Yale Forklift MPE080-F [B890] MPE060-F [B896] Maintenance Manual PDF

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Yale Forklift MPE080-F [B890] MPE060-F [B896] Maintenance Manual – PDF DOWNLOAD

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Yale Forklift MPE080-F [B890] MPE060-F [B896] Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 468
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift MPE080-F [B890] MPE060-F [B896] Maintenance Manual – PDF DOWNLOAD

toc 1
AC Motor Repair 1
Safety Precautions Maintenance and Repair 2
General 5
Accessing the Drive Unit Compartment 5
Special Precautions 6
Discharging the Capacitors 6
Description 7
AC Motor Repair 7
Remove 7
Disassemble 7
Inspect 9
Assemble 9
Install 9
Troubleshooting 10
toc 15
Brakes 15
Safety Precautions Maintenance and Repair 16
General 19
Accessing the Drive Unit Compartment 19
Description 19
Special Precautions 21
Brake Check 22
Brake Release 22
Brake Apply 22
Air Gap 22
Hold On Grade Test 24
Brake Assembly Repair 24
MPE060-F 24
Remove 24
Repair 25
Install 25
MPE080-F 26
Remove 26
Repair 27
Install 27
Troubleshooting 28
tables 15
Table 1 Stator Resistance 22
Table 2 Adjustment Specifications 23
toc 31
Capacities and Specifications 31
Safety Precautions Maintenance and Repair 32
Hydraulic System 35
Hydraulic Oils 35
Gear Oils 36
Grease 36
Truck Weight 36
Tire Sizes 37
Torque Specifications 37
Caster Assembly 37
Drive Wheel Assembly 37
Master Drive Unit 37
Standard Steering 37
Power Assist Steering 38
Brake 38
Electrical 38
Lift Mechanism 38
Hydraulics 38
Battery Specifications 39
tables 31
Table 1 MPE060-F 39
Table 2 MPE080-F 40
toc 43
Diagrams 43
Safety Precautions Maintenance and Repair 44
toc 57
Electrical System 57
Safety Precautions Maintenance and Repair 58
General 61
Accessing the Drive Unit Compartment 62
Special Precautions 63
Discharging the Capacitors 63
Electrical System Checks 64
Safety Precautions 64
Calibration 67
Calibration Mode 67
Repairs 67
Controller, Replace 67
Remove 67
Install 68
Contactor Coil, Check 69
Contactor, Replace 69
Fuses 69
Horn 70
Replace 70
Brake Switch Operation 70
Brake and Interlock Switches – (Manual Steering) 71
Disassemble 71
Assemble 71
Brake Switch and Handle Position Sensor – (Power Assist Steering 72
Brake Switch 72
Handle Potentiometer Sensor 73
Disassemble 73
Assemble 75
Height Limit 76
Control Handle 77
Disassemble 77
Assemble 77
Remote Control Box Switches 79
Remove 79
Install 79
Motor Tests 80
Excessive Current Draw 80
Measuring Current Draw 81
Excessive Resistance 81
Troubleshooting 81
tables 57
Table 1 Voltage Checks 66
toc 85
Frame 85
Safety Precautions Maintenance and Repair 86
General 89
Frame Separation and Assembly 89
Frame Separation 89
Frame Assembly 89
Painting Instructions 91
Label Replacement 91
toc 97
Walkie Hydraulic Systems 97
Safety Precautions Maintenance and Repair 98
General 101
Description of Operation 101
Lifting a Load 101
Lowering a Load 104
Hydraulic Lines 104
Hydraulic Oil 104
Clean 104
Sound Level 104
Special Precautions 105
Hydraulic Reservoir 105
Description 105
Drive Unit Compartment Covers 106
MPE060-E, MPE080-E, MPW060-E, MPW065-E, MPW080-E, MPC060-E, and 106
Remove 106
Install 106
MPE060-F and MPE080-F 106
Remove 106
Install 107
Lift Pump and Motor 107
General 107
Remove 107
Lift Pump and Motor Assembly 107
Disassemble 108
Remove Reservoir 108
Remove Pump Motor 109
MPE060-E, MPC060-E, MPW060-E, and MPE060-F 109
MPE080-E, MPC080-E, MPW065-E, MPW080-E, and MPE080-F 109
