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
MAINTENANCE AND REPAIR
e When lifting parts or assemblies, make sure that
all slings, chains, or cables are correctly fastened
and that the load being lifted is balanced. Make
sure that the crane, cables, and chains have the
capacity to support the weight of the load.
e Do not lift heavy parts by hand. Use a lifting
mechanism.
e Wear safety glasses.
e DISCONNECT THE BATTERY CONNECTOR
before doing any maintenance or repair on
electric lift trucks.
e Always use correct blocks to preventthe unit from
rolling or falling. See “How to Put the Lift Truck on
Blocks” in the OPERATOR’S MANUAL or
SECTION 2, GENERAL TRUCK AND
LUBRICATION.
e Keep the unit and working area clean and in order.
e Use the correct tools for the job.
e Keep the tools clean and in good condition
e Always use YALE APPROVED parts when
making repairs. Replacement parts must meet or
exceed the specifications of the original
equipment manufacturer.
e Make sure that all nuts, bolts, circlips, and other
fastening devices are removed before using force
to remove parts.
e Always fasten a DO NOT OPERATE sign to the
controls of the unit when making repairs or if the
unit needs repairs.
e Make sure you follow the DANGER, WARNING,
and CAUTION notes in the instructions.
e Wear a rubber apron, gloves, boots, and goggles
or a face shield when doing maintenance on
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
match or a lighter. No smoking and do not create
sparks. Make sure the area has ventilation. If the
battery is charged in the lift truck, open the bonnet.
Lift batteries correctly with a crane or equipment
designed for the job. Always use a spreader bar
designed and adjusted for the battery. Move
batteries with a lift truck, or a conveyor or rollers
designed for that purpose. If the battery does not
have a cover, a rubber mat or insulating material
must be put over the top of the battery to prevent a
short circuit with other equipment. Make sure the
the lifting equipment has enough capacity for the
job. Do not use chain or wire rope slings.
Never put metal materials or tools on a battery.
When maintenance on the battery or the battery
charger is required, disconnect both the AC and
DC power. If new battery connectors must be
installed, make sure the positive and negative
terminals and cables are kept separate and
insulated from each other. Even a momentary
short circuit can cause an explosion and damage
the battery.
Keep water readily available to flush spilled
electrolyte. Electrolyte in the eyes must be flushed
with water immediately and then quickly get
medical attention. Special showers and eye wash
systems are required in areas where battery
maintenance is done.
If electrolyte is spilled on a work surface or the
floor, flush the area with water, use a solution of
soda (sodium bicarbonate) to make the acid
neutral.
Only trained persons are permitted to do
maintenance on batteries and battery chargers.
Make sure that the regulations by government
safety agencies, government insurers, private
insurers, and private organizations are followed
when doing maintenance on batteries.
NOTE: The following symbols and words indicate
safety information in this manual:
DANGER: Indicates a condition that will
cause immediate death or injury!
A WARNING: Indicates a condition that can
cause death or injury!
A
CAUTION: Indicates a condition that can
cause property damage!
 CONTENTS
Section 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY AND INFORMATIONALLABELS . . . . . 1-2
OPERATOR PRECAUTIONS . . . . . . . . .
OPERATOR PRE-CHECKS AND INSPECTION 1-3
OPERATING PROCEDURE . . . . . . . . . . . . . . . . . 1-3
SHUT DOWN PROCEDURE . . . . . . . . . . . . . . . . . 1-4
FORK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 1-4
SAFETY AND OPERATIONAL CHECK LIST . . . 1-5
MODEL AND CONTROL INFORMATION . . . . . . 1-7
instrument Panel A (STANDARD) . . . . . . . . '-lo
Instrument Panel B (OPTIONAL) . . . . . . . . . 1-10
instrument Panel (OPTIONAL) . . . . . . . . '-lo
Temperature Indicator Lamp . . . . . . . . . . . . . 1-11
SAFE MAINTENANCE PROCEDURES . . . . . . 1-11
MOVING A DISABLED LIFT TRUCK . . . . . . . . 1-12
HOW TO TOW THE LIFT TRUCK . . . . . . . . . . 1-12
HOW TO PUT A LIFT TRUCK ON BLOCKS . 1-1 2
HOW TO RAISE THE STEERING TYRE . . . . 1-13
HOW TO RAISE THE DRIVE TYRES . . . . . . . 1-13
PRECAUTIONS FOR TRUCKS IN STORAGE 1-13
PRECAUTIONS FOR BATTERIES
IN STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Section 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
FLOOR PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
REAR COMPARTMENT COVER . . . . . . . . . . . . . 2-1
FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
STEERING COLUMN COVER . . . . . . . . . . . . . . . 2-2
HYDRAULIC CONTROL VALVE COVERS . . . . . 2-2
BATTERY COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
BATTERY REMOVAL AND INSTALLATION . . . . 2-3
BATTERY PLATFORM . . . . . . . . . . . . . . . . . . . . . . 2-3
OVERHEAD GUARD . . . . . . . . . . . . . . . . . . . . . . . 2-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Section 2
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Repairs. Small Leaks . . . . . . . . . . . . . . . . . . . . . 2-5
Repairs. Large Leaks . . . . . . . . . . . . . . . . . . . . 2-5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steam Method of Cleaning . . . . . . . . . . . . . . . . 2-6
Chemical Solution Method of Cleaning
Additional Preparations for Repair . . . . . . . . . . 2-6
WELDING REPAIRS . . . . . . . . . . .
TYRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . 2-6
HOW TO CHANGE THE WRES . . . . . . . . . . . . . 2-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
PNEUMATIC TYRES . . . . . . . . . . . . . . . . . . . . . . . 2-7
Remove the Wheel from the Lift Truck . . . . . . .2.7
Remove the Tyre from the Wheel . . . . . . . . . . 2-8
Install the Tyre on the Wheel . . . . . . . . . . . . . . 2-8
Add Air to the Tyres . . . . . . . . . . . . . . . . . . . . . . 2-9
PNEUMATIC SHAPED SOLID TYRES . . . . . . 2-10
Remove the Wheel from the Lift Truck . . . . 2-10
Remove the Tyre from the Wheel . . . . . . . . 2-10
Install the Tyre on the Wheel . . . . . . . . . . . . . 2-11
SOLID TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Remove the One Piece Wheel and Tyre . . 2-12
Install the Tyre on the One Piece Wheel . . 2-12
Install the Wheels on the Lift Truck . . . . . . . 2-12
LABEL REPLACEMENT . . . . . . . . . . . . . . . . . . . 2-13
YALE WARRANTY INFORMATION . . . . . . . . . 2-14
RECOMMENDED SCHEDULE
OF MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 2-14
LUBRICATION INSTRUCTIONS . . . . . . . . . . . 2-15
EVERY 8 HOURS . . . . . . . . . . . . . . . . . . . . . . . . 2-15
EVERY 350 HOURS . . . . . . . . . . . . . . . . . . . . . . 2-15
EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . 2-15
HYDRAULIC OILS . . . . . . . . . . . . . . . . . . . . . . . . 2-21
GEAR OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
FREEZER APPLICATIONS . . . . . . . . . . . . . . . . 2-24
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Complete Truck . . . . . . . . . . . . . . . . . . . . . . . 2-24
Control ComDartment . . . . . . . . . . . . . . . . . . 2-24
Electrical System . . . . . . . . . . . . . . . . . . . . . . 2-24
Battery Compartment . . . . . . . . . . . . . . . . . . 2-24
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Steering Linkage and Pivot Points . . . . . . . . 2-24
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . 2-24
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
Lift Pump and Motor Removal . . . . . . . . . . . 3-84
Lift Pump and Motor Installation . . . . . . . . . 3-84
Power Steering Pump and Motor Removal 3-84
Power Steering Pump and Motor Installation 3-85
TRACTION MOTOR REPAIR . . . . . . . . . . . . . . 3-85
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
COMMUTATOR REPAIRS ................. 3-85
TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Damaged Field and Armature . . . . . . . . . . .
