Yale A867 (MT10 12 15) Service Manual - PDF DOWNLOAD

Yale Axcess Online

Service Manuals Manuals Available For A867 (MT10/12/15) Manual

Manual Title

272485100

Service Repair Manual

272490600

Reducer

272491100

EPS-DC / Wire Guidance

524211261

Level Preselector

©2011 Yale Axcess Online

http://www.yaleaxcessonline.com/eng/myt/truck_details.cfm?action=4&h=107.09.2011 11:11:46

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/index.htm

272485100

Technical Information for YALE Service Centres

This manual is addressed exclusively to the specialised technicians of the Yale service network A867........... MT 10 - 12 - 15

Section: INDEX

GENERAL SAFETY PRESCRIPTIONS

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. http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/index.htm (1 of 2)07.09.2011 11:49:57

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/index.htm

When working on the machine outside the workshop, park on a level surface, if possible, and chock the wheels. If working on a gradient is unavoidable, chock the wheels to prevent the truck 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. Be careful of people close to the load to lift.

Do not get chains or metal ropes tangled up.

Do not trust bent or damaged chains and ropes: do not use them for lifting or pulling. Always wear safety gloves when handling ropes or 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: they constitute a 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.

NEVER CAUSE SPARKS OR ALLOW ANY NAKED FLAMES NEAR THE BATTERY! 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 connection in order to avoid the risk of electric shock.

Hydraulic system Pressurised 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

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/index.htm (2 of 2)07.09.2011 11:49:57

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/toc.htm

INDEX Section: ELECTRICAL SYSTEM STANDARD ELECTRICAL DIAGRAMS - STANDARD FUNCTIONAL ELECTRICAL DIAGRAM MODELS MT10 - 12 - 15 ELECTRICAL DIAGRAMS WITH WIRE GUIDANCE - FUNCTIONAL ELECTRICAL DIAGRAM WITH WIRE GUIDANCE SYSTEM MODELS MT10 - 12 - 15 - FUNCTIONAL ELECTRICAL DIAGRAM OF THE SOLENOID VALVES PRC CONTROLLER - FUNCTIONAL ELECTRICAL DIAGRAM - FUNCTIONAL ELECTRICAL DIAGRAM OF ELECTRIC STEERING WITH WIRE GUIDANCE SYSTEM - KEY TO ELECTRICAL AND CONNECTOR DIAGRAMS - ELECTRICAL COMPONENTS MODELS MT10 - 12 - 15 - FUNCTIONAL ELECTRICAL DIAGRAM OF THE SOLENOID VALVES PRC CONTROLLER - FUNCTIONAL ELECTRICAL DIAGRAM - KEY TO ELECTRICAL DIAGRAMS OF COMPONENTS 1.0 TABLE OF ELECTRICAL COMPONENTS 1.1 ELECTRICAL COMPONENTS 1.2 POSITION OF RELAYS BANK 1.3 DESCRIPTION OF RELAY FUNCTIONS - COMBI-C1 CONTROLLER 1.0 DESCRIPTION OF COMBI-C1 ELECTRONIC CONTROLLER 1.2 TECHNICAL SPECIFICATIONS 1.3 SCHEMATIC DIAGRAM 1.4 FUNCTIONAL CHARACTERISTICS 1.5 COMPENSATION CONCEPT 1.7 GENERAL WARNINGS AND PRECAUTIONS 2.0 POWER AND CONTROL CIRCUIT CONNECTORS 2.6 POWER CABLES CONNECTION DIAGRAM 2.7 CONTROL CIRCUIT CABLES CONNECTION DIAGRAM 3.0 PROGRAMMING CONSOLE 4.0 CONSOLE FUNCTIONS MAP 5.0 CONTROLLER PROGRAMMING 5.1 CONFIG. MENU SET OPTIONS 5.2 CONFIG. MENU ADJUSTMENT 5.3 MAIN MENU PARAMETER CHANGE 5.4 MAIN MENU TESTER 5.5 MAIN MENU SAVE PARAMETER 5.6 MAIN MENU RESTORE PARAMETER 5.7 MAIN MENU ALARM 5.8 MAIN MENU PROGRAM VACC 6.0 COMBI-C1 CONTROLLER CONFIGURATION TABLES 7.0 CALIBRATION SEQUENCE FOR INITIALIZATION OF A NEW CONTROLLER 7.2 PUMP UNIT CALIBRATION SEQUENCE 8.0 TROUBLESHOOTING 8.1 DECODING TRACTION SYSTEM DIAGNOSTIC LED ALARM SIGNALS 8.2 DECODING OF ALARMS DISPLAYED ON THE CONSOLE (TRACTION)

