Yale Material Handling Corporation Pallet Truck MTR-700

WARNING: Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct can create a dangerous operating condition. Do not operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, put a "DO NOT OPERATE"tag on the control handle. Removethe key from the key switch.

WARNING: Disconnect the battery and separate the connector before opening the drive unit compartment cover or inspecting or repairing the electrical system. If a tool causes a short-circuit, the high current flow from the battery can cause an injury or parts damage.

WARNING: The capacitor in the motor controller can hold an electrical charge after the battery is disconnected. To prevent electrical shock and injury, discharge the capacitor before inspecting or repairing any component in the drive unit compartment. Wear safety glasses. Make certain the battery has been disconnected. Use a screwdriver orjumper wire to make a short-circuit across the B+ and B-terminals of the motor controller.

- The current limit adjustment is factory-set at the maximum 400 amps. Increasing the current limit can cause damage to the motor controller or the traction motor and can cause the truck to run at a higher than normal speed, especially when driven unloaded.

Decreasing the current limit can affect the starting torque and can cause the truck to run at less than top speed when fully loaded.The current limit setting should remain at the factory setting. If necessary, turn the current limit adjustment screw clockwise to increase the current limit or counterclockwise to decrease the current limit.

If it is necessary to make any adjustments to the PMC, perform the following steps:

a. Turn the key switch to the OFF position and disconnect the battery cable.

b. Remove the compartment cover and discharge the capacitor.

c. Remove the 3 mm (0.12 in) socket head screws to access the adjustment screws.

Describe any damage found on the tires

Inspect the tread and remove any objects that will cause damage

Describe any objects found in the tread

Smooth any cuts or tears to prevent further damage

Describe any cuts or tears found

Describe any bent or damaged rims found

Check for loose or missing parts

Check the height limit switch for continuity

If there is no continuity, the switch must be replaced.

Make certain the leads are properly identified before they are removed.

Disconnect the leads to the switch

Remove the two capscrews, lockwashers and nuts retaining the switch to the frame.

Align a new switch with the holes in the frame and install the capscrews, lockwashers and nuts.

Connect the leads to the switch.

Test operate the lifting mechanism to determine if the switch is operating properly.

- Hydraulic Tank Fluid Level-Check Level

- Lift and Tilt Cylinders for Leaks and Proper Operation

Visual Inspection, Test and Adjust as Required:

WARNING: Parts of this procedure requires working on the lift truck with full electric current present. Do not wear any rings, watches or other jewelry while working around the contactor panel. Use a properly insulated tool when manually closing a contactor with power connected.

Block the lift truck so that the drive wheels are off the floor. Make certain that the hydraulic controls are in the neutral position.

Remove the drive unit compartment cover.

WARNING: Never operate the traction motor at full speed for more than a few seconds when the drive wheels are off the floor. A series wound DC motor will continue to accelerate indefinitely until it exceeds the designed maximum rpm, at which point it will self-destruct. Personal injury or damage to the lift truck can occur.

Check the condition of the battery. If it is not fully charged, replace the battery with a fully charged battery before continuing.

Visually check to see if the contactor closes when the circuit is energized.

Check the contactor for loose, broken or corroded connections at the contactor.

Check the mechanical function of the contactor. Use an insulated tool, such as an electricians screwdriver, to manually close the contactor tips. Check for looseness or binding of the moving parts of the contactor. The parts should move freely, but should not be loose.

Visually check the tips for pitting, burning or wear.