Yale Forklift C287 (MPE060VH, MVP080VH) Service Manual PDF

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Yale Forklift C287 (MPE060VH, MVP080VH) Service Manual – PDF DOWNLOAD

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Yale Forklift C287 (MPE060VH, MVP080VH) Service Manual – PDF DOWNLOAD

Language : English
Pages : 760
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift C287 (MPE060VH, MVP080VH) 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
524274699-0620YRM1283-(12-2018)-US-EN 149
General 153
Accessing the Drive Unit Compartment 153
MPE060VG and MPE080VGMPE060VH and MPE080VH 153
MPC060/080-F and MTR005/007-F 154
Special Precautions 156
Discharging the Capacitors 156
Description 158
AC Motor Repair 158
Remove 158
Disassemble 159
Inspect 161
Assemble 161
Install 161
Troubleshooting 162
550073166-0620YRM1621-(12-2018)-US-EN 167
General 171
Special Precautions 171
Discharging the Capacitors 171
Traction Motor Repair 171
Remove 172
Disassemble 174
Clean/Inspect 178
Assemble 179
Install 180
Hydraulic Motor Repair 181
Disassemble 181
Inspect 183
Assemble 184
Special Tools 185
Tool Chart 185
Troubleshooting 186
550073167-0630YRM1609-(03-2021)-US-EN 191
Master Drive Unit 195
General 195
Description 195
Maintenance 196
Changing the Oil 196
Remove 196
Clean and Inspect 201
Install 204
Troubleshooting 205
550091257-1800YRM1638-(10-2019)-US-EN 209
General 213
Accessing the Drive Unit Compartment 213
Description 214
Special Precautions 215
Brake Check 216
Brake Release 216
Brake Apply 217
Air Gap 217
Hold On Grade Test 219
Brake Assembly Repair 219
MPE060-F, MPE060-G, MPE060-VG and MPE060VH 219
Remove 219
Repair 221
Install 221
MPE080-VG and MPE080VH 221
Remove 221
Repair 223
Install 223
Troubleshooting 224
550091258-1900YRM1639-(12-2018)-US-EN 227
General 231
Description of Operation 231
Lifting a Load 232
Lowering a Load 236
Hydraulic Lines 236
Hydraulic Oil 236
Clean 236
Sound Level 236
Special Precautions 236
Hydraulic Reservoir 237
Drive Unit Compartment Covers 237
Lift Pump and Motor 239
General 239
Remove 239
Lift Pump and Motor Assembly 239
Disassemble 240
Remove Reservoir 240
Remove Pump Motor 242
Disassemble Pump 242
Assemble 242
Assemble Pump 242
Install Pump Motor 242
Install Reservoir to Pump 243
Install 243
Lift Pump and Motor Assembly 243
Valve Repair 244
Lowering Valve 244
Remove 244
Install 244
Relief Valve 245
Remove 245
Install 245
Check Valve 245
Remove 245
Install 246
Lift Cylinder 246
Remove 246
Disassemble 248
Assemble 248
Install 249
Relief Valve Pressure Check 249
Relief Valve Adjust 251
Troubleshooting 251
Lift Assemblies 251
Lift Cylinders 252
Lift Pump and Motor Assembly 253
550091262-4000YRM1641-(05-2019)-US-EN 257
General 261
Description of Operation 261
Load Wheel 261
Remove 261
Install 263
Casters 263
Caster Adjustment Check 263
Caster Adjust Heavy-Duty 264
Caster Replacement 264
Disassemble 265
Heavy-Duty 265
Assemble 266
Heavy-Duty 266
Rear Link and Load Wheel 266
Remove 266
Install 268
Pull Rod 269
Remove 270
End Replacement 270
Install 270
Fork Height Adjustment 271
Heavy Duty Trucks 271
Light Duty Trucks 272
Rocker Arm 273
Remove 273
Install 274
Upper Link 274
Remove 275
Install 275
Entry Rollers 276
Replacement 276
Troubleshooting 276
550091262-4000YRM1641-(08-2022)-US-EN 279
General 283
Description of Operation 283
Load Wheel 283
Remove 283
Install 285
Casters 286
Caster Adjustment Check 286
Caster Adjust Heavy-Duty 286
Caster Replacement 287
