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1. MPE060-VG (A292) MPE080-VG (A287) SERVICE MANUAL CONTENTS SECTION PART NUMBER YRM NUMBER REV 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...................................................................................................... 550025476 1600 YRM 1449 09/12 BRAKE SYSTEM............................................................................................................ 524274701 1800 YRM 1285 04/11 HYDRAULIC SYSTEM.................................................................................................... 550026124 1900 YRM 1450 04/11 TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS PROGRAM................................................................................................................. 524183085 2200 YRM 1058 04/11 AC MOTOR CONTROLLER........................................................................................... 524274702 2200 YRM 1286 04/11 USER INTERFACE SUPERVISOR FUNCTIONS ON-BOARD DASH DISPLAY.......... 524290090 2200 YRM 1323 04/11 USER INTERFACE SERVICE TECHNICIAN FUNCTIONS ON-BOARD DASH DISPLAY.................................................................................................................... 524290091 2200 YRM 1324 10/12 ELECTRICAL SYSTEM.................................................................................................. 550026125 2200 YRM 1451 04/11 INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14 LIFT MECHANISM.......................................................................................................... 550025477 4000 YRM 1452 12/12 METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13 DIAGRAMS..................................................................................................................... 524274698 8000 YRM 1288 08/12 PERIODIC MAINTENANCE............................................................................................ 550025465 8000 YRM 1453 04/11 CAPACITIES AND SPECIFICATIONS........................................................................... 550025478 8000 YRM 1454 04/11 Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 550025474 (09/14) 2. SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. • Keep the unit clean and the working area clean and orderly. • 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. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background. 3. Steering Mechanism Table of Contents TABLE OF CONTENTS General................................................................................................................................................................ 1 Accessing the Drive Unit Compartment .......................................................................................................... 1 Special Precautions............................................................................................................................................. 2 Electromagnetic Shield ................................................................................................................................... 3 Calibration ........................................................................................................................................................... 3 Power Assist Steering ..................................................................................................................................... 3 Control Handle..................................................................................................................................................... 4 Control Handle Head....................................................................................................................................... 4 Control Handle ................................................................................................................................................ 4 Standard Steering....................................................................................................................................... 4 Remove .................................................................................................................................................. 4 Install ...................................................................................................................................................... 5 Power Assist Steering................................................................................................................................. 6 Remove .................................................................................................................................................. 6 Install ...................................................................................................................................................... 7 Gas Spring .......................................................................................................................................................... 9 Discharging the Gas Spring ............................................................................................................................ 9 Remove........................................................................................................................................................... 9 Install............................................................................................................................................................... 10 Articulating Shaft and Pinions (Power Assist Models)......................................................................................... 11 Remove........................................................................................................................................................... 11 Pinion Repair................................................................................................................................................... 11 Upper Pinion ............................................................................................................................................... 11 Remove .................................................................................................................................................. 12 Install ...................................................................................................................................................... 12 Lower Pinion ............................................................................................................................................... 13 Install............................................................................................................................................................... 14 Steer Motor Assembly ......................................................................................................................................... 14 Repair.............................................................................................................................................................. 14 Steer Motor, Replace .................................................................................................................................. 14 Steer Motor Gear, Replace ......................................................................................................................... 15 Gearbox/Complete Assembly, Replace ...................................................................................................... 16 Steer Support Assembly...................................................................................................................................... 17 Standard Steering ........................................................................................................................................... 17 Remove (Complete Unit) ............................................................................................................................ 17 Disassemble ............................................................................................................................................... 17 Assemble .................................................................................................................................................... 