Yale C841 (MP13 MP16) Service Manual - PDF DOWNLOAD

Yale Axcess Online

Service Manuals Manuals Available For C841 (MP13 MP16) Manual

Manual Title

524177679

Service Repair Manual

524181955

Electronic Controller MPB

©2012 Yale Axcess Online

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524177679

Technical Information for Yale Service Centres

This manual is addressed exclusively to the specialised technicians of the Yale service network C841..................MP16, MP18, MP20 D842..................MP20L, MP22

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,

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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 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 steel 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 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 overshoes. 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 cables must be connected to the terminals as prescribed: (+) to (+) and (-) to (-).

- 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

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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 RATHER AS A SUPPLEMENT TO THIS LATTER

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INDEX Section: “COMBI” CONTROLLER FOR INFORMATION REGARDING THE “COMBI” ELECTRONIC CONTROLLER REFER TO SERVICE MANUAL P/N 272486700 Section: “MPB” CONTROLLER FOR INFORMATION REGARDING THE “MPB” ELECTRONIC CONTROLLER REFER TO SERVICE MANUAL P/N 524181955 Section: “MDI” DISPLAY INSTRUMENT FOR INFORMATION REGARDING THE “MDI” ELECTRONIC CONTROLLER REFER TO SERVICE MANUAL P/N 272487200 Section: REDUCTION GEAR CONSULT SERVICE MANUAL P/N 272490700 FOR COMPREHENSIVE INFORMATION ON THE REDUCTION GEAR Section: BC1 & UCB BATTERY CHARGER CONSULT SERVICE MANUAL P/N 524181960 FOR COMPREHENSIVE INFORMATION ON THE BATTERY CHARGERS USED Section: ELECTRICAL SYSTEM 1.00 PRESENTATION OF MODELS P1.6 - P1.8 - P2.0 - P2.0L - P2.2 1.01 TRUCK DELIVERY 10 1.00 KEY TO ELECTRICAL DIAGRAMS MODEL P1.6 ELECTRICAL DIAGRAMS MODEL P1.6 - FUNCTIONAL ELECTRICAL DIAGRAM WITH BATTRY CHARGER MODEL MP16 - WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC WITH BATTRY CHARGER MODEL MP16 - FUNCTIONAL ELECTRICAL DIAGRAM WITHOUT BATTERY CHARGER MODEL MP16 - WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC WITHOUT BATTERY CHARGER MODEL MP16 - CONNECTORS ELECTRICAL SCHEMATIC MODEL MP16 - POWER CABLES CONNECTION ELECTRICAL SCHEMATIC MODEL MP16 1.01 KEY TO ELECTRICAL DIAGRAMS MODELS P1.8 - P2.0 - P2.0L ELECTRICAL DIAGRAMS MODELS P1.8 - P2.0 - P2.0L - FUNCTIONAL ELECTRICAL DIAGRAM MODEL MP18 - MP20 - MP20L - WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC MODEL MP18 - MP20 - MP20L - CONNECTORS ELECTRICAL SCHEMATIC MODEL MP18 - MP20 - MP20L - POWER CABLES CONNECTION ELECTRICAL SCHEMATIC MODEL MP18 - MP20 - MP20L 1.02 KEY TO ELECTRICAL DIAGRAMS MODEL P2.2 ELECTRICAL DIAGRAMS MODEL P2.2 - FUNCTIONAL ELECTRICAL DIAGRAM MODEL MP22 - WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC MODEL MP22 - FUNCTIONAL ELECTRICAL DIAGRAM WITH HORN IN EXTERNAL POSITION MODEL MP22 - WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC WITH HORN IN EXTERNAL POSITION MODEL MP22 - CONNECTORS ELECTRICAL SCHEMATIC WITH HORN IN EXTERNAL POSITION MODEL MP22 - CONNECTORS ELECTRICAL SCHEMATIC MODEL MP22 - POWER CABLES CONNECTION ELECTRICAL SCHEMATIC MODEL MP22 2.00 ELECTRICAL COMPONENTS MODEL P1.6 2.02 ELECTRICAL COMPONENTS MODEL P1.8 2.04 ELECTRICAL COMPONENTS MODELS P2.0 - P2.0L 2.06 ELECTRICAL COMPONENTS MODEL P2.2 2.08 TILLER CONTROL BOX ELECTRICAL COMPONENTS 2.10 TILLER BOARD ELECTRICAL COMPONENTS

