Yale Forklift A245 (MPB045VG) Service Manual – PDF DOWNLOAD

Description

Yale Forklift A245 (MPB045VG) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A245 (MPB045VG) Service Manual – PDF DOWNLOAD

Language : English
Pages : 518
Downloadable : Yes
File Type : PDF
PART NO. 524150797

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A245 (MPB045VG) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524158040-2240YRM0001-(01-2023)-US-EN 43
General 49
Battery Type 49
Lead-Acid Batteries 49
Lithium-Ion Batteries 50
Specific Gravity 50
Chemical Reaction in a Cell 50
Electrical Terms 52
Battery Selection 53
Battery Voltage 54
Battery as a Counterweight 54
Battery Ratings 54
Kilowatt-Hours 54
Battery Maintenance 55
Safety Procedures 55
Maintenance Records 55
New Battery 55
Cleaning Battery 56
Adding Water to Battery 58
Hydrometer 58
Battery Temperature 59
Charging Battery 60
Types of Battery Charges 61
Methods of Charging 62
Troubleshooting Charger 63
Knowing When Battery Is Fully Charged 63
Where to Charge Batteries 63
Equipment Needed 63
Battery Connectors 64
Battery Care 64
Troubleshooting 66
524158040-2240YRM0001-(03-2020)-US-EN 71
General 75
Battery Type 75
Lead-Acid Batteries 75
Lithium-Ion Batteries 76
Specific Gravity 76
Chemical Reaction in a Cell 76
Electrical Terms 78
Battery Selection 78
Battery Voltage 79
Battery as a Counterweight 80
Battery Ratings 80
Kilowatt-Hours 80
Battery Maintenance 80
Safety Procedures 80
Maintenance Records 81
New Battery 81
Cleaning Battery 81
Adding Water to Battery 83
Hydrometer 84
Battery Temperature 85
Charging Battery 86
Types of Battery Charges 86
Methods of Charging 88
Troubleshooting Charger 88
Knowing When Battery Is Fully Charged 89
Where to Charge Batteries 89
Equipment Needed 89
Battery Connectors 90
Battery Care 90
Troubleshooting 92
550036879-0620YRM1513-(03-2015)-US-EN 97
550036879-0620YRM1513-(09-2022)-US-EN 113
General 119
Accessing the Drive Unit Compartment, Lift Trucks A249 120
Accessing the Drive Unit Compartment, Lift Trucks A245 and B245 121
Special Precautions 122
Discharging the Capacitors 122
Description 123
AC Motor Repair 124
Remove 124
Disassemble 124
Inspect 127
Assemble 127
Install 127
Troubleshooting 128
550036880-0630YRM1503-(03-2015)-US-EN 131
550036880-0630YRM1503-(09-2022)-US-EN 143
General 149
Safety Precautions 149
Drive Tire 151
Remove 151
Install 151
Master Drive Unit 151
Remove 151
Steering Bearing 153
Install 153
Troubleshooting 154
550036881-1600YRM1504-(12-2018)-US-EN 157
General 161
Special Precautions 161
Control Handle Head 162
Control Handle 162
Remove 162
Install 168
Gas Spring 169
Discharging the Gas Spring 169
Remove 169
Install 170
Troubleshooting 170
550036882-1800YRM1505-(03-2015)-US-EN 173
550036882-1800YRM1505-(09-2022)-US-EN 187
General 193
Description 194
Special Precautions 195
Brake Check 196
Hold On Grade Test 196
Brake Coil Check 197
Brake Assembly Repair 197
Remove 197
Install 198
Troubleshooting 199
550036883-1900YRM1506-(02-2015)-US-EN 201
550036885-2200YRM1508-(06-2018)-US-EN 223
General 227
Special Precautions 228
Discharging the Capacitors 228
Electrical System Checks 229
Safety Precautions 229
Repairs 231
Controller, Replace 231
Remove 231
Install 231
Pump Contactor Coil, Check 232
Pump Contactor, Replace 232
Contactor Tips, Replace 232
Remove 233
Install 233
Fuses 233

Disconnect SwitchBattery/Main Contactor and Coil 235
Disconnect Switch, Check 235

