WORKSHOP MANUAL

For Models
ERP/CI 6-2OATF

Copies of this and other publications for this range of lift trucks are available.
For details contact Your Local Dealer.

Yale Europe Materials Handling Limited For Service & Parts-Contact

St. David’s Court Authorized Dealer
Union Street
Wolverharnpton
ENGLAND W I 3JE
Telephone: (01902) 875500
Telex: 333642
Telefax: (01902) 875566

Part No. 5070385-01 @May 1995

EXPLANATION OF TRUCK MODEL CODE

- POWER
E - Electric

R - Sit Down Rider

TYRES
P - Pneumatic
C - Cushion

r RATED CAPACITY (in kg x 100)

16

A - Premium
B - Standard

E R P 1 8 A T F E 48 V 2084
L

L L MAST CLOSED HEIGHT (mm)

MAST TYPE
V -Two Stage Limited Free Lift
F -Two Stage Full Free Lift
E -Three Stage Full Free Lift
-VOLTAGE
48 Volts

- PLANT SOURCE
E - Europe

- SERIES CODE
A, B, C etc.

-MODEL
T - Three Wheel FWD
R - Three Wheel RWD
This Maintenance Manual is divided into major sections which are listed on this
page. Quick reference to these sections can be made by placing the right thumb on
the tab ofthe desired section, bending the book back and thumbing the pages to the
corresponding tab.

S ECTl0 NS
1 OPERATING INSTRUCTIONS

2 GENERAL TRUCK AND LUBRICATION

3 ELECTRICAL SYSTEM

4 DRIVE UNIT

5 BRAKE SYSTEM

6 TRAIL AXLE AND STEERING SYSTEM

7 HYDRAULIC SYSTEM

a MAST

9 BAlTERY AND CHARGING SYSTEM

10 USER SUPPORT INFORMATION

11 ALPHABETICAL INDEX
 SAFETY PRECAUTIONS Lift batteries correctly with a crane or equipment
MAINTENANCE AND REPAIR designed for the job. Always use a spreader bar
designed and adjusted for the battery. Move
e When lifting parts or assemblies, make sure that batteries with a lift truck, or a conveyor or rollers
all slings, chains, or cables are correctly fastened designed for that purpose. If the battery does not
and that the load being lifted is balanced. Make have a cover, a rubber mat or insulating material
sure that the crane, cables, and chains have the must be put over the top of the battery to prevent a
capacity to support the weight of the load. short circuit with other equipment. Make sure the
the lifting equipment has enough capacity for the
e Do not lift heavy parts by hand. Use a lifting job. Do not use chain or wire rope slings.
mechanism.
Never put metal materials or tools on a battery.
e Wear safety glasses.
When maintenance on the battery or the battery
e DISCONNECT THE BATTERY CONNECTOR
charger is required, disconnect both the AC and
before doing any maintenance or repair on DC power. If new battery connectors must be
electric lift trucks. installed, make sure the positive and negative
e Always use correct blocks to preventthe unit from terminals and cables are kept separate and
rolling or falling. See “How to Put the Lift Truck on insulated from each other. Even a momentary
Blocks” in the OPERATOR’S MANUAL or short circuit can cause an explosion and damage
SECTION 2, GENERAL TRUCK AND the battery.
LUBRICATION. Keep water readily available to flush spilled
e Keep the unit and working area clean and in order. electrolyte. Electrolyte in the eyes must be flushed
with water immediately and then quickly get
e Use the correct tools for the job. medical attention. Special showers and eye wash
systems are required in areas where battery
e Keep the tools clean and in good condition maintenance is done.
e Always use YALE APPROVED parts when If electrolyte is spilled on a work surface or the
making repairs. Replacement parts must meet or floor, flush the area with water, use a solution of
exceed the specifications of the original soda (sodium bicarbonate) to make the acid
equipment manufacturer. neutral.
e Make sure that all nuts, bolts, circlips, and other Only trained persons are permitted to do
fastening devices are removed before using force maintenance on batteries and battery chargers.
to remove parts. Make sure that the regulations by government
safety agencies, government insurers, private
e Always fasten a DO NOT OPERATE sign to the insurers, and private organizations are followed
controls of the unit when making repairs or if the when doing maintenance on batteries.
unit needs repairs.
NOTE: The following symbols and words indicate
e Make sure you follow the DANGER, WARNING, safety information in this manual:
and CAUTION notes in the instructions.
e Wear a rubber apron, gloves, boots, and goggles DANGER: Indicates a condition that will
or a face shield when doing maintenance on cause immediate death or injury!
batteries.
e Batteries generate hydrogen gas when they are
being charged. Keep open fire away from
batteries. Do not check the electrolyte level with a
A WARNING: Indicates a condition that can
cause death or injury!

