PDF DOWNLOAD: Yale A7T8 (MP16UX) Forklift Service Manual

Maintenance

FRAME AND MAIN COMPONENTS MP16UX [A7T8]

PART NO. 550252968

0100 YRM 2218

Table of Contents

TABLE OF CONTENTS Important................................................................................................................................................................. 2 General safety rules ............................................................................................................................................... 3 Torque settings for screws nuts and fittings ........................................................................................................... 7 Correct method for applying female fittings ............................................................................................................9 Instructions for installing flexible hoses and fittings...............................................................................................11 Truck presentation.................................................................................................................................................12 Truck and load identification data..........................................................................................................................13 General specification.............................................................................................................................................15 Removal of the covers...........................................................................................................................................19 Removal of rear cowl panel...................................................................................................................................23 Traction wheel....................................................................................................................................................... 24 Replacing of the traction wheel............................................................................................................................. 25 Single load wheel.................................................................................................................................................. 26 Replacing the single load wheel............................................................................................................................27 Tandem load wheel............................................................................................................................................... 28 Replacing the tandem load wheel......................................................................................................................... 29 Caster wheel......................................................................................................................................................... 30 Removal of the linkage assembly......................................................................................................................... 32 Disassembly of the linkage assembly................................................................................................................... 33 Adjustment of the fork height................................................................................................................................ 34 Removal of the electric motor................................................................................................................................36 Disassembly of rear and front truck frames.......................................................................................................... 38 Removal of the tiller...............................................................................................................................................39 Removal of the tiller spring....................................................................................................................................40

©2021 Yale Materials Handling Corp.

i

0100 YRM 2218

1

Important

0100 YRM 2218

Important The Service Manuals are updated regularly, but may not contain the most recent product design modifications. The updated technical information is in any case available from your nearest authorised Yale® dealer. The Service Manuals provide the guidelines for correct maintenance and are designed for use by appropriately trained technicians. Incorrect maintenance or non-compliance with the instructions

2

contained in this manual could cause damage to property or injury and even death to people.

We therefore recommend that you read this manual carefully and keep it in a good condition so it is always decipherable and complete. This manual does not replace the use and maintenance manual, it is a supplement to it.

0100 YRM 2218

General safety rules

General safety rules PERSONAL SAFETY • •

•

• •

Always wear the personal protective equipment in situations requiring it.

Pay particular attention to the risk of getting crushed due to moving parts, oscillations, material not properly secured when performing lifting operations or moving loads.

Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbuttoned jackets or tops with open zippers that can get caught up in moving parts.

Never do any cleaning, lubrication or maintenance work with the battery connected.

Using compressed air to clean the parts, protect yourself with goggles that have side protection.

The maximum air pressure must not exceed 1 bar.

SAFETY AT THE WORKPLACE •

•

•

•

•

•

•

Make sure that all the work tools are perfectly efficient and ready for use. Keep the work surfaces clean and clear of debris that can come into contact with parts of the machine and cause damage.

Make sure you keep sparks, naked lights and cigarettes away from fuels or flammable materials such as the gas of the batteries and fuels.

Make sure that the work area is ventilated, well illuminated, dry and clean. Remove any puddles of water or oil stains.

Make sure that the equipment, devices or lifting machinery used is able to sustain the load in a stable manner.

Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable and non-toxic trade solvents.

When working outside the garage, move the machine preferably onto the level and block it. If working on a slope is inevitable, block the machine beforehand and move it onto a level area as soon as possible with a certain margin of safety.

Disconnect the batteries and label all the controls to signal that work is in progress. Block the machine and every attachment that has to be raised.

•

•

• •

•

•

•

•

• •

•

• • •

Never perform any servicing on the machine with persons at the controls, unless they are accredited operators and help with the operation to be performed.

When towing use solely the prescribed coupling points and check that the pins and/or bolts are firmly secured before pulling. Lift and handle all the heavy parts with lifting equipment of adequate capacity. Use the lifting eyebolts intended for this purpose. Make sure no one is near the load to be lifted.

Avoid twisting chains or metal ropes.

Do not trust bent or damaged chains or ropes: do not use them for lifting or pulling. Always wear the safety gloves to handle them.

Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away into a closed metal container.

Used oil must be specially collected. It must not be disposed of into normal drainage system pipes. Special companies can be employed to dispose of or recycle industrial oils according to the laws in force in individual countries.

When welding is necessary, you must use appropriate safety protection: dark goggles, hard hat, overalls, gloves, safety footwear. Dark goggles must be worn also by those who are not doing the work if they remain nearby during the welding.

Before using the batteries, make sure that both ends of the cables are connected to the terminals as prescribed: (+) with (+) and (-) with (-).

Do not short-circuit the terminals.

The gas released when charging is highly flammable. When charging, leave the battery compartment uncovered for more effective ventilation and take off the plugs.

Never check the battery charge with "jumpers" obtained by putting metal items on the terminals.

Before taking any action, check that no elements are shorted.

Always disconnect the battery before working on the electrical system.

For battery chargers and similar equipment, use solely auxiliary power sources with an effective ground connection to avoid any electric shocks.

3

General safety rules •

•

Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate under the skin; in such cases, having to make a check, use a card or a piece of wood.

Having to check the system pressure, use the specific instruments.

BELTS, ROPES AND SUSPENSION ELEMENTS: USER ADVICE

•

Keep a record of all the suspension elements used, stating the characteristics of the suspension elements and the data given on the identification plate .

Never leave belts, cords or suspension elements in use whose identification plate has been lost.

Always use belts, ropes or suspension elements of suitable dimensions. Concerning the suspension elements, take into consideration the lifting angle and any unbalancing of the load.

The bells on the suspension elements must be sized in proportion to the hook of the overhead travelling crane and anyhow must be free to move easily.

Always rest the load in the race of the hook.

•

Never load the tip of the hook.

•

When lifting, avoid sudden operations that can jerk on the ropes and belts.

Never do any lifting with the ropes and belts twisted.

Knots are not permissible. Always protect the ropes and belts when they come into contact with sharp edges.

When moving with no load, to prevent impact and accidental hooking, hang the hooks in the bells and close the safety ones.

•

•

•

•

• •

•

Using suspension elements under conditions of unbalanced load If lifting unbalanced loads it is advised as a precaution to downrate the load capacities of the lifting elements: • •

Slings with 2 booms, consider them as corresponding to 1 boom.

Slings with 3 and 4 booms, consider them as corresponding to 2 booms.

Tips for maintenance Periodically examine the belts, ropes and suspension elements according to current legislation to define their state of service. Change them in the following cases:

4

0100 YRM 2218 • • •

When the components show: deformation, cracks, hollows, cuts or abrasions.

When the wear of the components exceeds 10% of the original dimensions.

When the sling shows signs of overloading.

0100 YRM 2218

General safety rules

Belt capacity table

Colour

Working load capacity

purple

1000

2000

1400

800

green

2000

4000

2800

1600

yellow

3000

6000

4200

2400

grey

4000

8000

5600

3200

red

5000

10000

7000

4000

brown

6000

12000

8400

4800

blue

8000

16000

11200

6400

orange

10000

20000

14000

8000

orange

12000

24000

16800

9600

orange

15000

30000

21000

12000

orange

20000

40000

28000

16000

orange

25000

50000

35000

20000

orange

30000

60000

42000

24000

1

2

1.4

0.8

Coefficient

Rope capacity table

Working load capacity (Kg)

Coefficient

Colour

Width (mm)

black

35

500

1000

700

400

purple

50

1000

2000

1400

800

black

50

1500

3000

2100

1200

green

60

2000

4000

2800

1600

yellow

75

3000

6000

4200

2400

grey

120

4000

8000

5600

3200

red

150

5000

10000

7000

4000

brown

180

6000

12000

8400

4800

blue

240

8000

16000

11200

6400

orange

300

10000

20000

14000

8000

1

2

1.4

0.8

5

General safety rules

0100 YRM 2218

Suspension element capacity table

Colour

Working load capacity (Kg)

Coefficient

purple

1000

1400

2100

2100

green

2000

2800

4200

4200

yellow

3000

3800

6300

6300

grey

4000

5600

8400

8400

red

5000

6600

9800

10500

1

1.4

2.1

2.1

NOTE: The working load capacity is calculated with an angle at the centre of 90°

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0100 YRM 2218

Torque settings for screws nuts and fittings

Torque settings for screws nuts and fittings NOTE: Before disassembling the various parts and nuts and bolts, read the following carefully.

To make the threaded matings secure, thread lock solution is used for tightening the screws. If it is not possible to unscrew the bolts because this product has been used, avoid applying extensions to the tools, instead slightly heat the area (at most 50°C) so as to eliminate the thread lock solution effect. In the cases described, reapply thread lock solution during installation in a moderate quantity (30% of the mating surface). The torque setting used for tightening the threaded couplings is extremely important to make the coupling secure and the machine safe. The tables on this page give the classes of bolts normally used with the relevant torque settings.

Nominal diameter

NUT TORQUE SETTING Nm Class 8

Class 10

M3

4

5.2

M4

7

9.15

M5

12.14

14.8

M6

17.2

20.9

M8

31.8

38.1

M10

50.5

60.3

M12

74.2

88.5

M14

101.2

120.8

M16

138.2

164.9

M18

176.6

203.5

M20

225.4

259.7

M22

278.8

321.2

M24

324.8

374.2

M27

422.3

486.5

M30

516.1

594.7

7

Torque settings for screws nuts and fittings

0100 YRM 2218

SCREW TORQUE SETTING Nm Pre-load N

8

Class 5.8

Class 8.8

with lubr.

Class 10.9

with lubr.

with lubr.

M4

0.7

7

3

2400

1.92

1.44

3.07

2.3

4.17

3.13

M5

0.8

8

4

3880

3.88

2.91

6.2

4.65

8.43

6.33

M6

1

10

5

5490

6.58

4.94

10.5

7.9

14.3

10.8

M8

1.25

13

6

9990

16

12

25.6

19.2

34.8

26.1

M8

1

13

6

10700

17.1

12.8

27.4

20.5

37.3

27.9

M10

1.5

16

8

15825

31.7

23.8

51

38

69

52

M10

1.25

16

8

16700

33.4

25.1

53

40.1

73

55

M12

1.75

18

10

23025

55

41.4

88

66

120

90

M12

1.25

18

10

25150

60

45.3

96

72

130

98

M14

2

21

12

31400

88

66

140

105

190

145

M14

1.5

21

12

34125

96

72

155

115

210

155

M16

2

24

14

42850

135

105

220

165

300

225

M16

1.5

24

14

45600

145

110

235

175

320

240

M20

2.5

30

17

66875

270

200

430

320

580

435

M20

1.5

30

17

74250

295

225

475

355

650

485

0100 YRM 2218

Correct method for applying female fittings

Correct method for applying female fittings To assure a reliable seal between female fittings and the adapters in this manual, it is necessary to observe the following procedure, which differs from the one for assembling rigid pipes.

Female fittings without a gasket (metal/metal joint) Screw on the nut by hand and then, with the aid of a wrench, tighten by another quarter turn.

Female fittings with O-ring Screw on the nut by hand and then, with the aid of a wrench, tighten by another half turn.

In every case make sure that the pipe is properly aligned before tightening the nut on the adapter.

METRIC REVOLVING FEMALE

REVOLVING FEMALE jic 37°

UNF thread

Outside diamater of the pipe

Nominal torque

min / max

M 12X1.5

6

20

15 - 25

M 14X1.5

8

38

30 - 45

45

38 - 52

M 16X1.5 M 18X1.5 M 20X1.5 M 22X1.5

8 10 10 12 12 14 15

Torque setting Nm

51

43 - 85

58

50 - 65

74

60 - 88

M 24X1.5

16

74

60 - 88

M 26X1.5

18

105

85 -125

135

115 - 155

M 30X2 M 36X2

20 22 25 28

Torque setting Nm UNF thread

Size

Nominal torque

min / max

7/16-20

-4

15

9-21

1/2-20

-5

20

13-27

9/16-18

-6

30

18-42

3/4-16

-8

50

30-70

7/8-14

-10

69

44-94

1.1/16-12

-12

98

63-133

1.3/16-12

-14

118

73-163

1.5/16-12

-16

140

90-190

1.5/8-12

-20

210

135-285

1.7/8-12

-24

290

200-380

2.1/2-12

-32

450

300-600

BSP REVOLVING FEMALE UNF thread

168

140 - 192

Torque setting Nm Nominal torque

max

G1/4

20

15 -25

M 42X2

30

240

210 - 270

G3/8

34

27 - 41

M 45X2

35

290

255 - 325

G1/2

60

42 - 76

330

280 - 380

G5/8

69

44 - 94

G3/4

115

95 - 135

G1

140

114 - 165

G1.1/4

210

140 - 280

G1.1/2

290

215 - 365

G2

400

300 - 500

M 52X2

38 42

9

Correct method for applying female fittings

0100 YRM 2218

ORFS REVOLVING FEMALE Torque setting Nm UNF thread

Size

Nominal torque

max.

9/16-18

-4

14

16

11/16-16

-6

24

27

g13/16-16

-8

43

47

1-14

-10

60

68

1.3/16-12

-12

90

95

1.3/16-12

-14

90

95

1.7/16-12

-16

125

135

1.11/16-12

-20

170

190

2-12

-24

200

225

2-1/2-20

-32

460

490

NOTE: The values given in the tables refer to galvanized steel fittings. Fittings of other materials have other values.

