Page 1

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

For Service & Parts-Contact Authorized Dealer

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 L

V

L

2084 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.

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.

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

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.

e

Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

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.

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.

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.

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.

NOTE: The following symbols and words indicate safety information in this manual:

A A

DANGER: Indicates a condition that will cause immediate death or injury!

Indicates a condition that can cause death or injury! WARNING:

Indicates a condition that can cause property damage! CAUTION:


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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2

1-14

2-1 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

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 Brake Lines and Linkage . . . . . . . . . . . . . . . 2-24 Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Upright and Carriage . . . . . . . . . . . . . . . . . . . 2-24 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

....................... Control Compartment . . . . . . . . . . . . . . . . . . Electrical System . . . . . . . . . . . . . . . . . . . . . . Battery Compartment . . . . . . . . . . . . . . . . . . Complete Truck

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .

2-24 2-24 2-25 2-25 2-25

Steering Linkage and Pivot Points . . . . . . . . 2-25 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . 2-25

. . . . . 2-25 Brake Lines and Linkage . . . . . . . . . . . . . . . 2-25 Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Upright and Carriage . . . . . . . . . . . . . . . . . . . 2-25 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 2-25 FASTENERS - INT R0DUCTI0N . . . . . . . . . . . 2-26 Threads. Nomenclature . . . . . . . . . . . . . . . . . 2-26 Strength Identification . . . . . . . . . . . . . . . . . . 2-26 Drive, Hydraulic and Steering Motors

Section 3

. . . . . . . . . . . 3-1 EV-1O O L X MOTOR CONTROLLER . . . . . . . . . . . 3-2 EV-100 DESCRIPTION AND OPERATION . . . . . 3-2 The Silicon Controlled Rectifier . . . . . . . . . . . . 3-2 A Motor Circuit that Operates with Pulses . . . 3-2 Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Hydraulic Pump Motor . . . . . . . . . . . . . . . . . . . . 3-4 The SCR 1 "OFF" Circuit . . . . . . . . . . . . . . . . . 3-4 INDUCTION CURRENT FROM THE MOTOR . . 3-6 THE CONTROL CARD . . . . . . . . . . . . . . . . . . . . . . 3-7 Pulse Monitor Trip . . . . . . . . . . . . . . . . . . . . . . . 3-8 SRO Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Control Card Adjustments . . . . . . . . . . . . . . . . . 3-8 Accelerator Control . . . . . . . . . . . . . . . . . . . . . 3-11 CONTROL CARD . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 ELECTRICAL SYSTEM-G ENERAL

Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11

SEQUENCE OF OPERATION . . . . . . . . . . . . . . 3-12 SCR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14

. . . . . . . . . 3-14 HAND SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 CONTROL CARD CONNECTIONS

CHECKS AND ADJUSTMENTS, CONTROL CARD . . . . . . . . . . . . . . . . . . . . . . . . Function Codes . . . . . . . . . . . . . . . . . . . . . . . Bench Tests . . . . . . . . . . . . . . . . . . . . . . . . . .

Tests-Control Card Installed in a Lift Truck FUNCT I0N SETT INGS

3-18 3-18 3-19 3-19

. . . . . . . . . . . . . . . . . . . 3-20

Section 3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-20

Connect. Disconnect. and Check the Hand Set . . . . . . . . . . . . . . . . . . . 3-20

Check and Adjust Functions . . . . . . . . . . . . . 3-20 FUNCTION DESCRIPTIONS . . . . . . . . . . . . . . 3-21 Traction Control Cards

. . . . . . . . . . . . . . . . . 3-21

PUMP CONTROL CARD (LABEL LETTER PX) 3-23 TABLES FOR FUNCTION VALUE SETTINGS 3-24 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 3-26

. . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 TESTING CONTACTORS . . . . . . . . . . . . . . . . . 3-59 CONTACTORS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TMM1 CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT PROTECTION . . . . . . . . . . . . . . . . . .