A
match or a lighter. No smoking and do not create
sparks. Make sure the area has ventilation. If the CAUTION: Indicates a condition that can
battery is charged in the lift truck, open the bonnet. cause property damage!
 CONTENTS
Section 1 Section 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
SAFETY AND INFORMATIONALLABELS . . . . . 1-2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
OPERATOR PRECAUTIONS . . . . . . . . . Repairs. Small Leaks . . . . . . . . . . . . . . . . . . . . . 2-5
OPERATOR PRE-CHECKS AND INSPECTION 1-3 Repairs. Large Leaks . . . . . . . . . . . . . . . . . . . . 2-5
OPERATING PROCEDURE . . . . . . . . . . . . . . . . . 1-3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steam Method of Cleaning . . . . . . . . . . . . . . . . 2-6
SHUT DOWN PROCEDURE . . . . . . . . . . . . . . . . . 1-4
Chemical Solution Method of Cleaning
FORK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 1-4
Additional Preparations for Repair . . . . . . . . . . 2-6
SAFETY AND OPERATIONAL CHECK LIST . . . 1-5
WELDING REPAIRS . . . . . . . . . . .
MODEL AND CONTROL INFORMATION . . . . . . 1-7
TYRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . 2-6
instrument Panel A (STANDARD) . . . . . . . . '-lo
HOW TO CHANGE THE WRES . . . . . . . . . . . . . 2-7
Instrument Panel B (OPTIONAL) . . . . . . . . . 1-10 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
instrument Panel (OPTIONAL) . . . . . . . . '-lo PNEUMATIC TYRES . . . . . . . . . . . . . . . . . . . . . . . 2-7
Temperature Indicator Lamp . . . . . . . . . . . . . 1-11 Remove the Wheel from the Lift Truck . . . . . . .2.7
SAFE MAINTENANCE PROCEDURES . . . . . . 1-11 Remove the Tyre from the Wheel . . . . . . . . . . 2-8
MOVING A DISABLED LIFT TRUCK . . . . . . . . 1-12 Install the Tyre on the Wheel . . . . . . . . . . . . . . 2-8
HOW TO TOW THE LIFT TRUCK . . . . . . . . . . 1-12 Add Air to the Tyres . . . . . . . . . . . . . . . . . . . . . . 2-9
HOW TO PUT A LIFT TRUCK ON BLOCKS . 1-1 2 PNEUMATIC SHAPED SOLID TYRES . . . . . . 2-10
HOW TO RAISE THE STEERING TYRE . . . . 1-13 Remove the Wheel from the Lift Truck . . . . 2-10
HOW TO RAISE THE DRIVE TYRES . . . . . . . 1-13 Remove the Tyre from the Wheel . . . . . . . . 2-10
PRECAUTIONS FOR TRUCKS IN STORAGE 1-13 Install the Tyre on the Wheel . . . . . . . . . . . . . 2-11
PRECAUTIONS FOR BATTERIES SOLID TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
IN STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Remove the One Piece Wheel and Tyre . . 2-12
Install the Tyre on the One Piece Wheel . . 2-12
Section 2 Install the Wheels on the Lift Truck . . . . . . . 2-12
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 LABEL REPLACEMENT . . . . . . . . . . . . . . . . . . . 2-13
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 YALE WARRANTY INFORMATION . . . . . . . . . 2-14
FLOOR PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 RECOMMENDED SCHEDULE
REAR COMPARTMENT COVER . . . . . . . . . . . . . 2-1 OF MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 2-14
FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 LUBRICATION INSTRUCTIONS . . . . . . . . . . . 2-15
STEERING COLUMN COVER . . . . . . . . . . . . . . . 2-2 EVERY 8 HOURS . . . . . . . . . . . . . . . . . . . . . . . . 2-15
HYDRAULIC CONTROL VALVE COVERS . . . . . 2-2 EVERY 350 HOURS . . . . . . . . . . . . . . . . . . . . . . 2-15
BATTERY COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . 2-15
HYDRAULIC OILS . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
GEAR OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
FREEZER APPLICATIONS . . . . . . . . . . . . . . . . 2-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
BATTERY REMOVAL AND INSTALLATION . . . . 2-3
Complete Truck . . . . . . . . . . . . . . . . . . . . . . . 2-24
BATTERY PLATFORM . . . . . . . . . . . . . . . . . . . . . . 2-3 Control ComDartment . . . . . . . . . . . . . . . . . . 2-24
OVERHEAD GUARD . . . . . . . . . . . . . . . . . . . . . . . 2-4 Electrical System . . . . . . . . . . . . . . . . . . . . . . 2-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Battery Compartment . . . . . . . . . . . . . . . . . . 2-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . 2-24
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Steering Linkage and Pivot Points . . . . . . . . 2-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . 2-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Drive. Hydraulic and Steering Motors . . . . . 2-24
 Section 2 Section 3
Brake Lines and Linkage . . . . . . . . . . . . . . . 2-24 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Connect. Disconnect. and
Upright and Carriage . . . . . . . . . . . . . . . . . . . 2-24 Check the Hand Set . . . . . . . . . . . . . . . . . . . 3-20
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Check and Adjust Functions . . . . . . . . . . . . . 3-20
FUNCTION DESCRIPTIONS . . . . . . . . . . . . . . 3-21
Complete Truck ....................... 2-24
Control Compartment . . . . . . . . . . . . . . . . . . 2-24
Traction Control Cards . . . . . . . . . . . . . . . . . 3-21
PUMP CONTROL CARD (LABEL LETTER PX) 3-23
Electrical System . . . . . . . . . . . . . . . . . . . . . . 2-25
TABLES FOR FUNCTION VALUE SETTINGS 3-24
Battery Compartment . . . . . . . . . . . . . . . . . . 2-25
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 3-26
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . 2-25
CONTACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Steering Linkage and Pivot Points . . . . . . . . 2-25
TESTING CONTACTORS . . . . . . . . . . . . . . . . . 3-59
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . 2-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Drive, Hydraulic and Steering Motors . . . . . 2-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Brake Lines and Linkage . . . . . . . . . . . . . . . 2-25
TMM1 CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Upright and Carriage . . . . . . . . . . . . . . . . . . . 2-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 2-25
CIRCUIT PROTECTION . . . . . . . . . . . . . . . . . . 3-63
FASTENERS - INT R0DUCTI0N . . . . . . . . . . . 2-26
Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Threads. Nomenclature . . . . . . . . . . . . . . . . . 2-26 Thermal Protection . . . . . . . . . . . . . . . . . . . . 3-63
Strength Identification . . . . . . . . . . . . . . . . . . 2-26 Suppressors (Filter Blocks) . . . . . . . . . . . . . 3-63
Section 3 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
ELECTRICAL SYSTEM-G ENERAL . . . . . . . . . . . 3-1 PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . 3-64
Steering Angle Control Board . . . . . . . . . . . . 3-64
EV-1O O L X MOTOR CONTROLLER . . . . . . . . . . . 3-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
EV-100 DESCRIPTION AND OPERATION . . . . . 3-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
The Silicon Controlled Rectifier . . . . . . . . . . . . 3-2
Lift Pump Control Board . . . . . . . . . . . . . . . . 3-69
A Motor Circuit that Operates with Pulses . . . 3-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Hydraulic Pump Motor . . . . . . . . . . . . . . . . . . . . 3-4
Bypassing the Lift Pump Control Board . . . 3-71
The SCR 1 "OFF" Circuit . . . . . . . . . . . . . . . . . 3-4
ACCELE RAT0R . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
INDUCTION CURRENT FROM THE MOTOR . . 3-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
THE CONTROL CARD . . . . . . . . . . . . . . . . . . . . . . 3-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Pulse Monitor Trip . . . . . . . . . . . . . . . . . . . . . . . 3-8
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . 3-73
SRO Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Control Card Adjustments . . . . . . . . . . . . . . . . . 3-8 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 3-73
Accelerator Control . . . . . . . . . . . . . . . . . . . . . 3-11 Standard Instrument Panel . . . . . . . . . . . . . . 3-74
CONTROL CARD . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 MOTOR MAINTENANCE - GENERAL . . . . . . 3-75
Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 BRUSH AND COMMUTATOR INSPECTION . 3-75
SEQUENCE OF OPERATION . . . . . . . . . . . . . . 3-12 NORMAL COMMUTATOR SERVICE . . . . . . . . 3-77
SCR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 COMMUTATOR PROBLEMS . . . . . . . . . . . . . . 3-78
CONTROL CARD CONNECTIONS . . . . . . . . . 3-14 BRUSH REPLACEMENT, DRIVE AND
HAND SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 HYDRAULIC PUMP MOTORS . . . . . . . . . . . . . 3-80
CHECKS AND ADJUSTMENTS, Traction Motor Removal . . . . . . . . . . . . . . . . 3-82
CONTROL CARD . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Hydraulic Pump Motor Installation . . . . . . . . 3-83
Function Codes . . . . . . . . . . . . . . . . . . . . . . . 3-18 Power Steering Pump Motor . . . . . . . . . . . . 3-83
Bench Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 MOTOR REMOVAL AND INSTALLATION . . . . 3-83
Tests-Control Card Installed in a Lift Truck 3-19 Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . 3-83
FUNCT I0N SETT INGS . . . . . . . . . . . . . . . . . . . 3-20 Traction Motor Installation . . . . . . . . . . . . . . . 3-83
 Section 3 Section 5
Lift Pump and Motor Removal . . . . . . . . . . . 3-84 PARKING BRAKE LEVER ASSEMBLY-
Lift Pump and Motor Installation . . . . . . . . . 3-84 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Power Steering Pump and Motor Removal 3-84 TROUBLESHOOTING ...................... 5-9
