Yale A866 MR20Y MR25Y Service Repair Manual - PDF DOWNLOAD

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272492700

Technical Information for YALE Service Centres

This manual is addressed exclusively to the skilled technicians of the YALE service network A866......MR20Y MR25Y

Section: INDEX GENERAL SAFETY PRESCRIPTIONS

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NEVER DO ANY CLEANING, LUBRICATING OR SERVICING WITH THE BATTERY CONNECTED.

DO NOT WEAR RINGS, WATCHES, JEWELLERY, LOOSE CLOTHING SUCH AS SCARVES, UNBUTTONED OR UNZIPPED JACKETS OR SHIRTS THAT COULD GET CAUGHT UP IN MOVING PARTS. WE RECOMMEND INSTEAD THAT THE OPERATOR WEAR APPROVED SAFETY CLOTHING: HARD HAT, NON-SLIP FOOTWEAR, GLOVES, SAFETY GLASSES. DO NOT USE PETROL, DIESEL FUEL OR OTHER FLAMMABLE LIQUIDS AS DETERGENTS: USE INSTEAD NON-FLAMMABLE, NON-TOXIC COMMERCIAL SOLVENTS.

DO NOT SMOKE, USE NAKED FLAMES OR CAUSE ANY SPARKS NEARBY WHEN HANDLING EASILY FLAMMABLE MATERIALS. When working on the machine outside the workshop, park on a level surface, if possible, and chock the wheels. If working on a slope is unavoidable, chock the wheels to prevent the machine moving and transfer it to a level area as soon as it is safe to do so.

Disconnect the batteries and label all the controls to warn of the work in progress. Immobilize the machine and all equipment that has to be lifted.

When towing, use solely the prescribed towing points and make sure the pins and/or bolts are firmly secured before starting to pull. Lift and handle all heavy parts with lifting equipment of suitable capacity. Use the lifting eyes provided. Pay attention to persons in the vicinity of the load to be lifted.

Do not get chains or wire ropes tangled up.

Do not use chains and ropes if they show signs of damage / kinking: do not use them for lifting or pulling.

Always wear safety gloves when handling ropes and chains.

Handle all parts carefully, do not put your hands or fingers between one part and another.

Wear approved safety clothing such as safety goggles, gloves and footwear.

The area where maintenance work is performed must be kept clean and dry. Clean up any spilt water or oil immediately.

Do not pile up greasy or oily rags: serious fire risk. Always store these materials in a closed metal container.

Do not carry out any servicing on the machine with persons at the controls, unless they are qualified operators helping in the work to be done.

When using compressed air to clean parts, protect your eyes with goggles that have side shields.

Welding When welding, always wear the prescribed safety gear: welding goggles, helmet, overalls, gloves and footwear. Dark goggles should also be worn by anyone working in the vicinity of the welding operation. Never look at the welding arc without appropriate eye protection.

Batteries When using batteries, remember that the both ends of cables must be connected to the terminals as prescribed: (+) with (+) and (-) with (-).

Take care not short the terminals.

The gas given off during battery recharging is highly flammable. When recharging, leave the battery compartment open for better ventilation and remove the caps.

KEEP SPARKS AND NAKED FLAMES WELL CLEAR OF THE BATTERY AREA! Do not check the battery charge level by placing metal objects across the terminals.

Before carrying any operations, check the electrical system for short-circuits.

Always disconnect the batteries before working on the electrical system.

For battery chargers and similar equipment, use only auxiliary power supplies with an efficient earth http://www.yaleaxcessonline.com/lib/service/itwservice/272492700/index.htm (2 of 3)06.09.2011 12:01:42

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connection in order to avoid the risk of electric shock.

Hydraulic system Pressurized fluid escaping through a tiny hole may be virtually invisible yet still strong enough to penetrate your skin; when checking for possible leaks, always use a piece of card or wood. Never use your hands.

Always use the appropriate instruments when checking system pressure.

