Yale Forklift D896 (MPE060-F) Service Manual – PDF DOWNLOAD

Description

Yale Forklift D896 (MPE060-F) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift D896 (MPE060-F) Service Manual – PDF DOWNLOAD

Language : English
Pages : 532
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift D896 (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
524274699-0620YRM1283-(12-2018)-US-EN 97
General 101
Accessing the Drive Unit Compartment 101
MPE060VG and MPE080VGMPE060VH and MPE080VH 101
MPC060/080-F and MTR005/007-F 102
Special Precautions 104
Discharging the Capacitors 104
Description 106
AC Motor Repair 106
Remove 106
Disassemble 107
Inspect 109
Assemble 109
Install 109
Troubleshooting 110
550090075-8000YRM1643-(03-2018)-US-EN 115
550091255-0100YRM1636-(02-2017)-US-EN 143
General 147
Frame Separation and Assembly 147
Disassemble 148
Assemble 148
Painting Instructions 149
Label Replacement 149
550091256-1600YRM1637-(02-2017)-US-EN 153
General 157
Accessing the Drive Unit Compartment 157
Special Precautions 158
Electromagnetic Shield 158
Calibration 159
Power Assist Steering 159
Control Handle 160
Control Handle Head 160
Control Handle 160
Standard Steering 160
Remove 161
Install 161
Power Assist Steering 163
Remove 163
Install 164
Gas Spring 165
Discharging the Gas Spring 165
Remove 165
Install 166
Articulating Shaft and Pinions (EPAS) 166
Remove 167
Pinion Repair 168
Upper Pinion 168
Lower Pinion 169
Install 170
Steer Motor Assembly 170
Repair 170
Steer Motor, Replace 171
Steer Motor Gear, Replace 172
Gearbox/Complete Assembly, Replace 172
Steer Support Assembly 173
Standard Steering 173
Remove (Complete Unit) 173
Disassemble 173
Assemble 175
Install (Complete Unit) 175
Power Assist Steering (Option) 176
Remove (Complete Unit) 176
Disassemble 176
Support Base 176
Steer Swivel 178
Assemble 178
Steer Swivel 178
Support Base 179
Install (Complete Unit) 180

Smart Coast Control (Option) 181
Disassemble 181
Assemble 183
Coast Control Adjustment Procedure 184
Troubleshooting 186
550091257-1800YRM1638-(10-2019)-US-EN 189
General 193
Accessing the Drive Unit Compartment 193
Description 194
Special Precautions 195
Brake Check 196
Brake Release 196
Brake Apply 197
Air Gap 197
Hold On Grade Test 199
Brake Assembly Repair 199
MPE060-F, MPE060-G, MPE060-VG and MPE060VH 199
Remove 199
Repair 201
Install 201
MPE080-VG and MPE080VH 201
Remove 201
Repair 203
Install 203
Troubleshooting 204
550091258-1900YRM1639-(12-2018)-US-EN 207
General 211
Description of Operation 211
Lifting a Load 212
Lowering a Load 216
Hydraulic Lines 216
Hydraulic Oil 216
Clean 216
Sound Level 216
Special Precautions 216
Hydraulic Reservoir 217
Drive Unit Compartment Covers 217
Lift Pump and Motor 219
General 219
Remove 219
Lift Pump and Motor Assembly 219
Disassemble 220
Remove Reservoir 220
Remove Pump Motor 222
Disassemble Pump 222
Assemble 222
Assemble Pump 222
Install Pump Motor 222
Install Reservoir to Pump 223
Install 223
Lift Pump and Motor Assembly 223
Valve Repair 224
Lowering Valve 224
Remove 224
Install 224
Relief Valve 225
Remove 225
Install 225
Check Valve 225
Remove 225
Install 226
Lift Cylinder 226
Remove 226
Disassemble 228
Assemble 228
Install 229
Relief Valve Pressure Check 229
Relief Valve Adjust 231
Troubleshooting 231
Lift Assemblies 231
Lift Cylinders 232
Lift Pump and Motor Assembly 233
550091259-2200YRM1658-(02-2017)-US-EN 237
General 241
Introduction 241