Disassemble Pump 109
MPE060-E, MPC060-E, MPW060-E, and MPE060-F 109
MPE080-E, MPC080-E, MPW065-E, MPW080-E, and MPE080-F 109
Assemble 109
Assemble Pump 109
MPE060-E, MPC060-E, MPW060-E, and MPE060-F 109
MPE080-E, MPC080-E, MPW065-E, MPW080-E, and MPE080-F 109
Install Pump Motor 109
Install Reservoir to Pump 113
Install 113
Lift Pump and Motor Assembly 113
Valve Repair 115
Lowering Valve 115
Remove 115
Install 115
Relief Valve 115
MPE080-E, MPC080-E, MPW065-E, MPW080-E, and MPE080-F 115
Remove 115
Install 115
MPE060-E, MPC060-E, MPW060-E, and MPE060-F 116
Remove 116
Install 116
Check Valve 116
MPE080-E, MPC080-E, MPW065-E, MPW080-E, and MPE080-F 116
Remove 116
Install 117
Lift Cylinder 117
Remove 117
Disassemble 118
Assemble 118
Install 119
Relief Valve Adjustment 119
Relief Valve Pressure Check 119
Adjust Relief Valve Pressure 120
MPE060-E, MPC060-E, MPW060-E, and MPE060-F 120
MPE080-E, MPC080-E, MPW065-E, MPW080-E, and MPE080-F 120
Troubleshooting 121
Lift Assemblies 121
Lift Cylinders 122
Lift Pump and Motor Assembly 122
tables 97
Table 1 Hydraulic Reservoir 105
Table 2 Relief Valve Settings 120
toc 129
Industrial Battery 129
Safety Precautions Maintenance and Repair 130
General 133
Lead-Acid Batteries 133
Specific Gravity 134
Chemical Reaction in a Cell 134
Electrical Terms 135
Battery Selection 136
Battery Voltage 137
Battery as a Counterweight 137
Battery Ratings 138
Kilowatt-Hours 138
Battery Maintenance 138
Safety Procedures 138
Maintenance Records 139
New Battery 139
Cleaning Battery 139
Adding Water to Battery 141
Hydrometer 142
Battery Temperature 142
Charging Battery 143
Types of Battery Charges 144
Methods of Charging 145
Troubleshooting Charger 146
Knowing When Battery Is Fully Charged 146
Where to Charge Batteries 146
Equipment Needed 146
Battery Connectors 147
Battery Care 147
tables 129
Table 1 Battery Capacity Terms 138
toc 151
Lifting Mechanism 151
Safety Precautions Maintenance and Repair 152
General 155
Description of Operation 155
Load Wheel 155
Remove 155
Install 156
Caster Wheels 157
Caster Shim Check 157
Caster Shim Adjustment 158
Caster Replacement 158
Disassemble 159
Assemble 159
Caster Lubrication 160
Rear Link and Load Wheel Assembly 162
Remove 162
Install 164
Pull Rod 166
Remove 166
End Replacement 166
Install 166
Adjust 167
Rear Fork Adjustment 168
Rocker Arm 169
Remove 169
Install 170
Upper Link 171
Remove 171
Install 171
Troubleshooting 172
toc 177
Master Drive Unit 177
Safety Precautions Maintenance and Repair 178
General 181
Check Oil Level 181
Change Gear Oil ( MPE060-F and MPE080-F ) 182
Safety Precautions 182
Drive Tire 185
Remove 185
Install 185
Master Drive Unit 185
Remove 185
Install 190
Troubleshooting 192
tables 177
Table 1 Drive Unit Specifications 181
toc 195
Metric and Inch (SAE) Fasteners 195
Safety Precautions Maintenance and Repair 196
General 199
Threaded Fasteners 199
Nomenclature, Threads 199
Strength Identification 200
Cotter (Split) Pins 200
Fastener Torque Tables 205
Conversion Table 207
tables 195
Table 1 Bolts and Screws 201
Table 2 Studs and Nuts 202
Table 3 Torque Nuts 203
Table 4 Torque Nuts with Nylon Insert 204
Table 5 Torque Values for Metric Fasteners* 205
Table 6 Torque Values for Inch Fasteners* 206
Table 7 Conversion Table for Metric and English Units 207
Table 8 Cotter Pin Dimensional Data 208
Table 9 Cotter Pin Dimensional Data 209
Table 10 Cotter Pin Dimensional Data 210
Table 11 Cotter Pin Dimensional Data 212
toc 215
Periodic Maintenance 215
Safety Precautions Maintenance and Repair 216