3-60 3-60 3-62 3-63 3-63 3-63

Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 Thermal Protection . . . . . . . . . . . . . . . . . . . . 3-63 Suppressors (Filter Blocks) . . . . . . . . . . . . . 3-63

FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64 PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . 3-64 Steering Angle Control Board . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Pump Control Board . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bypassing the Lift Pump Control Board . . . ACCELE RAT0R . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING . . . . . . . . . . . . . . . . . . . . . . KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . .

Standard Instrument Panel . . . . . . . . . . . . . . MOTOR MAINTENANCE - GENERAL . . . . . . BRUSH AND COMMUTATOR INSPECTION . NORMAL COMMUTATOR SERVICE . . . . . . . . COMMUTATOR PROBLEMS . . . . . . . . . . . . . . BRUSH REPLACEMENT, DRIVE AND HYDRAULIC PUMP MOTORS . . . . . . . . . . . . . Traction Motor Removal . . . . . . . . . . . . . . . . Hydraulic Pump Motor Installation . . . . . . . . Power Steering Pump Motor . . . . . . . . . . . . MOTOR REMOVAL AND INSTALLATION . . . . Traction Motor . . . . . . . . . . . . . . . . . . . . . . . .

3-64 3-64 3-65 3-69 3-69 3-70 3-71 3-72 3-72 3-72 3-73 3-73 3-73 3-74 3-75 3-75 3-77 3-78 3-80 3-82 3-83 3-83 3-83 3-83

Traction Motor Installation . . . . . . . . . . . . . . . 3-83


Section 5

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 . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

................. TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Damaged Field and Armature . . . . . . . . . . . Short-Circuit in an Armature Winding . . . . . Short-Circuit in the Armature . . . . . . . . . . . . Open Circuit in a Field Coil . . . . . . . . . . . . . . COMMUTATOR REPAIRS .

3-85 3-85 3-85 3-87 3-87 3-88 3-88 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 1REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-3 4.3

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

TROUBLESHOOTING

4.6

......................

Section 5 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. 1 5-1

SPECIFICAT IONS . . . . . . . . . . . . . . . . . . . . . . . . . . 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

. . 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 INSTALLATION-SERVICE BRAKE CALIPER

MASTER CYLINDER-INSTALLATION . . . . . . . . 5-6 MASTER CYLINDER-DISASSEMBLY

. . . . . . . . 5-6

MASTER CYLINDER- ASSEMBLY . . . . . . . . . . . . 5.7 PARKING BRAKE LEVER ASSEMBLYREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

PARKING BRAKE LEVER ASSEMBLYINSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7

TROUBLESHOOTING

5-9

......................

Section 6 TRAIL AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 6-1 6-1 6-1 6-1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING CYLINDER . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8 6-8 6-10 6-13 6-14 6-14 6-14 6-14 6-14

CHECKS AND ADJUSTMENTS . . . . . . . . . . . . 6-14 Remove Air from the System . . . . . . . . . . . . 6-14 Check the Operation . . . . . . . . . . . . . . . . . . . 6-15

Steering Pressure . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

6-15 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 Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . HOIST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . Disassembly-Seal Replacement

Section 8 7-2 7-2 7-3 7-3

............................

7-4 POWER STEERING PUMP AND MOTOR . . . . . 7.5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 MAST TILT ADJUSTMENT . . . . . . 7-12

CONTROL VALVE-EMERGENCY REPAIR . . 7-12 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 7-13

Section 8 MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

DESCRIPTION AND OPERATION . . . . . . . . . . . . 8-1 Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Mast Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 TWO STAGE MAST WITH LIMITED FREE LIFT 8-3 Description and Operation . . . . . . . . . . . . . . . . 8-3 TWO STAGE MAST WITH FULL FREE LIFT . . . 8-5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THREE STAGE MAST WITH FULL FREE LIFT Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY PROCEDURESWHEN WORKING NEAR THE MAST . . . . . . . . . . . . . . . . . . . . . . . . . . MAST REPLACEMENT . . . . . . . . . . . . . . . . . . . . . MAST REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARRIAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal, Standard Carriage . . . . . . . . . . . . Removal, Sideshift Carriage . . . . . . . . . . . . . Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation, Standard Carriage . . . . . . . . . . .