RemoveDisconnect Switch 235

InstallDisconnect Switch 235
Main Contactor Coil, Check 235
Horn 236
Remove 236
Install 236
Brake and Interlock Sensor 236
Remove 236
Install 237
Check 237
Steer Reduction Sensor 238
Remove 238
Install 238
Height Limit 238
Control Handle 239
Disassemble 239
Control Handle Card 239
Configure 239
Calibrate 241
Assemble 242
Charger and Convenience Port 244
Remove 244
Install 245
ACCUSENSE Battery Charger 245
Charger Mode/Battery Type Selection 245
Changing Mode Setting 248
Convenience Port 249
General 249
LED Status Display 250
Charging 250
Troubleshooting 251
General 251
Error Modes 252
A C Convenience Port Accessory (Optional) 254
Battery Pack Troubleshooting 254
BDI Display 256
Remove 256
Install 256
550036886-4000YRM1509-(09-2022)-US-EN 259
General 265
Description of Operation 265
Load Wheel 266
Remove 266
Install 267
Caster Wheels 268
Caster Adjustment 268
Caster Replacement 269
Disassemble 270
Assemble 270
Rear Link and Load Wheel Assembly 271
Remove 271
Disassemble 272
Assemble 272
Install 272
Rocker Arm and Pull Rods 273
Remove 273
Disassemble 275
Assemble 276
Install 276
Troubleshooting 277
550036886-4000YRM1509-(12-2013)-US-EN 279
550036888-8000YRM1511-(06-2016)-US-EN 297
Hydraulic System 301
Hydraulic Oils 301
Grease 302
Truck Weights 302
Tires 302
Torque Specifications 303
Caster Assembly 303
Caster Assembly (Dynamic) 303
Master Drive Unit 303
Steering 303
Electrical 303
Lift Mechanism 303
Covers 304
Operator Guard 304
Battery Specifications 304
550036889-8000YRM1512-(03-2018)-US-EN 309
General Notes 313
Schematic/Wiring Diagrams 314
550093874-0100YRM1665-(07-2016)-US-EN 327
General 331
Frame Separation and Assembly 332
Frame Separation 332
Frame Assembly 332
Moveable Load Backrest 332
Removal 332
Disassembly 334
Painting Instructions 334
Label Replacement 334
550093875-8000YRM1666-(03-2019)-US-EN 339
Introduction 343
General 343
Drive Unit Compartment Covers 344
How to Move a Disabled Truck 345
How to Tow the Lift Truck 346
How to Put the Truck on Blocks 346
How to Raise Drive/Steer Tire 346
How to Raise the Load Wheels 347
Special Precautions 347
Discharging Capacitors 347
Maintenance Schedule 348
Maintenance Procedures Every 8 Hours or Daily 350
Maintenance Procedures Every 350 Hours or Every 2 Months 355
CASTER LUBRICATION 356
DRIVE TIRE CHECK 356
Maintenance Procedures Every 2000 Hours or Yearly 357
HYDRAULIC SYSTEM 357
Oil Change 357
Battery Maintenance 358
HOW TO CHARGE THE BATTERY 358
Equalizing Charge 358
Normal Charge 358
Lithium-Ion Battery 359
Charging Lithium-Ion Battery 359
Troubleshooting Charger 359
Knowing When Battery Is Fully Charged 359
Where to Charge Batteries 359
Lithium-Ion Battery Care 359
HOW TO CHANGE THE BATTERY 360
Changing Battery With Rollers 361
Remove 361
Install 361
550095689-9000YRM1671-(10-2019)-US-EN 365
SECTION 9030 ELECTRICAL SYSTEM 371
Group 03 – General Maintenance and Diagnostic Data 375
Group 20 – Diagnostic Trouble Codes 389
550136713-2240YRM1890-(03-2019)-US-EN 449
General 453
Lithium-Ion Batteries 453
Multi-Pack Lithium-Ion Configurations 453
Electrical Terms 453
Battery Voltage 454
Sleep Mode 454
Sleep Mode 454
Battery Shut Down (Non Sleep Mode) 454
Wake-up circuit 455
Charging and Troubleshooting 455
Charger Mode/Battery Type Selection 455
Changing Mode Setting 457
Convenience Port 458
General 458
LED Status Display 460
Charging 460
Charger Troubleshooting 461
General 461
Error Modes 462
A C Convenience Port Accessory 465
General Troubleshooting 465
Wake-Up Circuit 465
Wake-up Relay 466
Lithium-Ion Pack 466
Battery Ratings 467
Kilowatt-Hours 467
Battery Maintenance 467
Safety Procedures 467
Cleaning Battery 468
Charging Battery 468
Troubleshooting Charger 468
Knowing When Battery Is Fully Charged 468
Where to Charge Batteries 468
Battery Care 468
Shipping and Handling 469
550136713-2240YRM1890-(09-2022)-US-EN 473
General 477
Lithium-Ion Batteries 477
Multi-Pack Lithium-Ion Configurations 477
Electrical Terms 478
Battery Voltage 478
Sleep Mode 479
Sleep Mode 479
Battery Shut Down (Non Sleep Mode) 479
Wake-up circuit 479
Charging and Troubleshooting 480
Charger Mode/Battery Type Selection 480
Changing Mode Setting 483
Convenience Port 484
General 484
LED Status Display 485
Charging 485
Charger Troubleshooting 486
General 486
Error Modes 488
A C Convenience Port Accessory 490
General Troubleshooting 490
Wake-Up Circuit 490
Wake-up Relay 491
Lithium-Ion Pack 491
Battery Ratings 493
Kilowatt-Hours 493
Battery Maintenance 494
Safety Procedures 494
Cleaning Battery 494
Charging Battery 494
Troubleshooting Charger 494
Knowing When Battery Is Fully Charged 494
Where to Charge Batteries 495
Battery Care 495
Shipping and Handling 495
550149026-2200YRM2030-(06-2017)-US-EN 499
General 503
AccuSense® Q-Series Charger 503
Charger Mode/Battery Type Selection 504
Mode Setting Check 505
Convenience Port 506
Multi-Stage Charging 507
LED Display, Multi-Stage Charge 509
Cell, Battery, and Battery Pack Voltage 510
Voltages 510
Troubleshooting 511
Charger Troubleshooting 511
Error Code Description 511
Diagnostics and Troubleshooting 513
Output Connector Circuit 514
Vehicle Lockout Control Option 515

S.V 05/24