1. WORKSHOP MANUAL
For Models
ERP/CI6-2OATF
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
ENGLANDW I 3JE
Telephone: (01902) 875500
Telex: 333642
Telefax: (01902) 875566
For Service & Parts-Contact
Authorized Dealer
Part No. 5070385-01 @May 1995

2. EXPLANATION OF TRUCK MODEL CODE
A - Premium
B - Standard
-POWER
E - Electric
E R P 1 8 A T F E 48 V 2084
R - Sit Down Rider
TYRES
P - Pneumatic
C - Cushion
RATED CAPACITY (in kg x 100)
r 16
L
LMAST CLOSED HEIGHT(mm)
MAST TYPE
V -Two Stage Limited Free Lift
F -Two Stage Full Free Lift
E -Three Stage Full Free Lift
L
-VOLTAGE
48 Volts
-PLANT SOURCE
E - Europe
-SERIES CODE
A, B, C etc.
-MODEL
T - Three Wheel FWD
R - Three Wheel RWD

3. This Maintenance Manual is divided into major sections which are listed on this
page. Quick referenceto these sections can be made by placingthe rightthumb on
the tab ofthe desired section, bending the book back andthumbing the pages to the
corresponding tab.
1
SECTl0NS
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

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SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
When lifting parts or assemblies, make sure that
all slings,chains, or cables are correctlyfastened
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.
Do not lift heavy parts by hand. Use a lifting
mechanism.
Wear safety glasses.
DISCONNECT THE BATTERY CONNECTOR
before doing any maintenance or repair on
electric lift trucks.
Always usecorrect blocksto preventthe unitfrom
rollingor falling. See “Howto Put the LiftTruck on
Blocks” in the OPERATOR’S MANUAL or
SECTION 2, GENERAL TRUCK AND
LUBRICATION.
Keepthe unitandworkingareacleanandinorder.
Use the correct tools for the job.
Keep the tools clean and in good condition
Always use YALE APPROVED parts when
making repairs.Replacementparts must meet or
exceed the specifications of the original
equipment manufacturer.
Make sure that all nuts, bolts, circlips, and other
fasteningdevicesare removedbeforeusingforce
to remove parts.
Always fasten a DO NOT OPERATE sign to the
controls of the unit when making repairs or if the
unit needs repairs.
Make sure you follow the DANGER, WARNING,
and CAUTION notes in the instructions.
Wear a rubberapron,gloves, boots, and goggles
or a face shield when doing maintenance on
batteries.
Batteries generate hydrogen gas when they are
being charged. Keep open fire away from
batteries.Donot checkthe electrolyte levelwith a
match or a lighter. No smoking and do not create
sparks. Make sure the area has ventilation. If the
batteryischargedinthe lifttruck, openthebonnet.
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
designedfor that purpose. If the battery does not
have a cover, a rubber mat or insulating material
must be putover the top of the batteryto preventa
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 circuitcan cause an explosionand damage
the battery.
Keep water readily available to flush spilled
electrolyte.Electrolyteinthe eyesmust beflushed
with water immediately and then quickly get
medicalattention. Specialshowers and eye wash
systems are required in areas where battery
maintenanceis 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 maintenanceon batteries.
NOTE: The following symbols and words indicate
safety information in this manual:
DANGER: Indicates a condition that will
cause immediatedeath or injury!
WARNING: Indicatesa condition that can
Acause death or injury!
Acause property damage!
CAUTION: Indicates a condition that can

