MPR080VG, MPR100VG (A284)

SERVICE MANUAL CONTENTS

PART YRM REV
SECTION NUMBER NUMBER DATE
FRAME............................................................................................................................ 550101333 0100 YRM 1694 06/14
AC MOTOR REPAIR...................................................................................................... 550101334 0620 YRM 1695 06/14
MASTER DRIVE UNIT S/N D801N03000L=> S/N A474N03000L=> S/N
A497N030000L=> S/N E826N03000L=>................................................................... 550073167 0630 YRM 1609 06/14
STEERING MECHANISM............................................................................................... 550101335 1600 YRM 1696 06/14
BRAKE SYSTEM............................................................................................................ 550101336 1800 YRM 1697 06/14
HYDRAULIC SYSTEMS................................................................................................. 550101337 1900 YRM 1698 06/14
USER INTERFACE SUPERVISOR FUNCTIONS........................................................... 550101338 2200 YRM 1699 09/14
USER INTERFACE SERVICE TECHNICIAN................................................................. 550101339 2200 YRM 1700 09/14
ELECTRICAL SYSTEM.................................................................................................. 550101340 2200 YRM 1701 09/14
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
LIFT MECHANISM.......................................................................................................... 550101341 4000 YRM 1702 06/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CAPACITIES AND SPECIFICATIONS........................................................................... 550101342 8000 YRM 1703 06/14
DIAGRAMS..................................................................................................................... 550101343 8000 YRM 1704 09/14
PERIODIC MAINTENANCE............................................................................................ 550101344 8000 YRM 1705 05/14
CONTROLLER DIAGNOSTICS...................................................................................... 550101345 9000 YRM 1706 09/14

PART NO. 550101332 (09/14)

 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.
 Table of Contents

TABLE OF CONTENTS

Hydraulic System ......................................................................................................................................................1

Hydraulic Oils ............................................................................................................................................................1
Gear Oils ...................................................................................................................................................................1
Grease ...................................................................................................................................................................... 2
Truck Weight .............................................................................................................................................................2
Tire Sizes ..................................................................................................................................................................3
Torque Specifications ............................................................................................................................................... 4
Drive Wheel Assembly ......................................................................................................................................... 4
Master Drive Unit ..................................................................................................................................................4
Traction Motor ...................................................................................................................................................... 4
Steering System ................................................................................................................................................... 4
Electrical ............................................................................................................................................................... 4
Lift Mechanism ..................................................................................................................................................... 4
Hydraulics .............................................................................................................................................................4
Battery Specifications ............................................................................................................................................... 5

This section is for the following models:

(MPR080VG, MPR100VG) [A284]

©2014 Yale Materials Handling Corp. i

8000 YRM 1703 Hydraulic System

Hydraulic System

Battery Ampere Lift Time Lower Time

Operating Pressure1 Relief Setting
Com- Draw2 (sec) (sec)
Unit
part- Rated No Rated Amp No Rated No Rated
ment No Load Pressure3
Load Load Load Draw Load Load Load Load
MPR080VG 340 mm 5.99 MPa 23.00 MPa 34 81 24.99 MPa 124 3.2 4.5 4.2 4.0
MPR100VG (13.4 in.) (870 psi) (3336 psi) (3625 psi)
[A284]
Standard Specifications Hydraulic Tank Capacity - 1.1 liter (1.1 qt) Pump Displacement (24 Volts) -
2.0 cm3/rev (0.122 in.3/rev) Creep Rate - 6.4 mm (0.25 in.) Maximum In 10 Minutes @ 32°C (90°F) Oil Temper-
ature
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

For All Hydraulically-Actuated Equipment
Specification ISO VG 46 Antiwear (HCE-140) Exxon Univis® HVI 26
Type Conventional Synthetic
Temperature Range 0.0 to −48.9°C (32 to −120.0°F) -17.6 to −48.9°C (0.0 to −120.0°F)
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.

Gear Oils

Operating Condition Standard/CS/Freezer/Food Arctic

Processing
SAE Grade 80W-90 75W-90
Type Multipurpose EP Multipurpose EP
Base Oil Conventional Synthetic
API Service Classification GL-5 GL-5
Anticipated Ambient Temperature −26 to +38°C (−15 to +100°F) As low as −51°C (−60°F)1
1
Primarily intended for cold storage and/or Arctic conditions; can be used as high as +32°C (+90°F).
Field Personnel Note: The products listed above are the approved sources that meet or exceed Yale specifications. The
use of products other than that listed above is unauthorized.

1
Grease 8000 YRM 1703

Grease

Fittings and Bearings

Application Standard/CS/Freezer Arctic/Food Processing Steer Bearings
Approved Vendor Mobilgrease 28®
Amsoil GHD ®
Amsoil GHD®
Oil Synthetic Synthetic Synthetic
Thickener Clay Lithium Complex Lithium Complex
Grade NGLI 1.5 2.0 2.0
Moly-Fortified No Yes Yes
Dropping Pt. 310°C (590°F) 288°C (550°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.