10

0100 YRM 2218

Instructions for installing flexible hoses and fittings

Instructions for installing flexible hoses and fittings Inspection of pipes and fittings

Pre-installation inspection

When even just one of the following conditions arises the pipe must immediately be disconnected and replaced:

Before installing a flexible hose it is necessary to inspect the pipes carefully. First check that the type, size, reference code and length are correct, then check there is no debris, blockages, bubbles, peeling of the outer layer or any other visible defects.

•

a shift of the connection on the pipe;

•

the presence of damage, cuts or abrasions on the superficial layer; hardening or stiffness of the pipe, the presence of burns or cracks due to heat exposure; the presence of cracks, damages or strong corrosion on the connection; the presence of leaks along the pipe or at the coupling joint; the presence of permanent creases, compression, flattening or twists in the pipe; the presence of blisters, softening, wear of the external coat.

• • • • •

Installation Avoid twisting the pipe, which could cause it to burst under pressure. There must be an adequate radius of curvature to prevent constriction and collapse. The life of the assembled pipe decreases considerably when below the minimum radius of curvature. The pressure can cause changes in the length of the pipe, up to + 2%. It will be wise to have a slightly greater length than the requirement in order to compensate for these changes.

11

Truck presentation

0100 YRM 2218

Truck presentation The trucks of this series are electric forklift trucks with driving on the ground, and horizontal load handling with nominal load capacity 1600 Kg: MP16UX These trucks are electric vehicles on which a battery provides sufficient current for driving and lifting. The

12

battery is in the compartment on the fork frame and is raised/lowered together with the movement of the forks. The battery compartment also acts as a load rack and helps keep the load blocked. The tiller is used to select the various functions, among which steering, selecting the drive mode, braking, directing the truck and controlling the speed, lifting and lowering of the forks.

0100 YRM 2218

Truck and load identification data

Truck and load identification data TRUCK IDENTIFICATION DATA PLATE The truck data plate is located on the battery cover and contains: •

Manufacturer's name

•

Serial number

•

Model

•

Year of manufacture

•

Nominal Load capacity

•

Weight without battery

•

Min./max. battery weight

•

Persons on board

•

Rated power

•

Battery voltage

13

Truck and load identification data TRUCK SERIAL NUMBER PUNCHING The truck serial number is punched on the caster bracket (ref.A figure below).

14

0100 YRM 2218

0100 YRM 2218

General specification

General specification MP16UX

15

General specification

0100 YRM 2218

Tyres, chassis

Weight

Characteristics

GENERAL SPECIFICATIONS

16

1.1

Manufacturer (abbreviation)

Yale

1.2

Manufacturer's type designition

MP16UX

1.3

Drive: electric (battery or mains), diesel, petrol, fuel gas

Electric

1.4

Operation: hand, pedestrian, standing, seated, orderpicker

Stand-driving

1.5

Rated capacity/Rated load

Q (t)

1.6

1.6

Load centre distance

c (mm)

600

1.8

Front overhang

x (mm)

987

1.9

Tread

y (mm)

1330

2.1

Service weight (with battery)

kg

420

2.2

Axle loading with load, front/rear

kg

992 / 1228

2.3

Axle loading without load, front/rear

kg

324 / 96

3.1

Tyres: polyurethane, topthane, NDIIThane, front/rear

3.2

Tyre size, front

ø (mm)

230x100

3.3

Tyre size, rear

ø (mm)

82 x 98 (70)

3.4

Additional wheels (dimensions)

ø (mm)

90 x 40

3.5

Wheels, number front/rear (x = driven wheels)

3.6

Tread, front

b 10 (mm)

478

3.7

Tread, rear

b 11 (mm)

375

Polyurethane

1x+2/2 (4)

0100 YRM 2218

General specification

Performance data

Dimensions

GENERAL SPECIFICATIONS 4.4

Lift

h3 (mm)

120

4.9

Height drawbar in driving position min./max.

h14 (mm)

750/1250

4.15

Height, lowered

h13 (mm)

82

4.19

Overall length

l1 (mm)

1666

4.20

Length to face of forks

l2 (mm)

516

4.21

Overall width

b1/b2 (mm)

710

4.22

Fork dimensions

s/e/l (mm)

55 / 160 / 1150

4.25

Forks spread

b 5 (mm)

550

4.32

Ground clearance, center of wheelbase

m2 (mm)

685

4.34.1 Aisle width for pallets 1000mm x 1200mm crossways

Ast (mm)

2302

4.34.2 Aisle width for pallets 800mm x 1200mm lengthwise

Ast (mm)

2156

4.35

Turning radius

Wa (mm)

1504

5.1

Travel speed, laden/unladen

km/h

5.8 / 6

5.2

Lift speed, laden/unladen

m/s

0.03 / 0.038

5.3

Lowering speed, laden/unladen

m/s

0.04 / 0.036

5.7

Gradeability

%

8 / 20

5.10

Service brake

Electromagnetic

17

General specification

0100 YRM 2218

Additional data Electric engine

GENERAL SPECIFICATIONS 6.1

Drive motor, S2 60 min rating

kW

1.2

6.2

Lift motor S3 15% rating

kW

0.8

6.4

Battery voltage/nominal capacity K5

V/Ah

24 / 160

6.5

Battery weight

kg

170

Battery dimensions

l/w/h

645 / 148 / 560

Sound pressure level at the driver's seat

dB (A)

< 70

8.4

All values are nominal values and they are subject to tolerances. For further information, please contact the manufacturer.

Yale products might be subject to change without notice. Lift trucks illustrated may feature optional equipment. Values may vary with alternative configurations.

18

0100 YRM 2218

Removal of the covers

Removal of the covers WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Set the key switch to OFF and disconnect the battery BATTERY BOX Remove screws A, nuts B and shaft sleeves C in order to remove battery box D (Figure 1).

Figure 1. Removal of the battery box

19

Removal of the covers

0100 YRM 2218

FRONT COVER Remove the 2 screws E that secure front cover F and remove it (Figure 2).

Figure 2. Removal of the front cover

20

0100 YRM 2218

Removal of the covers

LEFT AND RIGHT PLASTIC COVER Unscrew screws G on the left and on the right side. Remove the right and the left plastic covers H and rubber ring I (Figure 3).

Figure 3. Removal of the left and right plastic covers

21

Removal of the covers

0100 YRM 2218

REAR AND UPPER COVERS Unscrew screws L on the left and on the right sides respectively. Remove upper cover N and rear cover M (Figure 4)

Figure 4. Removal of the rear and upper covers

WARNING Be careful not to lose clip nut O on the rear cover M during the removal process (Figure 4).

22

0100 YRM 2218

Removal of rear cowl panel

Removal of rear cowl panel WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Set the key switch to OFF and disconnect the battery.

REMOVAL OF THE REAR COWL PANEL Step 1 Position the hooks in the proper holes on the frame.

Lift sligthly the frame by using a bridge crane and lay it on wooden beams D (Figure 5).

Step 2

Unscrew the 6 sets of bolts A and spacers B in order to remove the rear cowl panel C (Figure 5).

Figure 5. Removal of the rear cowl panel NOTE: While reassembling tighten bolts A (Figure 5) with a tightening torque of 80Nm

23

Traction wheel

0100 YRM 2218

Traction wheel KEY TO TRACTION WHEEL COMPONENTS

Ref.

24

Description

1

Traction wheel

2

Traction wheel retaining nut

0100 YRM 2218

Replacing of the traction wheel

Replacing of the traction wheel WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Set the key switch to OFF and disconnect the battery.

Step 1 Remove the wheel cover as described in section "Removal of the covers" in this publication.

Step 2 HYDRAULIC JACK - 2 WOODEN BLOCKS Rotate the steering gear assembly for 90°. Position the hydraulic jack on the centre of the truck body and raise the truck sufficiently to insert the wooden blocks underneath. Position the wooden blocks at the truck sides, lower the jack and place the truck so that it rests on the blocks.

Step 3 Unscrew and remove the 6 nuts A securing the traction wheel B to the axle shaft, remove the wheel and replace it (Figure 6). For illustrative purposes, the figure does not show the rear cowl panel, but it is not necessary to remove it.

Figure 6. Removal of the traction wheel

INSTALLATION While reassembling make sure the nuts securing the traction wheel are tightened with a torque of 160 Nm.

25

Single load wheel

0100 YRM 2218

Single load wheel KEY TO SINGLE LOAD WHEEL

Item

26

Description

1

Pin

2

Pin roll

3

Single wheel assembly

4

Shaft sleeve

5

Dust ring

6

Bearing

7

Wheel

0100 YRM 2218

Replacing the single load wheel

Replacing the single load wheel WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians.

DISASSEMBLY OF THE SINGLE LOAD WHEEL Remove shaft sleeves A, dust rings B and bearings C from wheel D (Figure 8).

Step 1 Raise the forks to the maximum height, position the wooden blocks under the forks close to the load wheel.

Lower the forks so that they rest on the wooden blocks and continue lowering until the load wheels are raised off the ground by about 2 cm.

WARNING Turn the keyswitch to OFF and disconnect the battery.

Figure 8. Disassembly of the single load wheel

WARNING Place the wooden beam beneath the forks for greater safety when working.

Step 2 Remove spring pin A and roll pin B to remove single wheel C (Figure 7).

Figure 7. Removal of the single wheel

27

Tandem load wheel

0100 YRM 2218

Tandem load wheel KEY TO TANDEM LOAD WHEEL

Item

28

Description

1

Pin

2

Pin roll

3

Tandem wheel assembly

4

Supporting plates

5

Link

6

Shaft sleeve

7

Dust ring

8

Bearing

9

Wheel

0100 YRM 2218

Replacing the tandem load wheel

Replacing the tandem load wheel WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians.

DISASSEMBLY OF THE TANDEM LOAD WHEEL Remove shaft sleeves A, dust rings B and bearings C from wheel D (Figure 10).

Step 1 Raise the forks to the maximum height, position the wooden blocks under the forks close to the load wheel.

Lower the forks so that they rest on the wooden blocks and continue lowering until the load wheels are raised off the ground by about 2 cm.

WARNING Turn the keyswitch to OFF and disconnect the battery.

WARNING Place the wooden beam beneath the forks for greater safety when working.

Figure 10. Disassembly of the single load wheel NOTE: When reassembling apply Lithium grease on the axle head of the supporting plates C (Figure 9).

Step 2 Remove spring pins A, roll pins B and supporting plates C to remove tandem wheel D (Figure 9).

Figure 9. Removal of the tandem wheel

29

Caster wheel

0100 YRM 2218

Caster wheel KEY TO CASTER WHEEL

Item Item

30

Description

Description

10

Spring

1

Screw

11

Wheel carriage

2

Lockwasher

12

Wheels

3

Washer

13

Bolts

4

Bearing

14

Bushings

5

Bearing housing

15

Nuts

6

Bearing

16

Bearings

7

Universal wheel holder

17

Bolts

8

Nut

9

Bolt

0100 YRM 2218

Caster wheel

ADJUSTMENT AND REPLACEMENT OF THE CASTER WHEEL The caster wheel is designed to float. To adjust it act on the adjusting nut A. The standard floating distance must be 4mm (Figure 11).

Figure 11. Adjustment of the caster wheel When the caster wheel is worn, increase the number of spacer D, to keep the good contact between the caster wheel and the ground. In case of skidding of the driving wheel due to poor road conditions or excessive contact between the caster wheel and the ground, reduce the number of spacers D correspondingly.

When the caster wheel is seriously worn or damaged, proceed with its replacement by removing screw B, gasket C, spacer D and then caster wheel E (Figure 12).

Figure 12. Replacement of the caster wheel

31

Removal of the linkage assembly

0100 YRM 2218

Removal of the linkage assembly Step 2

WARNING

Lift slightly the truck.

Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Step 3 Remove sping pin A and pin roll B (Figure 13).

Step 4 Remove screw C, spacer D and roll pin E (Figure 13).

Step 5

Step 1 Remove the battery. In order to remove the battery, reverse the installation procedure (see "Battery installation" in publication "INSTALLATION 8000YRM2219").

Remove spring pin F and roll pin G. Take out then linkage assembly H (Figure 13). For illustrative purposes the figure does not show the rear cowl panel.

It is not necessary to remove it.

Figure 13. Removal of the linkage assembly NOTE: When assembling, apply 3# Lithium grease on the surfaces of pin rolls B, E, and G as well as the shaft hole bushing (Figure 13).

32

0100 YRM 2218

Disassembly of the linkage assembly

Disassembly of the linkage assembly WARNING

Step 2

Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Step 1

Remove sping pin A and pin roll B to remove rocker arm C (Figure 14).

Step 3 Remove spring pin D and roll pin E to take out wheel carrier F (Figure 14).

Remove the linkage assembly as described in "Removal of the linkage assembly" in this publication.

Figure 14. Disassembly of the linkage assembly NOTE: When assembling, apply 3# Lithium grease on the surfaces of pin rolls B and E as well as the shaft hole bushing (Figure 14).

33

Adjustment of the fork height

0100 YRM 2218

Adjustment of the fork height The fork height must be adjusted so the truck surface on the top of the load wheel support is flush to the underside of the fork weldment when the lift truck is in the lowered position. If the load wheel supporr machined surface is not flush to the fork weldment or if the load wheels are not carrying the load equally, an adjustment must be made. Make certain to check both forks and both load wheels.