. 3-87
Short-Circuit in an Armature Winding . . . . . 3-88
Short-Circuit in the Armature . . . . . . . . . . . . 3-88
Open Circuit in a Field Coil . . . . . . . . . . . . . . 3-88
Short-circuit in a Field Coil . . . . . . . . . . . . . . 3-88
Short-circuit Between Field and Motor Case 3-88
Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
WIRING DIAGRAMS AND SCHEMATICS . . . . 3-90
Section 4
TRANSAXLE-GENERAL . . . . . . . . . . . . . . . . . . . . 4- 1
TRANSAXLE SPEC1FlCATlONS . . . . . . . . . . . . $ 4 1-
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
TROUBLESHOOTING ...................... 4.6
Section 5
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1
SPECIFICAT IONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . 5-1
SERVlCE BRAKE ADJUSTMENT . . . . . . . . . . . . 5-1
REMOVAL-SERVICE BRAKE PADS . . . . . . . . . . 5-1
INSTALLATION-SERVICE BRAKE PADS . . . . . . 5-1
REMOVAL-SERVICE BRAKE CALIPER . . . . . . . 5-2
INSTALLATION-SERVICE BRAKE CALIPER . . 5-3
DISASSEMBLY-SERVICE BRAKE CALIPER . . 5-3
ASSEMBLY-SERVICE BRAKE CALIPER . . . . . . 5-3
REMOVAL-PARKING BRAKE CALIPER . . . . . . 5-3
INSTALLATION-PARKING BRAKE CALIPER . . 5-4
DISASSEMBLY-PARKING BRAKE CALIPER . . 5-6
ASSEMBLY-PARKING BRAKE CALIPER . . . . . . 5-6
MASTER CYLlNDER- REMOVAL . . . . . . . . . . . . .5-6
MASTER CYLINDER-INSTALLATION . . . . . . . . 5-6
MASTER CYLINDER-DISASSEMBLY . . . . . . . . 5-6
MASTER CYLINDER- ASSEMBLY . . . . . . . . . . . . 5.7
PARKING BRAKE LEVER ASSEMBLY-
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Section 5
PARKING BRAKE LEVER ASSEMBLY-
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
TROUBLESHOOTING ...................... 5-9
Section 6
TRAIL AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
STEER AXLE ASSEMBLY . . . . . . . . . . . . . . :. . . . 6-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
POWER STEERING SYSTEM . . . . . . . . . . . . . . . 6-4
General . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
STEERING WHEEL AND COLUMN
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
. . . . . . . . . . 6-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
POWER STEERING CYLINDER . . . . . . . . . . . 6-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
CHECKS AND ADJUSTMENTS . . . . . . . . . . . . 6-14
Remove Air from the System . . . . . . . . . . . . 6-14
Check the Operation . . . . . . . . . . . . . . . . . . . 6-15
Steering Pressure . . . . . . . . . . . . . . . . . . . . . 6-15
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 6-16
Section 7
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
HOIST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
TILT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
AUXl LlARY FUNCTIONS . . . . . . . . . . . . . . . . . . . . 7-1
Third Function Location . . . . . . . . . . . . . . . . . . . 7-1
Fourth Function Location . . . . . . . . . . . . . . . . . 7-1
HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . 7-1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Hoist Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
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
Figure 1-2 - Name Plate Location
SAFETY AND INFORMATIONAL LABELS
Safety and informational labels are located in
conspicuous locations on this truck and should be
strictly adhered to. These safety and informational
labels must be replaced immediately if missing or
defaced. Labels will vary with type of truck and
equipment installed. Refer to Parts Manual for part
number of labels.
1-
HAZARD INTENSITY LEVEL
DANGER: Identified by a Red Label,
immediate hazards which WILL result in
severe personal injury or death.
1-
WARNING: Identified by an Orange Label,
hazards or unsafe practices which MAY result in
personal injury or death.
1-1
CAUTION: Identified by a Yellow Label, hazards or
unsafe practices which MAY result in minor personal
injury or product or property damage.
THE READER MAY FIND ANY OR ALL OF THE
FOLLOWING LABELS USED IN THIS PUBLICATION. AN
UNDERSTANDING OF THEIR USE, AS GIVEN BELOW
WILL AID THE READER.
1-2
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.
Directs attention to unsafe practices andfor existing hazards
which WILL result in severe personal injury or death if proper
precautions are not taken.
OPERATOR PRECAUTIONS
The following precautions have been prepared for your
safety and the safety of your fellow workers. Read and
A
understand this information before operating the lift truck.
WARNING: Use special care when travelling
without a load as THE RISK OF
OVERTURNING IS GREATER when cornering
and at high speed.
Check all gauges and indicator lights for correct operation.
Frequent reading ofthe instrument panel should be a habit.
Follow the Recommended Schedules of Maintenance.
Maintain your lift truck for dependable and economical
operation.
Report all accidents involving personnel, building structures
and equipment to the proper authority.
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
operate truck if it is in need of repair, if it is in an unsafe
condition, or might contribute to an unsafe condition.
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
matter immediately to the proper authority.

Basic maintenance information and the Recommended
Schedule of Maintenance are in the Operating Manual,
located in the document holder on the compartment cover.
Also refer to Section 2, GENERAL TRUCK AND
LUB R ICAT1ON.