8-5 8-5 . 8-7 8-7 8-7 8-9 8-9 8-10 8-10 8-10 8-10 8-10 8-10 8-12 8-12 8-12

Installation. Sideshift Carriage . . . . . . . . . . . MASTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Procedures for the Two Stage Mast with Limited or Full Free Lift . . . . . . . . Disassembly Procedures for the Three Stage Mast . . . . . . . . . . . . . . . . . . Cleaning and Inspection . . . . . . . . . . . . . . . . Assembly of the Two Stage Mast with Limited and Full Free Lift . . . . . . . . . . . Assembly of the Three Stage Mast with Full Free Lift . . . . . . . . . . . . . . . . . . . . . . Mast Installation . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . Removal of the Main Lift Cylinders . . . . . . . Removal of the Free Lift Cylinder . . . . . . . . Disassembly of a Lift Cylinder . . . . . . . . . . . Assembly of a Lift Cylinder . . . . . . . . . . . . . . Installation of the Main Lift Cylinders . . . . . . Installation of the Free Lift Cylinder HEADER HOSE ARRANGEMENTS . . . . . . . . Installation of Header Hoses for Two Stage Mast with Limited Free Lift . . . . Installation of Header Hoses for Two Stage Mast with Full Free Lift . . . . . . . Installation of Header Hoses for Three Stage Mast with Full Free Lift . . . . . . TILT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKS AND ADJUSTMENTS . . . . . . . . . . . . Check the Lift Cylinders for Leaks . . . . . . . . Check the Tilt Cylinders for Leaks . . . . . . . . Adjust the Tilt Cylinders . . . . . . . . . . . . . . . . . Adjust the Lift Chains . . . . . . . . . . . . . . . . . . . Adjust the Mast . . . . . . . . . . . . . . . . . . . . . . . . Adjust the Carriage . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

8-12 8-13 8-13 8-14 8-17 8-19 8-20 8-20 8-21 8-21 8-21 8-22 8-22 8-22 8-24 8-25 8-26 8-27 8-30 8-33 8-33 8-33 8-34 8-34 8-34 8-34 8-34 8-34 8-34 8-35 8-36 8-36 8-38

Section 9 BATTERY AND CHARGING SYSTEMGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 SAFETY TIPS FOR HANDLING INDUSTRIAL TRUCK BATTERIES . . . . . . . . . . . . 9-1 LEAD ACID BATTERIES . . . . . . . . . . . . . . . . . . . . 9-2 Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Chemical Reaction . . . . . . . . . . . . . . . . . . . . . . . 9-3


Section 9

Section 9 HOW TO SELECT THE BATTERY . . . . . . . . . . . . 9-4 Voltage of a Battery . . . . . . . . . . . . . . . . . . . . . . 9-4

. . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Kilowatt Hours . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 THE BATTERY AS A COUNTERWEIGHT . . . . . 9.5 THE NEW BATTERY . . . . . . . . . . . . . . . . . . . . . . . 9-5 BAlTERY MAINTENANCE . . . . . . . . . . . . . . . . . . 9-5 Maintenance Records . . . . . . . . . . . . . . . . . . . . 9-5 Battery Ratings

Cleaning the Battery . . . . . . . . . . . . . . . . . . . . .

9-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Hydrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Battery Temperature . . . . . . . . . . . . . . . . . . . . . 9-7 CHARGING THE BATTERY . . . . . . . . . . . . . . . . . 9-8

How to Know when the Battery is Fully Charged . . . . . . . . . . . . . . . . . . . . . . . . .

9-9

Battery Charging Area

9.9

....................

Equipment Needed . . . . . . . . . . . . . . . . . . . . . . 9-9 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 9-10

Section 10 SERVICE PARTS ORDERING INSTRUCTIONS . . . . . . . . . . . . . . 10-1 HOW TO ORDER SERVICE PARTS . . . . . . . . 10-1

. . . . . . . . . . . . . . . . 10-1

Adding Water

WHEN ORDERING PARTS

Types of Battery Charges . . . . . . . . . . . . . . . . . 9-8

TECHNICAL PUBLICATIONS . . . . . . . . . . . . . . PARTS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING MANUAL . . . . . . . . . . . . . . . . . . . . OPERATOR TRAINING . . . . . . . . . . . . . . . . . . .