CAUTION Improper adjustment of the fork height can cause excessive wear to one of the load wheels or poor pallet entry and exit. When making any adjustments, be sure the measurements are the same on both forks.

WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Set the key switch to OFF and disconnect the battery.

34

The fork height has been ajusted at factory. If further adjustments should be required, follow the steps below.

FRONT LINKAGE ROD Step 1 Loosen nut C, and adjust the linkage rod length by rotating the double stud nut D (Figure 15). Extend the linkage rod to decrease the fork height or retract the linkage rod to increase the fork height REAR LIMIT Step 2 Loosen nut A, and adjust the fork height by rotating nut B (Figure 15). Rotate the nut 2 clockwise to lower the fork and counterclockwise to lift the fork Step 3 After the adjustment, the fork height should be basically horizontal with smooth lifting and lowering travels. Lock the nuts after adjustment

0100 YRM 2218

Adjustment of the fork height

Figure 15. Adjustement of the fork height

35

Removal of the electric motor

0100 YRM 2218

Removal of the electric motor WARNING Before starting work, ensure that you are wearing suitable protective clothing. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery Step 1 Remove the front covers as described in section "Removal of the covers" in this publication.

Step 2 Disconnect the power cables U, V and W (Figure 16).

Figure 17. Disconnection of brake and motor connectors

Step 4

Figure 16. Disconnection of the power cables

Step 3 Disconnect the brake and motor connectors (Figure 17).

36

Rotate the steering gear assembly 90 degrees to the left. Unscrew and remove lock screw A and spacer B of the motor (Figure 18).

0100 YRM 2218

Removal of the electric motor

Step 5

Step 6

Rotate the steering gear assembly completely in the other direction and remove driving motor C (Figure 18).

Remove then split pin G, nut F, pinion D, and flat key E (Figure 18).

Figure 18. Removal of the electric motor NOTE: For illustrative purposes the figure does not show the rear cowl panel. It is not necessary to remove it.

37

Disassembly of rear and front truck frames

0100 YRM 2218

Disassembly of rear and front truck frames Step 2

WARNING Before starting work, ensure that you are wearing suitable protective clothing. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery Step 1 Remove the covers as described in section "Removal of the covers" in this publication.

Separate the electric harness of rear and front truck frames.

Step 3 Unscrew screws A on the tie rod on left and right sides. Unscrew lock screws B of the lower pivot point of the oil cylinder on the left and right.

Remove the spring pins C and pin rolls D on the rocker arm on the left and right. Disassemble the rear frame E from the front frame F (Figure 19).

Step 2 Remove the rear cowl panel as described in section "Removal of rear cowl panel" in this publication.

Figure 19. Disassembly of rear and front frames

38

0100 YRM 2218

Removal of the tiller

Removal of the tiller WARNING

Step 2

Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Step 1 Remove the front cover as described in section "Removal of the covers" as described in this publication.

Disconnect the wiring harness between the tiller and the truck.

Step 3 Unscrew lock screws A and spacers B to remove the tiller (Figure 20).

Figure 20. Removal of the tiller

39

Removal of the tiller spring

0100 YRM 2218

Removal of the tiller spring WARNING

Step 2

Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Step 1 Remove the front cover as described in section "Removal of the covers" in this publication.

Disconnect the wiring harness between the tiller and the truck.

Step 3 Unscrew top screw A. Unscrew and remove lower pivot screw B and upper pivot screw C of the tiller spring D.Proceed with its replacement. (Figure 21).

Figure 21. Removal of the tiller spring

40

0100 YRM 2218

7/21

Maintenance

INSTALLATION MP16UX [A7T8]

PART NO. 550256727

8000 YRM 2219

Table of Contents

TABLE OF CONTENTS Installation............................................................................................................................................................... 2 Topping up the oil reservoir..................................................................................................................................... 3 Battery installation...................................................................................................................................................4 List and description of the settings and adjustments to be carried out................................................................... 6

©2021 Yale Materials Handling Corp.

i

8000 YRM 2219

1

Installation

8000 YRM 2219

Installation BEFORE INSTALLATION Make sure in advance that all the tools required to unload the truck are available (bridge crane, lift truck, lifting slings, etc. with a capacity of 1000 Kg). Before delivering the truck to the customer it is very important to check the suitability of the place where the truck is going to be installed.

SHIPMENT PROCEDURE The trucks must be suitably packaged to protect its parts, fixed on pallets near the forks and then loaded

2

onto trucks for transport. Once loaded on the truck, they are secured with a belt.

8000 YRM 2219

Topping up the oil reservoir

Topping up the oil reservoir If required top up the oil in the hydraulic oil reservoir.

Before proceeding, make sure that the forks are fully lowered.

WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Set the key switch to OFF and disconnect the battery.

Step 2 Find the filling port A of the oil tank of the hydraulic station and remove the cap to fill the oil (Figure 1).

CAUTION Do not overfill the reservoir. Oil quantity 750 ml.

At the end of the operation screw the tank cap back on.

Step 1 Remove the covers as described in publication "FRAME AND MAIN COMPONENTS 0100YRM2218".

Figure 1. Topping up the oil

3

Battery installation

8000 YRM 2219

Battery installation as the battery compartment. Remove battery fixing plate D (Figure 2).

WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians.

Step 1 Remove side door fixing plate A and side door B. Position the battery removal trolley alongside the battery compartment and adjust the height of the battery removal trolley so that it is on the same level

Step 2 Hook the battery using the dedicated holes. Lift the battery place it on the battery removal trolley. Move the battery very carefully from the battery removal trolley to the battery compartment .

Step 3 Insert battery fixing plate D. Connect the battery from the truck electrical system via the handle C (Figure 2).

Figure 2. Battery installation

4

8000 YRM 2219

CAUTION Pay attention to the hands when placing the battery in its compartment in order to avoid injury.

During this step, be careful not to pinch the battery cable between the battery and the truck chassis.

Battery installation

NOTE: Make sure the battery is properly locked and that it does not protrude beyond the truck profile, to prevent it from coming out from the battery compartment when the truck is travelling.

NOTE: When replacing the battery carry out the reverse procedure.

5

List and description of the settings and adjustments to be carried out

8000 YRM 2219

List and description of the settings and adjustments to be carried out After assembling all the machine's components as described in the previous pages, the following operations must be carried out in the sequence given: •

Check the conditions of use of the truck

•

Set the battery voltage

•

the type of load to be moved

•

The general conditions of the warehouse, the aisles and the flooring

In particular carry out the checks described in the following table:

CHECK THE CONDITIONS OF USE OF THE TRUCK

CAUTION In order to ensure the safety personnel and materials, before proceeding with the operations described below, it is important to assess the following: Name

No.

Check point

Check content

Handle

When the operation handle is turned, with the handle switching between area A and B, there is a noise from the brake.

Braking clearance

The clearance between brakes should be kept between 0.2mm - 0.8mm.

3

Operation handle

Degree of tightness and rotary flexibility.

4

Oil pipe

Leakage or not.

5

Hydraulic oil

Appropriate oil quantity.

6

Lifting cylinder

Whether there is any oil leakage.

7

Pins, screws and all the fasteners

Check all the fasteners of the truck’s wheels, i.e. pins or screws, loose or not.

8

Wearing status

Compare the parameter list, replace the wheel when its diameter reduces by 5%.

9

Charge

Confirm the display state of the battery capacity.

10

Electrolyte

The solution level and density of electrolyte.

11

Connecting line

The connecting line and socket shall be firm.

1 Braking system 2

Steering system

Wheels

Battery

CAUTION In order to safeguard the safety of people and materials, before proceeding with the following operations, it is recommended to check: the type of load to be handled and the general conditions of the warehouse, the aisles and the flooring.

Having carried out these assessments verify whether the conditions given are compatible with the performance levels set: •

6

maximum traction speed

•

traction acceleration

•

reduction of traction speed

•

maximum fork lifting/lowering speed

•

braking

If necessary, reduce truck performance by using the programmer to customize the truck configuration parameters.

8000 YRM 2219

List and description of the settings and adjustments to be carried out

NOTE: In order not to jeopardize the carriage's safety, the configuration parameter customisation can only be carried out by exclusively reducing factory values.

Parameter values that exceed the factory-set values are not permitted.

BATTERY VOLTAGE SETTING If a battery that is not provided by the factory is installed on the truck, the battery voltage on the COMBI AC module must be set. To carry out this regulation, it is good practice to proceed with an additional charging period for the battery used on the carriage in order that it may provide the maximum voltage.

Procedure With the truck turned off connect the programmer Turn the machine on (ON switch) and select the following parameter: With the tester measure the exact voltage of the battery on the traction controller between the negative pole (-Batt) and the positive power connection (+Batt).

The parameter "adjust battery" must be set with the value of this tension.

Save the parameters. Turn the machine off (switch key OFF) and disconnect the programmer. Turn the machine back on (ON switch).

7

8000 YRM 2219

7/21

Maintenance

TROUBLESHOOTING AND ERRORS MP16UX [A7T8]

PART NO. 550256728

8000 YRM 2220

Table of Contents

TABLE OF CONTENTS Description of module connectors...........................................................................................................................2 Tester menu.............................................................................................................................................................4 Troubleshooting.......................................................................................................................................................7 Diagnosis system for Combi controller....................................................................................................................8 Electrical component measurements.................................................................................................................... 17

©2021 Yale Materials Handling Corp.

i

8000 YRM 2220

1

Description of module connectors

8000 YRM 2220

Description of module connectors COMBI AC0 CONTROL

Connector

2

Description

A1

Negative main contactor coil

A2

Positive main contactor coil and electromechanical brake coil

A3

Output for driving the electromechanical brake coil

A4

Negative of pump contactor coil

A5

Positive of pump contactor valve and electrovalve coil

A6

Negative of the lowering electrovalve coil

A7

Can low

A8

Not used

A9

Positive (+12V) traction encoder supply

A10

Negative (GND) Traction encoder supply

A11

Not used

A12

Negative battery (-BATT)

A13

Motor thermal sensor input.

A14

Not used

A15

Not used

A16

Not used

A17

Can high

A18

Not used

A19

Traction encoder channel A

A20

Traction encoder channel B

8000 YRM 2220

Description of module connectors

Connector

Description

B1

Key positive

B2

Not used

B3

Tiller sensor input

B4

Turtle mode request input

B5

Backward direction request input

B6

Forward direction request input

B7

Quick inversion function input

B8

Lowering request input

B9

Lifting request input

B10

Accelerator potentiometer input

B11

Not used

B12

Not used

The following inputs are available for the digital console connection Connector

Description

C1

Positive serial reception

C2

Negative serial reception

C3

Positive serial transmission

C4

Negative serial transmission

C5

Negative console power supply

C6

Positive console power supply

C7

Must be connected to C8 for the Flash memory programming

C8

Must be connected to C7 for the Flash memory programming

3

Tester menu

8000 YRM 2220

Tester menu TESTER MENU The main input and output signals can be measured in real time using the TESTER function of the programmer.

The programmer acts as a multimeter capable of reading voltage, current and temperature. Some of these menu parameters refer to functions whose status is received via Can bus, others refer to functions directly connected to the analogue/digital inputs of the module. The following list shows the relative measurements.

COMBI AC0 TRACTION CONTROL TESTER MENU PARAMETER BATTERY VOLTAGE Battery voltage measured at the key switch input (B1)

measurement unit Volt

MOTOR VOLTAGE Voltage supplied to the motor by the inverter ; it is expressed as a percentage of the maximum voltage (depending on the battery voltage)

%

VOLTAGE BOOSTER Booster of the voltage supplied to the motor in load condition; it is expressed as a percentage of the full voltage

%

FREQUENCY Frequency applied to the motor control and to the AC traction motor. The value is negative when the truck moves in fork direction and it is positive when the truck moves in operator direction.

Hz

ENCODER Real speed detected by the AC traction motor encoder. The value is negative when the truck moves in fork direction and it is positive when the truck moves in operator direction.

Hz

SLIP VALUE Speed difference between the rotation field and the motor rotor, expressed in the same unit as the frequency. The value is negative when the truck moves in fork direction and it is positive when the truck moves in operator direction.

CURRENT RMS RMS current applied to the AC traction motor BATTERY CHARGE Battery charge percentage level.

TEMPERATURE Temperature of the inverter measured on the heat sink MOTOR TEMPERATURE Traction motor temperature.

4

Hz

Arms % °C °C

8000 YRM 2220

Tester menu

PARAMETER ACCELERATOR Voltage of the accelerator potentiometer wiper

measurement unit V

LIFTING SWITCH Level of the lifting switch digital input. The value is ON when the switch is pressed.

ON/OFF

DESCENT SWITCH Level of the descent switch digital input.The value is ON when the switch is pressed.

ON/OFF

FORWARD SWITCH Level of the forward direction switch digital input.The value is ON when the throttle is in operator direction.

ON/OFF

BACKWARD SWITCH Level of the backward direction switch digital input. The value is ON when the throttle is in fork direction

ON/OFF

HANDLE/SEAT SWITCH Level of the handle microswitch digital input. The value is ON when the tiller is in work position.

ON/OFF

QUICK INVERSION Level of the quick inversion microswitch digital input. The value is ON when the belly switch is pressed.

CUTBACK SWITCH Level of the speed reduction microswitch input A15 INPUT Not used.