NOTE: THIS MANUAL IS NOT INTENDED AS A SUBSTITUTE FOR THE USER AND MAINTENANCE MANUAL, BUT AS A SUPPLEMENT TO IT

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INDEX Section: ELECTRICAL SYSTEM 1.0 KEY TO ELECTRICAL DIAGRAMS ELECTRICAL DIAGRAMS - FUNCTIONAL ELECTRICAL DIAGRAM - FUNCTIONAL ELECTRICAL DIAGRAM - ELECTRICAL SYSTEM COMPONENTS MODEL MR20Y - MR25Y Section: LONGITUDINAL / SIDEWAYS TRAVEL SYSTEM 2.0 STEERING SYSTEM - TABLE OF HYDRAULIC / ELECTRICAL FUNCTIONS - AUTOMATIC CHANGEOVER (FROM LONGITUDINAL TRAVEL TO SIDEWAYS TRAVEL).

- HYDRAULIC CIRCUIT STATUS IN CHANGEOVER PHASE (FROM LONGITUDINAL TO SIDEWAYS TRAVEL) - SETUP FOR SIDEWAYS TRAVEL MODE - HYDRAULIC CIRCUIT WITH PROVISION FOR MANUAL SIDEWAYS - STEERING - AUTOMATIC CHANGEOVER (FROM SIDEWAYS STEERING TO LONGITUDINAL STEERING) - HYDRAULIC CIRCUIT STATUS DURING CHANGEOVER PHASE (FROM LONGITUDINAL TO SIDEWAYS) - TRACTION WHEEL ARRIVAL AT ROTATION LIMIT POSITION - LOAD WHEELS ARRIVAL AT ROTATION LIMIT POSITION - HYDRAULIC CIRCUIT SET UP FOR MANUAL LONGITUDINAL STEERING - MANUAL RESET TO LONGITUDINAL STEERING 2.0.0 FUNCTIONS OF TIMER CARDS U3, U4 2.0.1 TROUBLESHOOTING GUIDE 3.0 TABLE OF ELECTRICAL COMPONENTS - ELECTRICAL COMPONENT Section: H2B TRACTION MOTOR ELECTRONIC CONTROLLER 4.0 H2B TRACTION MOTOR ELECTRONIC CONTROLLER 4.0.1 PRESENTATION 4.1 DEFINITION OF MACHINE TRAVEL DIRECTION 4.2 GENERAL CHARACTERISTICS OF CONTROLLER H2B 4.3 FUNCTIONAL CHARACTERISTICS OF CONTROLLER H2B. 4.4 CONTROLLER DIAGNOSTICS 4.5 CONTROLLER MECHANICAL DESIGN 4.6 CONNECTORS 4.7 DESCRIPTION OF CONNECTOR "B" INPUTS "B" 4.8 DESCRIPTION OF CONNECTOR "E" INPUTS 4.9 CONTROLLER CONNECTIONS DIAGRAM 4.10 PROGRAMMING CONSOLE 4.11 USING THE CONSOLE 4.12 CONSOLE FUNCTIONS MAP 4.13 PROGRAMMING THE CONTROLLER 4.13.0 CONFIG MENU 4.13.1 CONFIG MENU - SET MODEL 4.13.2 CONFIG MENU - SET OPTION 4.13.3 CONFIG MENU - ADJUSTMENT 4.13.4 MAIN MENU - PARAMETER CHANGE 4.13.5 MAIN MENU - TESTER