Description 241
Button Keypad 241
LED Indicator Lights 241
LCD Screen 241
Dash Display Menu Access 242
Menu Navigation 242
Dash Display Menu Operation 242
Nodes 242
Menu Structure 243
Supervisor-Level Menu 243
Hour Meters 244
H1 Truck Hours 244
H2 Traction Hours 244
H3 Pump Hours 244
H4 Steer Hours 244
H5 Odometer Hours 245
H10 Display Hours 245
H32 Combination Node Hours 245
H40 Steer Node Hours 245
Performance 245
Performance Level 1 246
P1 1 Forward 247
P1 2 Reverse 247
P1 3 Acceleration 247
P1 4 Plug 247
P1 5 Coast 247
P1 6 Lift Speed 247
P1 7 Lower Speed 247
P1 26 Pick Speed 247
P1 27 Pick Accel 247
P1 28 Pick Decel 248
P1 29 MIN Steer Assist F 248
P1 30 MIN Steer Assist R 248
P1 31 Max Steer Assist 248
Operator Passwords 248
Add Password 249
Delete Password 249
Edit Password 249
Operator Password 249
Clear Log 249
Operator Logs 250
Operator 1-150 250
Information 251
I1 Model 251
I3 Serial Number 251
I5 Truck Voltage 251
Software Versions 252
550091260-2200YRM1659-(02-2017)-US-EN 255
General 261
Introduction 261
Description 261
Button Keypad 261
LED Indicator Lights 261
LCD Screen 261
Dash Display Menu Access 262
Menu Navigation 262
Dash Display Menu Operation 262
Nodes 262
Menu Structure 263
Service-Level Menu 264
Hour Meters 265
H1 Truck Hours 266
H2 Traction Hours 266
H3 Pump Hours 266
H4 Steer Hours 266
H5 Odometer Hours 266
H10 Display Hours 266
H32 Combinatin Node Hours 266
H40 Steer Node Hours 266
Performance 266
Performance Level 1 267
P1 1 Forward 267
P1 2 Reverse 267
P1 3 Acceleration 267
P1 4 Plug 267
P1 5 Coast 267
P1 6 Lift Speed 268
P1 7 Lower Speed 268
Operator Passwords 268
Add Password 269
Delete Password 269
Edit Password 269
Operator Password 269
Clear Log 269
Operator Logs 269
Operator 1-150 269
Information 270
I1 Model 270
I3 Serial Number 270
I5 Truck Voltage 270
Settings 271
S1 Metric 273
S2 User Performance 273
S3 Timeout 273
S4 Battery Type 273
S5 BDI Startup Full 273
S6 BDI Full 273
S7 BDI Empty 273
S8 BDI Reset 273
S9 Lift Interrupt 273
S10 Audible Warning 273
S11 Visual Warning 274
S12 Checklist 274
S13 Maint Reminder 274
S14 Restore Default 274
S15 Truck Lockout 274
S61 Extended Shift 274
S63 Walk Speed Accel 274
S64 Walk Speed Decel 275
S65 Pick Accel 275
S66 Pick Decel 275
S67 Min Steer Assist F 275
S68 Min Steer Assist R 275
Software Versions 275
Error Log 276
(E1) Error Log 1 277
Error 1 1 (E1 1) 277
Error 1 2 (E1 2) 277
Error 1 3 (E1 3) 277
Error 1 4 (E1 4) 277
Diagnostics 278
Diagnostics 278
D1 Status 278
D2 Input 278
D3 Output 278
D1 Status 278
D1 1 CAN 279
D1 2 Contactor 279
D1 3 Full Traction 279
D1 4 Limp Traction 279
D1 5 Steering 279
D1 6 Lift 279
D1 7 Lower 279
D1 11 Emergency Reverse 279
D1 12 Pick Function 280
D2 Inputs 280
D2 10 Display 280
D2 10 1 Bus Error 281
D2 10 2 Bus Max Error 281
D2 10 32 Combination Controller 281
D2 10 40 Steer 281
D2 10 60 CTRL Hand 281
D2 32 Combination Controller 281
D2 32 1 Target Speed 284
D2 32 2 Motor Speed 284
D2 32 3 Motor Encoder 284
D2 32 4 Controller Temperature 284
D2 32 5 Motor Temperature 284
D2 32 6 Motor Current 284
D2 32 7 Cap Voltage 285
D2 32 8 Cap Maximum Voltage 285
D2 32 9 Cap Minimum Voltage 285
D2 32 10 Key Voltage 285
D2 32 11 Key Max Voltage 285
D2 32 12 Key Minimum Voltage 285
D2 32 16 MC Connct 285
D2 32 17 MC Current 285
D2 32 18 Horn Switch 285
D2 32 19 Brake Switch 285
D2 32 20 Horn Connect 285
D2 32 22 Pump Current 285
