Yale Forklift D902 (MTR005-F) Service Manual – PDF DOWNLOAD

Description

Yale Forklift D902 (MTR005-F) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift D902 (MTR005-F) Service Manual – PDF DOWNLOAD

Language : English
Pages : 390
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift D902 (MTR005-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
550090222-8000YRM1634-(03-2018)-US-EN 97
550090441-2200YRM1631-(07-2017)-US-EN 115
General 121
Introduction 121
Description 121
Button Keypad 121
LED Indicator Lights 121
LCD Screen 122
Dash Display Menu Access 122
Menu Navigation 122
Dash Display Menu Operation 122
Nodes 122
Menu Structure 123
Service-Level Menu 124
Hour Meters 125
H1 Truck Hours 125
H2 Traction Hours 125
H3 Pump Hours 125
H5 Odometer Hours 125
H10 Display Hours 125
H32 Combinatin Node Hours 125
Performance 126
Performance Level 1 126
P1 1 Forward 127
P1 2 Reverse 127
P1 3 Acceleration 127
P1 4 Plug 127
P1 5 Coast 127
P1 6 Lift Speed 127
P1 7 Lower Speed 127
Operator Passwords 128
Add Password 128
Delete Password 128
Edit Password 128
Operator Password 128
Clear Log 129
Operator Logs 129
Operator 1-150 129
Information 130
I1 Model 130
I3 Serial Number 130
I5 Truck Voltage 130
Settings 131
S1 Metric 131
S2 User Performance 131
S3 Timeout 131
S4 Battery Type 131
S5 BDI Startup Full 131
S6 BDI Full 131
S7 BDI Empty 131
S8 BDI Reset 131
S9 Lift Interrupt 132
S10 Audible Warning 132
S11 Visual Warning 132
S12 Checklist 132
S13 Maint Reminder 132
S14 Restore Default 132
S15 Truck Lockout 132
S61 Extended Shift 133
S63 Walk Speed Accel 133
S64 Walk Speed Decel 133
S65 Pick Accel 133
S66 Pick Decel 133
S67 Min Steer Assist F 133
S68 Min Steer Assist R 133
Software Versions 133
Error Log 134
(E1) Error Log 1 135
Error 1 1 (E1 1) 135
Error 1 2 (E1 2) 135
Error 1 3 (E1 3) 135
Error 1 4 (E1 4) 135
Diagnostics 136
Diagnostics 136
D1 Status 136
D2 Input 136
D3 Output 136
D1 Status 136
D1 1 CAN 137
D1 2 Contactor 137
D1 3 Full Traction 137
D1 4 Limp Traction 137
D1 6 Lift 137
D1 7 Lower 137
D2 Inputs 138
D2 10 Display 138
D2 10 1 Bus Error 138
D2 10 2 Bus Max Error 138
D2 10 32 Combination Controller 138
D2 10 60 CTRL Hand 138
D2 32 Combination Controller 139
D2 32 1 Target Speed 141
D2 32 2 Motor Speed 141
D2 32 3 Motor Encoder 141
D2 32 4 Controller Temperature 141
D2 32 5 Motor Temperature 141
D2 32 6 Motor Current 141
D2 32 7 Cap Voltage 142
D2 32 8 Cap Maximum Voltage 142
D2 32 9 Cap Minimum Voltage 142
D2 32 10 Key Voltage 142
D2 32 11 Key Max Voltage 142
D2 32 12 Key Minimum Voltage 142
D2 32 16 MC Connct 142
D2 32 17 MC Current 142
D2 32 18 Horn Switch 142
D2 32 19 Brake Switch 142
D2 32 20 Horn Connect 142
D2 32 22 Pump Current 142
D2 32 22 Rabbit Switch 142
D2 32 26 Regen Switch 142
D2 32 27 Lift Switch 142
D2 32 28 Lower Switch 142
D2 32 31 Load Hold Connect 142
D2 32 32 Load Hold Current 143
D2 32 33 SOC 143
D2 60 Control Handle 143
D2 60 1 Horn Switch 143
D2 60 2 Lift Switch 143
D2 60 4 Lower Switch 143
D2 60 10 Tilt Up SW 143
D2 60 11 Tilt Down SW 143
D2 50 14 4th Aux IN SW 143
D2 50 15 4th Aux OUT SW 144
D2 60 19 Trac Input 144
D3 Output 144
D3 10 Display 144
D3 10 10 Display Com 144
D3 10 32 Combination Com 144
D3 10 60 Handle Com 144
D3 32 Traction 145
D3 32 1 U-V Line DC Curr 146
D3 32 2 U-W Line DC Curr 146
D3 32 3 V-W Line DC Curr 146
D3 32 6 Pump DC Current 146
D3 32 7 Pump Motor Short 146
D3 32 9 Load Hold 146
D3 32 10 Backup Alarm 146
D3 32 11 Strobe 146
D3 32 12 Horn 146
Calibration 147
147
C4 Throttle 147
550090934-0100YRM1580-(01-2016)-US-EN 151
General 155
Description 155
Features 158

