Maintenance

FRAME
MP20 [A249]

PART NO. 550036878 100 YRM 1502

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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.
Frame Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Frame Separation and Assembly ........................................................................................................................ 1
Frame Separation............................................................................................................................................ 1
Frame Assembly ............................................................................................................................................. 2
Painting Instructions ............................................................................................................................................ 2
Label Replacement.............................................................................................................................................. 2

This section is for the following models:

MP20 [A249]

©2012 Yale Materials Handling Corp. i

100 YRM 1502
General
This section contains the description and repair proce-
dures for the frame weldments of the lift truck. This
model has integral mounting brackets and holes factory
drilled for the mounting of covers, the lift pump and mo-
tor, electrical components, lifting mechanisms, and the
master drive unit (MDU). See Figure 1. The fork frame
weldment is linked to the main frame weldment by the lift
Frame Separation and Assembly
FRAME SEPARATION
In some cases a fork frame or a drive unit frame may be
damaged, while the rest of the truck is still usable. The
two frames may be separated from each other by using
the following steps.
1. Raise the motorized lift truck to its maximum height.
Move the key to the OFF position. Disconnect the
battery.
1. FRAME 2. CASTING
Figure 1. Frame Weldment
Frame Separation and Assembly
links of the lifting mechanism system. The lift cylinder
actuates to evenly lift the fork frame and raise the load.
The battery end of the fork frame weldment is lifted di-
rectly by the cylinder and pivots on the lift links to the
main frame weldment. The fork tips are lifted simulta-
neously by push rods connecting the lift links to the load
wheel linkages near the end of the forks.
2. Remove the drive unit compartment covers. See
Accessing the Drive Unit Compartment in AC Mo-
tor Repair 620 YRM 1513.
3. Position blocks under both sides of the truck in the
area of the battery compartment and under both
forks. See How to Put a Lift Truck on Blocks in
Periodic Maintenance 8000 YRM 1510.
3. COVER
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Label Replacement
4. Remove the pin retaining the hydraulic cylinder to
the frame. See Hydraulic Cylinder in Hydraulic
System 1900 YRM 1506.
5. Manually retract the lift cylinder while holding the
lower switch on.
6. Remove the battery. See How to Change the Bat-
tery in Periodic Maintenance 8000 YRM 1510.
7. Remove the drive unit frame pivot pins retaining the
rocker arm to the drive unit frame. See Pull Rod,
Remove in Lifting Mechanism 4000 YRM 1509.
8. Carefully move one of the frames away from the
other.
FRAME ASSEMBLY
1. Align both frames so the pins may be installed to
assemble the frames to each other.
Painting Instructions
WARNING
Always use solvents and paints in an area with ven-
tilation. DO NOT use solvents or paints near heat or
fire.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. Wear protection for eyes
and skin. When using cleaning solvents, always
follow the recommendations of the manufacturer.
1. Remove all dirt from the surface to be painted.
Clean the area to be painted using a solvent for
painted surfaces. Remove all oil and grease.
Label Replacement
WARNING
Replace damaged Warning or Caution labels imme-
diately.
If labels or information plates are missing or damaged,
they must be replaced. See Figure 2.
NOTE: The nameplate cover is installed using rivets.
Remove old rivets before installing a new nameplate
cover. See your Yale® lift truck dealer to make sure the
nameplate cover information is correct and complete
before installing a new nameplate cover. Fasten the
nameplate cover with the rivet heads outside.
2
100 YRM 1502
2. Install both drive unit frame pivot pins to attach the
rocker arms to the drive unit frame. See Pull Rod,
Install in Lifting Mechanism 4000 YRM 1509.
3. Install the retainer pin to attach the hydraulic cylin-
der to the fork frame. See Hydraulic Cylinder, Install
in Hydraulic System 1900 YRM 1506.
4. Install the battery. Refer to How to Change the Bat-
tery in Periodic Maintenance 8000 YRM 1510.
5. Install the drive unit compartment cover.
6. Remove the blocks and lower the motorized lift
truck to the floor.
7. Test the operation of the truck before returning the
truck to service.
2. Remove the top surface of paint and all rust from
the metal using sandpaper. Paint all metal sur-
faces where the paint is completely removed using
primer. Apply the primer before applying the color
paint.
3. Protect all surfaces that will not be painted. DO
NOT paint cylinder rods, cables, labels, plates, or
controls.
4. Paint all the surfaces the original color, using Yale®
paint. Follow the directions on the container.
1. Make sure the surface is dry and free of oil or
grease. DO NOT use solvent on new paint. Clean
the surface of old paint using a cleaning solvent.
2. Remove the paper from the back of the label. DO
NOT touch the adhesive surface.
NOTE: The label cannot be moved after it touches the
surface.
3. Carefully hold the label in the correct position above
the surface. Put the label in the correct position
on the surface. Make sure all air is removed from
under the label and the corners and edges are tight.
See Figure 2.
100 YRM 1502 Label Replacement

1. PATENTS & TRADEMARKS LABEL 6. YALE LOGO LABEL

2. NAMEPLATE 7. LIFTING LOCATION LABEL
3. E - STOP LABEL 8. YALE LOGO LABEL
4. BDI LABEL 9. WARNING LABEL
5. YALE LOGO LABEL 10. PINCH WARNING LABEL

Figure 2. Labels and Decals

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 NOTES

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 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

100 YRM 1502 4/12 Printed in U.S.A.