ON/OFF

ON/OFF ON/OFF

5

Tester menu

8000 YRM 2220

PARAMETER

measurement unit

H&S CUTBACK Level of the H&S microswitch digital input. The Value is ON when the turtle is pressed.

STEER ANGLE Not used.

6

ON/OFF

°

8000 YRM 2220

Troubleshooting

Troubleshooting The diagnosis system is divided into two main groups: BLOCKING ALARMS When a blocking alarm occurs, the current to all controls is interrupted by the contactor and the electromagnetic brake is released (braking is activated).

These alarms are connected to: •

faults in the controls, if due to breakage in the power and/or auxiliary connections.

•

faults in the motors due to electrical problems.

•

faults due to components directly and/or indirectly connected to safety functions.

WARNING ALARMS Warning alarms are due to the following factors: •

incorrect starting sequences by the operator.

•

conditions that require a reduction of performance (for example high temperature, ...)

7

Diagnosis system for Combi controller

8000 YRM 2220

Diagnosis system for Combi controller The diagnostics system operates via CAN BUS communication.

COMBI CONTROLLER Alarm

Code MDI

WATCHDOG

8

Cause: The system is provided with a selfdiagnosis circuit. A microchip tests the selfdiagnosis circuit to verify its correct operation. This circuit's output changes state if the microchip does not perform the test correctly. In this case the contactor MC is disabled together with the power section.

The electromagnetic brake is activated during braking. The alarm appears when:

Troubleshooting

•

•

● the circuit output does not correspond to the input during the initial test on the selfdiagnosis circuit.

Check whether the controller connector is connected properly and the absence of false contact on the pins If the connections are good and the alarm persist, the fault can be internal to the controller and need to be replaced

● the circuit output changes during stand-by or during hydraulic functions (STANDBY AND MOTOR RUNNING diagnosis).

EEPROM KO Cause: This alarm is due to a defect in the hardware or in the non-volatile memory software that supports the module parameters. This alarm does not block the truck operation, but the truck operates with default values.

8

13 • • •

Turn the truck OFF and ON and check the result.

If the alarm persists, replace the controller.

If the alarm disappears, the parameters previously recorded will be replaced by default parameters.

8000 YRM 2220

Diagnosis system for Combi controller

Alarm

Code MDI

LOGIC FAILURE #3

17

Cause: The coil output circuit opens suddenly during operation.

LOGIC FAILURE #2

Cause: This alarm appears when the module detects overvoltage or undervoltage conditions. The overvoltage limit is 35V, the undervoltage limit is 9.5V.

● This type of fault is not connected to external components, so when it occurs the control must be replaced

18

● Check whether there is any problem in the power line circuit of the motor, including the fuse of the controller. ● Check the parameter list. ● If there is no problem in the above items, the controller shall be replaced.

19

● If the alarm appears at the start up or in standby, it is very likely that the problem is due to undervoltage.

In this case, check the battery voltage; Check whether the ADJUST BATTERY parameter value in the controller is consistent with the actual battery . If no issue is found, the fault is probably in the module hardware. In this case the module needs to be replaced. ● If the alarm appears during acceleration while in traction, it is most likely due to undervoltage; check the battery charge state and the power connections.

If the alarm appears when the brake is released, it is probably due to overvoltage; check the contactor contacts and the power connections.

Cause: A fault in the hardware section of the logic board that controls the retroaction of the phase voltage.

LOGIC FAILURE #1

Troubleshooting

9

Diagnosis system for Combi controller

8000 YRM 2220

Alarm

Code MDI

Troubleshooting

VMN LOW

30

If the problem appears at start up (the contactor does not close at all), check: ● the internal motor connections (ohmic continuity); ● the motor power connections; ● If the motor connections are correct, then the problem could be located in the control.

If the alarm takes place while the motor is operating, check: ● the motor connections: ● if the windings/cables of the motor phases have leakage towards the truck body; ● if the power contact of the contactor closes correctly, with a good contact. ● If no problem connected with the motors is detected, then the fault is in the control.

31

If the fault appears at start up (the contactor does not close at all), check: ● the connections inside the motor (ohmic continuity); ● the motor power cable connections. ● If the motor connections are correct, then the problem could be in the control.

If the problem appears after closing the contactor (the contactor closes and opens immediately after), check: ● the motor connections; ● if the windings/cables of the motor phases have leakage towards the truck chassis. ● If no problem connected with the motors is detected, then the fault is in the control.

Cause 1: start up testing.

Before closing the contactor, the software checks the power section: it turns on the Mosfets alternatively and waits until the phase voltage rises up to the capacitor values. If the voltage of the phases does not increase, this alarm appears.

Cause 2: test during operation.

When the motor is operating, the power bridge is ON and the motor power supply voltage is monitored; if it is below the set value, error status is activated.

VMN HIGH Cause 1: Before closing the contactor, the software checks the power section: it turns on the Mosfets alternatively and waits until the phase voltage drops down to -BATT. If the phase voltage does not decrease, this alarm appears.

Cause 2: This alarm may appear even when the start-up diagnosis has been completed and the contactor is closed. In this condition, the phase voltage should be at Vbatt 1/2. If it is higher than this value, an error status occurs.

10

8000 YRM 2220

Diagnosis system for Combi controller

Alarm

Code MDI

CONTACTOR CLOSED

37

Cause 1: Before activating the contactor coil, the module verifies if the contactor is blocked.

The module activates the power section for a few milliseconds trying to discharge the contactor capacitors. If this does not occur, an error status is activated.

CONTACTOR OPEN

● Check the main contactor power contacts; clean them and replace the contactor if necessary

38

● The cables of the contactor coil are interrupted or not connected, check the coil cabling. ● The problem could also be connected to a contactor contact that doesn't work. Try replacing the contactor.

49

● Check the 3 phase motor connection and that there is continuity. If the connection is open, the current cannot pass, in this way the test fails and the error code is displayed. ● If everything that concerns the motor is correct, the problem could be in the current sensor or the relative circuit. The controller needs to be replaced.

Cause: The main contactor coil is activated by the module, but the contactor doesn't close.

I=0 EVER Cause: The test is carried out when the motor is running, and checks that the current feedback sensor is not continuously blocked at 0.

STBY I HIGH

53 ●This type of fault is not connected to external components. When it appears the module must be replaced.

Cause: The current transducer or the current power supply circuit are damaged inside the module.

CAPACITOR CHARGE

Cause: When the key is turned to ON, the inverter tries to charge the capacitor through the power resistance and check if the capacitor is charged within a certain time frame. If this does not occur, an alarm appears; the main contactor is not closed.

Troubleshooting

60

● There is an external load parallel to the capacitors, which lowers the module pre charge circuit current, preventing its charging. Check if a lamp or a dc/dc converter or an auxiliary load is connected. ● The charge resistance is open; add a power resistance on the contactor terminals; if the alarm disappears it means that the charge resistance inside the module is damaged. Replace the control. ● The charging circuit has a fault in the module.

Replace the control. ● There is a problem in the module power section.

Replace the control.

11

Diagnosis system for Combi controller

8000 YRM 2220

Alarm

Code MDI

HIGH TEMPERATURE

61

Cause: This alarm appears if the temperature is above 78°C. When this temperature is reached, the current is reduced proportionally to the increase in temperature up to the value of 0 Ampere corresponding to 100°C. MOTOR TEMPERAT.

● Check the temperature of the control. ● If the alarm appears when the module is cold,there could be a fault in the internal thermal sensor or a fault in the logic card. In this case the control needs to be replaced.

65

● Check the heat sensor inside the motor (parameter / tester menu / motor temperature); ● Check the ohm value of the sensor and the wiring.

If the sensor does not have problems, improve motor ventilation. If the alarm is present when the motor is cold and the point above is okay, the problem is located inside the control.

66

● Charge the battery. ● If the alarm persists, measure the battery voltage with a voltmeter and compare it with the parameter, Adjustment / ADJUST BATTERY and if necessary adjust the value. ● If the alarm persists, the problem could be internal to the module, which must be replaced.

69

● The alarm disappears when the acquisition is completed. ● If the alarm persists, turn the truck off then on again. ● If the problem occurs frequently, replace the controller.

Cause: This warning appears when the temperature sensor is open or the motor temperature is geater yhan the value set.

The maximum current and speed are reduced.

BATTERY LOW Cause: When the charge level is 10% , this alarm is signalled DATA ACQUISITION Cause: Acquisition of current gains in progress.

CURRENT SENS KO

69 ● Recycle the key, if the alarm persists, the issue is in the controller that needs to be replaced.

Cause: This alarm is related to a Current sensor failure.

DRIVER SHORTED

74

Cause: At Key ON, the microprocessor checks that the MC coil driver is not shorted; if it is shorted the alarm appears.

CONTACTOR DRIVER Cause: When the initial diagnosis is finished the traction logic closes the MC and checks the voltage on the driver output. If this is not low, this alarm appears

12

Troubleshooting

● Recycle the key, if the alarm persists, the issue is in the controller that needs to be replaced.

75 ● Recycle the key, if the alarm persists, the issue is in the controller that needs to be replaced.

8000 YRM 2220

Diagnosis system for Combi controller

Alarm

Code MDI

COIL SHORTED

76 ● Check if there are short circuits. ● Check if the ohmic value in the main contactor coil is correct. ● If the problem persists, replace the controller.

Cause: Whent he key is switched on, the controller checks the main contactor driver. If it does not react in a correct way, the alarm appears.

VACC NOT OK

78

● When this warning message appears, the traction is stopped. Check the correct operation of the throttle; using the TESTER menu check the follow parameter: Accelerator: its value have to change from 0 V to 2.3 V when turning the accelerator throttle (0 in rest position) Otherwise the accelerator or its connection might be damaged.

79

● Check the correct operator sequence ● This alarm can also be caused by a traction or pump request, already present at the key ON ●Check the wiring and correct operation of the microswitches and tiller card button (see Tester menù parameters to facilitate the troubleshooting). ● If no malfunction is detected, replace the control.

80

When this warning message appears, the traction is stopped. ● Check the wiring of the "forward" and "backward” inputs (use the "TESTER MENU” to facilitate troubleshooting). ● Check for any faults with the microswitches or board. ● After checking that the traction request switches are working correctly and the wiring is correct, replace the module.

To restart the system carry out a traction request.

Cause: The test is carried out with the key ON and after 20 seconds the accelerator control is returned to neutral position. This alarm occurs if the value of the accelerator, read in the TESTER menu, is 1.0 V greater than the minimum value required, when the accelerator is in neutral position.

INCORRECT START Cause: This alarm appears in case of an incorrect start sequence.

FORW + BACK

Cause: This message only appears when both the (forward and backward) motion requests are activated at the same time

PEDAL WIRE KO Cause: This alarm occurs if a fault is detected in the accelerator unit wiring.

Troubleshooting

86

● By referring to the wiring diagram, check the correct connection and voltage (from 0V to 5V moving the throttle) on pin B10 of the controller.

13

Diagnosis system for Combi controller

8000 YRM 2220

Alarm

Code MDI

Troubleshooting

STALL ROTOR

225

● Check if the motor is mechanically locked. ● Check if the parameters Tester/ Frequency Tester/ Encoder are ok and change according to traction demand. ● Check the encoder connections

Cause: The traction motor is blocked or the controller does not receive the signal correctly.

TILL OPEN

226

Cause: The alarm appears if both parameters TILLER OPEN and TILLER OPEN ALARM are set at ON and the truck remains on for more than a minute without any traction of hydraulic request.

WRONG BATTERY

● Turn the truck off and on.

If the alarm persists , the issue is inside the controller that must be replaced.

236

Cause: This alarm appears when at start-up the controller checks the battery voltage and detects it is out of the nominal value range.

LIFT LOW ACTIVE

238

Cause: This message appears in case the lifting or lowering switch is triggered when the controller is started LIFT+LOWER

● Check tiller button and tiller wire harness

239

The pump motor stops. ● Check the wiring of the lifting and lowering inputs (use the TESTER readings in the menu to make troubleshooting easier). ● Check that the push button microswitches in the tiller head are not faulty. ● If the lifting and lowering buttons are working correctly and the wiring is correct, it is necessary to replace the controller. To restart the system carry out a hydraulic request.

240

●Recycle the key, if the alarm is still present perform a clear eeprom. ● In case it doesn't solve the issue, the controller needs to be replaced .

Cause: This alarm appears when there is a simultaneous request of forks lifting and lowering.

WRONG CONFIG Cause: This alarm appears in case of a configuration failure.

HW WRONG Cause: This alarm is related to an internal damage of the controller

14

● Check that parameter SET BATTERY matches the battery nominal voltage. ● Check that the parameter Tester / BATTERY VOLTAGE shows the same value as the battery voltage measured with a voltmeter. If it is does not match, do a “ADJUST BATTERY” function.

241 ● Recycle the key; if the alarm persist replace the controller.

8000 YRM 2220

Diagnosis system for Combi controller

Alarm

Code MDI

PEV NOT OK

247

Cause: This alarm appears when no load is connected between pins A5 and A6 of the controller.

CAN BUS KO

● Check the CAN BUS line and any false contacts on the related pins 249

Cause: This message warns that it is time to carry out the scheduled maintenance.

SENS MOT TEMP KO Cause: The output of the traction motor temperature sensor has a not admitted value.