Methods of Charging . . . . . . . . . . . . . . . . . . . . .

9-8

Troubleshooting the Charger . . . . . . . . . . . . . . 9-9

10-1 10-1 10-1 10-1

SERVICE TRAINING COURSES . . . . . . . . . . . 10-1 SERVICE TRAINING MATERIALS . . . . . . . . . . 10-1


SECTION 1

1

OPERATING INSTRUCTIONS


OPERATING INSTRUCTIONS

CONTENTS FORKADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

........................... HOW TO RAISE THE DRIVE TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-13

HOW TO RAISE THE STEERING TYRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-13

HOW TO TOW THE LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-12

HOW TO PUTA LIFT TRUCK ON BLOCKS

MODEL AND CONTROL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-12

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

......................................... OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATOR PRE-CHECKS AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . PRECAUTIONS FOR BATTERIES IN STORAGE . . . . . . . . . . . . . . . . . . . . . . . PRECAUTIONS FOR TRUCKS IN STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . SAFENAND INFORMATIONAL LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETYAND OPERATIONAL CHECK LIST ............................ SAFE MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHUT DOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATOR PRECAUTIONS

1-2 1-3

1-3 1-14 1-13

1-2

1-5 1-11

1-4


OPERATING INSTRUCTIONS GENERAL Before attempting to operate this truck, carefully read and understand these operating procedures. Make sure the truck is in proper operating condition. Be sure all safety devices such as the overhead guard and the load backrest extension are in place and properly secured. Visually inspect the entire truck for any damage that may have occurred during shipment.

NOTE: Throughout this manual the terms right, left, front and rear relate to theviewpoint of an operatorwalking with or riding on the truck. Familiarise yourself with the information contained on the name plate which is located on the cowl to the left of the steering column. See Figure 1-1 and Figure 1-2. Information on this name plate is as follows: 1. Serial Number - This is an identification number assigned to this particular truck and should be used when ordering service parts or when requesting any information from your Yale Industrial Truck Dealer. The serial number is a six digit number preceded by a letter and is stamped on the truck frame and on the name plate.

2. Model Code - An explanation of the model code is located on the back of the front cover of this manual.

3. Truck Weight - This is the approximate weight of the truckwithout a load on the forks. This weight plus the weight of the load to be moved must be considered when operating on raised floors, lifts, etc. 4. Capacity Rating - This rating shows the maximum load capacity of this truck with relation to load centres and fork heights (see diagram on name plate). Personal injury and damage to the truck can occur if the capacity rating is exceeded.

Safety and informational labels are located in conspicuous locations on this truckand should bestrictlyfollowed. Check the name plate of each truck before operation. 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 the Parts Manual for part number and location for all labels. The location of the labels is also shown in Section 2, GENERAL TRUCK AND LUBR ICATI0N. This truck meets all applicable mandatory requirements and safety standards for powered industrial trucks at the time of manufacture. No additions, omissions or modifications should be made that will affect compliance to the previously stated requirementsor in anyway minimizetheeffectiveness ofthe safety devices.

2 ~~

NOTICE TO USER

3

1

I 1 5

03 2

The U S A Occupational Safety and Health Act of 1970 an 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

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-

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 understand this information before operating the lift truck.

A

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.

WARNING: Identified by an Orange Label, hazards or unsafe practices which MAY result in personal injury or death.

Report all accidents involving personnel, building structures and equipment to the proper authority.

CAUTION: Identified by a Yellow Label, hazards or unsafe practices which MAY result in minor personal injury or product or property damage.

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.

1-1

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


OPERATING INSTRUCTIONS 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.

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.

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.

4.

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).

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.

Do not handle unstable or loosely stacked loads.

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. Travel with the lifting mechanism low and where possible, tilted back. Do not elevate the load except during stacking. 4.

1-3


OPERATING INSTRUCTIONS 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.

6. Look in the direction of travel and keep a clear view of 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.

8. Start, stop, travel, steer and brakesmoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to overturn or slide. 9. Before entering trucks or trailers, be certain the brakes 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 needed to prevent upending or corner dipping. Check the flooring of trucks, trailers and railroad cars for breaks and weakness before driving onto them.

