YALE A249 MP20 PALLET TRUCK Service Repair Manual

MP20 (A249) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

FRAME............................................................................................................................

AC MOTOR REPAIR......................................................................................................

MASTER DRIVE UNIT....................................................................................................

STEERING MECHANISM...............................................................................................

BRAKES.........................................................................................................................

HYDRAULIC SYSTEM....................................................................................................

HYDRAULIC CLEANLINESS PROCEDURES...............................................................

AC MOTOR CONTROLLER...........................................................................................

ELECTRICAL SYSTEM..................................................................................................

INDUSTRIAL BATTERY.................................................................................................

LIFTING MECHANISM...................................................................................................

METRIC AND INCH (SAE) FASTENERS.......................................................................

PERIODIC MAINTENANCE............................................................................................

CAPACITIES AND SPECIFICATIONS...........................................................................

DIAGRAMS.....................................................................................................................

550036878 550036879 550036880 550036881 550036882 550036883 550073240 550036884 550036885 524158040 550036886 524150797 550036887 550036888 550036889

0100 YRM 1502 0620 YRM 1513 0630 YRM 1503 1600 YRM 1504 1800 YRM 1505 1900 YRM 1506 1900 YRM 1620 2200 YRM 1507 2200 YRM 1508 2240 YRM 0001 4000 YRM 1509 8000 YRM 0231 8000 YRM 1510 8000 YRM 1511 8000 YRM 1512

04/12 12/13 12/13 12/13 12/13 12/13 12/14 04/14 12/14 09/14 12/13 10/13 04/12 12/13 12/14

PART NO. 550036877 (12/14)

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 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.

i

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.

1

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)

2

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)

3

Battery Specifications

8000 YRM 1511

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)

24

220

5.28

704 mm (27.7 in.)

223 mm (8.78 in.)

627 mm (24.7 in.)

Weight (Max) 212 kg (467 lb)

Table 2. Battery Specifications MPB045VG

4

Voltage

Ampere Hours (Max)

Kilowatt Hours (Max)

Compartment Length (X)

Compartment Width (Y) (Max)

Recommended Height (Max)

24

110

4.58

704 mm (27.7 in.)

153 mm (6.02 in.)

655 mm (25.8 in.)

Weight (Max) OPEN

Thank you very much for your reading.

Please Click Here Then Get More Information.