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Yale MPE060-VG Service Manual
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Yale MPE060-VG Service Manual

Yale MPE060-VG Service Manual

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SECTION
FRAME............................................................................................................................
AC MOTOR REPAIR * (WITH EPAS).............................................................................
MASTER DRIVE UNIT * (WITH EPAS)..........................................................................
STEERING SYSTEM......................................................................................................
BRAKE SYSTEM............................................................................................................
HYDRAULIC SYSTEM....................................................................................................
TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS
PROGRAM.................................................................................................................
AC MOTOR CONTROLLER...........................................................................................
USER INTERFACE SUPERVISOR FUNCTIONS ON-BOARD DASH DISPLAY..........
USER INTERFACE SERVICE TECHNICIAN FUNCTIONS ON-BOARD DASH
DISPLAY....................................................................................................................
ELECTRICAL SYSTEM..................................................................................................
INDUSTRIAL BATTERY.................................................................................................
LIFT MECHANISM..........................................................................................................
METRIC AND INCH (SAE) FASTENERS.......................................................................
DIAGRAMS.....................................................................................................................
PERIODIC MAINTENANCE............................................................................................
CAPACITIES AND SPECIFICATIONS...........................................................................
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
MPE060-VG (A292) MPE080-VG (A287)
SERVICE MANUAL CONTENTS
PART NO. 550025474 (09/14)
PART
YRM
NUMBER
NUMBER
550025475
0100 YRM 1448
524274699
0620 YRM 1283
524164715
0630 YRM 0961
550025476
1600 YRM 1449
524274701
1800 YRM 1285
550026124
1900 YRM 1450
524183085
2200 YRM 1058
524274702
2200 YRM 1286
524290090
2200 YRM 1323
524290091
2200 YRM 1324
550026125
2200 YRM 1451
524158040
2240 YRM 0001
550025477
4000 YRM 1452
524150797
8000 YRM 0231
524274698
8000 YRM 1288
550025465
8000 YRM 1453
550025478
8000 YRM 1454
REV
DATE
04/11
10/13
10/13
09/12
04/11
04/11
04/11
04/11
04/11
10/12
04/11
09/14
12/12
10/13
08/12
04/11
04/11

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Summary of Contents for Yale MPE060-VG

  • Page 1 MPE060-VG (A292) MPE080-VG (A287) SERVICE MANUAL CONTENTS PART SECTION NUMBER NUMBER DATE FRAME..........................550025475 0100 YRM 1448 04/11 AC MOTOR REPAIR * (WITH EPAS)................524274699 0620 YRM 1283 10/13 MASTER DRIVE UNIT * (WITH EPAS)................524164715 0630 YRM 0961 10/13 STEERING SYSTEM......................
  • Page 2 • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 3: Table Of Contents

    Install (Complete Unit) ..........................Power Assist Steering (Option) ........................Remove (Complete Unit) ..........................Disassemble ............................... Support Base............................Steer Swivel............................Assemble ..............................Steer Swivel............................Support Base............................Install (Complete Unit) ..........................Electronic Coast Control (Option)........................Disassemble..............................Assemble ................................ Checks ................................©2012 Yale Materials Handling Corp.
  • Page 4 Table of Contents Steering Mechanism TABLE OF CONTENTS (Continued) Troubleshooting ..............................This section is for the following models: MPE060-VG [A292]; MPE080-VG [A287]...

  • Page 5: General

    1600 YRM 1449 General General The control handle assembly is designed to perform place the floor mat into the operator platform around the several functions. The standard control handle includes cover. the speed/direction control and buttons for the horn, traction reversing, and hydraulic functions. The con- trol handle is connected to the Master Drive Unit (MDU) and is used to steer the truck as it turns the MDU.

  • Page 6: Special Precautions

    Special Precautions 1600 YRM 1449 Special Precautions WARNING The capacitor in the transistor controller can hold an electrical charge after the battery is discon- nected. To prevent electrical shock and personal injury, discharge the capacitor before inspecting or repairing any component. Wear safety glasses. Make certain the battery has been disconnected.

  • Page 7: Electromagnetic Shield

    1600 YRM 1449 Calibration ELECTROMAGNETIC SHIELD assist steering units. This shield deflects the elec- tromagnetic field generated by the MDU and brake assembly which can interfere with the operation of the WARNING torque sensor. Make certain that the Electromagnetic Never operate Power Assist models with the Elec- Shield is reinstalled before operating the lift truck after tromagnetic Shield removed.