10. Before driving over a dock board or bridge plate, be

certain that it is properly secured. Drive carefully and slowly across the dockboard or bridge plate and never exceed its rated capacity. 11. Maintain a safe distance from the edge of ramps or platforms. Do not push freight cars while on a raised dock or platform. Do not use this truck for opening or closing'freight doors.

12. Watch clearances, especially around forks. The driver must be aware that the forks can sometimes extend beyond the load. This may cause the forks to hit an object or lift another load. 13. Watch outfor obstructions, especiallyoverhead. Check clearances. 14. Do not run over objects on the roadway surface as truck stability and steering may be adversely affected. 15. When approaching cross aisles, slow down, sound 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.

1-4

20. Watch out for pedestrians at all times. Do not drive up to anyone standing in front of an object.

Q

21. Observe all traffic regulations, including authorised plant speed limits. Under normal traffic conditions, keep to the right. Maintain a safe distance from the truck ahead (approximately three truck lengths), and keep the truck under control at all times. 22. Yale lift trucks are not intended for use on public roads.

23. When leaving truck unattended, lower the lifting mechanism, shut off power, remove key and apply parking brake. Chock wheels if truck is parked on an slope. 24. Do not remove overhead guard or load backrest extension unless specifically authorised. 25. Always set the forks as far apart as the load will permit. Make sure that fork length is at least 213 of load length. 26. Carry the load flush against the truck. 27. Do not put any part of your body into the mast area or between the mast and truck. Be aware of pinch points on attachments, especially reach mechanisms. 28. Allow no one under or near load or lifting mechanism. 29. If a supplementary platform is used, make sure it is securely fastened to the carriage and forks.

SHUT DOWN PROCEDURE When leaving the truck, fully lower lifting mechanism, ensure controls are in neutral, shut off power, apply the brake, and remove key. If you park the truck on an slope, chock the wheels. 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.


OPERATING INSTRUCTIONS 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.

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.

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

Operator’s Daily Check List Electric Truck

Daily pre-shift inspection is an OSHA requirement. We recommend that you document that these inspections have been made.

