Yale MR Series Retractable Truck Service Manual – MR14 MR16 MR20 MR25 PDF

Description

The Yale MR Series Retractable Truck Service Manual is the workshop reference written for the MR family of retractable mast trucks. If you maintain, diagnose or repair an MR14, MR16, MR16N, MR20, MR25, MR16HD or MR20HD, this is the document the Yale service network uses as the guideline for correct maintenance of the truck. It is not the operator manual – it is the supplement to it, written for trained technicians.

File Details

• Manual type: Service Manual (Service Information)
• Brand: Yale
• Models covered: MR14, MR16, MR16N, MR20, MR25, MR16HD, MR20HD
• Language: English
• Page count: Approximately 376 pages
• File format: PDF
• Document number: 550066261
• Revision: 0 (01/2014)
• Manufacturer: Yale Europe, Centennial House, Frimley Business Park, Frimley, Surrey GU16 7SG, United Kingdom – Made in Italy

Chapters Covered

The manual is organised into eleven numbered sections, each starting with a black section band for fast navigation:

• Section 1 – Presentation: views of the truck, truck and load identification data, truck identification data plate, residual load plate, mast serial number punching and documentation location, general specifications, batteries table
• Section 2 – Installation and settings: weight tables, truck assembly, list of materials received from the dealer, unloading off the truck and fitting the mast to the truck base, topping up the oil reservoir, installation of the battery (vertical and lateral removal), assembly of moving forks, contrasting roller assembly, list of settings and adjustments, setting the ACE2 Traction and ACE2 Pump module battery voltages, checking conditions of use, checking contrasting aisle roller movement, enabling and programming the level pre-selector, middle fork lifting blocks and password
• Section 3 – Diagnostics and measurements: ACE2 Traction module, ACE2 Pump module, EPS ACW module, Master Control Card Premium module, tester menu, breakdown search, warning memorization, ACE2 pump and traction module diagnosis system and alarms, VCM module diagnosis system, VCM master and slave module alarm analysis and troubleshooting, EPS ACW module diagnosis system and alarm analysis
• Section 4 – Electrical system: electrical wiring diagrams, component reference tables, module introduction, PC Tool connector positioning, ACE2 inverter module, EPS ACW module, VCM module, module replacement instructions, removal of electrical components (encoder, reset sensor, load cell, horn, contactors, fuses, cooling fan, armrest and main panel controls, side shift position sensor, pallet presence sensor, tilt position sensor, 90 degree wheel sensor, steyed wheel sensor, battery out sensor, pedals, operator presence pedal, accelerator and brake pedals), configuration parameters, module parameters, module number identification
• Section 5 – Hydraulic system: hydraulic functions, hydraulic diagrams and symbols, main hydraulic diagram, function diagrams (fork lifting, fork lowering, retractable carriage out/in, fork tilt up/down, fork left/right side shift, emergency lowering, oil return through pressure relief valve), solenoid valve operation chart, hydraulic components and distributor identification, distributor dismantling and gasket replacement, removal and calibration of the pressure relief valve, cartridge solenoid valves, cylinders (single acting, central lift, side lift, retractable carriage, fork tilt, fork side shift), cylinder dismantling and air bleeding, lift pump dismantling and replacement, hydraulic pipes
• Section 6 – Truck base mechanics: wheels and tyres, traction wheel components, removal of the drive wheel, load wheel components and removal, battery block renewal, motors (traction motor components and removal, traction motor bearings replacement, steering motor components, disassembly and dismantling, steering system assembly), retractable carriage components and removal, bearings and pin renewal, retractable carriage potentiometer removal
• Section 7 – Mast assembly mechanics: mast characteristics, mast elevation, 3 stage mast components, bearing replacement, chain and chain tensioner replacement, middle section chain sheaves, middle cylinder chain sheave
• Section 8 – Small fork mast mechanics: fork carriage components, removal of the fork carriage, removal of the sliding blocks, bearing replacement
• Section 9 – Reduction gear: key to reduction unit components, removal of the reduction unit, replacement of the traction motor drive shaft radial O-ring, replacement of the wheel shaft radial O-ring, changing the reduction unit oil
• Section 10 – Braking system: traction motor electromagnetic brake components, load wheel electromagnetic brake components, operation of each braking system, braking systems (release braking, braking on direction reversal, emergency braking, parking brake), removal of the drive wheel electromagnetic brake and load wheel electromagnetic brake
• Section 11 – Standard maintenance: oils and lubricants, cleaning products, scheduled maintenance tables, maintenance procedures (frame, cab, roof assembly, outrigger height check, chain check, fork check), greasing points

Beyond the section index, the manual includes the general safety rules that apply to all work on the truck, the correct method for applying female fittings (with and without gaskets, O-ring fittings, UNF, metric revolving female, JIC 37 degree, ORFS, BSP), torque settings for screws, nuts and fittings (Class 5.8, 8.8 and 10.9), belt, rope and suspension element capacity tables and advice for use, and instructions for installing flexible hoses and fittings. Those preambles set the standard for every procedure that follows inside the technical sections.