1. Make sure overhead guard, load backrest extension,
and all other protective equipment is attached.
2. Make sure all capacity, safety and informational plates
or labels are attached. This truck is not considered safe to
use without a legible, properlyfilled out name plate. Contact
Yale Materials Handling Corporation or your local dealer for
Yale industrial trucks if the name plate is not present and
legible. See Section 2, GENERAL TRUCK AND
LUBRICATION or the Parts Manual for label and plate
locations.
3. Inspect truck for any damage that might have occurred
during the previous shift.
4. Inspect truck before and after operating, for any signs of
external leaking of the battery, steering system, hydraulic
system, etc.
5 . Check hydraulic hoses for leaking, chafing, cuts or
reinforcement showing through the outside of the hose.
6. Check for mistracking of the hoses on the sheaves.
7. Make sure chains are not damaged or kinked.
8. Make sure mast stops and finger guards are in place.
9. Make sure bonnet latches are adjusted (if equipped)
and fastened.
10. Operate service and parking brakes, all hydraulic
controls, (lift, tilt and auxiliary, if equipped), accelerator,
shifting linkages and steering. Make surethey operatefreely
and return to their proper positions. See section on
OPERATING CONTROLS for detailed descriptions.
11. Inspect condition of wheels and tyres.
12. Inspect forks for any damage. Make sure they are
properly attached and locking clips are in their proper
position.
13. Test horn, lights and all other accessories. Make sure
they are properly mounted and in good working order.
14. Operate truck and make sure all gauges and meters are
functioning properly.
15. Make sure any unusual noises are investigated
immediately.
OPERATOR PRE-CHECKS AND INSPECTION
1. When attachments are used, extra care should be
taken in securing, positioning and transporting the load.
Operate trucks equipped with attachments as partially
loaded trucks.
OPERATING INSTRUCTIONS
2. Watch that your load does not exceed the capacity
rating of the truck. The truck capacity is posted on the name
plate which is attached to the truck at the factory.
3. Do not handle unstable or loosely stacked loads.
4. Donotstartoroperatethistruckorany of itsfunctionsor
attachments if you are not in the operator's seat, which is the
designated operator's position for this Yale lift truck.
5. Never allow anyone to ride on your truck and never
allow anyone other than a qualified professional to operate
your truck.
6. Referto the Maintenanceand Lubrication section inthis
manual for the recommended hourly service intervals.
Regular attention at the specified time will pay dividends in
maximum efficiency and longer life of the truck. '
OPERATING PROCEDURE
Apply power to the truck by connecting the battery plug to
the truck receptacle. Be sure the plug is fully inserted and
locked into place so that there is enough pressure at the
contact mating surfaces.
Make sure the direction control levers are in the neutral
position before operating the truck.
The operator must sit on the seat to energise the
electrical circuit.
Place foot on the service brake pedal.
Turn key toward forks (clockwise).
Release the parking brake.
Select desired direction.
Release service brake pedal.
A
Depress accelerator pedal to travel
CAUTION: Operating the drive control in a
situation where the truck will not move will
damage the electric motor.
1. Keep hands, feet and other parts of your body inside the
operator's compartment. Parts of your body outside the
truck can be injured when passing obstructions.
2. Do not permit passengers to ride on the truck.
3. Observe and comply with instructions concerning floor
loadings. Know the weight of your truck and load combined.
Truck weight information is located on the name plate.
4. Travel with the lifting mechanism low and where
possible, tilted back. Do not elevate the load except during
stacking.
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
permit it to be brought to a stop in a safe manner.
17. On sloping surfaces, higher than 5 percent (a5ft. rise or
drop in 100 ft. of travel), operate loaded truck with the load
facing up hill. Do notturn on an slope. For stability reasons, a
lift truck must not be driven across a slope.
18. Operate unloaded truck on all grades with the lifting
mechanism downhill.
19. Do not push extra loads with the truck.
FORK ADJUSTMENT
Adjust the forks on the fork carriage. Forks should be spaced
as far apart as the load being moved will allow. Both forks
should always be the same distance from the centre of the
fork carriage.
Checkforthe presence and condition ofstuds at each end of
the carriage upper fork clip slide. If studs are damaged or
missing they should be repaired or replaced before the forks
are adjusted.

1-4

To adjust the forks, raise them a few inches off the floor. Lift
up on the keeper pin and slide theforks along the carriage by
pushing them away from you. Do not pull the forks toward
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
carriage plate.
