Yale MTC15 Forklift A869 Service Repair Manual

S.N: A869
Yale Model: MTC15

Section: TRUCK INSTALLATION

1.0 INTRODUCTION
1.1 VNA INSTALATION
1.2 VNA UNPACKING AND SET UP
1.3 VNA DELIVERY
2.0 VNA REMOVAL FROM CONTAINER / TRUCK
3.0 VNA STAND UP PROCEDURE
4.0 LOWER CAB AFTER STAND UP
5.0 INSTALLATION OF ATTACHMENT
6.0 ADD OIL TO HYDRAULIC TANK
7.0.A BATTERY INSTALLATION US: NTA030SA – NTA040SA EU: MTC10, MTC13, MTC15
7.0.B BATTERY INSTALLATION – US: NTA040DA EU: MTC18
8.0 INSTALLATION IN AISLE
8.1 LOAD UNIT DEPOSIT ADJUSTMENT
8.2 IMPORTANT (GUIDE ROLLERS / WIRE GUIDANCE)
9.0 OPERATOR TRAINING

Section: ELECTRICAL SYSTEM

1.0 ELECTRICAL COMPARTMENT ARRANGEMENT MODELS NTA030SA – NTA040SA-MTC10 – MTC13 – MTC15
1.0.1 ELECTRICAL COMPARTMENT ARRANGEMENT MODELS NTA040DA- MTC18
1.1 DESCRIPTION OF COMPONENTS
1.1.1 PHOTOCELLS
1.1.1A PHOTOCELL ADJUSTMENT
1.1.1B MALFUNCTION CAUSED BY INCORRECT ADJUSTMENT
1.1.2 THROTTLE ASSEMBLY
1.1.3 BATTERY DISCHARGE INDICATOR (BDI)
1.1.3A LOCK OUT LEVEL ADJUSTMENT
1.1.3B BDI TROUBLESHOOTING
1.1.4 DC / DC CONVERTER
1.2 TABLE OF ELECTRICALSYSTEM COMPONENTS
2.0 TRACTION MOTOR ELECTRONIC CONTROL
2.0.1 INTRODUCTION
2.1 DEFINITION OF THE TRUCK DIRECTION OF TRAVEL
2.2 CONTROLLER GENERAL FEATURES
2.3 CONTROLLER FUNCTIONAL FEATURES
2.4 CONTROLLER DIAGNOSTICS
2.5 CHOPPER H2B MECHANICAL DIAGRAM
2.6 CONNECTORS
2.7 CONNECTOR INCONNECTOR °E° INPUT DESCRIPTION
2.9 BASIC DIAGRAM OF THE TRACTION CONTROLLER CONNECTIONS
3.0 HAND SET
3.0.1 INTRODUCTION
3.2 USE OF THE HAND SET
3.2.1 CONNECTION TO CONTROLLER
4.0 CONSOLE FUNCTION CHART – TRACTION MOTOR CONTROLLER
4.1 CONTROLLER PROGRAMMING
4.1.0 CONFIGURATION MENU
4.2 CONFIGURATION TABLES FOR TRACTION CONTROLLER
4.3 PROGRAMMING LEVELS CORRESPONDENCE TABLE
4.4 SET UP OF A NEW CONTROLLER BEFORE OPERATION
5.0 TROUBLESHOOTING
5.1 DECODING DIAGNOSTIC LED ALARM CODES FOR TRACTION CONTROLLER
5.2 DECODING HAND SET ALARMS FOR TRACTION CONTROLLER
6.0 PUMP MOTOR CONTROLLER – DESCRIPTION
6.1 CONTROLLER FUNCTIONAL FEATURES
6.2 PUMP MOTOR CONTROLLER CIRCUIT
6.3 PUMP MOTOR CONTROLLER CONNECTORS
6.4 CONNECTOR INPUT DESCRIPTIONS (EXCEPT E)
6.5 CONNECTOR °E° INPUT DESCRIPTION
6.6.A CONSOLE FUNCTION CHART – PUMP MOTOR CONTROLLER
6.6 HAND SET PROGRAMMING OF THE PUMP MOTOR CONTROLLER
6.6.1 CONFIGURATION MENU
6.7 CONFIGURATION TABLE – PUMP MOTOR CONTROLLER
6.8 PARAMETER VALUE VERSUS PROGRAMMED LEVEL TABLE
6.14 TROUBLESHOOTING
6.14.1 DECODING DIAGNOSTIC LED ALARM CODES FOR PUMP CONTROLLER
6.14.2 DECODING HAND SET ALARMS FOR PUMP MOTOR CONTROLLER
7.0 CONFIGURATION TABLES – EPS ELECTRIC POWER STEERING CONTROLLER
7.1 EPS CONFIGURATION WITH SMART STEER (POT) STEERING
7.2 EPS CONFIGURATION WITH TACHO GENERATOR STEERING.