General 219
How to Move a Disabled Truck 219
How to Tow the Lift Truck 220
How to Put a Lift Truck on Blocks 220
How to Raise Drive/Steer Tire 220
How to Raise Load Wheels 221
Accessing the Drive Unit Compartment 221
Special Precautions 222
Discharging the Capacitors 222
Welding Repairs 224
Maintenance Schedule 224
Maintenance Procedures Every 8 Hours or Daily 228
Checks With Key Switch Turned OFF 228
Battery 228
Hydraulic Leaks 229
Drive Tire, Load Wheels, Casters, and Frame 229
Checks With Key Switch Turned ON 230
Operation 230
Maintenance Procedures Every 250 Hours or Every 6 Weeks 232
Caster Lubrication 232
Maintenance Procedures Every 500 Hours or Every 3 Months 233
Hydraulic System 233
Hydraulic Oil 233
Hydraulic Reservoir Breather 233
Steering System 233
Power Assist Steering 233
Lift Linkage and Load Wheels 234
Casters 234
Caster Shim Check 234
Caster Shim Adjust 235
Master Drive Unit 236
Change Gear Oil 236
Check Oil Level 236
Drive Tire Check 237
Maintenance Procedures Every 2000 Hours or Yearly 237
Lubrication 237
Repack Load Wheel Bearings 237
Repack Steer Bearings (Manual Steer Only) 237
Hydraulic System 237
Oil Change 237
Brake 238
Electrical 238
MDU 238
Oil Change 238
Battery Maintenance 239
How to Charge the Battery 239
Equalizing Charge 239
Normal Charge 239
How to Change the Battery 240
Transporting 241
Loading 241
Unloading 241
Preparation for Storage 242
Short-Term Storage (1 to 6 months) 242
Long-Term Storage (6 months or longer) 242
Preparation for Use 242
Preparation After Shipment 242
Preparation After Storage 242
tables 215
Table 1 Maintenance Schedule 225
Table 2 Specific Gravity Corrections 239
toc 245
Steering Mechanism 245
Safety Precautions Maintenance and Repair 246
General 249
Accessing the Drive Unit Compartment 249
Special Precautions 250
Discharging the Capacitors 250
Calibration 251
Power Assist Steering Sensor 251
Control Handle 252
Control Handle Head 252
Control Handle 252
Standard Steering 252
Remove 252
Install 253
Power Assist Steering 254
Remove 254
Install 255
Gas Spring 259
Discharging the Gas Spring 259
Remove 259
Install 260
Articulating Shaft and Pinions (Power Assist Models) 261
Remove 261
Pinion Repair 262
Upper Pinion 262
Lower Pinion 263
Install 264
Steer Motor Assembly 264
Repair 264
Steer Motor, Replace 264
Steer Motor Gear, Replace 265
Gearbox/Complete Assembly, Replace 266
Steer Support Assembly 267
Standard Steering 267
Remove (Complete Unit) 267
Disassemble 267
Assemble 269
Install (Complete Unit) 269
Power Assist Steering 271
Remove (Complete Unit) 271
Disassemble 271
Support Base 271
Steer Swivel 272
Assemble 272
Steer Swivel 272
Support Base 273
Install (Complete Unit) 274
Troubleshooting 275
toc 279
Troubleshooting and Adjustments Using the AC Controls Program (E 279
Safety Precautions Maintenance and Repair 280
General 283
Computer Requirements 283
Software, Install 283
Language Selection 283
Demo Mode 284
Connect PC to Lift Truck 288
Starting AC Controls Program 289
Lift Truck Control Setup 294
Change Lift Truck Serial Number or Hourmeter 294
Setting Factory Default Values or Changing Lift Truck Parameters 296
Create New Custom Lift Truck Configuration 301
Lift Truck Configuration Properties 304
Import New Lift Truck Configuration From Disk 308
Delete Custom Lift Truck Configuration or Password File 310
Dash Display 313
Custom Display Languages 313
Download Display Language 316
Clear Operator Log 318
Password Functions 320
Enable/Disable Password and Lift Truck Inspection Functions 320