D2 32 22 Rabbit Switch 285
D2 32 23 ACC Switch 285
D2 32 24 Donut Switch 285
D2 32 25 Belly Switch NC 285
D2 32 26 Regen Switch 285
D2 32 27 Lift Switch 286
D2 32 28 Lower Switch 286
D2 32 29 Steer Status 286
D2 32 31 Load Hold Connect 286
D2 32 32 Load Hold Current 286
D2 32 33 SOC 286
D2 40 Steer 286
D2 40 5 Cont Temp 286
D2 40 15 Torque 1 Switch 286
D2 40 17 Center Prox SW 286
D2 40 19 Steer Angle 287
D2 60 Control Handle 287
D2 60 1 Horn Switch 288
D2 60 2 Lift Switch 288
D2 60 3 Lift Switch 2 288
D2 60 4 Lower Switch 288
D2 60 5 Lower Switch 2 288
D2 60 6 Pick Switch 288
D2 60 7 Pick Switch 2 288
D2 60 8 Belly Switch NO 288
D2 60 9 Regen Switch 288
D2 60 10 Tilt Up SW 288
D2 60 11 Tilt Down SW 289
D2 50 14 4th Aux IN SW 289
D2 50 15 4th Aux OUT SW 289
D2 60 19 Trac Input 289
D2 60 20 Lift/Lower Input 289
D3 Output 289
D3 10 Display 289
D3 10 10 Display Com 289
D3 10 32 Combination Com 289
D3 10 40 Steer Com 290
D3 10 60 Handle Com 290
D3 32 Traction 290
D3 32 1 U-V Line DC Curr 291
D3 32 2 U-W Line DC Curr 291
D3 32 3 V-W Line DC Curr 291
D3 32 6 Pump DC Current 291
D3 32 7 Pump Motor Short 291
D3 32 8 ACC Coil 291
D3 32 9 Load Hold 291
D3 32 10 Backup Alarm 291
D3 32 11 Strobe 291
D3 32 12 Horn 291
Calibration 291
292
C4 Throttle 292
550091261-2200YRM1640-(02-2017)-US-EN 295
General 299
Accessing the Drive Unit Compartment 300
Special Precautions 301
Discharging the Internal Capacitors 301
Electromagnetic Shield 301
Electrical System Checks 302
Safety Precautions 302
Calibration 305
Power Assist Steering Sensor 305
Repairs 305
Controller, Replace 306
Remove 306
Install 306
Contactor Coil, Check 307
Fuses 307
Horn 308
Replace 308
Brake Switch Operation 308
Brake and Interlock Switches 308
Standard Steering 309
Power Assist Steering 310
Height Limit 310
Control Handle (Standard) 311
Disassemble 311
Assemble 311
Control Handle (HD Option) 312
Disassemble 313
Remove Top Cover 313
Remove Function Switches 313
Remove Throttle Sensor Assembly 313
Remove Handle Shaft Assembly 314
Remove Quick Pick Switches 314
Remove the Coast Control Switches 315
Assemble 315
Install the Coast Control Switches 315
Install Quick Pick Switches 315
Install Handle Shaft Assembly 315
Install Throttle Sensor Assembly 316
Install Function Switches 316
Install Top Cover 316
Control Module 317
Check 317
Remove 319
Install 319
Proximity Switch (Power Assist Steering) 320
Remove 320
Install 320
Remote Control Box Switches 321
Remove 321
Install 321
Troubleshooting 321
550091262-4000YRM1641-(05-2019)-US-EN 325
General 329
Description of Operation 329
Load Wheel 329
Remove 329
Install 331
Casters 331
Caster Adjustment Check 331
Caster Adjust Heavy-Duty 332
Caster Replacement 332
Disassemble 333
Heavy-Duty 333
Assemble 334
Heavy-Duty 334
Rear Link and Load Wheel 334
Remove 334
Install 336
Pull Rod 337
Remove 338
End Replacement 338
Install 338
Fork Height Adjustment 339
Heavy Duty Trucks 339
Light Duty Trucks 340
Rocker Arm 341
Remove 341
Install 342
Upper Link 342
Remove 343
Install 343
Entry Rollers 344
Replacement 344
Troubleshooting 344
550091262-4000YRM1641-(08-2022)-US-EN 347
General 351
Description of Operation 351
Load Wheel 351
Remove 351
Install 353
Casters 354
Caster Adjustment Check 354
Caster Adjust Heavy-Duty 354
Caster Replacement 355
Disassemble 355
Heavy-Duty 355
Assemble 356
Heavy-Duty 356
Rear Link and Load Wheel 357
Remove 357
Install 359
Pull Rod 361
Remove 361
