Yale A892 (MP20XD) Service Manual - PDF DOWNLOAD

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Service Manuals Manuals Available For A892 (MP20XD) Manual

Manual Title

272484600

Service Repair Manual

272486700

Controller Electronic COMBI

272487200

Multifunction Digital Instrument (MDI)

272490600

Reducer

©2012 Yale Axcess Online

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P.No. 272484600

Technical Information for YALE Service Centres

This manual is addressed exclusively to the specialised technicians of the Yale service network

This manual is addressed exclusively to the specialised technicians of the Yale service network B 843 MP20X B 847 MS12/15X, MS12X I.L. A 892 MP20X/D

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 THAT OPERATORS WEAR APPROVED SAFETY CLOTHING: HARD HAT, NON-SLIP FOOTWEAR, GLOVES, SAFETY GLASSES. DO NOT USE PETROL, DIESEL FUEL OR OTHER FLAMMABLE LIQUIDS FOR CLEANING PURPOSES: USE INSTEAD NON-FLAMMABLE, NON-TOXIC COMMERCIAL SOLVENTS. DO NOT SMOKE, USE NAKED FLAMES OR CAUSE ANY SPARKS NEARBY WHEN HANDLING EASILY FLAMMABLE MATERIALS. If working outside the workshop, park the truck preferably on the level and immobilize it. 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 only the prescribed points of connection and make sure the pins and/or bolts are firmly secured.

Lift and handle all heavy parts using lifting equipment of suitable capacity. Use the lifting eyes provided. Be careful of people in the vicinity of the load to lifted.

Do not get chains or metal ropes tangled up.

Do not trust damaged chains and ropes (kinked, etc.): do not use them for lifting or pulling. Always wear safety gloves when handling chains and ropes.

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

Wear type-approved accident-prevention equipment such as safety glasses, 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 operations on the machine with anyone 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 guards.

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 both ends of the cables must be connected to the terminals as prescribed: (+) with (+), and (-) with (-).

Do 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! Never check the battery charge level by placing metal objects across the battery terminals.

Before carrying out any operations, check that no elements are short-circuiting.

Always disconnect the batteries before carrying out any work 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 powerful enough to penetrate your

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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 OPERATING AND MAINTENANCE MANUAL, BUT AS A SUPPLEMENT TO IT.

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INDEX Section: COMBI ELECTRONIC SYSTEM FOR INFORMATION REGARDING THE NA.CO COMBI ELECTRONIC SYSTEM, CONSULT SERVICE MANUAL P/N 272486700 Section: ELECTRONIC SYSTEM MDI FOR INFORMATION REGARDING THE FUNCTIONS OF THE MDI, CONSULT SERVICE MANUAL P/N 272487200 Section: ELECTRICAL SYSTEM 1.0 ELECTRICAL DIAGRAMS - MP20X 1.1 KEY TO FUNCTIONAL ELECTRICAL DIAGRAM 1.2 FUNCTIONAL ELECTRICAL DIAGRAM 1.3 CONTROL CIRCUIT WIRING DIAGRAM 1.4 POWER CIRCUIT WIRING DIAGRAM 1.5 CONNECTOR WIRING DIAGRAM 2.0 ELECTRICAL DIAGRAMS - MS12/15X 2.1 KEY TO FUNCTIONAL ELECTRICAL DIAGRAM 2.2 FUNCTIONAL ELECTRICAL DIAGRAM 2.3 CONTROL CIRCUIT WIRING DIAGRAM 2.4 POWER CIRCUIT WIRING DIAGRAM 2.5 CONNECTOR WIRING DIAGRAM 3.0 ELECTRICAL DIAGRAMS - MP20X/D - MS12X I.L. 3.1 KEY TO FUNCTIONAL ELECTRICAL DIAGRAMS 3.2 FUNCTIONAL ELECTRICAL DIAGRAM 3.3 CONTROL CIRCUIT WIRING DIAGRAM 3.4 POWER CIRCUIT WIRING DIAGRAM 3.5 CONNECTOR WIRING DIAGRAM 4.0 COMMON ELECTRICAL DIAGRAMS 4.1 INTERFACE BOARD WIRING DIAGRAM 4.2 TILLER CONTROL BOARD DIAGRAM 5.0 COMBI CONTROLLER PROGRAMMING TABLE - MP20X - MS12/15X - MP20X/D - MS12X I.L. 5.1 TABLE OF COMBI “SET OPTIONS - ADJUST” PARAMETERS 5.2 TABLE OF COMBI “PARAMETER CHANGE” PARAMETERS 6.0 ELECTRICAL SYSTEM 6.1 TABLE OF ELECTRICAL SYSTEM COMPONENTS 6.1.1 ELECTRICAL SYSTEM COMPONENTS - MP20X 6.1.2 ELECTRICAL SYSTEM COMPONENTS - MS12/15X 20b 6.1.3 ELECTRICAL SYSTEM COMPONENTS - MP20X/d 6.1.4 ELECTRICAL SYSTEM COMPONENTS - MS12X I.L. 6.2 CONNECTING THE POWER CABLES TO THE COMBI CONTROLLER 6.3 COMPONENTS OF THE TILLER CONTROL BOX 6.3.1 TABLE OF TILLER CONTROL BOX COMPONENTS 6.4 TILLER CONTROL BOX 6.4.1 DESCRIPTION OF THE TILLER CONTROL BOX 6.4.2 FORKS UP/DOWN CONTROLS 6.5 TILLER ELECTRONIC CONTROL BOARD 6.5.1 TABLE OF ELECTRONIC BOARD COMPONENTS 6.6 DISASSEMBLY OF THE TILLER CONTROL BOX http://www.yaleaxcessonline.com/lib/service/itwservice/272484600/TOC.htm (1 of 4)20.02.2012 16:06:45