Disassemble 287
Heavy-Duty 287
Assemble 288
Heavy-Duty 288
Rear Link and Load Wheel 289
Remove 289
Install 291
Pull Rod 293
Remove 293
End Replacement 293
Install 293
Fork Height Adjustment 294
Heavy Duty Trucks 294
Light Duty Trucks 295
Rocker Arm 297
Remove 297
Install 298
Upper Link 299
Remove 299
Install 299
Entry Rollers 301
Replacement 301
Troubleshooting 302
550180406-8000YRM2105-(08-2022)-US-EN 305
General 311
How to Move a Disabled Truck 311
How to Tow the Lift Truck 312
How to Put a Lift Truck on Blocks 312
How to Raise Drive/Steer Tire 312
How to Raise Load Wheels 314
Accessing the Drive Unit Compartment 314
Special Precautions 316
Discharging the Capacitors 316
Welding Repairs 317
Maintenance Schedule 318
Maintenance Procedures Every 8 Hours or Daily 325
Checks With Key Switch Turned OFF 325
Battery 325
Hydraulic Leaks 326
Drive Tire, Load Wheels, Casters, and Frame 326
Checks With Key Switch Turned ON 327
Operation 327
Maintenance Procedures Every 250 Hours or Every 6 Weeks 329
Caster Lubrication 329
Electrical Connector Protection 329
Maintenance Procedures Every 1000 Hours or Every 6 Months 330
Hydraulic System 330
Hydraulic Oil 330
Hydraulic Reservoir Breather 330
Steering System 331
Power Assist Steering 331
Lift Linkage and Load Wheels 333
Casters 333
Caster Adjustment Check 333
Caster Adjust Heavy-Duty 333
Casters 334
Caster Shim Check 334
Caster Shim Adjust 335
Master Drive Unit, GK20 and GK25 336
Change Gear Oil 336
Check Oil Level 336
Kordel MDU 337
Drive Tire Check 337
Maintenance Procedures Every 2000 Hours or Yearly 338
Lubrication 338
Repack Load Wheel Bearings 338
Repack Steer Bearings (Manual Steer Only) 338
Hydraulic System 338
Oil Change 338
Brake 338
Electrical 339
MDU 339
Oil Change (GK20 or GK25) 339
Oil Change (Kordel) 340
Battery Maintenance 341
How to Charge the Battery 341
Equalizing Charge 341
Normal Charge 341
How to Change the Battery 342
Changing Battery With Rollers 343
Remove 343
Install 343
Transporting 344
Loading 344
Unloading 344
Preparation for Storage 345
Short-Term Storage (1 to 6 months) 345
Long-Term Storage (6 months or longer) 345
Preparation for Use 346
Preparation After Shipment 346
Preparation After Storage 346
550180406-8000YRM2105-(12-2018)-US-EN 349
General 353
How to Move a Disabled Truck 353
How to Tow the Lift Truck 354
How to Put a Lift Truck on Blocks 354
How to Raise Drive/Steer Tire 354
How to Raise Load Wheels 355
Accessing the Drive Unit Compartment 356
Special Precautions 357
Discharging the Capacitors 357
Welding Repairs 357
Maintenance Schedule 358
Maintenance Procedures Every 8 Hours or Daily 364
Checks With Key Switch Turned OFF 364
Battery 365
Hydraulic Leaks 365
Drive Tire, Load Wheels, Casters, and Frame 366
Checks With Key Switch Turned ON 366
Operation 366
Maintenance Procedures Every 250 Hours or Every 6 Weeks 368
Caster Lubrication 368
Electrical Connector Protection 368
Maintenance Procedures Every 1000 Hours or Every 6 Months 368
Hydraulic System 369
Hydraulic Oil 369
Hydraulic Reservoir Breather 369
Steering System 370
Power Assist Steering 370
Lift Linkage and Load Wheels 372
Casters 372
Caster Adjustment Check 372
Caster Adjust Heavy-Duty 372
Casters 373
Caster Shim Check 373
Caster Shim Adjust 374
Master Drive Unit, GK20 and GK25 375
Change Gear Oil 375
Check Oil Level 375
Kordel MDU 376
Drive Tire Check 376
Maintenance Procedures Every 2000 Hours or Yearly 376
Lubrication 377
Repack Load Wheel Bearings 377