Power Steering Pump and Motor Installation 3-85 Section 6
TRACTION MOTOR REPAIR . . . . . . . . . . . . . . 3-85 TRAIL AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85 WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
COMMUTATOR REPAIRS ................. 3-85 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87 WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Damaged Field and Armature . . . . . . . . . . .
. 3-87 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Short-Circuit in an Armature Winding . . . . . 3-88 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Short-Circuit in the Armature . . . . . . . . . . . . 3-88 STEER AXLE ASSEMBLY . . . . . . . . . . . . . . :. . . . 6-3
Open Circuit in a Field Coil . . . . . . . . . . . . . . 3-88 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Short-circuit in a Field Coil . . . . . . . . . . . . . . 3-88 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Short-circuit Between Field and Motor Case 3-88 POWER STEERING SYSTEM . . . . . . . . . . . . . . . 6-4
Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88 General . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
WIRING DIAGRAMS AND SCHEMATICS . . . . 3-90 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
STEERING WHEEL AND COLUMN
Section 4 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
TRANSAXLE-GENERAL . . . . . . . . . . . . . . . . . . . . 4- 1 . . . . . . . . . . 6-5
TRANSAXLE SPEC1FlCATlONS . . . . . . . . . . . . $ 4 1- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
TROUBLESHOOTING ...................... 4.6 POWER STEERING CYLINDER . . . . . . . . . . . 6-14
Section 5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
SPECIFICAT IONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . 5-1
CHECKS AND ADJUSTMENTS . . . . . . . . . . . . 6-14
SERVlCE BRAKE ADJUSTMENT . . . . . . . . . . . . 5-1
Remove Air from the System . . . . . . . . . . . . 6-14
REMOVAL-SERVICE BRAKE PADS . . . . . . . . . . 5-1
Check the Operation . . . . . . . . . . . . . . . . . . . 6-15
INSTALLATION-SERVICE BRAKE PADS . . . . . . 5-1
Steering Pressure . . . . . . . . . . . . . . . . . . . . . 6-15
REMOVAL-SERVICE BRAKE CALIPER . . . . . . . 5-2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 6-16
INSTALLATION-SERVICE BRAKE CALIPER . . 5-3
DISASSEMBLY-SERVICE BRAKE CALIPER . . 5-3 Section 7
ASSEMBLY-SERVICE BRAKE CALIPER . . . . . . 5-3 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
REMOVAL-PARKING BRAKE CALIPER . . . . . . 5-3 HOIST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
INSTALLATION-PARKING BRAKE CALIPER . . 5-4 TILT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
DISASSEMBLY-PARKING BRAKE CALIPER . . 5-6 AUXl LlARY FUNCTIONS . . . . . . . . . . . . . . . . . . . . 7-1
ASSEMBLY-PARKING BRAKE CALIPER . . . . . . 5-6 Third Function Location . . . . . . . . . . . . . . . . . . . 7-1
MASTER CYLlNDER- REMOVAL . . . . . . . . . . . . .5-6 Fourth Function Location . . . . . . . . . . . . . . . . . 7-1
MASTER CYLINDER-INSTALLATION . . . . . . . . 5-6 HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . 7-1
MASTER CYLINDER-DISASSEMBLY . . . . . . . . 5-6 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
MASTER CYLINDER- ASSEMBLY . . . . . . . . . . . . 5.7 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
PARKING BRAKE LEVER ASSEMBLY- Hoist Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Power Steering Pump . . . . . . . . . . . . . . . . . . . . 7-2
 Section 7 Section 8
Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Installation. Sideshift Carriage . . . . . . . . . . . 8-12
Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . 7-2 MASTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
HOIST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Disassembly Procedures for the Two Stage
Installation . . . . . . . . . . . . . . . . . . . Mast with Limited or Full Free Lift . . . . . . . . 8-14
Disassembly Procedures for
Disassembly-Seal Replacement
the Three Stage Mast . . . . . . . . . . . . . . . . . . 8-17
............................ 7-4
Cleaning and Inspection . . . . . . . . . . . . . . . . 8-19
POWER STEERING PUMP AND MOTOR . . . . . 7.5
Assembly of the Two Stage Mast
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 with Limited and Full Free Lift . . . . . . . . . . . 8-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Assembly of the Three Stage Mast
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 with Full Free Lift . . . . . . . . . . . . . . . . . . . . . . 8-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Mast Installation . . . . . . . . . . . . . . . . . . . . . . . 8-21
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Removal of the Main Lift Cylinders . . . . . . . 8-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Removal of the Free Lift Cylinder . . . . . . . . 8-22
Disassembly of a Lift Cylinder . . . . . . . . . . . 8-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Assembly of a Lift Cylinder . . . . . . . . . . . . . . 8-22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Installation of the Main Lift Cylinders . . . . . . 8-24
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Installation of the Free Lift Cylinder
MAST TILT ADJUSTMENT . . . . . . 7-12
HEADER HOSE ARRANGEMENTS . . . . . . . . 8-25
CONTROL VALVE-EMERGENCY REPAIR . . 7-12
Installation of Header Hoses for
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 7-13 Two Stage Mast with Limited Free Lift . . . . 8-26
Section 8 Installation of Header Hoses for
Two Stage Mast with Full Free Lift . . . . . . . 8-27
MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Installation of Header Hoses for
DESCRIPTION AND OPERATION . . . . . . . . . . . . 8-1 Three Stage Mast with Full Free Lift . . . . . . 8-30
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 TILT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Mast Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
TWO STAGE MAST WITH LIMITED FREE LIFT 8-3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Description and Operation . . . . . . . . . . . . . . . . 8-3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
TWO STAGE MAST WITH FULL FREE LIFT . . . 8-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 CHECKS AND ADJUSTMENTS . . . . . . . . . . . . 8-34
THREE STAGE MAST WITH FULL FREE LIFT . 8-7 Check the Lift Cylinders for Leaks . . . . . . . . 8-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Check the Tilt Cylinders for Leaks . . . . . . . . 8-34
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Adjust the Tilt Cylinders . . . . . . . . . . . . . . . . . 8-34
SAFETY PROCEDURESWHEN WORKING Adjust the Lift Chains . . . . . . . . . . . . . . . . . . . 8-35
NEAR THE MAST . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Adjust the Mast . . . . . . . . . . . . . . . . . . . . . . . . 8-36
MAST REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 8-9 Adjust the Carriage . . . . . . . . . . . . . . . . . . . . 8-36
MAST REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 8-38
FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Section 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
BATTERY AND CHARGING SYSTEM-
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
CARRIAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 SAFETY TIPS FOR HANDLING
Removal, Standard Carriage . . . . . . . . . . . . 8-10 INDUSTRIAL TRUCK BATTERIES . . . . . . . . . . . . 9-1
Removal, Sideshift Carriage . . . . . . . . . . . . . 8-12 LEAD ACID BATTERIES . . . . . . . . . . . . . . . . . . . . 9-2
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Installation, Standard Carriage . . . . . . . . . . . 8-12 Chemical Reaction . . . . . . . . . . . . . . . . . . . . . . . 9-3
 Section 9 Section 9
HOW TO SELECT THE BATTERY . . . . . . . . . . . . 9-4 How to Know when the Battery
Voltage of a Battery . . . . . . . . . . . . . . . . . . . . . . 9-4 is Fully Charged . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
. . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Battery Ratings Battery Charging Area .................... 9.9
Kilowatt Hours . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Equipment Needed . . . . . . . . . . . . . . . . . . . . . . 9-9
THE BATTERY AS A COUNTERWEIGHT . . . . . 9.5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 9-10
THE NEW BATTERY . . . . . . . . . . . . . . . . . . . . . . . 9-5 Section 10
BAlTERY MAINTENANCE . . . . . . . . . . . . . . . . . . 9-5 SERVICE PARTS
Maintenance Records . . . . . . . . . . . . . . . . . . . . 9-5 ORDERING INSTRUCTIONS . . . . . . . . . . . . . . 10-1
Cleaning the Battery . . . . . . . . . . . . . . . . . . . . . 9-6 HOW TO ORDER SERVICE PARTS . . . . . . . . 10-1
Adding Water . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 WHEN ORDERING PARTS . . . . . . . . . . . . . . . . 10-1
Hydrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 TECHNICAL PUBLICATIONS . . . . . . . . . . . . . . 10-1
Battery Temperature . . . . . . . . . . . . . . . . . . . . . 9-7 PARTS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
CHARGING THE BATTERY . . . . . . . . . . . . . . . . . 9-8 OPERATING MANUAL . . . . . . . . . . . . . . . . . . . . 10-1
Types of Battery Charges . . . . . . . . . . . . . . . . . 9-8 OPERATOR TRAINING . . . . . . . . . . . . . . . . . . . 10-1
Methods of Charging . . . . . . . . . . . . . . . . . . . . . 9-8 SERVICE TRAINING COURSES . . . . . . . . . . . 10-1
Troubleshooting the Charger . . . . . . . . . . . . . . 9-9 SERVICE TRAINING MATERIALS . . . . . . . . . . 10-1
 SECTION 1

