Yale Forklift E896 (MPE060-G) Service Manual – PDF DOWNLOAD

Description

Yale Forklift E896 (MPE060-G) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift E896 (MPE060-G) Service Manual – PDF DOWNLOAD

Language : English
Pages : 704
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift E896 (MPE060-G) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(03-2020)-US-EN 1
General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
524158040-2240YRM0001-(01-2023)-US-EN 21
General 27
Battery Type 27
Lead-Acid Batteries 27
Lithium-Ion Batteries 28
Specific Gravity 28
Chemical Reaction in a Cell 28
Electrical Terms 30
Battery Selection 31
Battery Voltage 32
Battery as a Counterweight 32
Battery Ratings 32
Kilowatt-Hours 32
Battery Maintenance 33
Safety Procedures 33
Maintenance Records 33
New Battery 33
Cleaning Battery 34
Adding Water to Battery 36
Hydrometer 36
Battery Temperature 37
Charging Battery 38
Types of Battery Charges 39
Methods of Charging 40
Troubleshooting Charger 41
Knowing When Battery Is Fully Charged 41
Where to Charge Batteries 41
Equipment Needed 41
Battery Connectors 42
Battery Care 42
Troubleshooting 44
524158040-2240YRM0001-(03-2020)-US-EN 49
General 53
Battery Type 53
Lead-Acid Batteries 53
Lithium-Ion Batteries 54
Specific Gravity 54
Chemical Reaction in a Cell 54
Electrical Terms 56
Battery Selection 56
Battery Voltage 57
Battery as a Counterweight 58
Battery Ratings 58
Kilowatt-Hours 58
Battery Maintenance 58
Safety Procedures 58
Maintenance Records 59
New Battery 59
Cleaning Battery 59
Adding Water to Battery 61
Hydrometer 62
Battery Temperature 63
Charging Battery 64
Types of Battery Charges 64
Methods of Charging 66
Troubleshooting Charger 66
Knowing When Battery Is Fully Charged 67
Where to Charge Batteries 67
Equipment Needed 67
Battery Connectors 68
Battery Care 68
Troubleshooting 70
524164715-0630YRM0961-(12-2018)-US-EN 75
General 83
Check Oil Level 84
Change Gear Oil MTR005-007-F, MPE060-080-F, MPC060-080-F, MPE060-VG, MPE080-VG, MPE060VH, and MPE080VH 85
Drive Tire 85
Remove 85
Install 85
Master Drive Unit 85
Remove 85
Disassemble 92
Remove Drive Axle Group 92
Remove Upper Housing Group 92
Remove Pinion Group 92
Install 95
Troubleshooting 97
524274699-0620YRM1283-(12-2018)-US-EN 101
General 105
Accessing the Drive Unit Compartment 105
MPE060VG and MPE080VGMPE060VH and MPE080VH 105
MPC060/080-F and MTR005/007-F 106
Special Precautions 108
Discharging the Capacitors 108
Description 110
AC Motor Repair 110
Remove 110
Disassemble 111
Inspect 113
Assemble 113
Install 113
Troubleshooting 114
550091257-1800YRM1638-(10-2019)-US-EN 119
General 123
Accessing the Drive Unit Compartment 123
Description 124
Special Precautions 125
Brake Check 126
Brake Release 126
Brake Apply 127
Air Gap 127
Hold On Grade Test 129
Brake Assembly Repair 129
MPE060-F, MPE060-G, MPE060-VG and MPE060VH 129
Remove 129
Repair 131
Install 131
MPE080-VG and MPE080VH 131
Remove 131
Repair 133
Install 133
Troubleshooting 134
550091258-1900YRM1639-(12-2018)-US-EN 137
General 141
Description of Operation 141
Lifting a Load 142
Lowering a Load 146
Hydraulic Lines 146
Hydraulic Oil 146
Clean 146
Sound Level 146
Special Precautions 146
Hydraulic Reservoir 147
Drive Unit Compartment Covers 147
Lift Pump and Motor 149
General 149
Remove 149
Lift Pump and Motor Assembly 149
Disassemble 150
Remove Reservoir 150
Remove Pump Motor 152
Disassemble Pump 152
Assemble 152
Assemble Pump 152
Install Pump Motor 152
Install Reservoir to Pump 153
Install 153
Lift Pump and Motor Assembly 153
Valve Repair 154
Lowering Valve 154
Remove 154
Install 154
Relief Valve 155
Remove 155
Install 155
Check Valve 155
Remove 155
Install 156
Lift Cylinder 156
Remove 156
Disassemble 158
Assemble 158
Install 159
Relief Valve Pressure Check 159
Relief Valve Adjust 161
Troubleshooting 161
Lift Assemblies 161
Lift Cylinders 162
Lift Pump and Motor Assembly 163