What a Technician Can Do With This Yale MR Series Service Manual

The content of this manual was clearly written for people who have to make decisions on a live truck – not for somebody flicking through a brochure. The electrical system is documented down to wiring diagrams with connector pin numbers, control module pin-out tables for the VCM, ACE2 Traction, ACE2 Pump and EPS ACW modules, tester menu readings, diagnostic alarm codes and the troubleshooting steps behind each code. That is the material you need when an alarm stops the machine and you have to decide whether the fault sits in the module, the harness or a sensor.

The hydraulic side is equally complete. The main hydraulic diagram and the individual function diagrams show exactly which solenoid valve coil is energised in each operation – fork lifting, lowering, retractable carriage out and in, fork tilt up and down, and left and right side shift. The solenoid valve operation chart condenses all of that into one grid. Pressure relief valve removal and calibration are covered, as are the cartridge solenoid valves and every cylinder on the truck.

Mechanical coverage matches that depth. Wheels and tyres, the traction motor, the steering motor, the reduction unit and its oil change, the retractable carriage, the three stage mast, the small fork mast and the braking system all have their own dismantling, replacement and reassembly procedures with component identification keys. Torque values appear throughout, from the 88-97 Nm on the mast side blocks to the 300-330 Nm on the mast-to-base fasteners and the 22 Nm on the reduction unit drain and filler plugs.

Diagnostics and Alarm Troubleshooting

A large part of the manual is dedicated to the diagnosis systems. Section 3 lists the alarms that each module can raise, what each alarm means, the effect on the truck, the state of the truck when it appears, and the re-start procedure. For the ACE2 pump and traction modules, for example, the manual walks through Watchdog, EEPROM KO, Logic Failure #1, #2 and #3, VMN Low, VMN High, Contactor Closed, Contactor Open, Capacitor Charge, Thermal Protection, Motor Temperature, Battery Low, Driver Shorted, Contactor Driver, VACC NOT OK, Incorrect Start, Forward + Backward, Encoder Error, and many more – each with a description, cause and troubleshooting guidance. The VCM master and slave modules and the EPS ACW module get the same treatment, so a single alarm code can usually be narrowed down before any component is touched.

Coverage Across the MR Series

The general specifications section lists the individual values for each model – load capacity, load centre of gravity, load distance from load wheel axle to forks, wheelbase, weight with no load, axle loads with and without load, tyre type and wheel sizes, mast tilt, closed mast height, free lift, lifting height, extended mast height, protective roof height, seat height, total length, overall width, fork dimensions, fork carriage class, retractable travel, ground clearances, working aisle dimensions and turning radius. Battery tables cover the different capacity options from 48/420 up to 48/930, along with their weights. Mast assemblies are tabulated by total auxiliary lift, free lift, lowered height and extended dimensions with their weight for each height option from 4650 mm up to 12763 mm on the HD models. Because the tables are model-specific, the same manual is usable across the entire MR Series.

Why This Manual Matters

Retractable trucks are complex machines. Traction, steering and pump functions are all managed by separate AC controllers communicating over two CAN-Bus lines, and the hydraulic system uses proportional solenoid valves with current-controlled outputs. Guessing at a fault, or re-torquing a mast fastener at the wrong setting, can damage components or put an operator at risk. The manual gives the factory figures – torque settings, calibration procedures, alarm definitions, parameter values, oil specifications and service intervals – so the work is done correctly the first time. The oils and lubricants table lists the exact products and types for standard and cold store operation, and the scheduled maintenance tables lay out the intervals for each task at every 8 hours, 1000 hours, 3000 hours and 5000 hours.

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Instant PDF Delivery

The manual is delivered as a PDF file, available for download immediately after checkout. There is no shipping and no waiting. It can be opened on a laptop, tablet or phone, and any page can be printed and taken to the truck if you prefer to work from paper. The file is the Yale MR Series Retractable Truck Service Manual, document 550066261, Revision 0 dated 01/2014 – the same publication the service network uses as its guideline for correct maintenance of the MR14, MR16, MR16N, MR20, MR25, MR16HD and MR20HD.