1 OPERATING INSTRUCTIONS
 OPERATING INSTRUCTIONS

CONTENTS

FORKADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
HOW TO PUTA LIFT TRUCK ON BLOCKS ........................... 1-12
HOW TO RAISE THE DRIVE TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
HOW TO RAISE THE STEERING TYRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
HOW TO TOW THE LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
MODEL AND CONTROL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Instrument Panel A (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Instrument Panel B (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70
Instrument Panel C (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Temperature Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
MOVING A DISABLED LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
OPERATOR PRECAUTIONS ......................................... 1-2
OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
OPERATOR PRE-CHECKS AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
PRECAUTIONS FOR BATTERIES IN STORAGE . . . . . . . . . . . . . . . . . . . . . . . 1-14
PRECAUTIONS FOR TRUCKS IN STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SAFENAND INFORMATIONAL LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SAFETYAND OPERATIONAL CHECK LIST ............................ 1-5
SAFE MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SHUT DOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
 OPERATING INSTRUCTIONS

GENERAL 3. Truck Weight - This is the approximate weight of the

truckwithout a load on the forks. This weight plus the weight
Before attempting to operate this truck, carefully read and
of the load to be moved must be considered when operating
understand these operating procedures.
on raised floors, lifts, etc.

4. Capacity Rating - This rating shows the maximum load

Make sure the truck is in proper operating condition. Be sure
all safety devices such as the overhead guard and the load
capacity of this truck with relation to load centres and fork
backrest extension are in place and properly secured.
heights (see diagram on name plate). Personal injury and
Visually inspect the entire truck for any damage that may
damage to the truck can occur if the capacity rating is
have occurred during shipment.
exceeded.
NOTE: Throughout this manual the terms right, left, front
Safety and informational labels are located in conspicuous
and rear relate to theviewpoint of an operatorwalking with or
locations on this truckand should bestrictlyfollowed. Check
riding on the truck.
the name plate of each truck before operation. These safety
and informational labels must be replaced immediately if
Familiarise yourself with the information contained on the
missing or defaced. Labels will vary with type of truck and
name plate which is located on the cowl to the left of the
equipment installed. Refer to the Parts Manual for part
steering column. See Figure 1-1 and Figure 1-2. Informa-
number and location for all labels. The location of the labels
tion on this name plate is as follows:
is also shown in Section 2, GENERAL TRUCK AND
LUBR ICATI0N.
1. Serial Number - This is an identification number
assigned to this particular truck and should be used when This truck meets all applicable mandatory requirements and
ordering service parts or when requesting any information safety standards for powered industrial trucks at the time of
from your Yale Industrial Truck Dealer. The serial number is manufacture.
a six digit number preceded by a letter and is stamped on the
truck frame and on the name plate. No additions, omissions or modifications should be made
that will affect compliance to the previously stated
2. Model Code - An explanation of the model code is requirementsor in anyway minimizetheeffectiveness ofthe
located on the back of the front cover of this manual. safety devices.

2 3 1

I
~~

NOTICE TO USER
1 5
The U S A Occupational Safety and Health Act of 1970 an
03 2
other national safety codes require a new plate d this unit
equipped other than 8s stated on plate Obtain the correcl
plale from your authorised denier I:
Ii
e
If a truck is shipped incomplete
from the factory, the name plate
will be covered by the decal
shown above. Do not operate the
lift truck until you obtain a
complete name plate from your
Yale Industrial Truck Dealer.
Capacities and Cautions
Contained on the Name
plate Must be Strictly
Followed.

Figure 1-1 - Name Plate

1-1
0PERATING INSTRUCT10NS

1 I

An advisory procedure, practice, condition, etc., which is

essential to emphasize.

Directs attention to hazards or unsafe practices which may

result in minor personal injury, product or property damage if
the proper precautions are not taken.

I /r\ WARNING^
Directs attention to unsafe practices which could result in
personal injury or death if proper precautions are not taken.

Figure 1-2 - Name Plate Location

Directs attention to unsafe practices andfor existing hazards
which WILL result in severe personal injury or death if proper
SAFETY AND INFORMATIONAL LABELS precautions are not taken.
Safety and informational labels are located in
conspicuous locations on this truck and should be OPERATOR PRECAUTIONS
strictly adhered to. These safety and informational
labels must be replaced immediately if missing or The following precautions have been prepared for your
defaced. Labels will vary with type of truck and safety and the safety of your fellow workers. Read and

A
equipment installed. Refer to Parts Manual for part understand this information before operating the lift truck.
number of labels.
WARNING: Use special care when travelling

1-
HAZARD INTENSITY LEVEL
without a load as THE RISK OF
OVERTURNING IS GREATER when cornering
and at high speed.
DANGER: Identified by a Red Label,
Check all gauges and indicator lights for correct operation.
immediate hazards which WILL result in
Frequent reading ofthe instrument panel should be a habit.
severe personal injury or death.

1- Follow the Recommended Schedules of Maintenance.

Maintain your lift truck for dependable and economical
operation.
WARNING: Identified by an Orange Label,
hazards or unsafe practices which MAY result in Report all accidents involving personnel, building structures
personal injury or death. and equipment to the proper authority.