● Check the continuity of the wire between lowering valve coil and pins A5 and A6. and the absence of false contact on terminals and pins. ● Check the correct value of the solenoid valve coil

248

Cause: This alarm appears when the can bus communication is not received.

CHECK UP NEEDED

Troubleshooting

● After carrying out the maintenance, set the parameter Adjustment menu / CHECK UP DONE to ON.

250 ● Check the value of the sensor and its wiring. ● If no faults were found in the sensor or in the wiring, the fault might be in the controller, replace it.

15

Diagnosis system for Combi controller

8000 YRM 2220

Alarm

Code MDI

ENCODER ERROR

253

Cause: This alarm appears in the following conditions: the frequency supplied to the motor is greater than 40Hz and the encoder signal feedback shows a jump of more than 40 Hz in just a few milliseconds. This behaviour is related to an encoder malfunction.

AUXOUTPUT KO Cause: The alarm appears when, after an internal autodiagnosis, the micro processor detects that the status of the electromgnetic brake coil does not match with signal coming from the micro processor

16

Troubleshooting

● Check both the electrical and mechanical functionality of the encoder and the wiring. ● If necessary, replace the encoder. If the problem persists after the replacement of the encoder, the fault lies in the control.

254 ● Check that there are no bad contacts. ● Check the proper connection of XA1-30, XA1-5 and XA1-8. ● Check the platform potentiometer is supplied correctly (5V on XA1-8).

8000 YRM 2220

Electrical component measurements

Electrical component measurements SOLENOID VALVE COIL

Ref

Solenoid valve

Value measured (Ohm)

A

Lowering solenoid valve

31.7 (in case of on/off lowering valve)

17

Electrical component measurements

8000 YRM 2220

ELECTROMAGNETIC BRAKE COILS

Coil

Value measured (Ohm)

Electromagnetic brake

29.8

MOTORS To measure the motor insulation resistance, disconnect the phase wires (U, V, W). Connect one of the tester probes to the U phase and the other probe to the bodywork in an unpainted zone. The resistance reading ( W) on the tester should be infinity (~). Otherwise, the motor is not insulated and must be replaced immediately. Repeat the operation with the other two phases (V, W).

18

8000 YRM 2220

7/21

Maintenance

ELECTRICAL SYSTEM MP16UX [A7T8]

PART NO. 550256729

2200 YRM 2221

Table of Contents

TABLE OF CONTENTS Wiring diagrams...................................................................................................................................................... 2 Electrical components............................................................................................................................................. 4 Key to tiller controls and main panel....................................................................................................................... 6 MDI Display.............................................................................................................................................................8 Truck functions........................................................................................................................................................ 9 Parameter standard configuration.........................................................................................................................15 Combi Controller................................................................................................................................................... 16 Description of the Combi controller parameters....................................................................................................20 Control devices......................................................................................................................................................29 Replacement of the controller............................................................................................................................... 30 Replacement of the tiller head.............................................................................................................................. 31 Replacement of the display...................................................................................................................................32 Replacement of the horn.......................................................................................................................................33 Replacement of the fuse....................................................................................................................................... 34 Replacement of the main contactor switch........................................................................................................... 35 Replacement of the proximity sensor....................................................................................................................36 Replacement of the general emergency switch.................................................................................................... 37 On board battery charger (optional)...................................................................................................................... 38 Replacement of the battery charger (optional)......................................................................................................39

©2021 Yale Materials Handling Corp.

i

2200 YRM 2221

1

Wiring diagrams

2200 YRM 2221

Wiring diagrams Ref.

2

Description

KC

Traction controller

WK

Tiller board

FU1

Fuse 10A

FU2

Fuse 160A

FU3

Fuse 160A

M1

Traction motor 1.2 Kw

M2

Pump motor 0.8 Kw

K1

Emergency switch

K2

Key switch

K3

Charging switch

K4

Speed limitation sensor (not used)

L1

Electromagnetic brake

L2

Lowering solenoid valve

LB

Horn

MC

Main contactor

PC

Pump contactor

2200 YRM 2221

Wiring diagrams

3

Electrical components

2200 YRM 2221

Electrical components IDENTIFICATION OF ELECTRICAL COMPONENTS

4

2200 YRM 2221

Electrical components

Ref.

Description

1

Charger

2

Bolted fuse

3

Contactor

4

Ac controller

5

Tiller

6

Electric horn

7

Electromagnetic brake

8

Ac motor

9

Lifting height limit switch

10

Lead-acid battery

11

Key switch

12

Display (MDI)

13

Emergency Stop Button

5

Key to tiller controls and main panel

2200 YRM 2221

Key to tiller controls and main panel

6

Ref.

Description

A

Fork lowering / lifting button

B

Horn button

C

Belly switch (reverse button)

D

Drive command throttles

E

Turtle button

2200 YRM 2221

Key to tiller controls and main panel

Ref.

Description

F

Display (MDI)

G

Ignition key switch

H

Emergency stop button

7

MDI Display

2200 YRM 2221

MDI Display

The normal working interface mainly displays the walking speed, battery level SOC, and hour meter. The speed is displayed in km/h with a minimum resolution of 0.1 km/h.

The battery level is indicated by percentage and a battery symbol.

The symbol includes six bars: all bars at a battery level of ≥ 90%, four bars at ≥ 80%, three bars at ≥ 60%, two bars at ≥ 40%, one bar at ≥ 20%, no bar at ≥ 0%.

The unit of hour meter is hour, the minimum resolution is 0.1 h (6 minutes), and the symbol "h" flashes at 1 Hz. When an alarm occurs, the display shows the alarm code, the backlight will be on and off at the frequency of 1 s, and the symbol "AL" will flash, while the speed isn't shown any longer.

When multiple alarms occur at the same time, the interface will cycle to display the alarm information, and the display sequence is the alarm occurrence time, and up to 4 alarm messages can be scrolled.

8

2200 YRM 2221

Truck functions

Truck functions FORWARD/BACKWARD TRACTION ACTUATION CONTROLS

Actuators involved

Status

Key switch

ON

Emergency switch

ON

Tiller tilt sensor

ON*

Forward/reverse traction control throttle

forward/reverse rotation

* OFF when the Snail Button is pressed.

9

Truck functions

2200 YRM 2221 CONFIGURATION PARAMETERS

Parameter change menu

Set option menu

Adjustment menu

Acceler delay

H&S (B4) Input NC

Set pot brk min

Release braking

H&S (B4) Input FUNCT.

Set pot brk max

Inverse braking

H&S (B4) State Saving

Throttle 0 zone

Pedal braking

Belly type

Throttle X point

Speed limit brk

Belly switch

Throttle Y point

Brake cutback

Battery check

Check up type

Tiller braking

Quick inversion

Check up done

Q.I. acceleration delay

Aux voltage #1

Q.I. inv braking

Quick inv. logic

Max speed forw

Belly alarm

Max speed back

Mdi speed

Bdi low speed H&S cutback Frequency creep Inching speed Inching time Auxiliary time Q.I. time Q.I. speed For the standard values of each individual parameter, see the paragraph "STANDARD CONFIGURATION OF MODULE PARAMETERS". For a description of each individual parameter see "DESCRIPTION OF MODULE PARAMETERS".

10

2200 YRM 2221

Truck functions

BRAKING The truck is equipped with four braking systems: •

Release braking

•

Reverse braking

•

Emergency braking

•

Service braking

Truck braking will be performed in different ways according to which one of the above systems is implemented.

Braking system

Tool

When does it come into operation?

Braking method

Release braking

Drive command throttle

Release of the control throttles

Electrical braking of the traction motor with subsequent engagement of the electromagnetic brake

Reverse braking

Drive command throttle

Inversion of the travel direction using the control throttles

Drive motor electric braking

Emergency stop button operation Emergency braking

Service braking

Emergency switch

Steering tiller

The truck has generated an alarm that requires the traction to be halted immediately The tiller is released in the rest position

Braking with electromagnetic brake engagement

Electrical braking of the traction motor with subsequent engagement of the electromagnetic brake

11

Truck functions

2200 YRM 2221

EMERGENCY REVERSE BUTTON It is a device located at the tiller end to reverse the direction of travel when it is hit. It works during the truck travel on the operator side. If bumped, the truck reverses immediately (ref. AFigure 1).

Figure 1. Emergency reverse manoeuvre TURTLE BUTTON By pressing this button B and operating the transfer control throttles C, the truck moves forwards or backwards at reduced speed (Figure 2).

Figure 2. Turtle button

12

2200 YRM 2221

Truck functions

FORK LIFTING/LOWERING ACTUATION CONTROLS

Actuators involved

Status

Key switch

ON

Emergency switch

ON

Forks lifting/lowering

ON/OFF button for lifting/ lowering enabled

Tiller sensor

ON (OFF if the snail button is pressed)

13

Truck functions

2200 YRM 2221

STEERING ACTUATION CONTROLS

14

Actuators involved

Status

Key switch

ON

Emergency switch

ON

Tiller sensor

ON

Tiller rotation

right / left rotation

2200 YRM 2221

Parameter standard configuration

Parameter standard configuration CONFIGURATION PARAMETER ACCESS PROCEDURE Thanks to the controller parameters can be configured by connecting the Handset p/n 582148624 to the connector C (Figure 3) in the controller and accessing the relative menu.

Figure 3. Connector controller PARAMETER STANDARD CONFIGURATION It is always advisable to keep the factory settings as designed in order to have the best compromise between performance and component wear. It is however possible to customise the performance based on the client's request, the characteristics of the warehouse and the materials to be moved, but no parameter must be changed if this jeopardises the safety of the truck.

15

Combi Controller

2200 YRM 2221

Combi Controller COMBI / menu parameter change COMBI / menu set options COMBI / menu adjustment COMBI / special adjustment COMBI / hardware settings

SET OPTIONS MENU

PARAMETER CHANGE MENU

16

PARAMETER

Default

TILLER SWITCH

handle

A13 TEMP SENSOR

present

SET INPUT #2

present

CUTBACK 2 N.C.

OFF

PARAMETER

Default

H&S CUTBACK NC

OFF

ACCELER DELAY

2

SET INPUT #4

BELLY

RELEASE BRAKING

9

HOUR COUNTER

KEYON

INVERS. BRAKING

8

BATTERY CHECK

1

PEDAL BRAKING

9

B.M.S.

NONE

SPEED LIMIT BRK.

2

HYDRO KEY ON

OFF

BRAKE CUTBACK

5

B9 INPUT

OPTION #1

TILLER BRAKING

6

STOP ON RAMP

ON

Q.I. ACCEL DELAY

0

AUX OUTPUT #1

BRAKE

Q.I. INVER BRAKING

4

PEDAL BRAKING

NONE

MAX SPEED FORW

120 Hz

QUICK INVERSION

TIMED

MAX SPEED BACK

120 Hz

AUX VOLTAGE #1

69%

BDI LOW SPEED

50%

DISPLAY TYPE

5

CURVE CUTBACK

40%

EPS

absent

H&S CUTBACK

26%

QUICK INV. LOGIC

OPTION #1

FREQUENCY CREEP

1.20 Hz

CONTACTOR CLOSED

OFF

MAXIMUM CURRENT

9

CAN TILLER

ABSENT

INCHING SPEED

0 Hz

BELLY ALARM

ON

INCHING TIME

0

MDI SPEED

OFF

AUXILIARY TIME

4 sec

B3 INPUT

ON

Q.I. TIME

2 sec

PUMP WITHOUT TIL

ON

TILLER DELAY

0

TILLER OPEN

OFF

STEER ANGLE MIN.

15

TILLER OPEN ALAR

OFF

STEER ANGLE MAX.

75

2200 YRM 2221

Combi Controller

ADJUSTMENT MENU PARAMETER

Default

SET POT BRK MIN

0V

SET POT BRK MAX

2.1 V

MOTOR OVERTEMP

150 °C

SET MOT TEMP.

25 °C

SET BATTERY TYPE

24 V

ADJUST BATTERY

25.1 V

THROTTLE 0 ZONE

9%

THROTTLE X POINT

54%

THROTTLE Y POINT

25%

ADJUSTMENT #01

2

ADJUSTMENT #02

6

LOAD HM FROM MDI

OFF

CLEAR MDI HM

OFF

RESTORE MDI HM

OFF

CHECK UP DONE

OFF

CHECK UP TYPE

NONE

CUTBACK SENS CNT

20

SPEED FACTOR

200

BDI LOW BATTERY

15%

PARAMETER

Default

CANBUS SPEED

0

ADJUSTMENT #01

96%

ADJUSTMENT #02

96%

SET TEMPERATURE

31°C

AUX FUNCTION 1

15

AUX FUNCTION 2

15

SPECIAL ADJUSTMENT MENU

17

Combi Controller

2200 YRM 2221

HARDWARE SETTING MENU

18

PARAMETER

Default

AC TYPE 0

ON

COMPENSATION

ON

SLIP CONTROL

ON

DC-LINK COMPENS.

ON

SAT FREQUENCY

60 Hz

BRAKING MODUL.

