Yale A284 Mpr080vg Mpr100vg Lift Truck Service Repair Manual

Maintenance

CAPACITIES AND SPECIFICATIONS MPR080VG, MPR100VG [A284]

PART NO. 550101342

8000 YRM 1703

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

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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 contained 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 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.

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.

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8000 YRM 1703

Hydraulic System

Hydraulic System

Unit

Battery Compartment

Operating Pressure1 Rated Load

No Load

MPR080VG 340 mm 5.99 MPa 23.00 MPa MPR100VG (13.4 in.) (870 psi) (3336 psi) [A284]

Ampere Draw2

Relief Setting

Lift Time (sec)

Lower Time (sec)

No Rated Amp No Rated No Rated Pressure3 Load Load Draw Load Load Load Load 34

81

24.99 MPa (3625 psi)

124

3.2

4.5

4.2

4.0

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 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

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 Processing

Arctic

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

2

Unit

Battery Compartment

Fork Length 1219 mm (48 in.)

Weight

Fork Length 2438 mm (96 in.)

Weight

Fork Length 4064 mm (160 in.)

Weight

MPR080VG, MPR100VG [A284]

340 mm (13.4 in.)

909 kg (2000 lb)

1040 kg (2290 lb)

1206 kg (2660 lb)

8000 YRM 1703

Tire Sizes

Tire Sizes Lift Truck Model

MPR080VG, MPR100VG [A284] 1

Drive Tire Size

13.5 × 5.50

Composition

Rating1

Availability

Smooth Polyurethane

90

STD

Red Polyurethane X Grooved

85

OPT

Red Polyurethane Grooved

85

OPT

Vulkollan

90

OPT

Durometer Rating

Load Wheels

1

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

Durometer Rating

3

Torque Specifications

8000 YRM 1703

Torque Specifications DRIVE WHEEL ASSEMBLY Drive Wheel Lugnuts (5 each) Use cross pattern to snug, half torque, then full torque. Apply antiseize to threads.

140 N•m (101 lbf ft)

MDU Pinion Gear to Steer Motor Capscrew 19.2 N•m (168 lbf in) Steering Handle Mechanism to Cowl Capscrews 12.9 N•m (114 lbf in)

ELECTRICAL

MASTER DRIVE UNIT

Traction Motor Power Wire Nuts (4 each) 8 N•m (6 lbf ft)

MDU to Frame Capscrews 95 N•m (70 lbf ft)

Steady-Rest to frame (4 each) 88 N•m (65 lbf ft)

Fill/Drain Plugs 22 N•m (16 lbf ft)

Auxiliary Control Box (4 each) 9 N•m (7 lbf ft)

Steering Bearing to MDU Capscrews 34 N•m (25 lbf ft)

Static Strap Mounting Capscrew 195 ±9 N•m (144 ±7 lbf ft)

Traction Motor to MDU Capscrews 23 N•m (17 lbf ft)

Assisted Steer Contactor Terminal Nuts 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 10.8 N•m (95.6 lbf in)

Pull Rod Jam Nuts (4 each Rod) 176 ±3 N•m (130 ±2 lbf ft)

Power Cables to Traction Motor Capscrews 23 to 25 N•m (203.5 to 221 lbf in)

HYDRAULICS

STEERING SYSTEM

Pump Assembly Mounting Capscrews 38 to 41 N•m (28 to 30 lbf ft)

Steer Swivel to Dash Lock Nut 27 N•m (20 lbf ft)

Pump to Mounting Bracket Arm Capscrew 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 according to voltage, size, and weight. Batteries that are significantly smaller than the battery compartment must be installed with spacers to hold them stable

during operation. Never use a battery that is a different voltage or that exceeds the maximum weight. See Figure 1.

Figure 1. Battery Compartment

Voltage

Ampere Hours (Max)

Kilowatt Hours (Max)

Compartment Length (X)

Compartment Width (Y) (Max)

Recommended Height (Max)

Weight (Max)

24

375

8.7

673.1 mm (26.5 in.) b

330.2 mm (13.0 in.)

591.8 mm (23.3 in.)

374.2 kg (825 lb)

24

425

9.9

673.1 mm (26.1 in.) b

325.1 mm (12.8 in.)

591.8 mm (23.3 in.)

392.3 kg (865 lb)

24

450

10.5

784.8 mm (30.9 in.) c

330.2 mm (13.0 in.)

591.8 mm (23.3 in.)

447.7 kg (987 lb)

24

510

11.9

784.8 mm (30.9 in.) c

330.2 mm (13.0 in.)

591.8 mm (23.3 in.)

469.5 kg (1035 lb)

24

600

14.0

784.8 mm (30.9 in.) c

330.2 mm (13 in.)

591.8 mm (23.3 in.)

544.3 kg (1200 lb)

24

750

17.6

784.8 mm (30.9 in.)

330.2 mm (13.0 in.)

787.46 mm (31.0 in.)

680.4 kg (1500 lb)

24

840

19.5

784.8 mm (30.9 in.)

330.2 mm (13.0 in.)

787.4 mm (31.0 in.)

680.4 kg (1500 lb)

24

930

21.6

784.8 mm (30.9 in.)

330.2 mm (13.0 in.)

787.4 mm (31.0 in.)

680.4 kg (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

NOTES

6

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