1-1 Before each shift, every 8 hours, it is the operator's

responsibility to carry out the following checks and
inspections before beginning truck operation. Do not
CAUTION: Identified by a Yellow Label, hazards or operate truck if it is in need of repair, if it is in an unsafe
unsafe practices which MAY result in minor personal condition, or might contribute to an unsafe condition.
injury or product or property damage. Remove the key and report the condition to the proper
authority. If the truck becomes unsafe in any way while you
are operating it, STOP operating the truck and report the
THE READER MAY FIND ANY OR ALL OF THE matter immediately to the proper authority.
FOLLOWING LABELS USED IN THIS PUBLICATION. AN
UNDERSTANDING OF THEIR USE, AS GIVEN BELOW
WILL AID THE READER.

1-2
 OPERATING INSTRUCTIONS

Basic maintenance information and the Recommended 2. Watch that your load does not exceed the capacity
Schedule of Maintenance are in the Operating Manual, rating of the truck. The truck capacity is posted on the name
located in the document holder on the compartment cover. plate which is attached to the truck at the factory.
Also refer to Section 2, GENERAL TRUCK AND
LUB R ICAT1ON. 3. Do not handle unstable or loosely stacked loads.

1. Make sure overhead guard, load backrest extension, 4. Donotstartoroperatethistruckorany of itsfunctionsor

and all other protective equipment is attached. attachments if you are not in the operator's seat, which is the
designated operator's position for this Yale lift truck.
2. Make sure all capacity, safety and informational plates
or labels are attached. This truck is not considered safe to 5. Never allow anyone to ride on your truck and never
use without a legible, properlyfilled out name plate. Contact allow anyone other than a qualified professional to operate
Yale Materials Handling Corporation or your local dealer for your truck.
Yale industrial trucks if the name plate is not present and
legible. See Section 2, GENERAL TRUCK AND 6. Referto the Maintenanceand Lubrication section inthis
LUBRICATION or the Parts Manual for label and plate manual for the recommended hourly service intervals.
locations. Regular attention at the specified time will pay dividends in
maximum efficiency and longer life of the truck. '
3. Inspect truck for any damage that might have occurred
during the previous shift.
OPERATING PROCEDURE
4. Inspect truck before and after operating, for any signs of Apply power to the truck by connecting the battery plug to
external leaking of the battery, steering system, hydraulic the truck receptacle. Be sure the plug is fully inserted and
system, etc. locked into place so that there is enough pressure at the
contact mating surfaces.
5 . Check hydraulic hoses for leaking, chafing, cuts or
reinforcement showing through the outside of the hose. Make sure the direction control levers are in the neutral
position before operating the truck.
6. Check for mistracking of the hoses on the sheaves.
The operator must sit on the seat to energise the
7. Make sure chains are not damaged or kinked. electrical circuit.

8. Make sure mast stops and finger guards are in place. Place foot on the service brake pedal.

9. Make sure bonnet latches are adjusted (if equipped) Turn key toward forks (clockwise).
and fastened.
Release the parking brake.
10. Operate service and parking brakes, all hydraulic
controls, (lift, tilt and auxiliary, if equipped), accelerator, Select desired direction.
shifting linkages and steering. Make surethey operatefreely
and return to their proper positions. See section on Release service brake pedal.
OPERATING CONTROLS for detailed descriptions.

A
Depress accelerator pedal to travel
11. Inspect condition of wheels and tyres.
CAUTION: Operating the drive control in a
12. Inspect forks for any damage. Make sure they are situation where the truck will not move will
properly attached and locking clips are in their proper damage the electric motor.
position.
1. Keep hands, feet and other parts of your body inside the
13. Test horn, lights and all other accessories. Make sure operator's compartment. Parts of your body outside the
they are properly mounted and in good working order. truck can be injured when passing obstructions.

14. Operate truck and make sure all gauges and meters are 2. Do not permit passengers to ride on the truck.
functioning properly.
3. Observe and comply with instructions concerning floor
15. Make sure any unusual noises are investigated loadings. Know the weight of your truck and load combined.
immediately. Truck weight information is located on the name plate.

4. Travel with the lifting mechanism low and where

OPERATOR PRE-CHECKS AND INSPECTION
possible, tilted back. Do not elevate the load except during
1. When attachments are used, extra care should be stacking.
taken in securing, positioning and transporting the load.
Operate trucks equipped with attachments as partially
loaded trucks.

1-3
OPERATING INSTRUCTIONS

Q
5. The operator can change the direction of travel while
the lifttruck is moving by moving the direction control lever in
the opposite direction. This is called plugging. 20. Watch out for pedestrians at
all times. Do not drive up to anyone
6. Look in the direction of travel and keep a clear view of standing in front of an object.
the path of travel.

7 . If visibility is impaired by the load, operate truck with the

forks trailing and always look in the direction of travel. 21. Observe all traffic regulations, including authorised
plant speed limits. Under normal traffic conditions, keep to
8. Start, stop, travel, steer and brakesmoothly. Slow down
the right. Maintain a safe distance from the truck ahead
for turns and on uneven or slippery surfaces that could
(approximately three truck lengths), and keep the truck
cause truck to overturn or slide.
under control at all times.
9. Before entering trucks or trailers, be certain the brakes
22. Yale lift trucks are not intended for use on public roads.
on the truck or trailer are applied and wheel chock(s) are in
place. If trailers are not coupled to a tractor, supports may be 23. When leaving truck unattended, lower the lifting
needed to prevent upending or corner dipping. Check the mechanism, shut off power, remove key and apply parking
flooring of trucks, trailers and railroad cars for breaks and
brake. Chock wheels if truck is parked on an slope.
weakness before driving onto them.
24. Do not remove overhead guard or load backrest
10. Before driving over a dock board or bridge plate, be extension unless specifically authorised.
certain that it is properly secured. Drive carefully and slowly
across the dockboard or bridge plate and never exceed its
25. Always set the forks as far apart as the load will permit.
rated capacity.
Make sure that fork length is at least 213 of load length.
11. Maintain a safe distance from the edge of ramps or
26. Carry the load flush against the truck.
platforms. Do not push freight cars while on a raised dock or
platform. Do not use this truck for opening or closing'freight
27. Do not put any part of your body into the mast area or
doors. between the mast and truck. Be aware of pinch points on
attachments, especially reach mechanisms.
12. Watch clearances, especially around forks. The driver
must be aware that the forks can sometimes extend beyond
28. Allow no one under or near load or lifting mechanism.
the load. This may cause the forks to hit an object or lift
another load. 29. If a supplementary platform is used, make sure it is
securely fastened to the carriage and forks.
13. Watch outfor obstructions, especiallyoverhead. Check
clearances.
SHUT DOWN PROCEDURE
14. Do not run over objects on the roadway surface as truck
When leaving the truck, fully lower lifting mechanism,
stability and steering may be adversely affected. ensure controls are in neutral, shut off power, apply the
brake, and remove key. If you park the truck on an slope,
15. When approaching cross aisles, slow down, sound chock the wheels.
horn and keep to the right side of aisle.

