MPB045VG (A245) SERVICE MANUAL CONTENTS SECTION
PART NUMBER
YRM NUMBER
REV DATE
FRAME............................................................................................................................ AC MOTOR REPAIR...................................................................................................... MASTER DRIVE UNIT.................................................................................................... STEERING MECHANISM............................................................................................... BRAKES......................................................................................................................... HYDRAULIC SYSTEM.................................................................................................... ELECTRICAL SYSTEM.................................................................................................. INDUSTRIAL BATTERY................................................................................................. LIFTING MECHANISM................................................................................................... METRIC AND INCH (SAE) FASTENERS....................................................................... CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CONTROLLER DIAGNOSTICS......................................................................................
550093874 550036879 550036880 550036881 550036882 550036883 550036885 524158040 550036886 524150797 550036888 550036889 550093875 550095689
0100 YRM 1665 0620 YRM 1513 0630 YRM 1503 1600 YRM 1504 1800 YRM 1505 1900 YRM 1506 2200 YRM 1508 2240 YRM 0001 4000 YRM 1509 8000 YRM 0231 8000 YRM 1511 8000 YRM 1512 8000 YRM 1666 9000 YRM 1671
12/13 12/13 12/13 12/13 12/13 12/13 12/14 09/14 12/13 10/13 12/13 12/14 12/13 01/15
PART NO. 550093873 (01/15)
Maintenance
CAPACITIES AND SPECIFICATIONS MP20 [A249]; MPB045VG [A245]
PART NO. 550036888
8000 YRM 1511
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •
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The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death. When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. Keep the unit clean and the working area clean and orderly. Use the correct tools for the job. Keep the tools clean and in good condition. Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:
WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.
Capacities and Specifications
Table of Contents
TABLE OF CONTENTS Hydraulic System ......................................................................................................................................................1 Hydraulic Oils ............................................................................................................................................................1 Grease ...................................................................................................................................................................... 1 Truck Weights ...........................................................................................................................................................2 Tires ..........................................................................................................................................................................2 Torque Specifications ............................................................................................................................................... 2 Caster Assembly .................................................................................................................................................. 2 Caster Assembly (Dynamic) ................................................................................................................................. 2 Master Drive Unit ..................................................................................................................................................2 Steering ................................................................................................................................................................ 2 Electrical ............................................................................................................................................................... 2 Lift Mechanism ..................................................................................................................................................... 3 Covers .................................................................................................................................................................. 3 Operator Guard .................................................................................................................................................... 3 Battery Specifications ............................................................................................................................................... 4 This section is for the following models: (MP20) [A249]; (MPB045VG) [A245]
Š2013 Yale Materials Handling Corp.
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8000 YRM 1511
Hydraulic System
Hydraulic System Unit
Volts
MP20, MPB045VG
24
Operating Pressure1 No Load
Ampere Draw2
Rated Load
Relief Setting
Lift Time (sec)
No Rated Amp Pressure3 Load Load Draw
2.07 14.82 MPa MPa (2150 psi) (300 psi)
37
100
24.1 MPa (3500 psi )
150
No Load 2.3
Lower Time (sec)
Rated No Rated Load Load Load 3.1
2.8
1.4
Standard Specifications Hydraulic Tank Capacity - 1.0 liter (1.06 qt) Pump Displacement (24 Volts) 1.25 cm3/rev (0.076 in.3/rev) Creep Rate - 6.4 mm (0.25 in.) Maximum In 10 Minutes @ 32°C (90°F) Oil Temperature Footnotes 1 ±0.35 MPa (±51 psi) @ 21°C (70°F) Oil Temperature 2 ±10 Amps @ 1.270 Battery Specific Gravity 3 +0.6 to 0.0 MPa (+87 to 0 psi) @ 32°C (90°F) Oil Temperature Full Flow
Hydraulic Oils Operating Condition
Standard
CS/Freezer
Truck Temperature Range
0 to −84°C (32 to −120°F)
−18 to −84°C (0 to −120°F)
For All Hydraulically Actuated Equipment Specification
ISO VG 46 Antiwear (HCE-140)
Exxon Univis® HVI 26
Pour Point Maximum
−15°C (5.0°F)
−60°C (−76.0°F)
Field Personnel Note: The product listed above is the approved source that meets or exceeds Yale specifications. The use of products other than that listed above is unauthorized.
Grease Fittings and Bearings Application
Standard/CS/Freezer
Steer Bearings
Approved Vendor
Mobilgrease 28
Amsoil GHD®
Oil
Synthetic
Synthetic
Thickener
Clay
Lithium Complex
Grade NGLI
1.5
2.0
Moly-Fortified
No
Yes
Dropping Pt.