  • Page 8: Control Handle

    Control Handle 1600 YRM 1449 9. If no power steering error appears, the power steer- 10. Check the lift truck for proper operation. Reinstall ing system was calibrated successfully. the drive unit compartment cover and return to the lift truck to service. Control Handle CONTROL HANDLE HEAD 2.

  • Page 9: Install

    1600 YRM 1449 Control Handle 11. If necessary, remove the control handle head. See 2. Install bushings into the control handle arm if re- the section Electrical System 2200 YRM 1451. moved. Remove nut and clamp and pull wiring harness 3.

  • Page 10: Power Assist Steering

    12. Connect the battery and test the operation of the 5. Gently pry the Yale plate from the center of the truck prior to returning the lift truck to service. swivel cover. Remove the two nuts and washers securing the cover to the steer support studs and 13.

  • Page 11: Install

    6. Position the cover to the steer swivel and install the when removing the gas spring. two screws and washers to secure. Gently snap the Yale plate into the center of the swivel cover. 8. Remove the gas spring. Refer to Gas Spring in this section.
  • Page 12 Control Handle 1600 YRM 1449 1. SWIVEL 8. CONTROL ARM 15. BUSHING 2. STUD 9. CAPSCREW 16. PIN 3. NUT 10. NUT 17. DRIVE PIN 4. CAPSCREW 11. BUSHING 18. SCREWS 5. GREASE FITTING 12. NUT 19. SPACER 6. BUSHING 13.

  • Page 13: Gas Spring

    1600 YRM 1449 Gas Spring Gas Spring upright position. Remove the plastic plugs to in- WARNING crease visibility of the gas spring. Disconnect the battery by separating the battery connector before opening the compartment cover CAUTION and before inspecting or repairing the electrical DO NOT damage the control handle wiring harness system.

  • Page 14: Install

    Gas Spring 1600 YRM 1449 2. Lubricate both connection points with multipurpose CAUTION lithium complex grease with 2 to 4% molybdenum. Be careful not to damage the sensor when driving out the pin. CAUTION 7. On Power Assist Models, tap the retaining pin from DO NOT damage the control handle wiring harness the sensor side out toward the brake switch side of inside the control handle arm.

  • Page 15: Articulating Shaft And Pinions (Power Assist Models)

    2. Discharge the capacitor. See Special Precautions Figure 10. in this section. 3. Gently pry the Yale cover from the center of the steer support cover. Remove the two screws and washers securing the cover to the steer support and lift the cover off.

  • Page 16: Remove

    Articulating Shaft and Pinions (Power Assist Models) 1600 YRM 1449 Remove 3. Remove the snap ring securing the bearing from the top side of the support base and remove the 1. Remove the two screws and washers securing the bearing as necessary. gear cover to the steer support and remove gear cover.

  • Page 17: Lower Pinion

    1600 YRM 1449 Articulating Shaft and Pinions (Power Assist Models) 3. From the underside of the support base, install the 2. Install new bearing onto shaft and position into snap ring onto the shaft end of the pinion gear. mounting bracket as removed. Install the Woodruff key into shaft.

  • Page 18: Install

    Steer Motor Assembly 1600 YRM 1449 INSTALL 4. Lower the steer support (control arm end) while guiding the articulated shaft onto the pinion shaft. CAUTION 5. Install the remaining two lower capscrews, wash- Ensure that the drive tire and notch of the lower ers, and nuts securing the steer support to the pinion shaft are aligned in the steer swivel (control frame.

  • Page 19: Steer Motor Gear, Replace

    1600 YRM 1449 Steer Motor Assembly Steer Motor Gear, Replace Refer to Figure 14 for the following procedures. 1. Remove the capscrew and washers from the bot- tom of the steer motor gear. 2. Slide the gear from the motor shaft and recover the Woodruff key.

  • Page 20: Gearbox/Complete Assembly, Replace

    Steer Motor Assembly 1600 YRM 1449 Gearbox/Complete Assembly, Replace 6. Position the steer motor assembly to the drive unit housing as removed. Refer to Figure 13 and Figure 14 for the following pro- cedures. CAUTION Very small variations can prevent steering systems CAUTION from operating properly.