MPC060-VG and MPC080-VG
158

MTR005-F and MTR007-F
158
Covers 158
Special Precautions 158
Frame Separation and Assembly 158

MPC060-VG and MPC080-VG
158
Frame Separation 158
Painting Instructions 159
Label Replacement 159
Battery Compartment 161
550090937-1600YRM1627-(01-2016)-US-EN 165
Introduction 169
General 169
Description of Operation 169
Special Precautions 170
Control Handle 171
Remove 171
Install 174
Support Assembly 174
Remove 174
Disassemble 174
Repair 175
Assemble 175
Install 175
Control Handle and Support Assembly (Complete) 176
Remove 176
Install 176
Troubleshooting 178
550090938-1800YRM1628-(01-2016)-US-EN 181
General 185
Accessing the Drive Unit Compartment 185
Description 186
Special Precautions 187
Brake Check 188
Brake Release 188
Brake Apply 188
Air Gap 189
Hold On Grade Test 190
Brake Assembly Repair 190

MPC060-VG and MTR005-F
191
Remove 191
Repair 192
Install 192

MPC080-VG and MTR007-F
193
Remove 193
Repair 194
Install 194
Troubleshooting 194
550090940-2200YRM1630-(01-2016)-US-EN 199
General 203
Introduction 203
Description 203
Button Keypad 203
LED Indicator Lights 203
LCD Screen 204
Dash Display Menu Access 204
Menu Navigation 204
Dash Display Menu Operation 205
Nodes 205
Menu Structure 205
Supervisor-Level Menu 206
Hour Meters 206
H1 Truck Hours 208
H2 Traction Hours 208
H3 Pump Hours 208
H5 Odometer Hours 208
H10 Display Hours 208
H32 Combination Node Hours 208
Performance 208
Performance Level 1 209
P1 1 Forward 210
P1 2 Reverse 210
P1 3 Acceleration 210
P1 4 Plug 210
P1 5 Coast 210
P1 6 Lift Speed 210
P1 7 Lower Speed 210
Operator Passwords 210
Add Password 211
Delete Password 211
Edit Password 211
Operator Password 211
Clear Log 211
Operator Logs 211
Operator 1-150 212
Information 212
I1 Model 213
I3 Serial Number 213
I5 Truck Voltage 213
Software Versions 213
550090942-2200YRM1632-(01-2016)-US-EN 217
General 221
Description of Operation 222
Special Precautions 226
Discharging the Capacitors 226
Electrical System Checks 227
Repairs 229
Calibration Mode 229
Controller, Replace 229
Remove 229
Install 230
Control Module 231
Check 231
Remove 233
Install 234
Contactor 234
Check 234
Remove 234
Install 235
Key Switch 235
Remove 235
Install 236
Parking Brake Switch 236
Remove 236
Install 237
Fuses 237
Horn 237
Replace 237
High Speed Switch Assembly 238
Remove 238
Install 239
Control Handle 239
Disassemble 239
Hand-brake 239
Upper Cover 240
Handle Shaft 241
Lower Cover 241
Directional/Throttle Switch 241
Neutral Switches 241
Throttle Sensor 241
Assemble 245
Directional/Throttle Switch 245
Neutral Switches 245
Throttle Sensor 246
Lower Cover 246
Handle Shaft 246
Upper Cover 247
Hand-brake 247
Lift Pump Motor (MPC060-VG and MPC080-VG Only) 247
Remove 248
Install 248
Troubleshooting 248
General Troubleshooting 248
550090945-9000YRM1657-(01-2016)-US-EN 253
SECTION 9030 ELECTRICAL SYSTEM 257
Group 03 – General Maintenance and Diagnostic Data 259