Repack Steer Bearings (Manual Steer Only) 377
Hydraulic System 377
Oil Change 377
Brake 377
Electrical 378
MDU 378
Oil Change (GK20 or GK25) 378
Oil Change (Kordel) 379
Battery Maintenance 379
How to Charge the Battery 379
Equalizing Charge 379
Normal Charge 379
How to Change the Battery 380
Changing Battery With Rollers 381
Remove 381
Install 381
Transporting 382
Loading 382
Unloading 382
Preparation for Storage 383
Short-Term Storage (1 to 6 months) 383
Long-Term Storage (6 months or longer) 383
Preparation for Use 383
Preparation After Shipment 383
Preparation After Storage 383
550180409-8000YRM2104-(01-2022)-US-EN 387
Schematics/Diagrams 393
550180409-8000YRM2104-(07-2019)-US-EN 419
Schematics/Diagrams 423
550183996-0100YRM2100-(10-2018)-US-EN 447
General 451
Frame Separation and Assembly 453
Disassemble 453
Assemble 454
Painting Instructions 455
Label Replacement 455
550183997-1600YRM2101-(01-2023)-US-EN 459
General 465
Accessing the Drive Unit Compartment 465
Special Precautions 468
Calibration 469
Power Assist Steering Calibration 469
Calibrate the EPAS 470
Tiller Assembly 471
Tiller Head 471
Tiller Handle 471
Manual Steering 471
Remove 471
Install 472
Advanced Coast Control (ACC) 473
Remove 473
Install 474
Gas Spring 475
Discharging the Gas Spring 475
Remove 475
Install 476
Steer Motor 477
Repair 477
Steer Motor, Remove 477
Steer Motor, Install 478
Steer Support Assembly 479
Manual Steering 479
Remove (Complete Unit) 479
Disassemble 480
Assemble 481
Install (Complete Unit) 481
Electronic Power Assist Steering (EPAS) 481
Remove (Complete Unit) 481
Disassemble 482
Assemble 483
Install (Complete Unit) 484
Proximity Switch 484
(Option) Smart Coast Control 485
Disassemble 485
Assemble 486
Coast Control Adjustment Procedure 487
Troubleshooting 489
550183997-1600YRM2101-(06-2019)-US-EN 491
General 495
Accessing the Drive Unit Compartment 495
Special Precautions 497
Calibration 498
Power Assist Steering 498
Tiller Assembly 499
Tiller Head 499
Tiller Handle 499
Manual Steering 499
Remove 499
Install 501
Advanced Coast Control (ACC) 501
Remove 502
Install 503
Gas Spring 503
Discharging the Gas Spring 503
Remove 504
Install 504
Steer Motor 505
Repair 505
Steer Motor, Remove 505
Steer Motor, Install 505
Steer Support Assembly 506
Manual Steering 506
Remove (Complete Unit) 506
Disassemble 506
Assemble 507
Install (Complete Unit) 508
Electronic Power Assist Steering (EPAS) 508
Remove (Complete Unit) 508
Disassemble 509
Assemble 510
Install (Complete Unit) 511
Proximity Switch 511
(Option) Smart Coast Control 512
Disassemble 512
Assemble 513
Coast Control Adjustment Procedure 514
Troubleshooting 516
550183998-2200YRM2102-(01-2023)-US-EN 519
General 525
Accessing the Drive Unit Compartment 528
Special Precautions 529
Discharging the Internal Capacitors 529
Electromagnetic Shield 529
Electrical System Checks 530
Safety Precautions 530
Dash Display 533
Description 533
Operation 533
Remove 533
Install 534
Calibration 535
Power Assist Steering Calibration 535
Calibrate the EPAS 536
Controller 537
Controller, Replace 537
Remove 538
Install 538
Contactor Coil, Check 539
Fuses 539
Horn 540
Replace 540
Brake Sensor Operation 540
Brake Sensor 541
Removal 541
Height Limit 541
Control Handle (Standard) 542
Disassemble 542
Assemble 542
Control Handle (HD Option) 544
Disassemble 544
Top Cover 544
Remove Function Switches 544
Remove Throttle Sensor Assembly 545
Remove Handle Shaft Assembly 545