550091262-4000YRM1641-(05-2019)-US-EN 167
General 171
Description of Operation 171
Load Wheel 171
Remove 171
Install 173
Casters 173
Caster Adjustment Check 173
Caster Adjust Heavy-Duty 174
Caster Replacement 174
Disassemble 175
Heavy-Duty 175
Assemble 176
Heavy-Duty 176
Rear Link and Load Wheel 176
Remove 176
Install 178
Pull Rod 179
Remove 180
End Replacement 180
Install 180
Fork Height Adjustment 181
Heavy Duty Trucks 181
Light Duty Trucks 182
Rocker Arm 183
Remove 183
Install 184
Upper Link 184
Remove 185
Install 185
Entry Rollers 186
Replacement 186
Troubleshooting 186
550091262-4000YRM1641-(08-2022)-US-EN 189
General 193
Description of Operation 193
Load Wheel 193
Remove 193
Install 195
Casters 196
Caster Adjustment Check 196
Caster Adjust Heavy-Duty 196
Caster Replacement 197
Disassemble 197
Heavy-Duty 197
Assemble 198
Heavy-Duty 198
Rear Link and Load Wheel 199
Remove 199
Install 201
Pull Rod 203
Remove 203
End Replacement 203
Install 203
Fork Height Adjustment 204
Heavy Duty Trucks 204
Light Duty Trucks 205
Rocker Arm 207
Remove 207
Install 208
Upper Link 209
Remove 209
Install 209
Entry Rollers 211
Replacement 211
Troubleshooting 212
550142686-0620YRM2005-(12-2018)-US-EN 215
General 219
Accessing the Drive Unit Compartment 219
Unit Codes: C896, D896, E896 219
Unit Codes: B894, B897, B891, D820, D819, D821, D902 220
Special Precautions 221
Discharging the Capacitors 221
Description 222
AC Motor Repair 222
Remove 222
Install 223
Troubleshooting 224
550142687-0630YRM2006-(12-2019)-US-EN 229
Safety Precautions 233
General 235
Check Oil Level 235
Drive Tire 236
Remove 236
Install 236
Master Drive Unit, Kordel® Before December, 2019 236
Remove 236
Disassemble 238
Bevel Gear Set (Ring and Pinion) 238
Remove 238
Install 240
Flange Shaft Seal 240
Remove 240
Install 241
Steering Bearing 241
Remove 241
Replace 241
Master Drive Unit, Kordel® After December, 2019 241
Remove 241
Disassemble 243
Seal Ring 243
Helical Pinion 243
Steering Bearing 244
Assemble 245
Steering Bearing 245
Helical Pinion 245
Seal Ring 245
Install 245
Troubleshooting 246
550180406-8000YRM2105-(08-2022)-US-EN 249
General 255
How to Move a Disabled Truck 255
How to Tow the Lift Truck 256
How to Put a Lift Truck on Blocks 256
How to Raise Drive/Steer Tire 256
How to Raise Load Wheels 258
Accessing the Drive Unit Compartment 258
Special Precautions 260
Discharging the Capacitors 260
Welding Repairs 261
Maintenance Schedule 262
Maintenance Procedures Every 8 Hours or Daily 269
Checks With Key Switch Turned OFF 269
Battery 269
Hydraulic Leaks 270
Drive Tire, Load Wheels, Casters, and Frame 270
Checks With Key Switch Turned ON 271
Operation 271
Maintenance Procedures Every 250 Hours or Every 6 Weeks 273
Caster Lubrication 273
Electrical Connector Protection 273
Maintenance Procedures Every 1000 Hours or Every 6 Months 274
Hydraulic System 274
Hydraulic Oil 274
Hydraulic Reservoir Breather 274
Steering System 275
Power Assist Steering 275
Lift Linkage and Load Wheels 277
Casters 277
Caster Adjustment Check 277
Caster Adjust Heavy-Duty 277
Casters 278
Caster Shim Check 278
Caster Shim Adjust 279
Master Drive Unit, GK20 and GK25 280
Change Gear Oil 280
Check Oil Level 280
Kordel MDU 281
Drive Tire Check 281
Maintenance Procedures Every 2000 Hours or Yearly 282
Lubrication 282
Repack Load Wheel Bearings 282
Repack Steer Bearings (Manual Steer Only) 282
Hydraulic System 282
Oil Change 282
Brake 282
Electrical 283
MDU 283
Oil Change (GK20 or GK25) 283
Oil Change (Kordel) 284
Battery Maintenance 285
How to Charge the Battery 285
Equalizing Charge 285
Normal Charge 285
How to Change the Battery 286
Changing Battery With Rollers 287
Remove 287
Install 287
Transporting 288
Loading 288
Unloading 288
Preparation for Storage 289
Short-Term Storage (1 to 6 months) 289
Long-Term Storage (6 months or longer) 289
Preparation for Use 290
Preparation After Shipment 290