50 Hz

MINIMUM VOLTAGE

3%

BOOST AT LO FREQ

24%

BOOST AT HI FREQ

50%

BOOST CORNER FRE

30 hz

BRAKING BOOSTER

0%

MOTOR RESISTANCE

LEVEL = 0

SLIP COEFFICIENT

LEVEL = 0

MAXSLIP RESET

0.60 Hz

MAXSLIP 0

7.0 Hz

MAXSLIP 1

7.0 Hz

FREQSLIP 1

20 Hz

MAXSLIP 2

8.0 Hz

FREQSLIP 2

40 Hz

MAXSLIP 3

8.0 Hz

FREQSLIP 3

80 Hz

MAXSLIP 4

8.0 Hz

FREQSLIP 4

110 Hz

2200 YRM 2221

Combi Controller

PARAMETER

Default

OPTION 07

1

OPTION 08

1

OPTION 06

6

AUX VOLTAGE #1

110%

AUX VOLTAGE #2

120%

NOTE: The parameters of special adjustment menu and of hardware setting menu are factory settings and cannot be changed at all.

19

Description of the Combi controller parameters

2200 YRM 2221

Description of the Combi controller parameters COMBI / main menu parameter change COMBI / menu set options COMBI / menu adjustment PARAMETER CHANGE MENU PARAMETERS ACCELER. DELAY This parameter determines the time required for the traction motor to accelerate from 0Hz to 100Hz. When the unit is "s", the longer the time, the slower the acceleration will be in the range of 0-10s; when the unit is LEVEL, the higher the LEVEL, the slower the acceleration will be in the range of 0-9.

RELEASE BRAKING This parameter determines the time required for the traction motor to decelerate from 100Hz to 0Hz when when the travel request is released. When the unit is s, the longer the time, the slower the deceleration will be within the range of 0-10s; when the unit is LEVEL, the higher the LEVEL, the faster the deceleration will be 0-9.

INVERS. BRAKING This parameter determines the time required for the traction motor to decelerate from 100Hz to 0Hz when the direction switch is reversed. When the unit is s, the longer the time, the slower the deceleration will be within the range of 0-10s; when the unit is LEVEL, the higher the LEVEL, the faster the deceleration will be 0-9.

PEDAL BRAKING Not used.

SPEED LIMIT BRK. This parameter determines the speed braking and the time required for traction motor to decelerate from 100Hz to 0Hz under turn deceleration. When the unit is s, the longer the time, the slower the deceleration will be within the range of 0-10s; when the unit is LEVEL, the higher the LEVEL, the faster the deceleration will be 0-9.

BRAKE CUTBACK This parameter determines the time required for the traction motor to decelerate from 100Hz to 0Hz when the speed reduction input becomes active and the motor slows down. When the unit is s, the longer the time, the slower the deceleration will be within the range of 0-10s; when the unit is LEVEL, the higher the LEVEL, the faster the deceleration will be 0-9.

20

2200 YRM 2221

Description of the Combi controller parameters

PARAMETERS TILLER BRAKING This parameter determines the time required for the traction motor to decelerate from 100Hz to 0Hz when the handle switch is released or completely lowered (tiller switch open) during running. When the unit is s, the longer the time, the slower the deceleration will be within the range of 0-10s; when the unit is LEVEL, the higher the LEVEL, the faster the deceleration will be 0-9 Q.I. ACCEL DELAY This parameter determines the time required for the reverse speed of the traction motor to accelerate from 0Hz to 100Hz receiving the emergency reverse signal. When is s, the longer the time, the slower the deceleration will be in the range of 0-10s; when the unit is LEVEL, the higher the level, the faster the acceleration will be 0-9 Q.I. INV BRAKING This parameter determines the time required for deceleration from 100-0Hz for fast reverse of traction after receiving the emergency reverse signal . The longer the time is, the slower the deceleration will be, with a range of 0-10s. When the unit is LEVEL, the higher the LEVEL is, the slower the deceleration will be.

MAX SPEED FORW The maximum forward speed is usually 90 to 160Hz with a range of 0-200Hz MAX SPEED BACK The maximum reverse speed is usually 90 to 160 Hz, in the range of 0-200 Hz BDI LOW SPEED This parameter determines what percentage of the maximum speed the current speed should account for when the battery power is low, in the range of 10% to 100% H&S CUTBACK The percentage of the maximum speed when the turtle mode (switch B4) is closed, usually 10% to 100%. This switch is invalid at 100% FREQUENCY CREEP The minimum speed at which the forward and reverse switch is closed, when the switch closure accelerator is in the minimal position, in the range of 0.3-3 Hz

21

Description of the Combi controller parameters

2200 YRM 2221

PARAMETERS MAXIMUM CURRENT Do not modify. It is the maximum current of the inverter.

INCHING SPEED Not used.

INCHING TIME Not used.

AUXILIARY TIME This parameter determines how long the tram will stay ON the RAMP, in the range of 0-5s, if the STOP ON RAMP is turned ON Q.I. TIME This parameter determines the duration of the action after quick reverse activation, ranging from 0 to 25.5s TILLER DELAY This parameter determines the time of the handle disconnect delay, ranging from 0 to 3.14s STEER ANGLE MIN Not used.

STEER ANGLE MAX Not used.

22

2200 YRM 2221

Description of the Combi controller parameters

SET OPTIONS MENU PARAMETERS TILLER SWITCH This parameter defines the B3 switch setting.

HANDLE: power must be turned on before the tiller is in work position, otherwise the alarm INCORRECT START will appear SEAT: no matter what is the tiller position at power ON; no alarm will appear A13 TEMP SENSOR A13 is the input of motor temperature sensor,ABSENT/PRESENT, the corresponding motor temperature sensor type KTY84 series, KTY84-130/KTY84-150 SET INPUT #2 Not used.

CUTBACK 2 N.C. Not used.

H&S (B4) INPUT NC This parameter defines how it is managed the turtle switch. ON: normally closed, OFF normally open.

SET INPUT #4 This parameter define how the Input #4 is managed: BELLY: input B7 is managed as a belly input BRAKE: input B7 is managed as serivce brake input.

EX.HYDRO: input B7 is managed as a " Exclusive Hydro" input.

HOUR COUNTER This parameter defines how the hour counter works. KEY ON begins to record after the switch is closed, RUNNING only records the time when the truck travels BATTERY CHECK Level 0, detection has no effect.

LEVEL 1: when the battery is lower than BDI LOW BATT, the battery indicator flashes, an alarm occurs and traction is reduced.

LEVEL 2: when the battery is lower than BDI LOW BATT, the battery indicator flashes, an alarm appears,the speed is limited and the lifting is prohibited.

LEVEL 3: when the battery is lower than BDI LOW BATT the power indicator flashes, the current is limited, lift can not be used, and an alarm appears B.M.S. Not used.

23

Description of the Combi controller parameters

2200 YRM 2221

PARAMETERS HYDRO KEY ON Not used.

B9 INPUT Lifting request input, active high STOP ON RAMP This parameter determines whether the ramp will stop. If on it will have an auxiliary time to stop. If off, the truck will descend slowly.

AUX OUTPUT #1 Do not modify. This option handles the digital output A3. It can be used one of four BRAKE: it drives an electromechanical Brake.

HYDROCONT: it drives the contactor for a hydraulic steering function when the direction input or a movement of the truck is detected EX.HYDRO: it drives the contactor for a hydraulic steering function when the exclusive hydro input is active FREE: it is not used.

PEDAL BRAKING Not used.

QUICK INVERSION This parameter determines the motor quickly reverse function: if TIMED is selected, quick function is effective and timing. It switches on and will remain in forks direction; it stops automatically after a specific time. if BELLY is selected, fast inverse function is effective but timing function is disabled.

If NONE is selected, it does not quick inverse if OPTION#2 is enabled, it will start inversion and remain in the reverse state for a specified period of time with an alarm AUX VOLTAGE #1 The main contactor coil and the electromagnetic brake are 10% to 100% of the current rated voltage.

DISPLAY TYPE Select the display instrument type.

EPS Not used.

QUICK INV. LOGIC When it is OPTION#1, B7 performs a fast reversal when it is on, and when it is OPTION#2, B7 performs a fast reversal when it is off OPTION 09 Not used.

CONTACTOR CLOSED This parameter is used to judge the contactor close fault. When there is no contactor, it is set to OFF and no fault is reported. When there is a contactor, it is set to ON

24

2200 YRM 2221

Description of the Combi controller parameters

PARAMETERS CAN TILLER This parameter is used to determine whether the CAN handle is to be used and to set communication connection between different controllers. If PRESENT, the CAN handle is to be used.

A14 FUNCTION Do not modify. This parameter determines how the input A14 is managed BELLY ALARM This parameter is used for quick reflection fault display. When on, the fault is normally displayed. When off, the fault is not displayed MDI SPEED Not used.

B3 INPUT Tiller request input. When ON , must be connected to the tiller microswitch, active high PUMP WITHOUT TIL When it is ON, the handle switch is not required for the lifting and lowing function, while when it is OFF, the handle switch is required for the lifting and lowing function.

TILLER OPEN When ON, if the truck remains switched on with the tiller in rest position (tiller switc OFF) without any traction or pump request; after a period of time (1 min), the main contactor will be open. When OFF nothing nothing will happen, because this function will be excluded.

TILLER OPEN ALAR When ON, if the truck remains switched on with the tiller in rest position (tiller switch OFF) without any traction or pump request; after a period of time (1 min), the main contactor will be open and an alarm appears. When OFF, no fault will be reported.

25

Description of the Combi controller parameters

2200 YRM 2221

ADJUSTMENT MENU PARAMETERS SET POT BRK MIN Not used.

SET POT BRK MAX Not used.

MOTOR OVERTEMP Do not modify. Set the motor temperature threshold and issue a warning when the motor reaches this temperature, in the range of 70-160 degrees SET MOT TEMP. Do not modify. This parameter allows setting the motor temperature sensor type SET BATTERY TYPE This parameter allows setting the battery voltage rating ADJUST BATTERY Right battery voltage value measured on the battery THROTTLE 0 ZONE This parameter allows setting a dead zone in the accelerator input curve so that the speed does not increase until the voltage reaches 0% - 17%.

THROTTLE X POINT The maximum speed percentage Y reached when MAX VACC reached point X.(This parameter can change the characteristics of the accelerator input curve) THROTTLE Y POINT The maximum speed percentage Y reached when MAX VACC reached point X.(This parameter changes the characteristics of the accelerator input curve) ADJUSTMENT #01 It adjusts the lower level of the battery charge table (Level 0 to 9)

26

2200 YRM 2221

Description of the Combi controller parameters

PARAMETERS ADJUSTMENT #02 It adjusts the upper level of the battery charge table (Level 0 to 9) LOAD HM FROM MDI Not used.

CLEAR MDI HM This parameter allows clearing the hour meter displayed on the meter to zero RESTORE MDI HM Not used.

CHECK UP DONE This parameter can be ON or OFF. If it is ON it is possible to reset the last maintenance hour-counter and the "CHECK UP NEEDED" warning CHECK UP TYPE This parameter specifies the handling of the CHECK UP NEEDED warning: NONE: No CHECK UP NEEDED warning appears OPTION#1: CHECK UP NEEDED warning shown on the hand set and MDI/DISPLAY after 300 hours OPTION#2: Equal to OPTION#1 but Speed reduction after 340 hours OPTION#3: Equal to OPTION#2 but the truck definitively stops after 380 hours CUTBACK SENS CNT Not used.

SPEED FACTOR Do not modify. Factor conversion from the number of HZ to the actual speed, is generally used for displaying the speed of the MDI instrument.

27

Description of the Combi controller parameters

2200 YRM 2221

PARAMETERS BDI LOW BATTERY This parameter sets a threshold value of battery voltage. The motor speed and lift will be inhibited when the battery level is lower than this value. The degree of inhibition is determined by the BATTERY CHECK level, with a range of 0-30%.

28

2200 YRM 2221

Control devices

Control devices TRACTION - PUMP CONTROLLER The controller has been designed to perform all the electrical functions normally present on the truck: •

Inverter for three-phase asynchronous AC motors

•

Regenerative braking functions

•

CanBus interface

•

Digital control using a microcontroller.

TECHNICAL SPECIFICATION Voltage Maximum inverter current (24V - 36V)

24V - 36V 150A (RMS) for 2'

Inverter operating frequency

8 kHz

External temperature limits

-30°C to -40°C

Maximum inverter temperature (at maximum power)

78°C

29

Replacement of the controller

2200 YRM 2221

Replacement of the controller CONTROLLER REPLACEMENT

WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Turn the keyswitch to OFF and disconnect the battery.

Step 1 Remove the front covers as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218".

Step 2 Disconnect the two connectors. Unscrew five terminal screws A and pull out the wire harness connector.

Unscrew four setscrews B and remove the controller (Figure 4).

Figure 4. Controller replacement

30

2200 YRM 2221

Replacement of the tiller head

Replacement of the tiller head WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Step 1 By using the T-handle hex spanner unscrew the 4 screws A, remove the upper cover B and pull out the connecting wire. Unscrew the 3 screws C to remove the tiller head (Figure 5).

Figure 5. Tiller head replacement

31

Replacement of the display

2200 YRM 2221

Replacement of the display Step 2

WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Unscrew the 2 nuts A and remove the bent plate B. Then ttake out the display from the top and proceed with its replacement (Figure 6).

Step 1 Remove the front cover as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218".

Figure 6. Display replacement

32

2200 YRM 2221

Replacement of the horn

Replacement of the horn Step 3

WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Use the Allen wrench to unscrew the setscrew B, pull out the spring and replace the horn (Figure 8).

Step 1 Remove the front cover as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218).

Step 2 Disconnect the two faston connectors A (Figure 7).

