MPR080VG, MPR100VG (A284) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ AC MOTOR REPAIR...................................................................................................... MASTER DRIVE UNIT S/N D801N03000L=> S/N A474N03000L=> S/N A497N030000L=> S/N E826N03000L=>................................................................... STEERING MECHANISM............................................................................................... BRAKE SYSTEM............................................................................................................ HYDRAULIC SYSTEMS................................................................................................. USER INTERFACE SUPERVISOR FUNCTIONS........................................................... USER INTERFACE SERVICE TECHNICIAN................................................................. ELECTRICAL SYSTEM.................................................................................................. INDUSTRIAL BATTERY................................................................................................. LIFT MECHANISM.......................................................................................................... METRIC AND INCH (SAE) FASTENERS....................................................................... CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CONTROLLER DIAGNOSTICS...................................................................................... PART NO. 550101332 (09/14)
PART NUMBER
YRM NUMBER
REV DATE
550101333 550101334
0100 YRM 1694 0620 YRM 1695
06/14 06/14
550073167 550101335 550101336 550101337 550101338 550101339 550101340 524158040 550101341 524150797 550101342 550101343 550101344 550101345
0630 YRM 1609 1600 YRM 1696 1800 YRM 1697 1900 YRM 1698 2200 YRM 1699 2200 YRM 1700 2200 YRM 1701 2240 YRM 0001 4000 YRM 1702 8000 YRM 0231 8000 YRM 1703 8000 YRM 1704 8000 YRM 1705 9000 YRM 1706
06/14 06/14 06/14 06/14 09/14 09/14 09/14 09/14 06/14 10/13 06/14 09/14 05/14 09/14
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)
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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.
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