Section: PLC

1.0 STANDARD INTERLOCK FUNCTIONS
2.0 ENABLE FUNCTION MANAGEMENT
2.1 DESCRIPTION OF THE SYSTEM THAT RUNS THE ENABLES PLC (PROGRAMMABLE LOGIC CONTROLLER)
2.2 GENERAL CHARACTERISTICS
3.0 PROGRAMMING
4.0 ELECTRIC ADJUSTMENT OF THE CAB AND AUXILIARY MAST LOWERING PROPORTIONAL
ELECTRO-HYDRAULIC VALVES
5.0 PLC DIGITAL INPUT / OUTPUT REFERENCE EU / US VERSIONS
5.1.A PLC TRUTH TABLE AND INTERFACE RELAY BOARD (US VERSION ONLY)
5.1.B PLC TRUTH TABLE AND INTERFACE RELAY BOARD (EU VERSION ONLY)
6.0 REMOVING/INSTALLING THE PLC
7.0 PLC BATTERY FUNCTION AND CHANGING
8.2 PROCEDURE FOR CHANGING FUSES

Section: DIAGNOSTICS

CAB DOES NOT LOWER
FORKS DO NOT EXTEND LEFT
FORKS DO NOT EXTEND RIGHT
FORKS DO NOT LOWER
FORKS DO NOT RAISE
FORKS DO NOT RETRACT FROM LEFT
FORKS DO NOT RETRACT FROM RIGHT
FORKS DO NOT ROTATE LEFT
FORKS DO NOT ROTATE RIGHT
HIGH TEMPERATURE
MINI MAST DOES NOTTRAVERSE LEFT
MINI MAST DOES NOTTRAVERSE RIGHT
SYNC CAB / FORKS DO NOT LOWER
SYNC TRAVERSE / ROTATE DOES NOTWORK
TRUCK DOES NOT TRAVEL .

Section: SLOW DOWN / STOP

1.0 AUTOMATIC SLOW DOWN AND STOP SYSTEM DESCRIPTION
1.1 MAGNET INSTALLATION IN AISLE
1.1.1 MAGNET LAYOUT FOR SYSTEMS WITH 2 MAGNETS IN AISLE
1.1.2 MAGNET LAYOUT FOR SYSTEMS WITH 4 MAGNETS IN AISLE
2.0 SYSTEM DESCRIPTIONS
2.1 (US) END OF AISLE AUTO-BRAKING
2.2 (EU) END OF AISLE AUTO-BRAKING
2.3 SLOW DOWN / STOP (SET / RESET)
3.0 SYSTEM FUNCTIONS (WITH STANDARD PLC PROGRAM)
3.1 SYSTEMS WITH 2 MAGNETS IN AISLE
3.2 SYSTEMS WITH 4 MAGNETS IN AISLE
4.0 TROUBLESHOOTING

