle Switch 407
Neutral Switches 407
Throttle Sensor 407
Lower Cover 408
Handle Shaft 408
Upper Cover 408
Hand-brake 409
Lift Pump Motor (MPC060-F and MPC080-F Only) 409
Remove 409
Install 409
Troubleshooting 410
General Troubleshooting 410
tables 381
Table 1 Voltage Checks 392
Table 2 Input Connector (J4) Voltages 395
524318493-2200YRM1352-(06-2018)-US-EN 413
General 417
Discharging the Capacitors 417
Description 417
Electrical System 418
AC Traction Motor 419
Controller 420
Service PC Connection 420
Parameters 420
General 420
Parameter Descriptions 421
Parameters 421
Extended Shift 421
Walk Speed (Both Directions) 421
Hi Speed (FWD) 421
Hi Speed (REV) 421
Minimum Acceleration 421
Maximum Acceleration 421
Plugging 422
ADS-Neutral 422
ADS-Throttle 422
Pick Acceleration 422
Pick Deceleration 422
Battery Full Voltage 422
Lift Interrupt 422
Service Hour Reminder 422
Troubleshooting 422
General 422
Status Codes 423
Control Card Functional Test 473
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 478
System Logic Diagram 479

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