Industrial Trucks

Record of Fluid Added ~~

~~~~~

~

~

Date

Operator

Battery Water

Truck Number

Model Number

Hydraulic Oil

Department

Serial Number

Shift

Drive Hour Meter Reading

Hoist Hour Meter Reading

SAFETY AND OPERATIONAL CHECKS (Prior to each shift) Have a qualified mechanic correct all problems Leaks - Hydraulic Oil, Battery

(0.K.V)

I Tyres - Condition and Pressure

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I Load BackrestiExtension

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I Forks, Top Clip Retaining Pin and Heel - Check Condition

Need Maintenance

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1 Finger Guards - Attached

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I Safety Warnings - Attached (Refer to Parts Manual for Location) I Internal Checks: I Battery - Check Water/Electrolyte Level and Charge I Hydraulic Fluid Level - Check Level I Drive Unit Fluid Level - Check Level I Operator’s Compartment: I Operating Manual - in Container

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- Securely Attached

I Hydraulic Hoses, Mast Chains and Stops - Check Visually I Overhead Guard - Attached

- Attached and information matches model, serial number and

Form 944-641 8-A (5/93) 0 Copyright 1993 Yale Materials Handling Corporation

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OPERATING INSTRUCTIONS MODEL AND CONTROL INFORMATION The ERP/C16-20ATF three wheel electric rider lift trucks have lifting capacities of 1600 kgs to 2000 kgs (3000 Ib to 4000 Ib). The trucks feature clean functional styling, low noise levels and an operator compartment designed for comfort and 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.

with a spinner knob. The horn button is located in the centre of the steering wheel. Push button to sound horn. 3. The Operating Manual is sent with the truck and is located in the container behind the operator’s seat. The Operating Manual is a permanent reference and must be available for the operator’s use at all times. Read and understand this manual before operating the lift 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. 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.

5.

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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.

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OPERATING INSTRUCTIONS

Figure 1-5

- Operating Controls

8. Operator Seat - The lever to adjust the operator's seat is located between the seat rails. Move the lever to the left and slide the seat to the desired position. Release the lever.

9. Parking Brake - To apply parking brake step on foot 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.

10. Direction Control Lever - There is a direction control lever on both sides of the steering column. The direction control levers have three positions, forward, neutral and reverse. Select the direction of travel by moving the lever. Both levers will move together when either lever is moved.

Figure 1-7

Figure 1-6

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- Parking Brake

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- 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.


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

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- Light Switch I

Figure 1-8

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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.

Figure 1-9

- 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 has a detented position for use with attachments that have a clamping actuation. This lever is actuated by pushing the 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.

- 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.

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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".

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Figure 1-10

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a.

Battery Voltmeter and Hour Meter

b.

Combination Dashboard Display

c.

Premium Dashboard Display

- 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.

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OPERATING INSTRUCTIONS Instrument Panel A (STANDARD) The battery voltmeter features a display showing the state-of-charge. The gauge is divided into three segments, green, yellow and red. When the needle is in the green segment, it indicates a charged battery. When the needle is 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.

is illuminated. At 70% of discharge an LED will flash, indicating "energy reserve". At 80% of discharge both led's will alternately flash, indicating "empty". Lift Interrupt will occur at approximately 80% but will not occur while the lift is being operated. The system will automatically reset when a charged battery is connected.

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.

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Figure 1-14

- Combination Dashboard Display

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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. The following Indicator lamps are found on all the dashboard displays.

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.

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This lamp is illuminated when the parking brake is applied.

Figure 1-15 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.

Brake Fluid Level Lamp 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

- Premium Dashboard Display

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.

Hour Meter Function Indicator


OPERATING INSTRUCTIONS 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.

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.

Only qualified and authorised personnel should be permitted to maintain, repair, adjust and inspect the truck.

3.

The work area should be properly ventilated. Keep shop clean and floor dry.

4.

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.

[-HIE] Temperature Indicator Lamp

10. Brakes, steering mechanisms, control mechanisms, warning devices, guards and safety devices should be inspected regularly and maintained in proper operating condition.

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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

following:

WARNING: Use extra care when towing a lift truck if there is a problem with any of the

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 not identified all problem areas.

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WARNING: Be sure to stay clear of the tow chain, towing vehicle and the lifttruckduring the towing operation to prevent injury.

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. 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.

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Brakes do not operate correctly

HOW TO PUT A LIFT TRUCK ON BLOCKS

2.

Steering does not operate correctly

3.

Tyres are damaged

4.

Traction conditions are bad

5.

If the lift truck must be towed on a steep grade

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:

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.

2.

The towed lift truck must have an operator.

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A

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 counterweight, put blocks under the mast assembly so that the lift truck cannot tip forward. Thesurface must be solid, even, and level when the lifttruck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one piece units.

HOW TO RAISE THE STEERING N R E 1. Apply the parking brake. Put blocks on both sides (front and back) of the drive tyres to prevent movement of the lift truck.

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.

NOTE: Some lift trucks have lifting eyes. These lifting eyes can be used to raise the lift truck so that blocks can be installed. HOW TO RAISE THE DRIVE TYRES 1. Put the mast in the vertical position. Put a block under each outer upright.

2. Tilt the mast fully forward until the drive tyres are raised from the surface.

3.

Put blocks under the frame behind the drive tyres.

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.

STEERING TYRES

DRIVE 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 grade SAE 30 or 40 weight engine oil.

Complications can arise as a result of improper handling of 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.

must choose an Before placing any truck in storage' airborne area which is 'lean* and free contaminants. When parking the truck chock the Do not use the 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

All hydraulic cylinders should be cycled several times each month to keep the seals active and to coat the interior walls with oil. Actuate each cylinder, in both directions, until the stops are reached. With the power off, actuate each hydraulic control valve to relieve hydraulic pressure.

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YALE (C807) ERP16ATF LIFT TRUCK Service Repair Manual  
YALE (C807) ERP16ATF LIFT TRUCK Service Repair Manual  
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