Section:HYDRAULIC SYSTEM

1.0 GENERAL DESCRIPTION
1.1 HYDRAULIC SYSTEM SYMBOL LEGEND
FUNCTIONAL HYDRAULIC DIAGRAM
HYDRAULIC SYSTEM COMPONENTS
1.2 TABLE OF HYDRAULIC SYSTEM COMPONENTS
1.3 FLOW CONTROL AND HOSE BREAK VALVES
1.4 COMPONENT ACTUATION TABLE: PUMPS AND ELECTRO-SOLENOIDS
1.4.1 HYDRAULIC SYSTEM FUNCTIONAL LAYOUT
2.1 MAIN HYDRAULIC VALVE ASSEMBLY
2.1.0 MAIN HYDRAULIC VALVE ASSEMBLY COMPONENTS
2.2 CAB LIFT PRESSURE RELIEF VALVE ADJUSTMENT
2.3 ADJUSTING THE CAB LOWER PROPORTIONAL VALVE
2.3.1 EMERGENCY LOWER SCREW
2.4 TROUBLE-SHOOTING
3.1 AUXILIARY MAST/ATTACHMENT VALVE ASSEMBLY
3.1.0 AUXILIARY MAST/ATTACHMENT VALVE COMPONENT TABLE
3.2 AUXILIARY MAST/ATTACHMENT VALVE MAIN PRESSURE RELIEF ADJUSTMENT
3.3 ADJUSTING AUXILIARY MAST LOWER PROPORTIONAL VALVE
3.4 TROUBLE-SHOOTING
4.1 CAB LIFT CYLINDER EXPLODED DRAWING NTA030SA – MTC10 – MTC13 (2 STAGE MAST)
4.2 CAB LIFT CYLINDER TABLE OF COMPONENTS FOR NTA030SA – MTC10 – MTC13
5.1 CAB LIFT CYLINDER EXPLODED DRAWING NTA030SA – MTC10 – MTC13 (3 STAGE MAST)
5.2 CAB LIFT CYLINDER TABLE OF COMPONENTS FOR NTA030SA – MTC10 – MTC13
6.1 CAB LIFT CYLINDER EXPLODED DRAWING NTA040SA – NTA040DA – MTC15 – MTC18 (2 STAGE MAST)
6.2 CAB LIFT CYLINDER TABLE OF COMPONENTS FOR NTA040SA – NTA040DA – MTC15 – MTC18
7.1 CAB LIFT CYLINDER EXPLODED DRAWING NTA040SA – NTA040DA – MTC15 – MTC18 (3 STAGE MAST)
7.2 CAB LIFT CYLINDER TABLE OF COMPONENTS FOR NTA040SA – NTA040DA – MTC15 – MTC18
8.1 DISSASSEMBLING THE MAIN LIFT CYLINDERS
8.2 CHANGING THE SEALS
8.3 INSTALLING THE MAIN LIFTCYLINDERS ON THE MACHINE
8.4 BLEEDING THE AIR FROM THE MAIN HOIST CYLINDER
9.1 AUXILIARY MAST LIFT CYLINDER EXPLODED DRAWING
9.2 AUXILIARY MAST LIFT CYLINDER PART TABLE FOR
10.1 DISMANTLING AUXILIARY MAST LIFT CYLINDER
10.2 CHANGING THE SEALS
10.3 REASSEMBLING THE AUXILIARY MAST LIFT CYLINDER
10.4 BLEEDING THE AIR FROM THE AUXILIARY MAST LIFTCYLINDER

Section: ATTACHMENT

1.1 ATTACHMENT COMPONENTS
1.2 ATTACHMENT COMPONENT TABLE
2.1 TRILATERAL ATTACHMENT FUNCTIONING
3.1 TRUCK INSTALLATION
3.1.1 ATTACHMENT ASSEMBLY PROCEDURES
4.1 MECHANIC ADJUSTMENT OF THE ATTACHMENT SUPPORT BEARINGS
5.1 MECHANIC STROKE END ADJUSTMENT
5.2 ROTATING MECHANIC STROKE END AND CAMS
5.3 TRASLATION SPEED REDUCER MICROSWITCH
6.1 MECHANICAL ADJUSTMENTS OF THE LOAD HANDLER BEARINGS
7.1 MAINTENANCE
8.1 TROUBLESHOOTING

Section: MAST

1.1 REMOVING THE CAB FROM THE MAST
1.0 MAST REMOVAL PROCEDURE
MOD. EU MTC10 – MTC13 – MTC15 – MTC18
MOD. US NTA030SA – NTA040SA- NTA040DA
2.0 REMOVING THE CYLINDERS
MOD. EU MTC10 – MTC13 – MTC15
MOD. US NTA030SA – NTA040SA
2.1 REMOVING THE MAST
MOD. EU MTC10 – MTC13 – MTC15
MOD. US NTA030SA – NTA040SA
3.0 REMOVING THE BOTTOM GUIDE BEARING OF THE INNER MAST SECTION
MOD. EU MTC10 – MTC13
MOD. US NTA030SA
4.0 REMOVING THE ROLLERS FROM THE CAB AND INNER TELESCOPING SECTION
MOD. EU MTC15 – MTC18
MOD. US NTA040SA – NTA040DA
5.0 REMOVING SIDE ROLLERS FROM THE MAST
MOD. EU MTC15 – MTC18
MOD. US NTA040SA – NTA040DA

Section: BILATERAL EQUIPMENT

1.0 DESCRIPTION OF EQUIPMENT
1.0.1 COMPOSITION
1.0.2 TELESCOPING ACTION
1.1 TOP TELESCOPING SECTION OR LOAD PLATFORM
1.2 INTERMEDIATE TELESCOPING SECTION
1.3 TELESCOPING SECTION SUPPORT
1.4 TELESCOPING ASSEMBLY
1.5 TABLE OF COMPONENTS
2.0 MAINTENANCE
2.0.1 HOW TO DISMANTLE THE EQUIPMENT
2.0.2 TIGHTENING TORQUES
2.0.3 PRECAUTIONS WHEN USING MAINTENANCE PRODUCTS
2.0.4 COMPONENTS REQUIRING MAINTENANCE
2.0.5 ROUTINE MAINTENANCE OPERATIONS
2.0.6 ITEMS NOT REQUIRING RELUBRICATION
2.0.7 SYMBOLS
2.0.8 FAULT-FINDING AND REMEDIES
3.0 REMOVING THE VARIOUS SECTORS
4.0 DISASSEMBLING EQUIPMENT
5.0 REMOVALPROCEDURE