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4.13.6 MAIN MENU - SAVE PARAMETER 4.13.7 MAIN MENU - RESTORE PARAMETER 4.13.8 MAIN MENU - ALARMS 4.13.9 MAIN MENU - PROGRAM VACC 4.14 H2B SYSTEM CONFIGURATION TABLE 4.15 TABLE SHOWING EQUIVALENCE BETWEEN PARAMETER VALUES AND PROGRAMMING 4.16 LEVELS.TION PROCEDURE FOR INITIALIZATION OF A NEW SYSTEM. 4.17 TROUBLESHOOTING 4.17.0 DECODING ALARM SIGNALS ON THE DIAGNOSTIC LED Section: PUMP MOTOR CONTROLLER HP 350A 5.0 PUMP MOTOR ELECTRONIC CONTROLLER 5.1 CONTROLLER GENERAL CHARACTERISTICS 5.1.0 FUNCTIONAL CHARACTERISTICS OF THECONTROLLER 5.2 CONTROLLER MECHANICAL DRAWING 5.3 CONNECTORS 5.4 CONTACTOR COIL POWER SUPPLY CONNECTOR 5.5 DESCRIPTION OF CONNECTOR "B" INPUTS 5.6 CONTROLLER CONNECTIONS DIAGRAM 5.7 PROGRAMMING CONSOLE 5.7.0 PROGRAMMING 5.7.1 USING THE PROGRAMMING CONSOLE 5.8 CONSOLE FUNCTIONS MAP 5.9 CONTROLLER PROGRAMMING 5.9.0 CONFIG MENU 5.9.1 CONFIG MENU SET MODEL 5.9.2 CONFIG MENU SET OPTION 5.9.3 CONFIG MENU SEL BATTERY 5.9.4 CONFIG MENU AUX OUTPUT 5.9.5 MAIN MENU PARAMETER CHANGE 5.9.6 LIFT UNIT SETTINGS SEQUENCES 5.9.7 MAIN MENU TESTER 5.9.8 MAIN MENU SAVE PARAMETER 5.9.9 MAIN MENU RESTORE PARAMETER 5.9.10 MAIN MENU ALARMS 5.9.11 MAIN MENU PROGRAM VACC 5.10 CONTROLLER CONFIGURATION TABLE 5.11 DECODING DIAGNOSTIC LED ALARM SIGNALS Section: REPLACING ELECTRICAL COMPONENTS 6.0 REPLACING THE LOAD WHEEL POTENTIOMETER 6.0.0 PROCEDURE FOR INSTALLING THE LOAD WHEEL POTENTIOMETER 6.0.1 PROCEDURE FOR ACQUISITION OF POTENTIOMETER SIGNAL BY STEERING INDICATOR 100 7.0 REPLACING THE TRACTION WHEEL POTENTIOMETER 7.0.0 PROCEDURE FOR FITTING THE TRACTION WHEEL POTENTIOMETER. 7.0.1 PROCEDURE FOR ACQUISITION OF POTENTIOMETER SIGNAL BY STEERING INDICATOR 103 8.0 REPLACING THE MAST LIFT POTENTIOMETER 8.0.0 INSTALLATION PROCEDURE 9.0 REPLACING THE TRACTION CONTROL PEDAL 10.0 REPLACING LOAD WHEELS ROTATION MICROSWITCHES B17 - B19

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11.0 REPLACING RELAYS D1 - D2 - D4 - D5 - D6 - D7 11.0.0 REPLACING RELAYS D4, D7 11.0.1 REPLACING RELAY D1 11.0.2 REPLACING RELAYS D2, D5, D6 11.0.3 REPLACING CARDS U3, U4 12.0 REPLACING MICROSWITCH B20 Section: HYDRAULIC UNIT COMPONENTS 1.0 KEY TO HYDRAULIC SYMBOLS - HYDRAULIC DIAGRAM 2.0 HYDRAULIC UNIT 2.1 TABLE OF HYDRAULIC UNIT COMPONENTS

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ELECTRICAL DIAGRAMS 1.0 KEY TO ELECTRICAL SYMBOLS MODEL MR20Y - MR25Y

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2.0 STEERING SYSTEM MODELS MR20Y - MR25Y http://www.yaleaxcessonline.com/lib/service/itwservice/272492700/01_ELETT/C1a.htm (2 of 9)06.09.2011 12:02:47

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A) LONGITUDINAL STEERING In this configuration the truck is utilized with the wheels positioned in parallel to the forks; the operator steering position is similar to that of a reach truck.

The truck is steered by means of the traction wheel.

B) SIDEWAYS STEERING In this configuration the truck is utilized with the wheels rotated transversly with respect to the body.

The load wheels are utilized to steer the truck.

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