Preparation After Storage 290
550180406-8000YRM2105-(12-2018)-US-EN 293
General 297
How to Move a Disabled Truck 297
How to Tow the Lift Truck 298
How to Put a Lift Truck on Blocks 298
How to Raise Drive/Steer Tire 298
How to Raise Load Wheels 299
Accessing the Drive Unit Compartment 300
Special Precautions 301
Discharging the Capacitors 301
Welding Repairs 301
Maintenance Schedule 302
Maintenance Procedures Every 8 Hours or Daily 308
Checks With Key Switch Turned OFF 308
Battery 309
Hydraulic Leaks 309
Drive Tire, Load Wheels, Casters, and Frame 310
Checks With Key Switch Turned ON 310
Operation 310
Maintenance Procedures Every 250 Hours or Every 6 Weeks 312
Caster Lubrication 312
Electrical Connector Protection 312
Maintenance Procedures Every 1000 Hours or Every 6 Months 312
Hydraulic System 313
Hydraulic Oil 313
Hydraulic Reservoir Breather 313
Steering System 314
Power Assist Steering 314
Lift Linkage and Load Wheels 316
Casters 316
Caster Adjustment Check 316
Caster Adjust Heavy-Duty 316
Casters 317
Caster Shim Check 317
Caster Shim Adjust 318
Master Drive Unit, GK20 and GK25 319
Change Gear Oil 319
Check Oil Level 319
Kordel MDU 320
Drive Tire Check 320
Maintenance Procedures Every 2000 Hours or Yearly 320
Lubrication 321
Repack Load Wheel Bearings 321
Repack Steer Bearings (Manual Steer Only) 321
Hydraulic System 321
Oil Change 321
Brake 321
Electrical 322
MDU 322
Oil Change (GK20 or GK25) 322
Oil Change (Kordel) 323
Battery Maintenance 323
How to Charge the Battery 323
Equalizing Charge 323
Normal Charge 323
How to Change the Battery 324
Changing Battery With Rollers 325
Remove 325
Install 325
Transporting 326
Loading 326
Unloading 326
Preparation for Storage 327
Short-Term Storage (1 to 6 months) 327
Long-Term Storage (6 months or longer) 327
Preparation for Use 327
Preparation After Shipment 327
Preparation After Storage 327
550180409-8000YRM2104-(01-2022)-US-EN 331
Schematics/Diagrams 337
550180409-8000YRM2104-(07-2019)-US-EN 363
Schematics/Diagrams 367
550183996-0100YRM2100-(10-2018)-US-EN 391
General 395
Frame Separation and Assembly 397
Disassemble 397
Assemble 398
Painting Instructions 399
Label Replacement 399
550183997-1600YRM2101-(01-2023)-US-EN 403
General 409
Accessing the Drive Unit Compartment 409
Special Precautions 412
Calibration 413
Power Assist Steering Calibration 413
Calibrate the EPAS 414
Tiller Assembly 415
Tiller Head 415
Tiller Handle 415
Manual Steering 415
Remove 415
Install 416
Advanced Coast Control (ACC) 417
Remove 417
Install 418
Gas Spring 419
Discharging the Gas Spring 419
Remove 419
Install 420
Steer Motor 421
Repair 421
Steer Motor, Remove 421
Steer Motor, Install 422
Steer Support Assembly 423
Manual Steering 423
Remove (Complete Unit) 423
Disassemble 424
Assemble 425
Install (Complete Unit) 425
Electronic Power Assist Steering (EPAS) 425
Remove (Complete Unit) 425
Disassemble 426
Assemble 427
Install (Complete Unit) 428
Proximity Switch 428
(Option) Smart Coast Control 429
Disassemble 429
Assemble 430
Coast Control Adjustment Procedure 431
Troubleshooting 433
550183997-1600YRM2101-(06-2019)-US-EN 435
General 439
Accessing the Drive Unit Compartment 439
Special Precautions 441
Calibration 442
Power Assist Steering 442
Tiller Assembly 443
Tiller Head 443
Tiller Handle 443
Manual Steering 443
Remove 443
Install 445
Advanced Coast Control (ACC) 445
Remove 446
Install 447
Gas Spring 447
Discharging the Gas Spring 447
Remove 448
Install 448
Steer Motor 449
Repair 449
Steer Motor, Remove 449
Steer Motor, Install 449
Steer Support Assembly 450
Manual Steering 450
Remove (Complete Unit) 450
Disassemble 450
Assemble 451
Install (Complete Unit) 452
Electronic Power Assist Steering (EPAS) 452
Remove (Complete Unit) 452
Disassemble 453
Assemble 454
Install (Complete Unit) 455
Proximity Switch 455
(Option) Smart Coast Control 456
Disassemble 456
Assemble 457