Truck Inspection Checklist 320
Password 320
Password Properties 322
Create New Password File 326
Download Passwords 328
Upload Passwords 330
Reports Menu 332
Devices Report 332
Custom Report 334
Password Report 335
Operator Report 340
Current Settings Report 342
Status Code Report 346
Status Codes Log 348
Troubleshooting 350
Diagnostics 350
Help Menu 354
General 354
Contents 354
Technical Support 356
About Electric Truck AC Controls Program 358
toc 363
User Interface 363
Safety Precautions Maintenance and Repair 364
General 367
Description 367
Dash Display Menu Access 367
Menu Navigation 368
Technician Menu 369
View Versions 370
Hourmeters 370
Diagnostics 370
Fault Log 370
Controller Inputs 371
Control Handle Inputs 372
Run Time Diagnostics 372
Power Steering 374
Traction Motor 374
Pump Motor and Valve 374
Control Handle Outputs 375
Service Reminder 375
Change Supervisor Password 375
Operator Modes 376
Set Performance 376
Extended Shift 376
Walk Speed 378
High Speed (FWD) 378
High Speed (REV) 378
Minimum Acceleration 379
Maximum Acceleration 379
Plugging 379
ADS-Neutral 380
ADS-Throttle 380
Pick Acceleration 380
Pick Deceleration 380
Battery Full 381
Lift Interrupt 381
Min Steer Assist FWD (Power Steering Assist Only) 381
Min Steer Assist REV (Power Steering Assist Only) 382
Max Steer Assist (Power Steering Assist Only) 382
Defaults 382
Save and Exit 383
Exit Without Saving 383
Set General Items 383
Motion Alarm 384
Clear Fault Log 384
Calibrations 385
Throttle 385
Steer Handle 386
Change Service Technician Password 386
Exit to Run Mode 387
tables 363
Table 1 Technician Menu 369
Table 2 Diagnostics Menu 371
Table 3 Controller Inputs 371
Table 4 Tiller Inputs 372
Table 5 Run Time Diagnostics Menu 373
Table 6 Set Performance Menu 377
Table 7 Set General Items Menu 384
Table 8 Calibrations Menu 385
toc 391
User Interface 391
Safety Precautions Maintenance and Repair 392
General 395
Description 395
Dash Display Menu Access 395
Menu Navigation 396
Supervisor Menu 397
View Versions 397
Hourmeters 398
Diagnostics 398
Fault Log 398
Controller Inputs 399
Control Handle Inputs 399
Run Time Diagnostics 400
Power Steering 401
Traction Motor 401
Pump Motor and Valve 401
Control Handle Outputs 402
Operator Modes 402
Service Reminder 402
Change Supervisor Password 403
Exit to Run Mode 403
tables 391
Table 1 Supervisor Menu 397
Table 2 Diagnostics Menu 398
Table 3 Controller Inputs 399
Table 4 Control Handle Inputs 399
Table 5 Run Time Diagnostics Menu 400
toc 407
AC Motor Controller 407
Safety Precautions Maintenance and Repair 408
General 411
Discharging the Capacitors 411
Description 412
AC Traction Motor 413
Controller 413
Service PC Connection 413
Parameters 413
General 413
Parameter Description 414
Extended Shift 414
Battery Full Voltage 414
Lift Interrupt 414
Auto Decel (Coast Mode) ADS-Throttle 414
Minimal Deceleration (Auto Decel) ADS-Neutral 415
Plugging 415
Walk Speed (Both Directions) 415
Hi Speed (FWD) 415
Hi Speed (REV) 415
Minimum Acceleration 415
Maximum Acceleration 415
Service Hour Reminder 415
Maximum Steering Assist 415
Min Steering Assist (High Speed FWD) 415
Min Steering Assist (High Speed REV) 415
Troubleshooting 416
General 416
Status Codes 416
Dash Display 462
General 462
Startup 462
Status LED 462
Performance Mode Indicator 462
Hourmeter 463
Battery Charge Indicator 463
Fault Log 463
Connector Pin-Outs 464
System Logic Diagram 466
tables 407
Table 1 Parameter Descriptions 414
Table 2 Fault Codes 417

S.V 07/24