Remove the Coast Control Switches 545
Assemble 546
Install the Coast Control Switches 546
Install Switches Quick Pick 546
Install Handle Shaft Assembly 546
Install Throttle Sensor Assembly 546
Install Function Switches 547
Install Top Cover 547
Power Assist Steering (EPAS) 548
Steer Motor 548
Proximity Switch 548
Remove 549
Install 549
Smart Steer 550
Remove 550
Install 550
Aux Control Box Switches 551
Remove 551
Install 551
Lights 552
Work Light 552
Remove 552
Install 552
Strobe Light 552
Remove 552
Install 552
Platform Lights 553
Remove 553
Install 553
Trailer Unloading Lights 553
Remove 553
Install 553
Telemetry Wireless Asset Management System 554
General 554
Level 1 – Wireless Monitoring (WIFI Group) 554
Communication Module 558
Basic Operations 558
ID Card / ID Reader 558
Interlock Relay 559
Buzzer 559
Wakeup 559
Checklist 560
Locate and Install the Communication Module 560
Install the Power Harness 561
Install the Interlock Harness 563
Install the Access Control Kit, Antenna and Buzzer 564
Install the antenna 565
Install buzzer 565
Install the ID Card Reader 566
Install the Checklist Display and Harness 568
First Switch On 569
Tool Operation 570
Connection 571
Wireless Settings 573
Telemetry Tool Communication Problems 574
Truck Activation 578
DC to DC Converter 579
Troubleshooting 580
550183998-2200YRM2102-(06-2019)-US-EN 583
General 587
Accessing the Drive Unit Compartment 589
Special Precautions 590
Discharging the Internal Capacitors 590
Electromagnetic Shield 591
Electrical System Checks 591
Safety Precautions 591
Dash Display 593
Description 593
Operation 593
Remove 594
Install 594
Calibration 595
Power Assist Steering Sensor 595
Controller 595
Controller, Replace 596
Remove 597
Install 597
Contactor Coil, Check 598
Fuses 598
Horn 599
Replace 599
Brake Sensor Operation 599
Brake Sensor 600
Removal 600
Height Limit 600
Control Handle (Standard) 601
Disassemble 601
Assemble 601
Control Handle (HD Option) 603
Disassemble 603
Top Cover 603
Remove Function Switches 603
Remove Throttle Sensor Assembly 604
Remove Handle Shaft Assembly 604
Remove the Coast Control Switches 604
Assemble 605
Install the Coast Control Switches 605
Install Switches Quick Pick 605
Install Handle Shaft Assembly 605
Install Throttle Sensor Assembly 605
Install Function Switches 606
Install Top Cover 606
Power Assist Steering (EPAS) 607
Steer Motor 607
Proximity Switch 607
Remove 607
Install 607
Calibration 608
Smart Steer 609
Remove 609
Install 609
Aux Control Box Switches 610
Remove 610
Install 610
Lights 611
Work Light 611
Remove 611
Install 611
Strobe Light 611
Remove 611
Install 611
Platform Lights 612
Remove 612
Install 612
Trailer Unloading Lights 612
Remove 612
Install 612
Telemetry Wireless Asset Management System 613
General 613
Level 1 – Wireless Monitoring (WIFI Group) 613
Communication Module 617
Basic Operations 617
ID Card / ID Reader 617
Interlock Relay 618
Buzzer 618
Wakeup 618
Checklist 618
Locate and Install the Communication Module 619
Install the Power Harness 620
Install the Interlock Harness 621
Install the Access Control Kit, Antenna and Buzzer 624
Install the antenna 624
Install buzzer 625
Install the ID Card Reader 625
Install the Checklist Display and Harness 627
First Switch On 629
Tool Operation 629
Connection 630
Wireless Settings 632
Telemetry Tool Communication Problems 634
Truck Activation 638
DC to DC Converter 639
Troubleshooting 639
550183999-8000YRM2103-(01-2019)-US-EN 641
Hydraulic System 645