16. Operate truck under all conditions at a speed that will FORK ADJUSTMENT
permit it to be brought to a stop in a safe manner. Adjust the forks on the fork carriage. Forks should be spaced
as far apart as the load being moved will allow. Both forks
17. On sloping surfaces, higher than 5 percent (a5ft. rise or
should always be the same distance from the centre of the
drop in 100 ft. of travel), operate loaded truck with the load fork carriage.
facing up hill. Do notturn on an slope. For stability reasons, a
lift truck must not be driven across a slope. Checkforthe presence and condition ofstuds at each end of
the carriage upper fork clip slide. If studs are damaged or
18. Operate unloaded truck on all grades with the lifting missing they should be repaired or replaced before the forks
mechanism downhill.
are adjusted.
19. Do not push extra loads with the truck.

1-4
 OPERATING INSTRUCTIONS

To adjust the forks, raise them a few inches off the floor. Lift The check listsare available in tablet form with 50sheets per
up on the keeper pin and slide theforks along the carriage by tablet and can be obtained from your local Yale Industrial
pushing them away from you. Do not pull the forks toward Truck Dealer for a nominal fee.
you. When the forks are set to the desired position, make
sure the keeper pin is down in a slot on the top of the fork Both this manual and the Operating Manual contain the
carriage plate. Recommended Schedule of Maintenance which should be
used as a guide along with the Lubrication Instructions.
SAFETY AND OPERATIONAL CHECK LIST
A “Daily Check List” similar to the one shown on the next
page should be used every day before operating the truck.

1-5
OPERATING INSTRUCTIONS

NOTE: This Daily Check List is available for the Operator. Some items on this list may not be applicable to yourtruck.
This convenient check list is in tablet form and can be ordered through your YALE Industrial Truck Dealer. Form Number
944-641&A.

Yale
Industrial Trucks
Daily pre-shift inspection is an OSHA requirement.
We recommend that you document that these
inspections have been made.
Operator’s Daily Check List
Electric Truck

Record of Fluid Added

~~ ~~~~~ ~ ~

Date Operator Battery Water

Truck Number Model Number Hydraulic Oil

Department Serial Number

Shift Drive Hour Hoist Hour

Meter Reading Meter Reading

SAFETY AND OPERATIONAL CHECKS (Prior to each shift)

Have a qualified mechanic correct all problems (0.K.V) Need Maintenance

Leaks - Hydraulic Oil, Battery

I Tyres - Condition and Pressure I I I

I Forks, Top Clip Retaining Pin and Heel - Check Condition I I I
I Load BackrestiExtension - Securely Attached I I I
I Hydraulic Hoses, Mast Chains and Stops - Check Visually I I I
1 Finger Guards - Attached I I I
I Overhead Guard - Attached I I I
I Safety Warnings - Attached (Refer to Parts Manual for Location) I I I
I Internal Checks: I I I
I Battery - Check Water/Electrolyte Level and Charge I I I
I Hydraulic Fluid Level - Check Level I I I
I Drive Unit Fluid Level - Check Level I I I
I Operator’s Compartment: I I I
I Operating Manual - in Container I I I
- Attached and information matches model, serial number and

Form 944-641 8-A (5/93)

0 Copyright 1993 Yale Materials Handling Corporation

1-6
 OPERATING INSTRUCTIONS

MODEL AND CONTROL INFORMATION with a spinner knob. The horn button is located in the centre
of the steering wheel. Push button to sound horn.
The ERP/C16-20ATF three wheel electric rider lift trucks
have lifting capacities of 1600 kgs to 2000 kgs (3000 Ib to
3. The Operating Manual is sent with the truck and is
4000 Ib).
located in the container behind the operator’s seat. The
Operating Manual is a permanent reference and must be
The trucks feature clean functional styling, low noise levels
available for the operator’s use at all times. Read and
and an operator compartment designed for comfort and
understand this manual before operating the lift truck.
efficiency. Afull line of two stage and three stage masts are
available for this truck as standard equipment and a four
stage mast is available as an option. Pneumatic tyres are
standard. Solid tyres, bonded on a rim or solid pneumatic
shaped tyres are available as options for this truck. ’

No additions, omissions, changes or modifications should

be made that will affect compliance to the previously stated
requirements or in anyway minimizethe effectivenessofthe
safety devices.

Before attempting to operate this truck, carefully read and

understand these operating procedures. Make sure the
truck is in proper operating condition. Ensure all safety
devices such as the overhead guard, operator restraint
system and the load backrest extension are in place and
properly secured.

Figure 1 4 - Operating Controls

4. Storage Box - The storage box is within easy reach of
the operator and provides a convenient place for pens,
paper and other miscellaneous items.

5. Battery Connector - The battery connector is in two

parts. One half of the connector is attached to the battery
cables. The other half of the connector is connected to the
electrical system of the lift truck. Make sure both halves of
the connectors are the same type and colour. Make sure the
voltage of the battery is the same as specified on the name
plate. The halves of the connector must be joined for
operation. Pull up on the handle to separate the halves ofthe
connector to disconnect the battery.

-
Figure 1-3 Three Wheel Electric Rider 6. Accelerator Pedal - The accelerator pedal controls the
speed of the truck. To INCREASE travel speed depress the
The following item number call outs may be found in either pedal. To DECREASE travel speed release the pedal.
Figure 1-4 or Figure 1-5.
7 . Brake Pedal - The large service brake pedal is located
1. Key Switch - The key switch in the “ON” position will for left or right foot operation. Depress the foot pedal to apply
energise the electrical system. The indicator lamps on the the service brakes. Another method of stopping the lift truck
dashboard display should illuminate when the key switch is is plugging. Plugging means reversing the direction control
turned to on. while travelling, causing the truck to slow to a stop. See
Direction Control Lever information.
2. Steering Column - The steering column is adjustable to
five tilt positions. The molded steering wheel is equipped

1-7
OPERATING INSTRUCTIONS

Figure 1-5 - Operating Controls

8. Operator Seat - The lever to adjust the operator's seat 10. Direction Control Lever - There is a direction control
is located between the seat rails. Move the lever to the left lever on both sides of the steering column. The direction
and slide the seat to the desired position. Release the lever. control levers have three positions, forward, neutral and
reverse. Select the direction of travel by moving the lever.
9. Parking Brake - To apply parking brake step on foot Both levers will move together when either lever is moved.
pedal. An indicator lamp on the instrument panel will
illuminate when the parking brake is applied. To release
parking brake pull on parking brake release lever. The
parking brake must be applied whenever the operator
leaves the truck. A buzzer will sound if the parking brake is
not applied. When carrying the maximum permitted load the
parking brake should hold the truck on a 15% grade.
Experienced maintenance personnel should make
adjustments to the parking brake when necessary.

Figure 1-7 - Direction Control Lever

The operator can change the direction of travel while the lift
truck is moving by moving the direction control lever in the
opposite direction. The lift truck will slow to a stop and then
accelerate in the opposite direction. This action is called
Plugging. Always return the lever to neutral before
dismounting.
I
Figure 1-6 - Parking Brake

1-8
 OPERATING INSTRUCTIONS

11. Light Assemblies - Rocker switches used to control the

rear light bar assemblies are located on the control lever
cover. Make sure the dual tail, brake and back-up lights are
functioning. Other optional light packages are available for
this truck.