Coast Control Adjustment Procedure 458
Troubleshooting 460
550183998-2200YRM2102-(01-2023)-US-EN 463
General 469
Accessing the Drive Unit Compartment 472
Special Precautions 473
Discharging the Internal Capacitors 473
Electromagnetic Shield 473
Electrical System Checks 474
Safety Precautions 474
Dash Display 477
Description 477
Operation 477
Remove 477
Install 478
Calibration 479
Power Assist Steering Calibration 479
Calibrate the EPAS 480
Controller 481
Controller, Replace 481
Remove 482
Install 482
Contactor Coil, Check 483
Fuses 483
Horn 484
Replace 484
Brake Sensor Operation 484
Brake Sensor 485
Removal 485
Height Limit 485
Control Handle (Standard) 486
Disassemble 486
Assemble 486
Control Handle (HD Option) 488
Disassemble 488
Top Cover 488
Remove Function Switches 488
Remove Throttle Sensor Assembly 489
Remove Handle Shaft Assembly 489
Remove the Coast Control Switches 489
Assemble 490
Install the Coast Control Switches 490
Install Switches Quick Pick 490
Install Handle Shaft Assembly 490
Install Throttle Sensor Assembly 490
Install Function Switches 491
Install Top Cover 491
Power Assist Steering (EPAS) 492
Steer Motor 492
Proximity Switch 492
Remove 493
Install 493
Smart Steer 494
Remove 494
Install 494
Aux Control Box Switches 495
Remove 495
Install 495
Lights 496
Work Light 496
Remove 496
Install 496
Strobe Light 496
Remove 496
Install 496
Platform Lights 497
Remove 497
Install 497
Trailer Unloading Lights 497
Remove 497
Install 497
Telemetry Wireless Asset Management System 498
General 498
Level 1 – Wireless Monitoring (WIFI Group) 498
Communication Module 502
Basic Operations 502
ID Card / ID Reader 502
Interlock Relay 503
Buzzer 503
Wakeup 503
Checklist 504
Locate and Install the Communication Module 504
Install the Power Harness 505
Install the Interlock Harness 507
Install the Access Control Kit, Antenna and Buzzer 508
Install the antenna 509
Install buzzer 509
Install the ID Card Reader 510
Install the Checklist Display and Harness 512
First Switch On 513
Tool Operation 514
Connection 515
Wireless Settings 517
Telemetry Tool Communication Problems 518
Truck Activation 522
DC to DC Converter 523
Troubleshooting 524
550183998-2200YRM2102-(06-2019)-US-EN 527
General 531
Accessing the Drive Unit Compartment 533
Special Precautions 534
Discharging the Internal Capacitors 534
Electromagnetic Shield 535
Electrical System Checks 535
Safety Precautions 535
Dash Display 537
Description 537
Operation 537
Remove 538
Install 538
Calibration 539
Power Assist Steering Sensor 539
Controller 539
Controller, Replace 540
Remove 541
Install 541
Contactor Coil, Check 542
Fuses 542
Horn 543
Replace 543
Brake Sensor Operation 543
Brake Sensor 544
Removal 544
Height Limit 544
Control Handle (Standard) 545
Disassemble 545
Assemble 545
Control Handle (HD Option) 547
Disassemble 547
Top Cover 547
Remove Function Switches 547
Remove Throttle Sensor Assembly 548
Remove Handle Shaft Assembly 548
Remove the Coast Control Switches 548
Assemble 549
Install the Coast Control Switches 549
Install Switches Quick Pick 549
Install Handle Shaft Assembly 549
Install Throttle Sensor Assembly 549
Install Function Switches 550
Install Top Cover 550
Power Assist Steering (EPAS) 551
Steer Motor 551
Proximity Switch 551
Remove 551
Install 551
Calibration 552
Smart Steer 553
Remove 553
Install 553
Aux Control Box Switches 554
Remove 554
Install 554
Lights 555
Work Light 555
Remove 555
Install 555
Strobe Light 555
Remove 555
Install 555
Platform Lights 556
Remove 556
Install 556
Trailer Unloading Lights 556
Remove 556
Install 556
Telemetry Wireless Asset Management System 557
General 557
Level 1 – Wireless Monitoring (WIFI Group) 557
Communication Module 561
Basic Operations 561
ID Card / ID Reader 561
Interlock Relay 562
Buzzer 562
Wakeup 562
Checklist 562
Locate and Install the Communication Module 563
Install the Power Harness 564
Install the Interlock Harness 565
