Yale Forklift A485 (MP20AP) Service Manual – PDF DOWNLOAD

Description

Yale Forklift A485 (MP20AP) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A485 (MP20AP) Service Manual – PDF DOWNLOAD

Language : English
Pages : 242
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A485 (MP20AP) 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
550057245-0100YRM1544-(08-2012)-US-EN 43
toc 43
Frame 43
Safety Precautions Maintenance and Repair 44
General 47
Frame Separation and Assembly 48
Frame Separation 48
Frame Assembly 48
Painting Instructions 48
Label Replacement 49
Operator Platform 51
Operator Platform Assembly 51
Remove 51
Install 51
Platform Spring 52
Remove 52
Install 52
Adjustment 52
Platform Gas Spring 53
Remove 53
Install 54
550057246-0620YRM1545-(08-2012)-US-EN 57
toc 57
AC Motor Repair 57
Safety Precautions Maintenance and Repair 58
General 61
Accessing the Drive Unit Compartment 61
Special Precautions 62
Discharging the Capacitors 62
Description 63
AC Motor Repair 63
Remove 63
Disassemble 63
Inspect 64
Assemble 64
Install 64
Troubleshooting 66
550057247-0630YRM1546-(08-2012)-US-EN 71
toc 71
Master Drive Unit 71
Safety Precautions Maintenance and Repair 72
General 75
Safety Precautions 75
Drive Tire 76
Remove 76
Install 76
Master Drive Unit 77
Remove 77
Steering Bearing 79
Install 79
Troubleshooting 80
550057248-1600YRM1547-(08-2012)-US-EN 83
toc 83
Steering Mechanism 83
Safety Precautions Maintenance and Repair 84
General 87
Special Precautions 87
Control Handle Head 88
Control Handle 88
Remove 88
Install 89
Gas Spring 89
Remove 89
Install 90
Steering Knob Assembly 90
Remove 90
Disassemble 91
Assemble 91
Install 91
Troubleshooting 92
550057249-1800YRM1548-(08-2012)-US-EN 95
toc 95
Brakes 95
Safety Precautions Maintenance and Repair 96
Description 99
Special Precautions 100
Brake Check 101
Hold On Grade Test 101
Brake Coil Check 101
Brake Assembly Repair 101
Remove 101
Install 102
Troubleshooting 103
tables 95
Table 1 Brake Coil Resistance 101
550057250-1900YRM1549-(08-2012)-US-EN 107
toc 107
Hydraulic System 107
Safety Precautions Maintenance and Repair 108
Special Precautions 111
Operation 112
Lifting a Load 112
Lowering a Load 112
Hydraulic Lines 112
Hydraulic Oil 112
Clean 112
Sound Level 112
Hydraulic Unit 113
Remove 113
Install 114
Hydraulic Pump 114
Remove 114
Install 114
Hydraulic Pump Reservoir 116
Remove 116
Install 116
Hydraulic Cylinder 117
Remove 117
Repacking 118
Install 119
Relief Valve Adjustment 120
Relief Valve Pressure Check 120
Relief Valve Adjust 121
Troubleshooting 122
Lift Assemblies 122
Hydraulic Cylinders 122
Hydraulic Pump 123
tables 107
Table 1 Relief Valve Settings 120
550057251-2200YRM1550-(08-2012)-US-EN 127
toc 127
AC Motor Controller 127
Safety Precautions Maintenance and Repair 128
General 131
Safety Precautions 131
Description 132
AC Motor Controller 132
Principles of Operation 132
Install 132
Programming Controller 132
1311 Programmer Handset 136
Description/Features 136
Menu Navigation Key 136
Data Increase/Decrease Key 137
Bookmark Keys 137
Operation 138
Connecting Handset to Traction Motor Controller 138
Disconnecting the Handset From the Traction Motor Controller 138
Main Menu Selections 138
Program Menu 138
Monitor Menu 139
Faults Menu 140
Functions menu 141
Information Menu 141
Programmer Setup Menu 141
Programming the Traction Motor Controller – 1311 Handset 142
Display (BDI)/Hourmeter 143
Fault Codes 143
tables 127
Table 1 Program Menu 133
550057252-2200YRM1551-(08-2012)-US-EN 161
toc 161
Electrical System 161
Safety Precautions Maintenance and Repair 162
General 165
Special Precautions 166
Discharging the Capacitors 166
Electrical System Checks 167
Safety Precautions 167
Repairs 168
Controller, Replace 169
Remove 169
Install 169
Contactor Coil, Check 169
Contactor, Replace 169
Contactor Tips, Replace 169
Remove 170
Install 170
Fuses 171
Emergency Disconnect Switch 171
Remove 171
Install 171
Horn 172
Remove 172
Install 172
Brake and Interlock Sensor 172
Remove 172
Install 173
Check 173
Control Handle 173
Disassemble 173
Control Handle Card 174
Configure 174
Calibrate 175
Assemble 176
tables 161
Table 1 Voltage Checks 168
550057253-4000YRM1552-(08-2012)-US-EN 181
toc 181
Lifting Mechanism 181
Safety Precautions Maintenance and Repair 182
General 185
Description of Operation 185
Load Wheel 185
Remove 185
Install 186
Caster Wheels 186
Standard Caster Adjustment 186
Standard Caster Replacement 187
Disassemble 188
Assemble 188
Dynamic Caster Replacement 189
Disassemble 189
Assemble 189
Shock Absorber Replacement (Dynamic Caster) 190
Remove 190
Install 190
Rear Link and Load Wheel Assembly 190
Remove 190
Disassemble 191
Assemble 191
Install 191
Rocker Arm and Pull Rods 192
Remove 192
Disassemble 194
Assemble 194
Install 194
Troubleshooting 195
550057254-8000YRM1553-(08-2012)-US-EN 199
toc 199
Periodic Maintenance 199
Safety Precautions Maintenance and Repair 200
General 203
How to Move a Disabled Truck 203
How to Tow the Lift Truck 204
How to Put a Lift Truck on Blocks 204
How to Raise Drive/Steer Tire 204
How to Raise Load Wheels 205
Welding Repairs 205
Maintenance Schedule 206
Checks and Inspection Procedures 206
Hydraulic System 206
Lifting Mechanism 207
Controls 207
Electrical and Battery 208
Wheels and Tires 208
Casters 209
Lubrication Instructions 209
Every 8 Hours or Daily 209
Every 50 Hours or 1 Month 209
Every 350 Hours or 2 Months 209
Check Hydraulic Oil Level 209
Every 2000 Hours or 1 Year 209
To Fill Hydraulic Reservoir 210
Recommended Schedule of Maintenance 211
Battery Maintenance 216
How to Charge the Battery 216
Equalizing Charge 216
Normal Charge 216
How to Change the Battery 217
tables 199
Table 1 Specific Gravity Corrections 216
550057255-8000YRM1554-(08-2012)-US-EN 221
toc 221
Capacities and Specifications 221
Safety Precautions Maintenance and Repair 222
Hydraulic System 225
Hydraulic Oils 225
Grease 225
Truck Weights 226
Tires 226
Torque Specifications 226
Caster Assembly (Standard) 226
Caster Assembly (Dynamic) 226
Master Drive Unit 226
Steering 226
Electrical 226
Lift Mechanism 227
Covers 227
Operator Platform 227
Operator Guard 227
Battery Specifications 228
550057256-8000YRM1555-(08-2012)-US-EN 231
toc 231
diagrams 231
Safety Precautions Maintenance and Repair 232
General Notes 235

S.V 05/24