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6.6.1 REMOVAL OF THE TILLER CONTROL BOARD 6.6.2 CALIBRATION OF THE DRIVE POTENTIOMETER 6.6.3 PROCEDURE 6.6.4 RENEWAL OR INSTALLATION OF THE OPTIONAL “SNAIL” FUNCTION (S10) 6.6.5 RENEWAL OF THE ON/OFF MICROSWITCH AND THE POTENTIOMETRIC MICROSWITCHES 6.6.6 RENEWAL OF THE BUTTERFLY CONTROL SPRING 6.6.7 RENEWAL OF THE BELLY SWITCH 6.6.8 RENEWAL OF THE HORN PUSHBUTTON 6.7 RENEWAL OF THE MAIN SWITCH AND MIDI 6.7.1 REMOVAL OF THE MIDI 6.7.2 REMOVAL OF THE MAIN SWITCH Section: HYDRAULIC SYSTEM 1.0 KEY TO HYDRAULIC SYSTEM SYMBOLS 2.0 OIL SPECIFICATIONS TABLE 3.1 FUNCTIONAL HYDRAULIC DIAGRAM - MP20X 3.2 HYDRAULIC POWER UNIT - MP20X 4.1 FUNCTIONAL HYDRAULIC DIAGRAM - MS12/15X 4.2 HYDRAULIC POWER UNIT - MS12/15X 5.0 ADJUSTMENT OF THE STACKER FORKS LIFT PRESSURE RELIEF VALVE - MP20X - MS12/15X 6.1 FUNCTIONAL HYDRAULIC DIAGRAM - MP20X/D - MS12X I.L. 6.2 FUNCTIONAL HYDRAULIC DIAGRAM - MS12X I.L. 7.1 HYDRAULIC POWER UNIT - MP20X/D - MS12X I.L. 7.2 TABLE OF HYDRAULIC POWER UNIT COMPONENTS 8.0 ADJUSTMENT OF THE STACKER FORKS LIFT PRESSURE RELIEF VALVE MP20X/D - MS12X I.L. 9.1 HYDRAULIC SYSTEM - MS12/15X 9.2 HYDRAULIC SYSTEM - MP20X/D - MS12X I.L. 9.3 HYDRAULIC SYSTEM - MP20X 9.4 PLUNGER-TYPE PALLET FORKS LIFT CYLINDER 9.5 PLUNGER-TYPE LATERAL LIFT CYLINDER 9.6 SINGLE-ACTING 3-STAGE CENTRAL LIFT CYLINDER 10.0 REMOVAL OF THE PALLET FORKS LIFT CYLINDER 10.1 REMOVAL PROCEDURE 10.2 SEAL RENEWAL 11.0 REMOVAL OF THE LATERAL LIFT CYLINDER - SEAL RENEWAL 11.1 REMOVAL PROCEDURE 11.2 SEAL RENEWAL 11.3 BLEEDING AIR FROM THE CYLINDER 12.0 REMOVAL OF THE CENTRAL LIFT CYLINDER 12.1 CYLINDER REMOVAL PROCEDURE 12.2 SEAL RENEWAL 12.3 CYLINDER ASSEMBLY 13.0 RENEWAL OF THE ELECTRIC PUMP - RENEWAL OF THE PUMP BODY 13.1 REMOVAL OF THE HYDRAULIC POWER UNIT 13.2 REMOVAL OF THE PUMP MOTOR - MP20X/D 13.3 REMOVAL OF THE PUMP MOTOR - MS12/15X - MS12X I.L. 13.4 REMOVAL OF THE PUMP BODY 14.0 RENEWAL OF THE ELECTRIC PUMP - RENEWAL OF THE PUMP BODY - MP20X 14.1 REMOVAL PROCEDURE 14.2 REMOVAL OF THE HYDRAULIC UNIT

