This document provides service manual contents and safety precautions for MPR080VG and MPR100VG lift truck models. It includes sections on the frame, AC motor repair, master drive unit, steering mechanism, brake system, hydraulic systems, user interface, electrical system, industrial battery, lift mechanism, fasteners, capacities and specifications, diagrams, periodic maintenance, and controller diagnostics. The document outlines important safety warnings and cautions for maintenance and repair work. It notes that only Yale approved parts should be used for repairs.

1. MPR080VG, MPR100VG (A284)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
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)

2. 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.

3. ©2014 Yale Materials Handling Corp.
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]
Table of Contents
i

5. Hydraulic System
Unit
Battery
Com-
part-
ment
Operating Pressure1
Ampere
Draw2 Relief Setting
Lift Time
(sec)
Lower Time
(sec)
No Load
Rated
Load
No
Load
Rated
Load
Pressure3 Amp
Draw
No
Load
Rated
Load
No
Load
Rated
Load
MPR080VG
MPR100VG
[A284]
340 mm
(13.4 in.)
5.99 MPa
(870 psi)
23.00 MPa
(3336 psi)
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 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
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.
8000 YRM 1703 Hydraulic System
1

6. 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
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)
Grease 8000 YRM 1703
2

7. Tire Sizes
Lift Truck Model
Drive Tire
Size Composition Rating1 Availability
MPR080VG,
MPR100VG
[A284]
13.5 × 5.50
Smooth Polyurethane 90 STD
Red Polyurethane X Grooved 85 OPT
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
8000 YRM 1703 Tire Sizes
3

8. Torque Specifications
DRIVE WHEEL ASSEMBLY
Drive Wheel Lugnuts (5 each)
Use cross pattern to snug, half torque, then full tor-
que. Apply antiseize to threads.
140 N•m (101 lbf ft)
MASTER DRIVE UNIT
MDU to Frame Capscrews
95 N•m (70 lbf ft)
Fill/Drain Plugs
22 N•m (16 lbf ft)
Steering Bearing to MDU Capscrews
34 N•m (25 lbf ft)
Traction Motor to MDU Capscrews
23 N•m (17 lbf ft)
TRACTION MOTOR
Traction Motor to MDU Capscrews
23 N•m (17 lbf ft)
Brake Assembly to Traction Motor Capscrews
10.8 N•m (95.6 lbf in)
Power Cables to Traction Motor Capscrews
23 to 25 N•m (203.5 to 221 lbf in)
STEERING SYSTEM
Steer Swivel to Dash Lock Nut
27 N•m (20 lbf ft)
Steer Motor to Frame Capscrews
19.2 N•m (168 lbf in)
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
Traction Motor Power Wire Nuts (4 each)
8 N•m (6 lbf ft)
Steady-Rest to frame (4 each)
88 N•m (65 lbf ft)
Auxiliary Control Box (4 each)
9 N•m (7 lbf ft)
Static Strap Mounting Capscrew
195 ±9 N•m (144 ±7 lbf ft)
Assisted Steer Contactor Terminal Nuts
8 ±2 N•m (6 ±1 lbf ft)
Assisted Steer Fuse Terminal Nuts
7 ±1 N•m (62 ±9 lbf in)
LIFT MECHANISM
Pull Rod Jam Nuts (4 each Rod)
176 ±3 N•m (130 ±2 lbf ft)
HYDRAULICS
Pump Assembly Mounting Capscrews
38 to 41 N•m (28 to 30 lbf ft)
Pump to Mounting Bracket Arm Capscrew
8 to 11 N•m (6 to 8 lbf ft)
Torque Specifications 8000 YRM 1703
4

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10. 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 differ-
ent 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.
8000 YRM 1703 Battery Specifications
5