Figure 1-11 - Tilt Control Lever

15. Auxiliary Function Levers - These levers are used to
operate additional hydraulic functions. Two different
function levers are available for the third function. One lever
I has a detented position for use with attachments that have a
- Light Switch
I I

Figure 1-8 clamping actuation. This lever is actuated by pushing the

lever slightly to the right and then forward or backward. This
12. Steering Column Tilt Lever - The steering column can lever will be installed on trucks if the type of attachment is
be adjusted to five positive locked angles. Support column unknown. The other lever is not detented and is used for
weight for easier operation. Lift the lever at the base of the attachments with a non-clamping action. The fourth function
steering column and move the column to desired position. lever is spring loaded to a detented position toward the
operator. This lever will be used on all trucks with four
functions. All levers are spring loaded to the neutral position.
Refer to the attachment publication supplied by the
manufacturer for attachment operation.

Figure 1-9 - Steering Column Tilt Lever

13. Lift Control Lever - To raise the forks PULL the hand
lever. To lower the forks PUSH the hand lever. To stop/hold,
move the hand lever to the neutral position. The lever is
spring loaded to the neutral position. I Symbol varies by attachment

Figure 1-12 - Auxiliary Function Levers

16. Instrument Panels - There are several instrument

panels available for this truck. The standard instrument
panel is Item "A'.
Two optional instrument panels are also
described in Items "B" and "C".

a. Battery Voltmeter and Hour Meter

b. Combination Dashboard Display

I1 I \I I\ \
c. Premium Dashboard Display

Figure 1-10 - Lift Control Lever

-
14. Tilt Control Lever To tilt the mast/forks forward PUSH
the hand lever. To tilt the masvforks backward PULL the
hand lever. To hold tilt position move the hand lever to the
neutral position. The lever is spring loaded to the neutral
position.

1-9
OPERATING INSTRUCTIONS

Instrument Panel A (STANDARD) is illuminated. At 70% of discharge an LED will flash,

indicating "energy reserve". At 80% of discharge both led's
The battery voltmeter features a display showing the
will alternately flash, indicating "empty". Lift Interrupt will
state-of-charge. The gauge is divided into three segments,
occur at approximately 80% but will not occur while the lift is
green, yellow and red. When the needle is in the green
being operated. The system will automatically reset when a
segment, it indicates a charged battery. When the needle is
charged battery is connected.
in the yellow segment, the battery voltage is falling off and
when the needle reaches the red segment, the battery must
be replaced by a charged battery.

The hour meter continually displays total operation hours.

The primary function of the hour meter is to determine
maintenance intervals as outlined in the Recommended
Schedule of Maintenance located in this manual.

- Combination Dashboard Display

I I

Figure 1-14

The hour meter continually displays total operation hours.

The primary function of the hour meter is to determine
maintenance intervals as outlined in the Recommended
Schedule of Maintenance located in this manual.

Figure 1-13 - Battery Voltmeter and Hour Meter Instrument Panel C (OPTIONAL)
This premium dashboard display has a four segment LED
Gauges and indicator lamps located on the instrument that displays hour meter readings for traction and pump
panels are described in the following paragraphs. When the motors, battery discharge and a fault indicator lamp. The
key switch is turned on, all indicator lamps should light. The following indicator lamps operate with the Status Code
parking brake lamp remains lit until the parking brake is Function.
released. The other indicator lamps should go out.

The following Indicator lamps are found on all the dashboard

I f, ,i I
displays.

This lamp is illuminated when the parking brake is applied.

Figure 1-15 - Premium Dashboard Display

The hour meter function shows the operating time of the
Parking Brake Lamp truck. The hour meter indicator lamp is illuminated for four
seconds after the lift truck has been turned off. During this
If this lamp is illuminated the brake fluid is low. Have the time the operating time is displayed on the digital display. If
brake system checked for leaks and add fluid to the there is an hour meter for the pump motor it will be displayed
reservoir. for another four seconds.

Brake Fluid Level Lamp Hour Meter Function Indicator

Instrument Panel B (OPTIONAL)

This combination dashboard display has a battery indicator
which features a LED (Light Emitting Diode) display of
state-of-charge. Onlythe LED indicating the state-of-charge

7-70
 OPERATING INSTRUCTIONS

The Status Code numbers indicate symptoms or SAFE MAINTENANCE PROCEDURES

malfunctions that the control card can sense. The numbers
This truck meets all applicable mandatory requirements and
will appear on the digital display. The fault symbol indicator
safety standards for powered industrial trucks at the time of
lamp (wrench and maintenance manual) will flash if the
manufacture. The truck is also equipped with certain safety
control card senses a symptom or malfunction. All status
devices as standard equipment. For example, all high lift
codes will have a minus sign before the first digit.
trucks are equipped with a load backrest extension and high
lift rider trucks with an operator’s overhead guard. When
remote elevating control is specified, an operator’s work
platform is supplied.

No additions, omissions or modifications should be made

that will affect compliance to the mandatory requirements or
Fault Indicator Lamp in any way reduce the effectiveness of the safety devices.

The battery function indicator shows the battery charge The following instructions have been prepared for your
represented by numbers between 0 and 100. The indicator safety and the safety of your fellow workers during
in the battery symbol will flash when the display reads 19 maintenance operations and should be strictly followed.
(battery is approximately 70% discharged). The lift pump Carefully read and understand the maintenance procedures
circuit will be disabled at a display of 10 (approximately 80% before attempting to repair the truck. When in doubt of any
of discharge). The status control also checks the battery maintenance procedure, contact your local Yale Industrial
voltage each time a battery is connected. The lift truck will Truck Dealer.
not operate if the battery voltage is not correct. Contact
authorised maintenance personnel if a status code appears 1. Powered industrial trucks may become hazardous if
on the dashboard display. maintenance is neglected. Therefore, adequate
maintenancefacilities, personnel and procedures should be
provided.

2. The Recommended Schedule of Maintenance should

be used as a guide for inspection ofthe truck. See Section 2,
GENERAL TRUCK AND LUBRICATION or the
Battery Function Indicator OPERATING MANUAL.

If this lamp is Illuminated the lift pump or traction motor 3. Only qualified and authorised personnel should be
brushes are worn and must be replaced. lfthetyre and arrow permitted to maintain, repair, adjust and inspect the truck.
symbol is illuminated the traction motor brushes must be
replaced. If the fork and arrow symbol is illuminated the lift 4. The work area should be properly ventilated. Keep
pump motor brushes must be replaced. shop clean and floor dry.

[pi]
5. Avoid fire hazards and have fire protection equipment
present. Do not use an open flame to check level of
electrolyte. Do not use open pans of fuel or inflammable
cleaning fluids for cleaning parts.

1-8881 6. Raise the lift truck only if it is on a solid level floor. Use
solid one piece blocks or other positive truck positioning
devices to support the truck. Chock the wheels to prevent
Brush Wear Indicator movement of the truck.

The traction motor and lift pump motor have thermal 7. Disconnect the battery. Attach a DO NOT OPERATE
sensors. The red LED in the display thermometer will tag to the control handle.
illuminate if a motor is getting too hot. If the fork and arrow
symbol is illuminated the lift pump motor is too hot. If the tyre 8. Before removing any component from the truck, make
and arrow symbol is illuminated the traction motor is too hot. sure that the lifting mechanism (hoist) and slings are of the
Allow the motor to cool if the red LED’s are illuminated. proper capacity and in good condition.