Figure 8. Horn replacement

Figure 7. Faston disconnection

33

Replacement of the fuse

2200 YRM 2221

Replacement of the fuse WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Step 1 Remove the front cover as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218".

Step 2 Loosen the two nuts A, remove bolt fuse B and proceed with its replacement (Figure 9).

34

Figure 9. Replacement of the fuse

2200 YRM 2221

Replacement of the main contactor switch

Replacement of the main contactor switch WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Step 1 Remove the front cover as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218".

Step 2 Unscrew the two nuts A and remove the connected power cord. Unscrew the two screws B and remove the contactor switch (Figure 10).

Figure 10. Contactor switch replacement

35

Replacement of the proximity sensor

2200 YRM 2221

Replacement of the proximity sensor WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Step 3 Unscrew and remove the two screws B and proceed with the proximity sensor replacement (Figure 12).

Step 1 Remove the front cover as described in section "Removal of the covers" in publication "Removal of the covers".

Step 2 Unscrew the screw A fixing the proximity sensor group and remove (Figure 11).

Figure 12. Proximity sensor replacement

Figure 11. Proximity sensor group removal

36

2200 YRM 2221

Replacement of the general emergency switch

Replacement of the general emergency switch WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Remove the front cover as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218".

Step 2 Put the screwdriver into the hole B and rotate the mushroom head A counterclockwise to remove the mushroom head. Unscrew 2 screws C and remove the emergency switch. Unscrew the bolt D and then remove the connecting power line to replace the emergency switch (Figure 13).

Figure 13. Emergency switch replacement

37

On board battery charger (optional)

2200 YRM 2221

On board battery charger (optional) Trucks can be equipped with an on-board battery charger in the motor compartment and the relative charger socket (AC port) A on truck frame side (Figure 14) that allows recharging of the battery.

The flashing sequence of LED on the top of the battery charger indicates the status of the battery charger during the charging cycle and/ or any error codes present.

Figure 14. Charger socket

Indicator light

no load indicator power indicator light

Traffic lights flickered alternatively.

Charging: red light flashing.

Full: the green light is always on.

Overcurrent (pressure) fault

Fault indicator

38

red green red - - -

Ambient temperature is too high red green red green - or too low Charger overheat

green red - - - -

Output voltage undershoot

red green - -

Input AC abnormal

red green red green red

2200 YRM 2221

Replacement of the battery charger (optional)

Replacement of the battery charger (optional) WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Step 1 Remove the front cover as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218".

Step 2 Remove the connecting wire of the charger and unscrew the 4 screws A to remove the charger (Figure 15).Then proceed with its replacement.

Figure 15. Battery charger replacement

39

2200 YRM 2221

7/21

Maintenance

HYDRAULIC MP16UX [A7T8]

PART NO. 550256730

1900 YRM 2222

Table of Contents

TABLE OF CONTENTS Hydraulic functions..................................................................................................................................................2 Hydraulic diagrams..................................................................................................................................................4 Hydraulic diagrams for functions.............................................................................................................................6 Hydraulic components...........................................................................................................................................10 Calibration of the pressure relief valve..................................................................................................................12 Topping up the hydraulic oil...................................................................................................................................13 Removal of the hydraulic power unit..................................................................................................................... 14 Removal of the cylinder assembly........................................................................................................................ 15 Cylinder disassembly............................................................................................................................................ 16

©2021 Yale Materials Handling Corp.

i

1900 YRM 2222

1

Hydraulic functions

1900 YRM 2222

Hydraulic functions HYDRAULIC FUNCTIONS •

Forks lifting

•

Forks lowering

FORK LIFTING/LOWERING The fork lifting speed is determined by the rpm at which the pump motor transmits drive to the pump drive shaft.

In the lowering stage the check valve prevents the flow of oil through the pump and the oil returns to the reservoir through the flow control valve.

2

1900 YRM 2222

Hydraulic functions

OIL SUPPLY TO THE HYDRAULIC CIRCUIT Fixed displacement pumps With fixed displacement pumps, the oil flow is constant, providing the rotation speed of the motor shaft remains unchanged. A reduction in the shaft rpm will reduce the pump capacity: if the rpm are reduced so is the flow rate and vice versa; the pressure, providing the load is unchanged, remains constant.

PRESSURE CONTROL VALVES Pressure limiting valves The "pressure limiting" or "pressure relief" valves are mainly used to guarantee that the maximum permissible system pressure is not exceed in the system and to protect the pump from damaging pressure levels that exceed its structural characteristics. The use of pressure limiting devices is not restricted to the functions described above, but they are commonly used in many devices where it is crucial to prevent pressure build ups. An example are anti-shock and anti-knock valves. As long as the circuit is not subjected to excess pressure conditions, the pressure limiting device remains in the closed position: the force exerted by the pressurised oil is lower than that exerted by the opposing spring. With the piston at its end-of-stroke or if an anomalous situation arises which generates forces in excess of the set level (for example with a load in excess of the load capacity), the overpressured oil overcomes the force of the spring and flows towards the oil outlet.

DIRECTIONAL CONTROL VALVES One-way valves and check valves The function of "one-way" or "non-return" valves is to allow the oil to flow in one direction only, while preventing the flow in the opposite direction. They are essentially comprised of a fixed part connected to the end of the pipe; in the appropriate inner housing runs the moving element which might be a bearing or a conical plug. Check valves instead have an opposing spring. In the direction of free flow, the oil pressure must exceed the force exerted by the spring.

3

Hydraulic diagrams

1900 YRM 2222

Hydraulic diagrams SYMBOLS

Item

4

Description

Item

Description

1

solenoid valve

6

Pressure relief valve

2

Filter

7

One-way valve

3

Cylinder

8

Line connection

4

Pump

9

Electric motor

5

Reservoir

1900 YRM 2222

Hydraulic diagrams

HYDRAULIC DIAGRAM

5

Hydraulic diagrams for functions

1900 YRM 2222

Hydraulic diagrams for functions FUNCTIONS •

Fork Lifting

•

Fork Lowering

SOLENOID VALVE OPERATION Function

Pump

EV1

Fork Lifting

on

-

Slow fork lowering

-

supplied

Item

6

Description

A

Lowering solenoid valve EV1

B

Pressure relief valve

1900 YRM 2222

Hydraulic diagrams for functions

HYDRAULIC DIAGRAM FOR FORK LIFTING

7

Hydraulic diagrams for functions HYDRAULIC DIAGRAM FOR FORK LOWERING

8

1900 YRM 2222

1900 YRM 2222

Hydraulic diagrams for functions

HYDRAULIC DIAGRAM FOR OIL RETURN TO TANK THROUGH PRESSURE RELIEF VALVE Pressure relief or pressure limiting valves are used in hydraulic systems to maintain the pressures permitted by the system and to protect and safeguard the system against sudden pressure surges that could seriously damage the components. The pressure relief valve may intervene in the following cases: • •

Pressure control not suitable for the truck load capacity Attempt to lift a load in excess of the truck's load capacity

•

Faulty or stuck valve

9

Hydraulic components

1900 YRM 2222

Hydraulic components KEY TO HYDRAULIC COMPONENTS

10

1900 YRM 2222

Hydraulic components

Item

Description

1

Oil cylinder

2

Gasket

3

Hinge bolt

4

High pressure oil pipe

5

High pressure oil pipe

6

Hinge bolt

7

Gasket

8

Oil cylinder assembly

9

Tank

10

Solenoid valve

11

Pump motor

11

Calibration of the pressure relief valve

1900 YRM 2222

Calibration of the pressure relief valve CALIBRATION OF THE PRESSURE RELIEF VALVE The rated pressure of the safety valve has been adjusted at the factory. It should not be adjusted by the user; otherwise, it will damage the hydraulic system and the forklift itself. If the oil pressure is not in accordance with the specified value, it should be adjusted. To adjust the pressure relief valve follow the steps below:

WARNING Before starting work, ensure that you are wearing suitable protective clothing.

Step 1 Connect the battery and switch on the truck (starter key to ON). Place on the forks a load equivalent to the truck's load capacity, as indicated on the truck's dataplate.

Step 2 Remove the front covers as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218" Step 3 Loose lock nut B and turn the pressure regulating screw A left or right to adjust the pressure to the specified value. When the screw A is adjusted inward, the system pressure increases. When the screw A is adjusted outward, the system pressure decreases.

Adjust the screw to make the forklift be able to just lift the rated load, and to where the maximum lifting weight shall not exceed 115% of the rated load. After the adjustment, tighten the lock nut B (Figure 1).

Figure 1. Calibration of the pressure relief valve

12

1900 YRM 2222

Topping up the hydraulic oil

Topping up the hydraulic oil TOPPING UP THE HYDRAULIC OIL

WARNING Before starting work, ensure that you are wearing suitable protective clothing.

Step 2 Unscrew and remove cap A of the hydraulic oil tank and fill with the proper amount of oil (up to 750 ml) (Figure 2).

Step 1 Remove the front covers as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218".

Figure 2. Topping up the hydraulic oil

13

Removal of the hydraulic power unit

1900 YRM 2222

Removal of the hydraulic power unit Step 2 Remove the wiring harness of the hydraulic unit.

WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from the transit areas of other vehicles and pedestrians. Lower the forks to the ground.

Step 3 Unscrew and remove hinge bolt A and spacers B and hinge bolt C and spacers D to remove pipe E (Figure 3).

Step 1 Remove the front covers as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218".

Step 4 Unscrew and remove hinge bolt F and spacers G. Unscrew and remove screw H and take out the hydraulic power unit I (Figure 3).

Figure 3. Removal of the hydraulic unit

14

1900 YRM 2222

Removal of the cylinder assembly

Removal of the cylinder assembly WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from the transit areas of other vehicles and pedestrians. Lower the forks to the ground.

Step 2 Unscrew and remove screwA and screw B (Figure 4).

Step 3 Unscrew and remove hinge bolt C and spacer D (Figure 4).

Step 1 Remove the front and upper covers as described in section "Removal of the covers" in publication "FRAME AND MAIN COMPONENTS 0100YRM2218".

Figure 4. Removal of the cylinder assembly

Step 4 Lift slowly the frame by means of the bridge crane (hook the bridge crane to the frame in the point indicated by the labels) until the cylinders can be removed (Figure 5).

Figure 5. Cylinder removal

15

Cylinder disassembly

1900 YRM 2222

Cylinder disassembly WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from the transit areas of other vehicles and pedestrians. Lower the forks to the ground.

Step 1 Remove cylinder assembly as described in section "Removal of the cylinder assembly" in this publication.

Step 2 Take out top cap assembly C to remove piston rod assembly B and cylinder A (Figure 6).

Figure 7. Removal of the piston rod

Step 4 Take out top cap assembly C (Figure 6) to remove dust ring F, sailing ring G, top cap H O-ring I and guiding strips L (Figure 8).

Figure 6. Cylinder disassembly

Step 3 Disassemble piston rod assemblyB (Figure 6) to remove snap ring E and piston rod D (Figure 7).

Figure 8. Top cap disassembly

NOTE: When assembling, apply 3# Lithium grease on the engaging surfaces of seals.

16

1900 YRM 2222

7/21

Maintenance

MASTER DRIVE UNIT MP16UX [A7T8]

PART NO. 550256732

0630 YRM 2223

Table of Contents

TABLE OF CONTENTS Removal of the reduction unit................................................................................................................................. 2 Disassembly of the reduction unit .......................................................................................................................... 5 Braking System....................................................................................................................................................... 7 Removal of the electromagnetic brake..................................................................................................................10

©2021 Yale Materials Handling Corp.

i

0630 YRM 2223

1

Removal of the reduction unit

0630 YRM 2223

Removal of the reduction unit WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Set the key switch to OFF and disconnect the battery

WARNING Use caution as the oil in the reduction unit will be hot after use of the truck. It is advisable to wear gloves that are resistant to oil and high temperatures.

WARNING Do not dispose of used oil in the ground or by pouring it down the drain. Special companies must be charged with disposal or the recycling of industrial oils.

Step 1 Position the oil pan under the reduction unit. Unscrew and remove the gearbox bleed screw A. Unscrew oil drain plug screw B and remove it together with compund gasket C. Drain the oil into the pan. Clean the drain plug screw and the bleed screw throughly to remove any impurities that may have accumulated during operation of the reduction unit and screw it back in place (Figure 1).

Figure 1. Drain the oil fromthe gearbox

Step 2 Hook the two ends of the lift belt to the holes of the truck base made for lifting . Using the bridge crane, raise the truck by 200 mm. Put the blocks under the truck, lower the bridge crane and set the truck on the blocks keeping the lift belt under tension .

Step 3 Position a hydraulic jack beneath the reduction unit and lift until the jack is supporting the reduction unit.

Unscrew the 5 screws Dsecuring the reduction unit to the frame and recover them together with spacers E. Remove the drive wheel assembly together with the turntable assembly F (Figure 2).

2

0630 YRM 2223

Removal of the reduction unit

Figure 2. Turntable assembly removal

Step 4 Fully lower the jack, taking care to support the reduction unit. Using the bridge crane, lift the truck base frame just enough to remove the gearbox.

DISASSEMBLY OF THE REDUCTION UNIT Step 5 Unscrew screws G and spacers H. Remove turntable I (Figure 3).