  • Page 21: Steer Support Assembly

    1600 YRM 1449 Steer Support Assembly Steer Support Assembly STANDARD STEERING 8. Remove the four capscrews, washers, and nuts se- curing the steer support assembly to the frame. WARNING 9. Using the overhead lifting device, carefully remove The steering assembly and dash is heavy and re- the steer support from the frame.
  • Page 22 Steer Support Assembly 1600 YRM 1449 1. SCREWS 9. BRAKE SWITCHES 17. STEER SHAFT 2. SWIVEL COVER 10. SCREWS 18. WIRE SLEEVE 3. WIRE SLEEVE 11. UPPER BEARING CONE 19. NUT 4. BEARING NUT 12. UPPER BEARING CUP 20. WASHER 5.

  • Page 23: Assemble

    1. Install bearing races to support using a hammer and proper size bearing driver, if removed. 9. Place cover on swivel and secure with screws. 2. Pack bearings with Yale synthetic grease, P/N Install (Complete Unit) 524226586, using a standard bearing packing 1.

  • Page 24: Power Assist Steering (Option)

    Steer Support Assembly 1600 YRM 1449 POWER ASSIST STEERING (OPTION) The following instructions are for removing the entire steer support assembly without disassembly. This pro- cedure is useful when the dash and control handle must WARNING be removed for access to other parts of the lift truck The steering assembly and dash is heavy and re- such as when removing the traction motor.

  • Page 25: Remove (Complete Unit)

    Refer to Articulating Shaft and Pinions (Power Assist Models). 3. Gently pry the Yale cover from the center of the steer support cover. Remove the two screws and washers securing the cover to the steer support and lift the cover off.

  • Page 26: Steer Swivel

    Steer Support Assembly 1600 YRM 1449 3. Remove two capscrews and washers from the bot- pin securing the torsion shaft to the swivel. Refer tom of the support base. See Figure 18. Lower the to Figure 21. support base from the center support. 2.
  • Page 27 1600 YRM 1449 Steer Support Assembly 1. SUPPORT BASE 2. SNAP RING 3. CAPSCREW AND LOCKWASHER 1. SWIVEL NUT 4. CENTER SUPPORT 2. SWIVEL SHAFT 5. PINION SHAFT 3. CENTER SUPPORT 4. GUARD Figure 18. Support Base 5. TORQUE SENSOR 6.
  • Page 28 Steer Support Assembly 1600 YRM 1449 CAUTION Fit should be tight but be careful not to damage sen- sor when installing over threaded swivel shaft; no tools are necessary to assemble torque sensor to swivel shaft. NOTE: The swivel shaft may have multiple grooves. Make sure the sensor alignment rails are aligned with the sensor harness and that the sensor is installed onto the shaft so that it seats directly into the sensor guard.
  • Page 29 1600 YRM 1449 Steer Support Assembly 1. SUPPORT BASE 2. SUPPORT BEARING AND SNAP RING 3. CAPSCREW AND LOCKWASHER 1. SWIVEL NUT 4. CENTER SUPPORT 2. SWIVEL SHAFT 5. PINION SHAFT 3. CENTER SUPPORT 4. GUARD Figure 24. Support Base 5.

  • Page 30: Install (Complete Unit)

    Position the place. Place the Yale plate into the center of the articulated shaft to the pinion. steer support cover and press to secure in place.

  • Page 31: Electronic Coast Control (Option)

    1600 YRM 1449 Electronic Coast Control (Option) Electronic Coast Control (Option) DISASSEMBLE 6. On Power Steer trucks only, remove the insert from the steering pivot cover and remove the two screws 1. Remove six screws and remove the cover halves retaining the cover.
  • Page 32 Electronic Coast Control (Option) 1600 YRM 1449 1. INSERT 2. SCREW 3. COVER 1. PIN 4. CONTROL HANDLE 2. SCREW 3. NUT Figure 28. Cover 4. WASHER 5. RETAINING RING 6. CONTROL HANDLE Figure 27. Mounting...

  • Page 33: Assemble

    1600 YRM 1449 Electronic Coast Control (Option) 4. Thread the clevis onto the rod until it touches the nut. Tighten the nut against the clevis to lock the clevis in place. 5. Assemble the coast control unit to the control han- dle using the pin and retaining ring.

  • Page 34: Troubleshooting

    Troubleshooting 1600 YRM 1449 Troubleshooting PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION Steering is rough or difficult. Power steering sensor out of calibra- Calibrate power steering sensor. tion. Power steering "Relaxed" due to sen- Check for error codes. (PS may re- sor or system fault.
  • Page 35 Thank you very much for your reading. Please Click Here Then More Information.

This manual is also suitable for:

Mpe080-vgA292A287