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/toc.htm (1 of 2)07.09.2011 11:50:40

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/toc.htm

9.1 DECODING OF PUMP UNIT DIAGNOSTIC LED ALARMS 9.2 DECODING OF ALARMS DISPLAYED ON THE CONSOLE (PUMP UNIT) - PRC HYDRAULIC CONTROLLER 1.0 INTRODUCTION TO PRC CONTROLLER 2.0 CONSOLE FUNCTIONS MAP 3.0 PRC CONTROLLER CONFIGURATION TABLE 4.0 CONFIGURATION OF POTENTIOMETERS ON PRC 4.1 DESCRIPTION OF PARAMETERS 5.0 DESCRIPTION OF ALARMS 6.0 PROGRAM VACC Section: HYDRAULIC SYSTEM HYDRAULIC SYSTEM 1.0 FUNCTIONAL HYDRAULIC DIAGRAM 1.1 TABLE OF HYDRAULIC COMPONENTS 1.2 TABLE OF HYDRAULIC COMPONENTS 1.3 MAST LIFT - HYDRAULIC CIRCUIT STATUS 1.4 MAST LOWER - HYDRAULIC CIRCUIT STATUS 1.5 FORKS RIGHT-HAND SIDESHIFT - HYDRAULIC CIRCUIT STATUS 1.6 FORKS LEFT-HAND SIDESHIFT - HYDRAULIC CIRCUIT STATUS 1.7 FORKS RIGHT-HAND ROTATION HYDRAULIC CIRCUIT STATUS 1.8 FORKS LEFT-HAND ROTATION HYDRAULIC CIRCUIT STATUS 2.0 MAST LIFT/LOWER AND LOAD HANDLER CONTROL VALVES 2.1 TABLE OF VALVE COMPONENTS

Section: LOAD HANDLER - THREE-SIDED LOAD HANDLER 1.0 STANDARD LOAD HANDLER COMPONENTS 1.1 TABLE OF STANDARD LOAD HANDLER COMPONENTS 1.2 COMPONENTS OF LOAD HANDLER WITH CARRIAGE 1.3 TABLE OF LOAD HANDLER COMPONENTS WITH CARRIAGE 2.0 LOAD HANDLER FUNCTION 2.1 INSTALLATION OF LOAD HANDLER WITH CARRIAGE 2.2 MECHANICAL ADJUSTMENT OF LIMIT POSITIONS 2.5 MAINTENANCE 2.6 TROUBLESHOOTING 3.0 MECHANICAL ADJUSTMENT OF THE LOAD HANDLER BEARINGS Section: TRUCK INSTALLATION 1.0 INSTALLING THE TRUCK 2.0 TRUCK OPERATING CONDITIONS OUTSIDE AND INSIDE AISLE 2.1 DESCRIPTION OF TRUCK OPERATION OUTSIDE AND INSIDE AISLE 3.0 INSTALLING TRUCK IN AISLE 4.0 WIDE GUIDANCE ADJUSTMENT PROCEDURE 5.0 LAYOUT FOR POSITIONING OF MAGNETS IN AISLE 6.0 LAYOUT FOR POSITIONING OF GUIDES IN AISLE

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/toc.htm (2 of 2)07.09.2011 11:50:40

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm

FUNCTIONAL ELECTRICAL DIAGRAM WITH WIRE GUIDANCE SYSTEM MODELS MT10 - 12 - 15

FUNCTIONAL ELECTRICAL DIAGRAM OF THE SOLENOID VALVES PRC CONTROLLER

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm (1 of 9)07.09.2011 11:51:36

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm

FUNCTIONAL ELECTRICAL DIAGRAM

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm (2 of 9)07.09.2011 11:51:36

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm

KEY TO ELECTRICAL AND CONNECTOR DIAGRAMS

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm (3 of 9)07.09.2011 11:51:36

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm

ELECTRICAL COMPONENTS MODELS MT10 - 12 - 15

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm (4 of 9)07.09.2011 11:51:36

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm

STANDARD FUNCTIONAL ELECTRICAL DIAGRAM MODELS MT10 - 12 - 15

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm (5 of 9)07.09.2011 11:51:36

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm

FUNCTIONAL ELECTRICAL DIAGRAM OF THE SOLENOID VALVES PRC CONTROLLER

http://www.yaleaxcessonline.com/lib/service/itwservice/272485100/A3_elett/c5a.htm (6 of 9)07.09.2011 11:51:36