End Replacement 361
Install 361
Fork Height Adjustment 362
Heavy Duty Trucks 362
Light Duty Trucks 363
Rocker Arm 365
Remove 365
Install 366
Upper Link 367
Remove 367
Install 367
Entry Rollers 369
Replacement 369
Troubleshooting 370
550091264-9000YRM1660-(02-2017)-US-EN 373
SECTION 9030 ELECTRICAL SYSTEM 377
Group 03 – General Maintenance and Diagnostic Data 379
Group 20 – Diagnostic Trouble Codes 389
550142686-0620YRM2005-(12-2018)-US-EN 455
General 459
Accessing the Drive Unit Compartment 459
Unit Codes: C896, D896, E896 459
Unit Codes: B894, B897, B891, D820, D819, D821, D902 460
Special Precautions 461
Discharging the Capacitors 461
Description 462
AC Motor Repair 462
Remove 462
Install 463
Troubleshooting 464
550142687-0630YRM2006-(12-2019)-US-EN 469
Safety Precautions 473
General 475
Check Oil Level 475
Drive Tire 476
Remove 476
Install 476
Master Drive Unit, Kordel® Before December, 2019 476
Remove 476
Disassemble 478
Bevel Gear Set (Ring and Pinion) 478
Remove 478
Install 480
Flange Shaft Seal 480
Remove 480
Install 481
Steering Bearing 481
Remove 481
Replace 481
Master Drive Unit, Kordel® After December, 2019 481
Remove 481
Disassemble 483
Seal Ring 483
Helical Pinion 483
Steering Bearing 484
Assemble 485
Steering Bearing 485
Helical Pinion 485
Seal Ring 485
Install 485
Troubleshooting 486
550175945-8000YRM2073-(04-2017)-US-EN 489
Hydraulic System 493
Hydraulic Oils 493
Gear Oils 493
Grease 493
Truck Weight 494
Tire Sizes 494
Torque Specifications 495
Caster Assembly 495
Drive Wheel Assembly 495
Master Drive Unit 495
Standard Steering 495
Power Assist Steering 495
Brake 495
Electrical 495
Lift Mechanism 495
Hydraulics 495
Battery Specifications 496
550175948-8000YRM2074-(04-2017)-US-EN 501
General 505
How to Move a Disabled Truck 505
How to Tow the Lift Truck 506
How to Put a Lift Truck on Blocks 506
How to Raise Drive/Steer Tire 507
How to Raise Load Wheels 508
Accessing the Drive Unit Compartment 508
Special Precautions 509
Discharging the Capacitors 509
Welding Repairs 510
Maintenance Schedule 510
Maintenance Procedures Every 8 Hours or Daily 515
Checks With Key Switch Turned OFF 515
Battery 515
Hydraulic Leaks 516
Drive Tire, Load Wheels, Casters, and Frame 516
Checks With Key Switch Turned ON 517
Operation 517
Maintenance Procedures Every 250 Hours or Every 6 Weeks 519
Caster Lubrication 519
Maintenance Procedures Every 500 Hours or Every 3 Months 519
Hydraulic System 520
Hydraulic Oil 520
Hydraulic Reservoir Breather 520
Steering System 520
Power Assist Steering 520
Lift Linkage and Load Wheels 521
Casters 521
Caster Adjustment Check 521
Caster Adjust Heavy-Duty 521
522
Caster Shim Check 522
Caster Shim Adjust 523
Master Drive Unit 524
Change Gear Oil 524
Check Oil Level 524
Drive Tire Check 525
Maintenance Procedures Every 2000 Hours or Yearly 525
Lubrication 525
Repack Load Wheel Bearings 525
Repack Steer Bearings (Manual Steer Only) 525
Hydraulic System 525
Oil Change 525
Brake 526
Electrical 526
MDU 526
Oil Change 526
Battery Maintenance 527
How to Charge the Battery 527
Equalizing Charge 527
Normal Charge 528
How to Change the Battery 528
Transporting 528
Loading 529
Unloading 529
Preparation for Storage 530
Short-Term Storage (1 to 6 months) 530
Long-Term Storage (6 months or longer) 530
Preparation for Use 530
Preparation After Shipment 530
Preparation After Storage 530

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