Hydraulic Oils 645
Gear Oils 646
Grease 646
Truck Weight 646
Tire Sizes 647
Torque Specifications 648
Caster Assembly 648
Drive Wheel Assembly 648
Master Drive Unit 648
Standard Steering 648
Power Assist Steering 649
Brake 649
Electrical 649
Lift Mechanism 649
Hydraulics 649
Battery Specifications 649
550205681-2200YRM2161-(01-2023)-US-EN 653
How to navigate display 659
Navigation Key 659
Startup Sequence 660
Home screen 663
Logging in 664
Log in 664
Enable/disable password (optional) 665
View the fault log 666
Fault log 666
View hour meters 668
Hour Meters 668
View the hardware and software versions 669
View hardware and software versions 669
View diagnostics information 670
View diagnostics information 670
Inputs diagnostics information 670
Drive diagnostics information 671
Metrics diagnostics information 672
Setting up performance modes 674
Set up performance modes 674
Selecting a performance mode 676
Select a performance mode 676
Setting up Coast Control 677
Set up Coast Control 677
Setting up Smart Cruise 679
Set up Smart Cruise 679
Setting up Dual Acceleration 681
Set up Dual Acceleration 681
Setting up the energy system 683
Set up energy system 683
Set Battery Type 683
Set BDI Source 684
Set BDI settings 685
BDI Startup Full 685
BDI Full 685
BDI Empty 685
BDI Reset 685
Lift Interrupt 685
Setting up the Electronic Positional Assist Steering (EPAS) 686
Set Up EPAS 686
Min Str Assist Fwd 686
Min Str Assist Rev 686
Setting up Unloading Lights 687
Unloading lights 687
Activate 688
True Direction 688
Time Rate On 688
Time Rate Off 688
Reverse Time 688
Forward Time 688
Calibrating EPAS 689
Power Assist Steering Calibration 689
Calibrate the EPAS 690
Other settings 691
Set up other features 691
Performance Mode parameters 692
Coast Control parameters 693
Display Flowchart 693
550205681-2200YRM2161-(03-2020)-US-EN 697
How to navigate display 701
Navigation Key 701
Startup Sequence 701
Home screen 705
Logging in 705
Log in 705
Enable/disable password (optional) 707
View the fault log 707
Fault log 707
View hour meters 709
Hour Meters 709
View the hardware and software versions 710
View hardware and software versions 710
View diagnostics information 710
View diagnostics information 710
Inputs diagnostics information 711
Drive diagnostics information 712
Metrics diagnostics information 713
Setting up performance modes 714
Set up performance modes 714
Selecting a performance mode 716
Select a performance mode 716
Setting up Coast Control 716
Set up Coast Control 716
Setting up Smart Cruise 718
Set up Smart Cruise 718
Setting up Dual Acceleration 720
Set up Dual Acceleration 720
Setting up the energy system 722
Set up energy system 722
Set Battery Type 722
Set BDI Source 723
Set BDI settings 723
BDI Startup Full 723
BDI Full 723
BDI Empty 723
BDI Reset 724
Lift Interrupt 724
Setting up the Electronic Positional Assist Steering (EPAS) 724
Set Up EPAS 724
Min Str Assist Fwd 725
Min Str Assist Rev 725
Setting up Unloading Lights 725
Unloading lights 725
Activate 725
True Direction 725
Time Rate On 725
Time Rate Off 726
Reverse Time 726
Forward Time 726
Calibrating EPAS 726
Calibrate the EPAS 726
Other settings 727
Set up other features 727
Performance Mode parameters 727
Coast Control parameters 729
Display Flowchart 729
550276785-9000YRM2486-(09-2022)-US-EN 733
Error code reference charts 737
Vehicle System Manager (VSM) Error Code Reference Chart 737

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