19 Install (Complete Unit) ................................................................................................................................ 19 Power Assist Steering (Option) ....................................................................................................................... 20 Remove (Complete Unit) ............................................................................................................................ 21 Disassemble ............................................................................................................................................... 21 Support Base.......................................................................................................................................... 21 Steer Swivel............................................................................................................................................ 22 Assemble .................................................................................................................................................... 22 Steer Swivel............................................................................................................................................ 22 Support Base.......................................................................................................................................... 22 Install (Complete Unit) ................................................................................................................................ 26 Electronic Coast Control (Option)........................................................................................................................ 27 Disassemble.................................................................................................................................................... 27 Assemble ........................................................................................................................................................ 29 Checks ............................................................................................................................................................ 29 ©2012 Yale Materials Handling Corp. i 4. Table of Contents Steering Mechanism TABLE OF CONTENTS (Continued) Troubleshooting ................................................................................................................................................... 30 This section is for the following models: MPE060-VG [A292]; MPE080-VG [A287] ii 5. 1600 YRM 1449 General General The control handle assembly is designed to perform several functions. The standard control handle includes 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. Move the control handle left or right to turn the drive/steer tire and steer the truck. Controls mounted in the handle are linked to the control panel by a wiring harness that passes through the center of the handle. The brake is applied when the handle is in the full up or down posi- tion. A top-mounted control handle assembly is used on these lift trucks and is designed to be used while the operator is either walking beside the truck or riding on a small platform to the left or right side of the handle. A power assist option is available that senses when the operator begins to move the control handle side to side and activates a motor in the drive unit compartment to turn the drive unit. This greatly reduces the operator effort needed to steer the lift truck. ACCESSING THE DRIVE UNIT COMPARTMENT The drive unit compartment is concealed behind a molded cover which fits securely around the steer support assembly and into the frame. The floor mat fits snugly in the operator platform after the drive unit cover has been installed. To remove the drive unit cover, first lift the corners of the floor mat and pull it out away from the drive unit. See Figure 1. Next, reach under the side of the drive unit cover near the bottom and find the grip slot. See Fig- ure 2. With both hands, pull up and away from the truck until the bottom of the cover kicks out from the retaining clips. Repeat this for the other side of the cover. Work around the edge of the cover until it is freed from the truck. To install the drive unit cover, make sure the floor mat is pulled away from the drive unit and place the bottom of the drive unit cover onto the operator platform. Po- sition the lower edges partially into the lower retaining clips. Push the top of the cover partially into the upper retaining clips. Do not push either edge of the cover in completely before starting all edges into the proper place. When the cover is aligned and started properly, press the cover completely into the retaining clips and place the floor mat into the operator platform around the cover. 1. FLOOR MAT 2. DRIVE UNIT COMPARTMENT COVER 3. FRAME 4. CASTER ADJUSTMENT ACCESS Figure 1. Floor Mat 1. DRIVE UNIT COMPARTMENT COVER 2. RETAINER TABS 3. GRIP SLOT 4. FRAME Figure 2. Drive Unit Compartment Cover 1 6. 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. DO NOT use a screwdriver to discharge the traction motor controller. WARNING To avoid personal injury and prevent electrical shock, perform the following steps before per- forming any troubleshooting or adjustments, and connecting or disconnecting a handset or PC. CAUTION To avoid controller damage, always disconnect the battery. Discharge the capacitor and never put power to the controller with any power wire dis- connected. Never short any controller terminal or motor terminal to battery. Make sure to use proper procedures when servicing the controller. 1. Turn the key switch to the OFF position and discon- nect the battery. 2. Remove the drive unit compartment cover to ac- cess the controller. See Accessing the Drive Unit Compartment. 3. Discharge the capacitors in the controllers by connecting a 200-ohm, 2-watt resistor across the controller’s B+ and B terminals using insulated jumper wires. See Figure 3. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Remove the 200-ohm, 2-watt resistor before reconnecting the battery. 1. CONTROLLER 2. POSITIVE CONNECTION 3. INSULATED JUMPER WIRES 4. 200-OHM, 2-WATT RESISTOR 5. NEGATIVE CONNECTION Figure 3. Discharging Capacitors 2 7. 1600 YRM 1449 Calibration ELECTROMAGNETIC SHIELD WARNING Never operate Power Assist models with the Elec- tromagnetic Shield removed. A metallic shield is installed between the MDU and brake assembly and the steering assembly on power 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 torque sensor. Make certain that the Electromagnetic Shield is reinstalled before operating the lift truck after servicing to prevent erratic operation of the power assist steering function. Calibration POWER ASSIST STEERING The following calibration instructions apply to all power assist steering models. WARNING If at any time a tiller handle slowly moves in one di- rection during startup, it is likely calibration needs to be performed. Power assist steering calibration should be performed if either the torque sensor or power assist steering unit is serviced or replaced or anytime the drive tire is re- placed. 1. Position the lift truck on a normal, smooth surface floor away from personnel or other equipment with the drive tire centered. 2. Turn the key switch to the OFF position and remove the drive unit compartment cover. 3. The Calibration Tab is an unconnected wire with a female spade connector hanging near the ETACC CAN connector. Attach the Calibration Tab to the B+ terminal (right post) of the contactor, using a 914 mm (36 in.) 14 Ga. jumper wire with an alli- gator clip on one end and a male spade connector on the other. NOTE: If the lift truck is not equipped with coast control, wedge a deep well socket or 50 mm (2.00 in.) by 20 mm (0.75 in.) wood block into the control arm/swivel joint area to hold the handle in an operating position. 4. Position the control arm in the brake OFF position and secure using the coast control. See Figure 4. 5. Standing clear of the steer handle, turn the key switch to the ON position. NOTE: Communication error codes may appear during this process. This is a normal part of the calibration process. 6. The lift truck will start up in calibration mode and the tiller handle will begin to move on its own power during the calibration cycle. 7. Wait at least 5 seconds after the calibration cycle has ended (the till