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.
OPERATING INSTRUCTIONS
The check listsare available in tablet form with 50sheets per
tablet and can be obtained from your local Yale Industrial
Truck Dealer for a nominal fee.
Both this manual and the Operating Manual contain the
Recommended Schedule of Maintenance which should be
used as a guide along with the Lubrication Instructions.
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
The following item number call outs may be found in either
Figure 1-4 or Figure 1-5.
1. Key Switch - The key switch in the “ON” position will
energise the electrical system. The indicator lamps on the
dashboard display should illuminate when the key switch is
turned to on.
2. Steering Column - The steering column is adjustable to
five tilt positions. The molded steering wheel is equipped
6. Accelerator Pedal - The accelerator pedal controls the
speed of the truck. To INCREASE travel speed depress the
pedal. To DECREASE travel speed release the pedal.
7 . Brake Pedal - The large service brake pedal is located
for left or right foot operation. Depress the foot pedal to apply
the service brakes. Another method of stopping the lift truck
is plugging. Plugging means reversing the direction control
while travelling, causing the truck to slow to a stop. See
Direction Control Lever information.

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

12. Steering Column Tilt Lever - The steering column can
be adjusted to five positive locked angles. Support column
weight for easier operation. Lift the lever at the base of the
steering column and move the column to desired position.
lever slightly to the right and then forward or backward. This
lever will be installed on trucks if the type of attachment is
unknown. The other lever is not detented and is used for
attachments with a non-clamping action. The fourth function
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
Gauges and indicator lamps located on the instrument
panels are described in the following paragraphs. When the
key switch is turned on, all indicator lamps should light. The
parking brake lamp remains lit until the parking brake is
released. The other indicator lamps should go out.
Instrument Panel C (OPTIONAL)
This premium dashboard display has a four segment LED
that displays hour meter readings for traction and pump
motors, battery discharge and a fault indicator lamp. The
following indicator lamps operate with the Status Code
Function.

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

Parking Brake Lamp
If this lamp is illuminated the brake fluid is low. Have the
brake system checked for leaks and add fluid to the
reservoir.
The hour meter function shows the operating time of the
truck. The hour meter indicator lamp is illuminated for four
seconds after the lift truck has been turned off. During this
time the operating time is displayed on the digital display. If
there is an hour meter for the pump motor it will be displayed
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

The Status Code numbers indicate symptoms or
malfunctions that the control card can sense. The numbers
will appear on the digital display. The fault symbol indicator
lamp (wrench and maintenance manual) will flash if the
control card senses a symptom or malfunction. All status
codes will have a minus sign before the first digit.
Fault Indicator Lamp
The battery function indicator shows the battery charge
represented by numbers between 0 and 100. The indicator
in the battery symbol will flash when the display reads 19
(battery is approximately 70% discharged). The lift pump
circuit will be disabled at a display of 10 (approximately 80%
of discharge). The status control also checks the battery
voltage each time a battery is connected. The lift truck will
not operate if the battery voltage is not correct. Contact
authorised maintenance personnel if a status code appears
on the dashboard display.
Battery Function Indicator
If this lamp is Illuminated the lift pump or traction motor
brushes are worn and must be replaced. lfthetyre and arrow
symbol is illuminated the traction motor brushes must be
replaced. If the fork and arrow symbol is illuminated the lift
pump motor brushes must be replaced.
[pi]
1-8881
Brush Wear Indicator
The traction motor and lift pump motor have thermal
sensors. The red LED in the display thermometer will
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
and arrow symbol is illuminated the traction motor is too hot.
Allow the motor to cool if the red LED’s are illuminated.
[-HIE]
Temperature Indicator Lamp
OPERATING INSTRUCTIONS
SAFE MAINTENANCE PROCEDURES
This truck meets all applicable mandatory requirements and
safety standards for powered industrial trucks at the time of
manufacture. The truck is also equipped with certain safety
devices as standard equipment. For example, all high lift
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
in any way reduce the effectiveness of the safety devices.
The following instructions have been prepared for your
safety and the safety of your fellow workers during
maintenance operations and should be strictly followed.
Carefully read and understand the maintenance procedures
before attempting to repair the truck. When in doubt of any
maintenance procedure, contact your local Yale Industrial
Truck Dealer.
1. Powered industrial trucks may become hazardous if
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
OPERATING MANUAL.
3. Only qualified and authorised personnel should be
permitted to maintain, repair, adjust and inspect the truck.