310°C (590°F)
288°C (550°F)
®
Field Personnel Note: The product listed above is the approved source that meets or exceeds Yale specifications. The use of products other than that listed above is unauthorized.
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Tires
8000 YRM 1511
Truck Weights Unit
Fork Length Fork Length Fork Length 900 mm (35.4 in.) Weight 1000 mm (39.4 in.) Weight 1150 mm (45.2 in.) Weight
MP20, MP035-D and MP045VG
518 kg (1142 lb)
523 kg (1153 lb)
530 kg (1168 lb)
Tires Unit
Size
Item
Torque
MP20
230 mm × 84 mm
Wheel Lug Nut
120 N•m (88 lbf ft)
MPB045VG
254mm x 102mm
Wheel Lug Nut
120 N•m (88 lbf ft)
Torque Specifications CASTER ASSEMBLY Caster Mounting Capscrews (4 each) 57 N•m (42 lbf ft) Caster Axle Capscrews (2 each) 35 N•m (25 lbf ft)
Steering Bearing to MDU Casting (8) 23 N•m (17 lbf ft) Drive Unit to Steering Bearing (8) 23 N•m (17 lbf ft)
STEERING
Caster Pivot Bolt (1 each) 85 N•m (63 lbf ft)
Steer Bracket to MDU (4) 19.2 N•m (15 lbf ft)
CASTER ASSEMBLY (DYNAMIC)
Steer Handle to Tiller Bracket (2) 27 N•m (20 lbf ft)
Caster Mounting Capscrews (4 each) 38 N•m (28 lbf ft) Caster Axle Capscrew (1 each) 220 N•m (162 lbf ft) Caster Support to Frame (2 each) 38 N•m (28 lbf ft) Caster Shock Absorber Assembly Mounting Capscrews (2 each) 88 N•m (65 lbf ft)
Butterfly Throttle Control to Handle (2) 1 N•m (9 lbf in) Return Spring Mounting Stud (1) 35 N•m (26 lbf ft) Return Spring to Support Bracket (1) 35 N•m (26 lbf ft) Control Arm Pivot Pin to Support Bracket (1) 35 N•m (26 lbf ft)
MASTER DRIVE UNIT
ELECTRICAL
Motor Mounting Capscrews (4) 17 N•m (13 lbf ft)
Brake Assembly to Traction Motor Capscrews (3) 10 N•m (89 lbf in)
Transmission to Frame Mounting Bolts (4) 225 N•m (165 lbf ft)
Traction Motor Power Wire Nuts (3) 8 N•m (71 lbf in)
Drive Tire Wheel Lug Nuts (5) 120 N•m (88 lbf ft)
Contactor to Control Panel (2) 4 N•m (35 lbf in)
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8000 YRM 1511
Torque Specifications
Contactor Wire Nuts (2) 8 N•m (71 lbf in)
Rear Fork Pivot Shaft to Fork (2) 35 N•m (26 lbf ft)
Controller to Control Panel Nuts (4) 14 N•m (124 lbf in)
Hydraulic Cylinder Gland Nut (1) 275 N•m (203 lbf ft)
Power Wires to Controller Capscrews (5) 14 N•m (124 lbf in)
COVERS
Horn to Control Panel (2) 35 N•m (26 lbf ft) Control Panel to Frame (5) 35 N•m (26 lbf ft) Emergency Stop and Ignition Bracket to Frame (4) 25 N•m ( lbf ft) Battery Retainer Capscrew (1) 35 N•m (26 lbf ft)
LIFT MECHANISM Hydraulic Power Unit Mounting Capscrews (2) 35 N•m (26 lbf ft) Drive Frame Pivot Shaft to Master Drive Unit Assembly (2) 35 N•m (26 lbf ft)
Battery Tray Mounting Capscrews (4) 35 N•m (26 lbf ft) Battery Retainer Capscrew (1) 35 N•m (26 lbf ft) Center Top Cover Capscrew (1) 35 N•m (26 lbf ft) Center Main Cover Mounting Nuts (3) 35 N•m (26 lbf ft) Main Cover Mounting Nuts (2) 35 N•m (26 lbf ft)
OPERATOR GUARD Guard Assembly to Frame Capscrews (6) 25.6 N•m (19 lbf ft) Wire Retention Clamp to Guard Assembly Capscrew (1) 52 N•m (38 lbf ft)
Front Fork Frame Pivot Shaft to Fork (2) 35 N•m (26 lbf ft) Pull Rod Pivot Shaft to Rocker Assembly (2) 35 N•m (26 lbf ft)
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