Figure 3. Turntable removal NOTE: After reassembling the reduction unit, top it up by filling the oil into the filler plug. Unscrew and remove screw M, unscrew screw N and recover it together with compund gasket O. Fill an appropriate amount of hyperbolic gear oil 85 W/90 (GL-5) via oil filling port P (about 0.6 liter). Place the gearbox in upright position. if the oil overflown from peep hole R, the filling amount is right. Otherwise keep on filling, until the oil overflows. If there is too much oil, wait until the exceeding oil is drained from the peep hole R; then install screw N, compound gasket Oand bleed screw M (Figure 4).

3

Removal of the reduction unit

Figure 4. Fill oil into the gearbox

4

0630 YRM 2223

0630 YRM 2223

Disassembly of the reduction unit

Disassembly of the reduction unit WARNING Before starting work, ensure that you are wearing suitable protective clothing. Move the truck to a safe place, away from areas of transit of other vehicles and all pedestrians. Set the key switch to OFF and disconnect the battery

WARNING Use caution as the oil in the reduction unit will be hot after use of the truck. It is advisable to wear gloves that are resistant to oil and high temperatures.

Step 1 Remove the reduction unit as described in section: Removal of the reduction unit.

Step 2 Unscrew five long motor screws A and remove them together with respective washers C. Unscrew ten gearbox cover screws B and remove them with respective washers. Remove gearbox end cover D by using notches F located on both sides of the reduction unit. Remove guide pin E (Figure 5).

WARNING Do not dispose of used oil in the ground or by pouring it down the drain. Special companies must be charged with disposal or the recycling of industrial oils.

Figure 5. Gearbox end cover disassembly NOTE: When reassembling install guide pin E first and then the screws (Figure 5).

5

Disassembly of the reduction unit

0630 YRM 2223

Step 3 Remove sealing ring G; this latter should be coated with 3# Lithium grease when being installed to avoid cuts. Remove bearing H, which must be strucked to end cover D (Figure 5) when being diassembled and thus handled with caution. Remove gear I, shaft L, flat key M to recover bearing N, then proceed with its

replacement. Remove nut O which should be removed by prying the rivet opening of the nut first, and be riveted after assembly to avoid loosening during use.

Remove gear P, flat key Q and shaft R. Remove oil seal S and retaining ring T to extract bearings U and V and proceed with the replacement (Figure 6).

Figure 6. Gearbox disassembly NOTE: Before reassembling the gearbox all the components must be cleaned to avoid possible damages. Lubricate the engaging surfaces of the seal

6

with 3# lithium grease. Once the gearbox has been assembled, apply anti-rust oil on the exposed mounted surfaces.

0630 YRM 2223

Braking System

Braking System OPERATION The electromagnetic brake attached to the traction motor is a spring brake. When the electromagnet is powered it attracts the brake plate and unblocks the ferode allowing to turn freely. When the power supply to the electromagnet is cut, the springs push the brake plate down onto the friction disc, thus applying the brake.

BRAKING SYSTEMS There are 4 braking systems used: •

Release braking

•

Braking on direction reversal

•

Emergency braking

•

Service braking

Release braking Release braking is performed by the drive motor and controls the deceleration ramp when the drive control is released.

Braking on direction reversal Controls the deceleration ramp when the travel direction is inverted. “Braking on direction reversal", also know as counter current braking, consists of reversing the current supplied to the motor, thus changing the direction of travel when the truck is in motion. The braking current must be adjusted so that the truck stops in a distance that is at least not less than the length of the truck itself

Figure 7.

Item

Description

1

Gear request release

2

Direction reversal

7

Braking System

8

0630 YRM 2223

0630 YRM 2223

Braking System

Emergency braking

Service braking

Emergency braking occurs when an alarm is triggered that requires an immediate arrest of the truck traction.

The braking action is performed by the electromagnetic brake mounted on the traction motor.

The "service braking" occurs when the tiller sensor is disabled (tiller in rest position or completely lowered).

The braking is operated by traction motor with subsequent engagement of the electromagnetic brake.

9

Removal of the electromagnetic brake

Removal of the electromagnetic brake WARNING Before starting work, ensure that you are equipped with all suitable safety clothing. Move the truck to a safe place, away from the transit areas of other vehicles and pedestrians. Lower the forks to the ground, turn the keyswitch to OFF and disconnect the battery.

Step 1 Disconnect the electrical connection of the brake Step 2 Unscrew the three screws A on the brake. Remove the brake assembly B. Remove jump ring C, shaft sleeve D, and flat key E (Figure 8).

Figure 8. Removal of the brake NOTE: Parts C and E must be kept from loss when disassembling and reused during the reassembling.

10

0630 YRM 2223

0630 YRM 2223

7/21

Maintenance

PERIODIC MAINTENANCE MP16UX [A7T8]

PART NO. 550256733

8000 YRM 2224

Table of Contents

TABLE OF CONTENTS Maintenance Warnings............................................................................................................................................1 Oils and Lubricants..................................................................................................................................................3 Cleaning products................................................................................................................................................... 4 Scheduled Maintenance..........................................................................................................................................5

©2021 Yale Materials Handling Corp.

i

8000 YRM 2224

Maintenance Warnings

Maintenance Warnings WARNINGS •

•

• •

•

•

•

•

•

•

•

If maintenance operations are carried out immediately after the truck is stopped, some components of the motor and of the hydraulic system could be hot. Always wear the personal protective equipment in situations requiring it.

Do not wear any rings, watches, jewellery, loose or hanging items of clothing such as scarves, unbuttoned jackets or tops with open zippers that can get caught up in moving parts.

Never do any cleaning, lubrication or maintenance work with the battery connected.

Never perform any servicing on the machine with persons at the controls, unless they are accredited operators and help with the operation to be performed.

Using compressed air to clean the parts, protect yourself with goggles that have side protection.

The maximum air pressure must not exceed 1 bar.

Never use gasoline, diesel fuel or other flammable liquids such as detergents: instead use non-flammable and non-toxic trade solvents.

Do not accumulate rags soaked in grease or oil: they are a great fire hazard. Always put them away into a closed metal container.

The capacitors in the transistor control unit can keep an electric charge even after disconnecting the battery. To avoid electric shocks and personal injury, discharge the capacitors before inspecting or repairing any component in the electric compartment. Wear safety glasses. Make sure the battery has been disconnected.

Do not file or lubricate the contacts of the contactors. This could cause the contacts to stick and, as a result, loss of control and damage to property or injury to people.

Used oil must be specially collected. It must not be disposed of into normal drainage system pipes. Special companies can be employed to dispose of or recycle industrial oils according to the laws in force in individual countries.

Fluid passing through a very small orifice can be virtually invisible and have sufficient force to penetrate under the skin; in such cases, having to make a check, use a card or a piece of wood.

•

•

•

•

•

•

•

•

Protect the hydraulic system from dirt or contaminants getting inside when checking the fluid level of changing the filter.

Never operate the pump without an adequate quantity of fluid in the hydraulic system.

Operation with low levels of hydraulic fluid will damage the hydraulic pump.

Do not place any tools on the battery. Metal items on the battery can generate accidental short-circuiting and possibly damage or injury.

The batteries generate explosive gases. Keep the vents clean. Keep sparks and flames well away from the battery compartment. Pay attention not to create any sparks when disconnecting the battery cables. Disconnect the battery during maintenance work.

Always use a spreader bar and slings to raise the battery vertically with the specific eyelets.

Do not use chains or slings without a spreader bar, you would risk damaging the battery casing.

Check that the battery compartment is clean and dry. When the battery is in service, the aeration plugs must all be installed. If the aeration plugs are not installed, electrolyte can come out, corroding the battery casing and compartment.

The acid in the electrolyte can cause injury. If the electrolyte gets spilled it should be cleaned up with water. Neutralize the acid with a solution of sodium bicarbonate (soda). Areas of the skin that come into contact with the acid must be rinsed with water immediately. Acid splashed into the eyes must be washed away with water constantly for at least 10 minutes, then call a doctor.

The batteries belong to the counterweight system of the lift truck. When installing a battery that is too small, the lift truck might not have enough weight for the nominal load. When replacing a battery, see the truck identification data plate to check that the battery has the rated capacity and correct dimensions. See “TRUCK AND LOAD CAPACITY IDENTIFICATION DATA” in the “FRAME AND MAIN COMPONENTS” section for the exact battery specifications for the lift truck at issue.

Do not work under a raised fork carriage. Lower the carriage or use a safety chain to prevent the carriage from lowering during maintenance work on the mast and on the lifting chains.

1

Maintenance Warnings •

2

Never repair damaged forks using heat or welding. The forks are made of steel that is hardened with special procedures. Replace damaged forks.

8000 YRM 2224 •

Before servicing the hydraulic system you must eliminate any residual circuit pressure. Close the valves at the end of the maintenance work.

8000 YRM 2224

Oils and Lubricants

Oils and Lubricants OILS AND LUBRICANTS Application

Standard

OIL for lubrication of the HYDRAULIC CIRCUIT

SHELL TELLUS S3 V 46 HYPERBOLIC GEAR OIL 85W-90 (GL-5)

Oil for lubrication of the REDUCTION UNIT Gear lubricant

lithium grease

Pin lubricant

lithium grease

Insulation of BATTERY TERMINALS

Pure Vaseline

OIL QUANTITIES Components

Quantity

Hydraulic circuit

0.75 Liter

Reduction unit

0.60 Liter

3

Cleaning products

8000 YRM 2224

Cleaning products CLEANING OF CASING, PLASTIC COVERS, PLATES, DECALS AND PAINTED PARTS Use only dry air, cloths moistened with water, or cleaning products.

CAUTION Do not use jets of water or steam, a solvent or explosive, oxidizing, flammable, toxic, corrosive and harmful/ irritant product which can damage the truck, plates, decals or that can be dangerous for the operator.

CLEANING OF HYDRAULIC SYSTEM, REDUCTION GEAR AND BEARING SLIDING GUIDES Use degreasing products.

CAUTION Do not use jets of water or steam, a solvent or explosive, oxidizing, flammable, toxic, corrosive and harmful/ irritant product which can damage the truck, plates, decals or that can be dangerous for the operator.

NOTE: To clean the battery, follow the directions on the manual of the battery.

CLEANING OF ENGINES, BRAKING SYSTEM AND ELECTRIC PANEL Use only dry air at low pressure and a clean dry brush.

CAUTION Do not use wet rags, water jets, vapour, solvents or flammable products that may damage the truck or that may be dangerous for the operator.

4

8000 YRM 2224

Scheduled Maintenance

Scheduled Maintenance SCHEDULED MAINTENANCE ● = check and maintenance ■ = operator check

Maintenance intervals

TRUCK FRAME

BRAKING SYSTEM

x = replacement Operation description

After 50 hr (weekly)

Pull the tiller to working position and turn the throttle.

Immediately the operator should hear the sound of the brake release

■

Wipe out dirt and oil on steering gear

■

Brake clearance shall be kept between 0.2 to 0.8 mm

■

After 200 hr (monthly)

After 1200 hr (half a year)

●

●

Overall condition, abnormal condition

●

Horn sound, abnormal or not

●

Truck frame, fasteners, functions, crackings, lubricating condition, fasteners loose or not

■

Connection rod and wheel carriage, functions, crackings, crooking, distortion, lubricating condition

■

STEERING SYSTEM

Forkwheel and forkwheel bearing, wearing condition, replace when hearing the abnormal sound from the bearing, even if properly greased

X

Pull the tiller to working position and turn the throttle.

Immediately the operator should hear the sound of the brake release

■

Operation tiller, degree of tightness and flexibility of steering

■

5

Scheduled Maintenance

8000 YRM 2224

● = check and maintenance ■ = operator check

Maintenance intervals

x = replacement

ELECTRICAL SYSTEM

Operation description

6

After 50 hr (weekly)

After 200 hr (monthly)

Plug, function, damage

■

Key switch, function

■

Contactor, performance and function

■

Inching, function

●

Controller, function

●

Wearing condition of driving motor

●

Wearing condition of lifting motor, carbon brush and commutator

●

Wearing condition of steering motor, carbon brush and commutator

●

Fuse, complete or not

●

Wiring harness and terminal, losse or damaged

●

After 1200 hr (half a year)

Polish uneven contacts with abrasive paper

●

Replace when fail to function well

X

Electrolyte capacity, check liquid level, distilled water

■

■

Electrolyte density, tested value after charging should be 1.28 g/ml

■

■

Clean storage battery, fasten cap, and rinse with tap water

●

Check contactor; polish the rough side of contacts with abrasive paper

●

8000 YRM 2224

Scheduled Maintenance

● = check and maintenance ■ = operator check

Maintenance intervals

x = replacement

REDUCTION GEARBOX

HYDRAULIC SYSTEM

Operation description

After 50 hr (weekly)

After 200 hr (monthly)

Oil pipes leak or not

■

Hydraulic oil, proper amount

■

Lifting oil cylinder, leak or not

■

After 1200 hr (half a year)

Filter cleansing

●

Replace hydraulic oil, check if lifting oil cylinder has leakage; replace sealings when necessary(1)

X

Replace gear oil

X

(1)

Hydraulic oil changed at initial 350 hour interval.

Full inspections on truck can prevent it from faults and shorter service life.

Hours listed in the maintenance procedures is based on the condition that the truck works 8 hours a day and 200 hours a month.

For safe operation, please mantain the truck according to the procedures.

Equalization Charge approximately each month but not more than each week.

7

8000 YRM 2224

7/21