4. The work area should be properly ventilated. Keep
shop clean and floor dry.
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.
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
movement of the truck.
7. Disconnect the battery. Attach a DO NOT OPERATE
tag to the control handle.
8. Before removing any component from the truck, make
sure that the lifting mechanism (hoist) and slings are of the
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,
warning devices, guards and safety devices should be
inspected regularly and maintained in proper operating
condition.
1-11
OPERATING INSTRUCTIONS
11. All parts of lifting mechanisms should be carefully and
regularly inspected and maintained in correct operating
condition.
12. All hydraulic systems should be regularly inspected and
maintained in conformance with the maintenance
schedules. Lift cylinders, valves and other similar parts
should be checked to ensure that’ldrift” has not developed to
the extent that it would create a hazard. See the ROAD AND
LOAD TEST, in Section 2, GENERAL TRUCK AND
LUBR ICATI0N.
13. Special trucks or devices designed and approved for
hazardous area operation should receive special attention
to ensure that maintenance preserves the original,
approved safe operating features.
14. Modifications and additions which affect capacity and
safe truck operation should not be performed by the
customer or user without the manufacturer’s prior written
approval. Capacity, operation and maintenance instfiuction
plates, tags or labels should be changed accordingly.
15. Capacity, operation and maintenance instfiuction
plates, tags and labels should be maintained in legible
condition.
16. The truck should be kept in clean condition to minimize
fire hazards and facilitate detection of loose or damaged
parts.
17. Checking the performance of the truck or attachments
should be conducted in an authorised safe area.
18. Always useYALE replacement parts to be surethey are
interchangeable with the original parts and are of a quality
equal to that provided in the original equipment.
You should also become familiar with additional, local
maintenance safety instructions.
A
MOVING A DISABLED LIFT TRUCK
WARNING: Use extra care when towing a lift
truck if there is a problem with any of the
following:
1. Brakes do not operate correctly
2.
3.
4.
Steering does not operate correctly
Tyres are damaged
Traction conditions are bad
5. If the lift truck must be towed on a steep grade
If the steering pump motor does not operate steering the lift
truck can be difficult. Poor traction can cause the disabled lift
truck or towing vehicle to slide. Steep grades will increase
the required brake effort.
HOW TO TOW THE LIFT TRUCK
1. The towed lift truck must have an operator.
1-12
2. Tow the lift truck slowly.
3. Raise the carriage and forks approximately 12 inches
(30 cm) from the surface. Install a chain to prevent the
carriage and upright channels from moving. See Section 8,
MAST.
4. If another lift truck is used to tow the disabled lift truck,
that lift truck must have an equal or larger capacity than the
disabled lift truck. Install an approximate half capacity load
on the forks of the lift truck that is being used to tow the
disabled lift truck. This half capacity load will increase the
traction of the lift truck. Keep the load as low as possible.
5. Use a steel towing chain attached to the tow pins in the
counterweights of both lift trucks.
Never lift a disabled lift truck unless the lift truck must be
moved and cannot be towed. The lift truck used for lifting the
disabled truck must have a rated capacity equal to or greater
than the weight of the disabled lift truck. The capacity must
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
approximate total weight. The forks must extend the full
width of the disabled lift truck. Centre the weight of the
disabled lift truck on the forks and be careful not to damage
the under side of the lift truck.
NOTE: There may be problems with more than one of the
above areas of the truck. Do not tow the lift truck if you have
A
not identified all problem areas.
WARNING: Be sure to stay clear of the tow
chain, towing vehicle and the lifttruckduring the
towing operation to prevent injury.
A
WARNING: Travel slowly and do not tow on
grades. NEVER tow the lift truck faster than a
normal walking speed. Always tow smoothly
without sudden starts or stops.
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.
HOW TO PUT A LIFT TRUCK ON BLOCKS
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
the lift truck is put on blocks, put additional blocks in the
following positions to maintain stability:
a. Before removing the mast or transaxle, put blocks
under the rear frame so that the lift truck cannot tip
backward.
 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
the jacks have a capacity of at least 2/3 of the total weight of
the lift truck as shown on the name plate.
3. Put the jacks under the rear of the frame to raise the lift
truck. Put blocks under the frame to support the lift truck.
4. Put additional blocks on each side (front and back) of
the steering tyre to prevent movement of the truck.
5. If the hydraulic system will not operate, use a hydraulic
jackunderthesideoftheframe nearthe front. Makesurethe
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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