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2.12 CONNECTION OF POWER CABLES TO THE “MPB” CONTROLLER 2.13 CONNECTION OF POWER CABLES TO THE “COMBI” CONTROLLER 3.00 “MPB” CONTROLLER PARAMETERS TABLE MODELS P1.6 - P1.8 - P2.0 - P2.0L 3.01 “COMBI” CONTROLLER PARAMETERS TABLE MODEL P2.2 3.02 TRACTION START SEQUENCE 3.03 PROCEDURE FOR SELECTING “SOFT, STD, HARD” PERFORMANCE 3.04 SELECTION PROCEDURE WITH THE CONSOLE 4.00 DISASSEMBLY OF THE TILLER CONTROL BOX 4.02 TRACTION POTENTIOMETER SIGNALS ACQUISITION PROCEDURE 4.03 REPLACING THE LIFT / LOWER ON/OFF PUSHBUTTON 5.00 “MPB” CONTROLLER REPLACEMENT PROCEDURE 5.01 “COMBI” CONTROLLER REPLACEMENT PROCEDURE 5.02 “MDI” REPLACEMENT PROCEDURE 6.00 DIAGNOSTICS, TROUBLESHOOTING GUIDEd - DESCRIPTION OF ALARMS AND TROUBLESHOOTING GUIDE, PAGE 1/3 MODEL ALL MODELS - DESCRIPTION OF ALARMS AND TROUBLESHOOTING GUIDE, PAGE 2/3 MODEL ALL MODELS - DESCRIPTION OF ALARMS AND TROUBLESHOOTING GUIDE, PAGE 3/3 MODEL ALL MODELS Section: HYDRAULIC SYSTEM 1.00 KEY TO HYDRAULIC SYSTEM SYMBOLS 1.01 ASSEMBLY METHOD FOR FEMALE UNIONS 2.00 FUNCTIONAL HYDRAULIC DIAGRAM 2.01 COMPONENTS OF HYDRAULIC UNIT WITH 1200W MOTOR 2.02 COMPONENTS OF HYDRAULIC UNIT WITH 1000W MOTOR 2.03 COMPONENTS OF HYDRAULIC UNIT WITH 2000W MOTOR 2.04 TABLE OF HYDRAULIC UNIT COMPONENTS (2000W MOTOR) 2.05 LIFT CYLINDER COMPONENTS 2.07 HYDRAULIC SYSTEM 3.00 RELIEF VALVE REPLACEMENT PROCEDURE 3.02 RELIEF VALVE ADJUSTMENT PROCEDURE 4.00 CYLINDER DISASSEMBLY PROCEDURE 4.01 GASKETS REPLACEMENT PROCEDURE Section: LINKAGES 1.00 LINKAGE COMPONENTS 1.01 LINKAGE COMPONENTS TABLE 2.00 TIE ROD REMOVAL PROCEDURE 2.01 REAR LEVER REPLACEMENT PROCEDURE 2.02 POSITION OF GREASE NIPPLES ON THE TRUCK Section: MECHANICS 1.00 GUIDE TABLE FOR THE CHOICE OF LIFTING STRAPS 1.02 TABLE OF SCREW TIGHTENING TORQUES 2.00 DRIVE WHEEL REPLACEMENT PROCEDURE 2.01 SWIVEL WHEEL ASSEMBLY REPLACEMENT PROCEDURE 2.03 SWIVEL WHEEL SPRING REPLACEMENT PROCEDURE 2.04 LOAD ROLLER REPLACEMENT PROCEDURE 3.00 TILLER GAS SPRING REPLACEMENT PROCEDURE 3.01 TILLER REPLACEMENT PROCEDURE 4.00 TRACTION MOTOR REPLACEMENT PROCEDURE

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4.01 4.02 4.03 4.06 4.08 4.11 5.00 5.01 5.02 5.05 5.06 5.09

800/1000W TRACTION MOTOR COMPONENTS TABLE OF 800/1000W TRACTION MOTOR COMPONENTS BEARING REPLACEMENT PROCEDURE FOR 800/1000W MOTOR 1500W TRACTION MOTOR COMPONENTS BEARING REPLACEMENT PROCEDURE FOR 1500W MOTOR TRACTION MOTOR BRUSHES REPLACEMENT PROCEDURE HYDRAULIC POWER UNIT DISASSEMBLY PROCEDURE 1200W MOTOR COMPONENTS TIGHTENING TORQUES TABLE 1200W PUMP MOTOR REPLACEMENT PROCEDURE 2000W MOTOR COMPONENTS TIGHTENING TORQUES TABLE 2000W PUMP MOTOR REPLACEMENT PROCEDURE PUMP MOTOR BRUSHES REPLACEMENT PROCEDURE

Section: REDUCTION GEAR 1.00 REDUCTION GEAR COMPONENTS 2.00 REDUCTION GEAR REMOVAL PROCEDURE 2.03 MAINTENANCE Section: BRAKING SYSTEM 1.00 ELECTROMAGNETIC BRAKE COMPONENTS 2.00 BRAKING SYSTEM 3.00 ELECTROMAGNETIC BRAKE REMOVAL PROCEDURE 3.01 INSPECTION AND MAINTENANCE INSTRUMENT CODES P/N 272210700 CONSOLE (ELECTRICAL SECTION) P/N 580036555 CONSOLE ADAPTER (ELECTRICAL SECTION) P/N 580039551 TILLER GAS SPRING RECOVERY TOOL (MECHANICAL SECTION)

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http://www.yaleaxcessonline.com/lib/service/itwservice/524177679/01_Electrical/c1a.htm 1.00 PRESENTATION OF MODELS “MP16 - MP18 - MP20 - MP20L - MP22”

The new range of pallet trucks has been designed around the needs of users.

The range is currently composed of 5 models with three different chassis and varying performance depending on the installed equipment.

The trucks are equipped with a dataplate located on the right hand side of the motor compartment hood, showing the serial number and carrying capacity.

Following is a brief presentation of each model with a description of performance and the components.

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