service repair manual

1. MP20 (A249)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 550036878 0100 YRM 1502 04/12
AC MOTOR REPAIR...................................................................................................... 550036879 0620 YRM 1513 12/13
MASTER DRIVE UNIT.................................................................................................... 550036880 0630 YRM 1503 12/13
STEERING MECHANISM............................................................................................... 550036881 1600 YRM 1504 12/13
BRAKES......................................................................................................................... 550036882 1800 YRM 1505 12/13
HYDRAULIC SYSTEM.................................................................................................... 550036883 1900 YRM 1506 12/13
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
AC MOTOR CONTROLLER........................................................................................... 550036884 2200 YRM 1507 04/14
ELECTRICAL SYSTEM.................................................................................................. 550036885 2200 YRM 1508 12/14
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
LIFTING MECHANISM................................................................................................... 550036886 4000 YRM 1509 12/13
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
PERIODIC MAINTENANCE............................................................................................ 550036887 8000 YRM 1510 04/12
CAPACITIES AND SPECIFICATIONS........................................................................... 550036888 8000 YRM 1511 12/13
DIAGRAMS..................................................................................................................... 550036889 8000 YRM 1512 12/14
PART NO. 550036877 (12/14)

2. SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 con-
tained 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 re-
move 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 man-
ual:
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 back-
ground. The CAUTION symbol and word are on yellow background.

3. ©2013 Yale Materials Handling Corp.
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]
Capacities and Specifications Table of Contents
i

5. Hydraulic System
Unit Volts
Operating
Pressure1
Ampere
Draw2 Relief Setting Lift Time (sec)
Lower Time
(sec)
No
Load
Rated
Load
No
Load
Rated
Load
Pressure3 Amp
Draw
No
Load
Rated
Load
No
Load
Rated
Load
MP20, MPB045VG 24 2.07
MPa
(300
psi)
14.82 MPa
(2150 psi)
37 100 24.1 MPa
(3500 psi
)
150 2.3 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.
8000 YRM 1511 Hydraulic System
1

6. Truck Weights
Unit
Fork Length
900 mm (35.4 in.) Weight
Fork Length
1000 mm (39.4 in.) Weight
Fork Length
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)
Caster Pivot Bolt (1 each)
85 N•m (63 lbf ft)
CASTER ASSEMBLY (DYNAMIC)
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 Cap-
screws (2 each)
88 N•m (65 lbf ft)
MASTER DRIVE UNIT
Motor Mounting Capscrews (4)
17 N•m (13 lbf ft)
Transmission to Frame Mounting Bolts (4)
225 N•m (165 lbf ft)
Drive Tire Wheel Lug Nuts (5)
120 N•m (88 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
Steer Bracket to MDU (4)
19.2 N•m (15 lbf ft)
Steer Handle to Tiller Bracket (2)
27 N•m (20 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)
ELECTRICAL
Brake Assembly to Traction Motor Capscrews (3)
10 N•m (89 lbf in)
Traction Motor Power Wire Nuts (3)
8 N•m (71 lbf in)
Contactor to Control Panel (2)
4 N•m (35 lbf in)
Tires 8000 YRM 1511
2

7. Contactor Wire Nuts (2)
8 N•m (71 lbf in)
Controller to Control Panel Nuts (4)
14 N•m (124 lbf in)
Power Wires to Controller Capscrews (5)
14 N•m (124 lbf in)
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 As-
sembly (2)
35 N•m (26 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)
Rear Fork Pivot Shaft to Fork (2)
35 N•m (26 lbf ft)
Hydraulic Cylinder Gland Nut (1)
275 N•m (203 lbf ft)
COVERS
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 Cap-
screw (1)
52 N•m (38 lbf ft)
8000 YRM 1511 Torque Specifications
3

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9. Battery Specifications
Battery Compartment is shown in Figure 1.
Figure 1. Battery Compartment
Table 1. Battery Specifications MP20
Voltage
Ampere
Hours
(Max)
Kilowatt
Hours
(Max)
Compartment
Length (X)
Compartment
Width (Y) (Max)
Recommended
Height (Max)
Weight (Max)
24 220 5.28
704 mm
(27.7 in.)
223 mm
(8.78 in.)
627 mm (24.7 in.) 212 kg
(467 lb)
Table 2. Battery Specifications MPB045VG
Voltage
Ampere
Hours
(Max)
Kilowatt
Hours
(Max)
Compartment
Length (X)
Compartment
Width (Y) (Max)
Recommended
Height (Max)
Weight (Max)
24 110 4.58
704 mm
(27.7 in.)
153 mm (6.02 in.) 655 mm
(25.8 in.)
OPEN
Battery Specifications 8000 YRM 1511
4