Truck Weight

Fork Length Fork Length Fork Length

Unit Battery Compartment 1219 mm (48 in.) 2438 mm (96 in.) 4064 mm (160 in.)
Weight Weight Weight
MPR080VG,
MPR100VG 340 mm (13.4 in.) 909 kg (2000 lb) 1040 kg (2290 lb) 1206 kg (2660 lb)
[A284]

2
8000 YRM 1703 Tire Sizes

Tire Sizes

Drive Tire
Lift Truck Model
Size Composition Rating1 Availability
Smooth Polyurethane 90 STD
MPR080VG, Red Polyurethane X Grooved 85 OPT
MPR100VG 13.5 × 5.50
[A284] Red Polyurethane Grooved 85 OPT
Vulkollan 90 OPT
1
Durometer Rating

Load Wheels
Size Composition Rating1 Availability
3.25 x 6.50 Single Poly (4 Bearing) 97 OPT
3.25 × 6.50 Single Poly (2 Bearing) 95 STD
3.25 × 3.125 Dual Poly 97 OPT
3.25 x 6.50 Tandem Poly 96 OPT
1
Durometer Rating

3
Torque Specifications 8000 YRM 1703

Torque Specifications
DRIVE WHEEL ASSEMBLY MDU Pinion Gear to Steer Motor Capscrew
19.2 N•m (168 lbf in)
Drive Wheel Lugnuts (5 each)
Steering Handle Mechanism to Cowl Capscrews
Use cross pattern to snug, half torque, then full tor- 12.9 N•m (114 lbf in)
que. Apply antiseize to threads.
ELECTRICAL
140 N•m (101 lbf ft)
Traction Motor Power Wire Nuts (4 each)
MASTER DRIVE UNIT 8 N•m (6 lbf ft)
MDU to Frame Capscrews Steady-Rest to frame (4 each)
95 N•m (70 lbf ft) 88 N•m (65 lbf ft)
Fill/Drain Plugs Auxiliary Control Box (4 each)
22 N•m (16 lbf ft) 9 N•m (7 lbf ft)
Steering Bearing to MDU Capscrews Static Strap Mounting Capscrew
34 N•m (25 lbf ft) 195 ±9 N•m (144 ±7 lbf ft)
Traction Motor to MDU Capscrews Assisted Steer Contactor Terminal Nuts
23 N•m (17 lbf ft) 8 ±2 N•m (6 ±1 lbf ft)
TRACTION MOTOR Assisted Steer Fuse Terminal Nuts
7 ±1 N•m (62 ±9 lbf in)
Traction Motor to MDU Capscrews
23 N•m (17 lbf ft) LIFT MECHANISM
Brake Assembly to Traction Motor Capscrews Pull Rod Jam Nuts (4 each Rod)
10.8 N•m (95.6 lbf in) 176 ±3 N•m (130 ±2 lbf ft)
Power Cables to Traction Motor Capscrews HYDRAULICS
23 to 25 N•m (203.5 to 221 lbf in)
Pump Assembly Mounting Capscrews
STEERING SYSTEM 38 to 41 N•m (28 to 30 lbf ft)
Steer Swivel to Dash Lock Nut Pump to Mounting Bracket Arm Capscrew
27 N•m (20 lbf ft) 8 to 11 N•m (6 to 8 lbf ft)
Steer Motor to Frame Capscrews
19.2 N•m (168 lbf in)

4
8000 YRM 1703 Battery Specifications

Battery Specifications
The battery used in the lift truck should be selected during operation. Never use a battery that is a differ-
according to voltage, size, and weight. Batteries that ent voltage or that exceeds the maximum weight. See
are significantly smaller than the battery compartment Figure 1.
must be installed with spacers to hold them stable

Figure 1. Battery Compartment

Ampere Kilowatt
Compartment Compartment Recommended
Voltage Hours Hours Weight (Max)
Length (X) Width (Y) (Max) Height (Max)
(Max) (Max)
673.1 mm 330.2 mm 591.8 mm 374.2 kg
24 375 8.7
(26.5 in.) b (13.0 in.) (23.3 in.) (825 lb)
673.1 mm 325.1 mm 591.8 mm 392.3 kg
24 425 9.9
(26.1 in.) b (12.8 in.) (23.3 in.) (865 lb)
784.8 mm 330.2 mm 591.8 mm 447.7 kg
24 450 10.5
(30.9 in.) c (13.0 in.) (23.3 in.) (987 lb)
784.8 mm 330.2 mm 591.8 mm 469.5 kg
24 510 11.9
(30.9 in.) c (13.0 in.) (23.3 in.) (1035 lb)
784.8 mm 330.2 mm 591.8 mm 544.3 kg
24 600 14.0
(30.9 in.) c (13 in.) (23.3 in.) (1200 lb)
784.8 mm 330.2 mm 787.46 mm 680.4 kg
24 750 17.6
(30.9 in.) (13.0 in.) (31.0 in.) (1500 lb)
784.8 mm 330.2 mm 787.4 mm 680.4 kg
24 840 19.5
(30.9 in.) (13.0 in.) (31.0 in.) (1500 lb)
784.8 mm 330.2 mm 787.4 mm 680.4 kg
24 930 21.6
(30.9 in.) (13.0 in.) (31.0 in.) (1500 lb)
Note: If Y is less than 327.6 mm (12.9 in.), a supplemental retainer is required. a – Adjust both A and B
retainers. b – Adjust A and remove B retainer. c – Remove both A and B retainer.

5
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