Install the Access Control Kit, Antenna and Buzzer 568
Install the antenna 568
Install buzzer 569
Install the ID Card Reader 569
Install the Checklist Display and Harness 571
First Switch On 573
Tool Operation 573
Connection 574
Wireless Settings 576
Telemetry Tool Communication Problems 578
Truck Activation 582
DC to DC Converter 583
Troubleshooting 583
550183999-8000YRM2103-(01-2019)-US-EN 585
Hydraulic System 589
Hydraulic Oils 589
Gear Oils 590
Grease 590
Truck Weight 590
Tire Sizes 591
Torque Specifications 592
Caster Assembly 592
Drive Wheel Assembly 592
Master Drive Unit 592
Standard Steering 592
Power Assist Steering 593
Brake 593
Electrical 593
Lift Mechanism 593
Hydraulics 593
Battery Specifications 593
550205681-2200YRM2161-(01-2023)-US-EN 597
How to navigate display 603
Navigation Key 603
Startup Sequence 604
Home screen 607
Logging in 608
Log in 608
Enable/disable password (optional) 609
View the fault log 610
Fault log 610
View hour meters 612
Hour Meters 612
View the hardware and software versions 613
View hardware and software versions 613
View diagnostics information 614
View diagnostics information 614
Inputs diagnostics information 614
Drive diagnostics information 615
Metrics diagnostics information 616
Setting up performance modes 618
Set up performance modes 618
Selecting a performance mode 620
Select a performance mode 620
Setting up Coast Control 621
Set up Coast Control 621
Setting up Smart Cruise 623
Set up Smart Cruise 623
Setting up Dual Acceleration 625
Set up Dual Acceleration 625
Setting up the energy system 627
Set up energy system 627
Set Battery Type 627
Set BDI Source 628
Set BDI settings 629
BDI Startup Full 629
BDI Full 629
BDI Empty 629
BDI Reset 629
Lift Interrupt 629
Setting up the Electronic Positional Assist Steering (EPAS) 630
Set Up EPAS 630
Min Str Assist Fwd 630
Min Str Assist Rev 630
Setting up Unloading Lights 631
Unloading lights 631
Activate 632
True Direction 632
Time Rate On 632
Time Rate Off 632
Reverse Time 632
Forward Time 632
Calibrating EPAS 633
Power Assist Steering Calibration 633
Calibrate the EPAS 634
Other settings 635
Set up other features 635
Performance Mode parameters 636
Coast Control parameters 637
Display Flowchart 637
550205681-2200YRM2161-(03-2020)-US-EN 641
How to navigate display 645
Navigation Key 645
Startup Sequence 645
Home screen 649
Logging in 649
Log in 649
Enable/disable password (optional) 651
View the fault log 651
Fault log 651
View hour meters 653
Hour Meters 653
View the hardware and software versions 654
View hardware and software versions 654
View diagnostics information 654
View diagnostics information 654
Inputs diagnostics information 655
Drive diagnostics information 656
Metrics diagnostics information 657
Setting up performance modes 658
Set up performance modes 658
Selecting a performance mode 660
Select a performance mode 660
Setting up Coast Control 660
Set up Coast Control 660
Setting up Smart Cruise 662
Set up Smart Cruise 662
Setting up Dual Acceleration 664
Set up Dual Acceleration 664
Setting up the energy system 666
Set up energy system 666
Set Battery Type 666
Set BDI Source 667
Set BDI settings 667
BDI Startup Full 667
BDI Full 667
BDI Empty 667
BDI Reset 668
Lift Interrupt 668
Setting up the Electronic Positional Assist Steering (EPAS) 668
Set Up EPAS 668
Min Str Assist Fwd 669
Min Str Assist Rev 669
Setting up Unloading Lights 669
Unloading lights 669
Activate 669
True Direction 669
Time Rate On 669
Time Rate Off 670
Reverse Time 670
Forward Time 670
Calibrating EPAS 670
Calibrate the EPAS 670
Other settings 671
Set up other features 671
Performance Mode parameters 671
Coast Control parameters 673
Display Flowchart 673
550276785-9000YRM2486-(09-2022)-US-EN 677
Error code reference charts 681
Vehicle System Manager (VSM) Error Code Reference Chart 681

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