9. When working on the hydraulic system, be sure the

power is turned off and the hydraulic pressure is relieved in
hoses and tubes.

10. Brakes, steering mechanisms, control mechanisms,

[-HIE] warning devices, guards and safety devices should be
inspected regularly and maintained in proper operating
condition.
Temperature Indicator Lamp

1-11
OPERATING INSTRUCTIONS

11. All parts of lifting mechanisms should be carefully and 2. Tow the lift truck slowly.
regularly inspected and maintained in correct operating
condition. 3. Raise the carriage and forks approximately 12 inches
(30 cm) from the surface. Install a chain to prevent the
12. All hydraulic systems should be regularly inspected and carriage and upright channels from moving. See Section 8,
maintained in conformance with the maintenance MAST.
schedules. Lift cylinders, valves and other similar parts
should be checked to ensure that’ldrift” has not developed to 4. If another lift truck is used to tow the disabled lift truck,
the extent that it would create a hazard. See the ROAD AND that lift truck must have an equal or larger capacity than the
LOAD TEST, in Section 2, GENERAL TRUCK AND disabled lift truck. Install an approximate half capacity load
LUBR ICATI0N. on the forks of the lift truck that is being used to tow the
disabled lift truck. This half capacity load will increase the
13. Special trucks or devices designed and approved for traction of the lift truck. Keep the load as low as possible.
hazardous area operation should receive special attention
to ensure that maintenance preserves the original, 5. Use a steel towing chain attached to the tow pins in the
approved safe operating features. counterweights of both lift trucks.

14. Modifications and additions which affect capacity and Never lift a disabled lift truck unless the lift truck must be
safe truck operation should not be performed by the moved and cannot be towed. The lift truck used for lifting the
customer or user without the manufacturer’s prior written disabled truck must have a rated capacity equal to or greater
approval. Capacity, operation and maintenance instfiuction than the weight of the disabled lift truck. The capacity must
plates, tags or labels should be changed accordingly. be for a load centre equal to half the width of the disabled lift
truck. See the name plate of the disabled lift truck for the
15. Capacity, operation and maintenance instfiuction approximate total weight. The forks must extend the full
plates, tags and labels should be maintained in legible width of the disabled lift truck. Centre the weight of the
condition. disabled lift truck on the forks and be careful not to damage
the under side of the lift truck.
16. The truck should be kept in clean condition to minimize
fire hazards and facilitate detection of loose or damaged NOTE: There may be problems with more than one of the
parts. above areas of the truck. Do not tow the lift truck if you have

A
not identified all problem areas.
17. Checking the performance of the truck or attachments
should be conducted in an authorised safe area. WARNING: Be sure to stay clear of the tow
chain, towing vehicle and the lifttruckduring the
18. Always useYALE replacement parts to be surethey are towing operation to prevent injury.

A
interchangeable with the original parts and are of a quality
equal to that provided in the original equipment. WARNING: Travel slowly and do not tow on
grades. NEVER tow the lift truck faster than a
You should also become familiar with additional, local normal walking speed. Always tow smoothly
maintenance safety instructions. without sudden starts or stops.

A
MOVING A DISABLED LIFT TRUCK

WARNING: Use extra care when towing a lift

truck if there is a problem with any of the
A WARNING: Until repairs are complete keep a
tag on the steering wheel stating - DO NOT
OPERATE. After the lift truck is moved to the
new location, install blocks at the wheels to prevent the lift
truck from moving. Remove the key from the key switch.
following:
1. Brakes do not operate correctly HOW TO PUT A LIFT TRUCK ON BLOCKS
2.
3.
4.
Steering does not operate correctly
Tyres are damaged
Traction conditions are bad
A WARNING: The lift truck must be put on blocks
for some types of maintenance and repair. The
removal of the following assemblies will cause
large changes in the centre of gravity: mast, reach
mechanism, transaxle or the steering axle assembly. When
5. If the lift truck must be towed on a steep grade
the lift truck is put on blocks, put additional blocks in the
following positions to maintain stability:
If the steering pump motor does not operate steering the lift
truck can be difficult. Poor traction can cause the disabled lift
a. Before removing the mast or transaxle, put blocks
truck or towing vehicle to slide. Steep grades will increase
under the rear frame so that the lift truck cannot tip
the required brake effort.
backward.

HOW TO TOW THE LIFT TRUCK

1. The towed lift truck must have an operator.

1-12
 OPERATING INSTRUCTIONS

b. Before removing the steering axle assembly or NOTE: Some lift trucks have lifting eyes. These lifting
counterweight, put blocks under the mast assembly so eyes can be used to raise the lift truck so that blocks can be
that the lift truck cannot tip forward. installed.

Thesurface must be solid, even, and level when the lifttruck

HOW TO RAISE THE DRIVE TYRES
is put on blocks. Make sure that any blocks used to support
the lift truck are solid, one piece units. 1. Put the mast in the vertical position. Put a block under
each outer upright.
HOW TO RAISE THE STEERING N R E
2. Tilt the mast fully forward until the drive tyres are raised
1. Apply the parking brake. Put blocks on both sides (front from the surface.
and back) of the drive tyres to prevent movement of the lift
truck. 3. Put blocks under the frame behind the drive tyres.

2. Use hydraulic jacksto raisethe steeringtyre. Makesure 4. Put additional blocks on each side (front and back) of
the jacks have a capacity of at least 2/3 of the total weight of the steering tyre to prevent movement of the truck.
the lift truck as shown on the name plate.
5. If the hydraulic system will not operate, use a hydraulic
3. Put the jacks under the rear of the frame to raise the lift jackunderthesideoftheframe nearthe front. Makesurethe
truck. Put blocks under the frame to support the lift truck. jack has a capacity equal to at least half the weight of the lift
truck. See the name plate for truck weight.

DRIVE TYRES STEERING TYRES

Figure 1-16 - Putting a Lift Truck on Blocks

PRECAUTIONS FOR TRUCKS IN STORAGE stored with forks attached the forks should be fully lowered.
Coat all exposed portions of cylinder rods with fresh high
Complications can arise as a result of improper handling of
grade SAE 30 or 40 weight engine oil.
trucks during periods of storage.The main areas of concern
are electricmotors, hydrauliccomponents and electrictruck Electric trucks should be stored without batteries, therefore
batteries. Electric powered trucks can best be protected by you will have to provide a fully charged battery for the
being operated for a short period of time each month.
exercise period.
Before placingany truck in storage' must choose an
All hydraulic cylinders should be cycled several times each
area which is 'lean* and free airborne
month to keep the seals active and to coat the interior walls
contaminants.
with oil. Actuate each cylinder, in both directions, until the
stops are reached. With the power off, actuate each
When parking the truck chock the Do not use the hydraulic control valve to relieve hydraulic pressure.
hand brake. The mast should be fully lowered and tilted
back. For safetyand increased usable Roor area remove the
forks and tag them with the truck serial number. If truck is

1-13
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