Section: WHEELS

1.0 REMOVING THE LOAD WHEELS
2.0 REMOVING THE DRIVE WHEELS MOD. US – NTA030SA – NTA040SA4 EU – MTC10 (EU ONLY) – MTC13 – MTC15
3.0 REMOVING THE DRIVE WHEELS MOD. US – NTA040DA EU – MTC18 .

Section: BRAKING SYSTEM

1.0 BRAKING SYSTEMS DESCRIPTION
2.0 REMOVAL AND ADJUSTMENTOF THE ELECTROMAGNETIC BRAKE
3.0 ADJUSTMENT AND PUTTING INTO SERVICE

Section: TRANSMISSION

1.1 DISMANTLING THE TRANSMISSION FROM THE TRUCK
US – NTA030SA – NTA040SA EU – MTC10 (EU ONLY) – MTC13 – MTC15
1.2 INTRODUCTION
1.3 DISMANTLING THE CONNECTIONS
1.4 CHAIN
1.5 REMOVING THE TRANSMISSION UNIT
1.6 TRANSMISSION OIL
1.7 REMOVING THE MOTOR
1.7A REMOVING THE PLATE
1.8 DISMANTLING THE CHAIN
1.9 DISMANTLING THE WHEEL
2.0 DISMANTLING THE TRANSMISSION FROM THE TRUCK MOD. NTA040DA- MTC18
3.0 GENERAL INFORMATION NTA030SA – NTA040SA – MTC10 – MTC13 – MTC15
3.1 TRANSMISSION COMPONENTS
3.2 CONSUMABLE GOODS
3.4 STANDARD TOOLS AND FIXTURES
4.0 DISASSEMBLY
4.1 INTRODUCTION
4.2 REMOVAL AND DISASSEMBLY OF THE TRANSMISSION HOUSING UPPER PART
4.3 REMOVING OF THE TRANSMISSION COVER
4.4 DISMANTLING THE CROWN GEAR AND WHEEL SHAFT
4.5 REMOVING THE TAPER ROLLER BEARING INNER RACE FROM THE WHEEL SHAFT AND CROWN GEAR
4.6 DISASSEMBLY OF THE PINION SHAFT
4.7 DISASSEMBLY OF THE TAPER ROLLER BEARING OUTER RACE FROM THE TRANSMISSION HOUSING
4.8 REMOVING THE THREAD PROTECTIVE SHIELD
5.0 ASSEMBLY
5.1 INTRODUCTION
5.2 MEASURING THE ASSEMBLY DIMENSIONOF THE PINION SHAFT
5.3 PRE-ASSEMBLY OF THE TRANSMISSION HOUSING
5.4 PRE-ASSEMBLY OF THE WHEEL SHAFT
5.5 MOUNTING THE TAPER ROLLER BEARING INNER RACE ON THE CROWN GEAR
5.6 PRE-ASSEMBLY OF THE PINION SHAFT
5.7 MOUNTING THE PINION SHAFT IN THE TRANSMISSION HOUSING
5.8 MEASURING THE BEARING CLEARANCE OF THE PINION SHAFT AND ADJUSTING THE PRE-STRESS
5.9 MOUNTING THE WHEEL SHAFT AND THE CROWN GEAR ON THE TRANSMISSION HOUSING
5.10 MEASURING AND ADJUSTING THE CROWN GEAR CIRCUMFERENTIAL BACKLASH
5.11 CHECKING THE TOOTH PATTERN
5.12 MEASURING THE WHEEL SHAFT BEARING CLEARANCE AND ADJUSTING THE BEARING PRE-STRESS
5.13 MOUNTING THE THREAD PROTECTIVE SHIELD IN THE TRANSMISSION HOUSING
5.14 MOUNTING THE RADIAL SHAFT SEAL IN THE TRANSMISSION HOUSING
5.15 MOUNTING THE HOUSING COVER
5.16 TRANSMISSION UPPER PART
6.0 ADJUSTMENT DATA
6.1 TIGHTENING TORQUE
7.0 TROUBLESHOOTING
8.0 STORAGE
8.1 DECOMMISSIONING