MP20 (A249)

SERVICE MANUAL CONTENTS

PART YRM REV
SECTION NUMBER NUMBER 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)

 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.
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]

©2013 Yale Materials Handling Corp. i

8000 YRM 1511 Hydraulic System

Hydraulic System
Operating Ampere Lower Time
Relief Setting Lift Time (sec)
Pressure1 Draw2 (sec)
Unit Volts
No Rated No Rated Amp No Rated No Rated
Pressure3
Load Load Load Load Draw Load Load Load Load
MP20, MPB045VG 24 2.07 14.82 MPa 37 100 24.1 MPa 150 2.3 3.1 2.8 1.4
MPa (2150 psi) (3500 psi
(300 )
psi)
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
Fork Length Fork Length Fork Length
Unit
900 mm (35.4 in.) Weight 1000 mm (39.4 in.) Weight 1150 mm (45.2 in.) Weight
MP20, MP035-D and
518 kg (1142 lb) 523 kg (1153 lb) 530 kg (1168 lb)
MP045VG

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 Steering Bearing to MDU Casting (8)
23 N•m (17 lbf ft)
Caster Mounting Capscrews (4 each)
57 N•m (42 lbf ft) Drive Unit to Steering Bearing (8)
23 N•m (17 lbf ft)
Caster Axle Capscrews (2 each)
35 N•m (25 lbf ft) STEERING
Caster Pivot Bolt (1 each) Steer Bracket to MDU (4)
85 N•m (63 lbf ft) 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) Butterfly Throttle Control to Handle (2)
1 N•m (9 lbf in)
Caster Axle Capscrew (1 each)
220 N•m (162 lbf ft) Return Spring Mounting Stud (1)
35 N•m (26 lbf ft)
Caster Support to Frame (2 each)
38 N•m (28 lbf ft) Return Spring to Support Bracket (1)
35 N•m (26 lbf ft)
Caster Shock Absorber Assembly Mounting Cap-
screws (2 each) Control Arm Pivot Pin to Support Bracket (1)
88 N•m (65 lbf ft) 35 N•m (26 lbf ft)

MASTER DRIVE UNIT ELECTRICAL

Motor Mounting Capscrews (4) Brake Assembly to Traction Motor Capscrews (3)
17 N•m (13 lbf ft) 10 N•m (89 lbf in)

Transmission to Frame Mounting Bolts (4) Traction Motor Power Wire Nuts (3)
225 N•m (165 lbf ft) 8 N•m (71 lbf in)

Drive Tire Wheel Lug Nuts (5) Contactor to Control Panel (2)
120 N•m (88 lbf ft) 4 N•m (35 lbf in)

2
8000 YRM 1511 Torque Specifications

Contactor Wire Nuts (2) Rear Fork Pivot Shaft to Fork (2)
8 N•m (71 lbf in) 35 N•m (26 lbf ft)

Controller to Control Panel Nuts (4) Hydraulic Cylinder Gland Nut (1)
14 N•m (124 lbf in) 275 N•m (203 lbf ft)

Power Wires to Controller Capscrews (5) COVERS

14 N•m (124 lbf in)
Battery Tray Mounting Capscrews (4)
Horn to Control Panel (2) 35 N•m (26 lbf ft)
35 N•m (26 lbf ft)
Battery Retainer Capscrew (1)
Control Panel to Frame (5) 35 N•m (26 lbf ft)
35 N•m (26 lbf ft)
Center Top Cover Capscrew (1)
Emergency Stop and Ignition Bracket to Frame 35 N•m (26 lbf ft)
(4)
25 N•m ( lbf ft) Center Main Cover Mounting Nuts (3)
35 N•m (26 lbf ft)
Battery Retainer Capscrew (1)
35 N•m (26 lbf ft) Main Cover Mounting Nuts (2)
35 N•m (26 lbf ft)
LIFT MECHANISM
OPERATOR GUARD
Hydraulic Power Unit Mounting Capscrews (2)
35 N•m (26 lbf ft) Guard Assembly to Frame Capscrews (6)
25.6 N•m (19 lbf ft)
Drive Frame Pivot Shaft to Master Drive Unit As-
sembly (2) Wire Retention Clamp to Guard Assembly Cap-
35 N•m (26 lbf ft) screw (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

Ampere Kilowatt
Compartment Compartment Recommended
Voltage Hours Hours Weight (Max)
Length (X) Width (Y) (Max) Height (Max)
(Max) (Max)
704 mm 223 mm 627 mm (24.7 in.) 212 kg
24 220 5.28
(27.7 in.) (8.78 in.) (467 lb)

Table 2. Battery Specifications MPB045VG

Ampere Kilowatt
Compartment Compartment Recommended
Voltage Hours Hours Weight (Max)
Length (X) Width (Y) (Max) Height (Max)
(Max) (Max)
704 mm 153 mm (6.02 in.) 655 mm OPEN
24 110 4.58
(27.7 in.) (25.8 in.)

4
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.