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14.3 REMOVAL OF THE PUMP MOTOR 14.4 REMOVAL OF THE PUMP BODY Section: MECHANICAL LINKAGES 1.0 MECHANICAL LINKAGE COMPONENTS - MP20X 2.0 MECHANICAL LINKAGE COMPONENTS - MP20X/D - MS12X I.L. 3.0 RENEWAL OF THE FRONT LEVERS - RENEWAL OF THE REAR LEVER 3.1 REMOVAL OF FRONT LEVERS 3.2 REMOVAL OF REAR LEVER Section: MECHANICS 1.0 TABLE OF TIGHTENING TORQUES 2.0 REAR BODY COMPONENTS 2.1 TABLE OF REAR BODY COMPONENTS 3.0 REMOVAL OF THE OPERATOR PLATFORM - RENEWAL OF THE PLATFORM RETURN SPRING 3.1 REMOVAL OF THE PLATFORM 4.0 REMOVAL OF SIDE GUARDS - REMOVAL OF SIDE GUARD SUPPORT SPRING 4.1 REMOVAL OF THE GAS SPRING 4.2 REMOVAL OF THE SIDE GUARD ASSEMBLY 4.3 RENEWAL OF THE SIDE GUARDS 5.0 RENEWAL OF THE TILLER SPRING 5.1 REMOVAL PROCEDURE 6.0 RENEWAL OF THE DRIVE WHEEL - RENEWAL OF THE PIVOTING WHEEL 6.1 REMOVAL OF THE DRIVE WHEEL 6.2 RENEWAL OF THE PIVOTING WHEEL 6.3 RENEWAL OF THE PIVOTING ASSEMBLY 7.0 REMOVAL OF THE TILLER ASSEMBLY - REMOVAL OF THE TRACTION MOTOR 7.1 REMOVAL OF THE TILLER 7.2 REMOVAL OF THE TRACTION MOTOR 8.0 REMOVAL OF THE REDUCTION GEAR SUPPORT SPRINGS 8.1 REMOVAL PROCEDURE 9.0 RENEWAL OF THE DRIVE UNIT SUPPORT - RENEWAL OF THE UPPER LEVER -RENEWAL OF THE LOWER LEVER 9.1 REMOVAL PROCEDURE

Section: MECHANICS - MASTS 1.0 MAST TYPES 2.0 REMOVAL OF THE FORK CARRIAGE ON 3-STAGE MASTS 2.1 REMOVAL PROCEDURE 3.0 REMOVAL OF THE FORK CARRIAGE ON 2-STAGE MASTS 3.1 REMOVAL PROCEDURE 4.0 REMOVAL OF THE INNER MAST SECTION ON 2-STAGE MASTS 4.1 REMOVAL PROCEDURE 5.0 REMOVAL OF THE INNER MAST SECTIONS ON 3-STAGE MASTS 5.1 REMOVAL OF THE INNER MAST SECTION 5.2 REMOVAL OF THE INTERMEDIATE MAST SECTION 6.0 REMOVAL OF THE COMPLETE MAST ASSEMBLY 6.1 REMOVAL PROCEDURE

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Section: REDUCTION GEAR 1.0 GR-96 REDUCTION GEAR COMPONENTS 1.1 TABLE OF GR-96 REDUCTION GEAR COMPONENTS 2.0 REMOVAL OF THE REDUCTION GEAR 2.1 REMOVAL PROCEDURE Section: BRAKING SYSTEM 1.0 COMPONENTS OF THE ELECTROMAGNETIC BRAKE 2.0 BRAKING SYSTEM 2.1 SERVICE BRAKE 2.2 REGENERATIVE BRAKING 2.3 EMERGENCY AND PARKING BRAKE 3.0 REMOVAL AND ADJUSTMENT OF THE ELECTROMAGNETIC BRAKE 3.1 REMOVAL PROCEDURE 4.0 ADJUSTMENT AND PUTTING INTO SERVICE

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1.0 ELECTRICAL DIAGRAMS - MP20X 1.1 KEY TO FUNCTIONAL ELECTRICAL DIAGRAM MODEL MP20X

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2.0 ELECTRICAL DIAGRAMS - MS12/15X 2.1 KEY TO FUNCTIONAL ELECTRICAL DIAGRAM MOD. MS12/15X

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3.0 ELECTRICAL DIAGRAMS - MP20X/D - MS12X I.L. 3.1 KEY TO FUNCTIONAL ELECTRICAL DIAGRAMS MOD. MP20X/D - MS12X I.L.

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