Group 20 – Diagnostic Trouble Codes 269
550142686-0620YRM2005-(12-2018)-US-EN 317
General 321
Accessing the Drive Unit Compartment 321
Unit Codes: C896, D896, E896 321
Unit Codes: B894, B897, B891, D820, D819, D821, D902 322
Special Precautions 323
Discharging the Capacitors 323
Description 324
AC Motor Repair 324
Remove 324
Install 325
Troubleshooting 326
550142687-0630YRM2006-(12-2019)-US-EN 331
Safety Precautions 335
General 337
Check Oil Level 337
Drive Tire 338
Remove 338
Install 338
Master Drive Unit, Kordel® Before December, 2019 338
Remove 338
Disassemble 340
Bevel Gear Set (Ring and Pinion) 340
Remove 340
Install 342
Flange Shaft Seal 342
Remove 342
Install 343
Steering Bearing 343
Remove 343
Replace 343
Master Drive Unit, Kordel® After December, 2019 343
Remove 343
Disassemble 345
Seal Ring 345
Helical Pinion 345
Steering Bearing 346
Assemble 347
Steering Bearing 347
Helical Pinion 347
Seal Ring 347
Install 347
Troubleshooting 348
550142688-8000YRM2007-(01-2016)-US-EN 351
Master Drive Unit Specifications 355
Gear Oils 355
Grease 355
Tire Specifications 356
Torque Specifications 357
Master Drive Unit 357
Brake 357
Steering 357
Electrical 357
Coupler 357
Travel Speeds 358
Truck Weight 358
Battery Specifications and Adjustments 358
550142689-8000YRM2008-(04-2020)-US-EN 363
Maintenance Procedures Every 8 Hours or Daily 367
Checks With the Key Switch OFF 367
Safety Labels 367
Battery 367
Frame 368
Drive Tire, Casters (Optional), and Trail Wheels or Load Wheels 368
Lift Linkage ()MPC060/080-VG 368
Coupler ()MTR005/007-F 368
Steering Operation 368
Checks With the Key Switch ON 369
Control Handle 369
Gauges 369
Fuses 369
High Speed Switch 369
Hydraulic ()MPC060/080-VG 370
Hand Brake 370
Maintenance Procedures Every 250 Hours or Every 6 Weeks 370
Caster Lubrication 370
Maintenance Procedures Every 500 Hours or Every 3 Months 371
Hydraulic System 371
Hydraulic Oil 371
Hydraulic Reservoir Breather 371
Steering System 372
Steer Column and Tilt Mechanism 372
Lift Linkage and Load Wheels (MPC060/080-VG) 372
Casters 372
Caster Adjustment Check 372
Caster Adjust Heavy-Duty 372
Master Drive Unit 373
Change Gear Oil 373
Check Oil Level 373
Drive Tire Check 374
Maintenance Procedures Every 2000 Hours or Yearly 374
Trail Wheel Bearings ()MTR005/007-F 374
Remove 374
Inspect 374
Install 374
Hydraulic System (MPC060/080-VG) 376
Oil Change 376
Master Drive Unit 376
Oil Change 376
Brakes 377
Battery Maintenance 377
How to Charge the Battery 377
Equalizing Charge 378
Normal Charge 378
How to Change the Battery 378
Welding Repairs 379
Maintenance Schedule 379
Special Precautions 384
Discharging the Capacitors 384
Introduction 385
General 385
Drive Unit Compartment Covers 386
Remove 386
Install 387
How to Move a Disabled Truck 387
How to Tow the Truck 388
How to Put the Truck on Blocks 389
How to Raise Drive/Steer Tire 389
How to Raise the Load Wheels 389

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