5. CONTENTS
Section 1 Section 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULICTANK . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
SAFETY AND INFORMATIONALLABELS . . . . . 1-2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Repairs. Small Leaks . . . . . . . . . . . . . . . . . . . . . 2-5
OPERATOR PRECAUTIONS . . . . . . . . .
Repairs. Large Leaks . . . . . . . . . . . . . . . . . . . . 2-5
OPERATOR PRE-CHECKSAND INSPECTION 1-3
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING PROCEDURE . . . . . . . . . . . . . . . . . 1-3
Steam Method of Cleaning . . . . . . . . . . . . . . . .2-6
SHUT DOWN PROCEDURE. . . . . . . . . . . . . . . . .1-4
Chemical Solution Method of Cleaning
FORK ADJUSTMENT ....................... 1-4
Additional Preparationsfor Repair . . . . . . . . . .2-6
SAFETY AND OPERATIONALCHECK LIST . . . 1-5
MODELAND CONTROL INFORMATION 1-7
WELDING REPAIRS . . . . . . . . . . .
. . . . . .
TYRES AND WHEELS 2-6
. . . . . . . . . . . . . . . . . . . . . .
instrument PanelA (STANDARD) . . . . . . . . '-lo
HOW TO CHANGE THE WRES . . . . . . . . . . . . . 2-7
. . . . . . . . . General 2-7
InstrumentPanel B (OPTIONAL) 1-10
instrument Panel (OPTIONAL) . . . . . . . . '-lo PNEUMATICTYRES . . . . . . . . . . . . . . . . . . . . . . . 2-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Indicator Lamp . . . . . . . . . . . . . 1-11
SAFE MAINTENANCEPROCEDURES . . . . . . 1-11
MOVING A DISABLEDLIFT TRUCK . . . . . . . . 1-12
HOW TO TOW THE LIFT TRUCK . . . . . . . . . . 1-12
HOW TO PUT A LIFT TRUCK ON BLOCKS 1-12
HOW TO RAISETHE STEERINGTYRE . . . . 1-13
HOW TO RAISETHE DRIVETYRES . . . . . . . 1-13
PRECAUTIONSFOR TRUCKS IN STORAGE 1-13
.
PRECAUTIONSFOR 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
Removethe Wheel from the Lift Truck . . . . . . .2
.
7
Removethe Tyre from the Wheel . . . . . . . . . . 2-8
Installthe Tyre on the Wheel . . . . . . . . . . . . . .2-8
Add Air to the Tyres . . . . . . . . . . . . . . . . . . . . . . 2-9
Removethe Wheel from the Lift Truck . . . . 2-10
Removethe Tyre from the Wheel . . . . . . . . 2-10
. . . . . . . . . . . . .2-11
SOLID TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
PNEUMATIC SHAPED SOLID TYRES . . . . . . 2-10
Installthe Tyre on the Wheel
Removethe One Piece Wheel and Tyre . . 2-12
Installthe Tyre on the One Piece Wheel . . 2-12
Installthe Wheels on the Lift Truck . . . . . . . 2-12
LABEL REPLACEMENT. . . . . . . . . . . . . . . . . . . 2-13
YALE WARRANTY INFORMATION . . . . . . . . . 2-14
RECOMMENDEDSCHEDULE
OF MAINTENANCE ...................... 2-14
LUBRICATIONINSTRUCTIONS . . . . . . . . . . . 2-15
EVERY 8 HOURS ........................ 2-15
EVERY 350 HOURS ...................... 2-15
EVERY 2000 HOURS ..................... 2-15
HYDRAULICOILS ........................ 2-21
GEAR OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
FREEZERAPPLICATIONS . . . . . . . . . . . . . . . . 2-24
HYDRAULICCONTROLVALVE COVERS . . . . . 2-2
BATTERY COVER .......................... 2-2
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
BATTERY REMOVALAND INSTALLATION 2-3
BATTERY PLATFORM 2-3
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
CompleteTruck 2-24
Control ComDartment 2-24
. . . .
.......................
...................... . . . . . . . . . . . . . . . . . .
.......................
OVERHEADGUARD 2-4 Electrical System ...................... 2-24
Removal 2-4 Battery Compartment .................. 2-24
Installation 2-4 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Accelerator Pedal ...................... 2-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Drive. Hydraulic and Steering Motors . . . . . 2-24
...............................
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COUNTERWEIGHT ........................ 2-4 Steering Linkage and Pivot Points . . . . . . . . 2-24

6. Section 2
Brake Lines and Linkage . . . . . . . . . . . . . . . 2-24
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Upright and Carriage . . . . . . . . . . . . . . . . . . . 2-24
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
CompleteTruck . . . . . . . . . . . . . . . . . . . . . . . 2-24
Electrical System ...................... 2-25
IgnitionSwitch . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Control Compartment . . . . . . . . . . . . . . . . . . 2-24
Battery Compartment . . . . . . . . . . . . . . . . . . 2-25
Steering Linkage and Pivot Points . . . . . . . . 2-25
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . 2-25
Drive, Hydraulic and Steering Motors . . . . . 2-25
Brake Lines and Linkage . . . . . . . . . . . . . . . 2-25
Section 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Connect. Disconnect.and
Check the Hand Set . . . . . . . . . . . . . . . . . . . 3-20
Check and Adjust Functions . . . . . . . . . . . . . 3-20
FUNCTIONDESCRIPTIONS . . . . . . . . . . . . . . 3-21
Traction Control Cards . . . . . . . . . . . . . . . . . 3-21
PUMP CONTROLCARD (LABEL LETTER PX) 3-23
TABLES FOR FUNCTIONVALUE SETTINGS 3-24
TROUBLESHOOTING .................... 3-26
CONTACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
TESTING CONTACTORS . . . . . . . . . . . . . . . . . 3-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
TMM1 CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Upright and Carriage . . . . . . . . . . . . . . . . . . . 2-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
CIRCUIT PROTECTION 3-63
Hydraulic System 2-25
Current Limit 3-63
Thermal Protection 3-63
Threads. Nomenclature 2-26
Strength Identification 2-26 Suppressors (Filter Blocks) . . . . . . . . . . . . . 3-63
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
FASTENERS - INTR0DUCTI0N 2-26 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Section 3
ELECTRICAL SYSTEM-G ENERAL . . . . . . . . . . .3-1
EV-1OOLX MOTOR CONTROLLER . . . . . . . . . . . 3-2
EV-100DESCRIPTIONAND OPERATION . . . . . 3-2
The Silicon Controlled Rectifier . . . . . . . . . . . .3-2
A Motor Circuit that Operateswith Pulses . . .3-2
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hydraulic Pump Motor . . . . . . . . . . . . . . . . . . . . 3-4
The SCR 1 "OFF" Circuit . . . . . . . . . . . . . . . . . 3-4
INDUCTIONCURRENT 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
Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
SEQUENCE OF OPERATION . . . . . . . . . . . . . . 3-12
SCR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
CONTROL CARD CONNECTIONS . . . . . . . . . 3-14
HAND SET .............................. 3-17
CHECKSAND ADJUSTMENTS,
CONTROL CARD . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Function Codes . . . . . . . . . . . . . . . . . . . . . . . 3-18
Bench Tests .......................... 3-19
Tests-Control Card Installedin a Lift Truck 3-19
FUNCTI0N SETTINGS . . . . . . . . . . . . . . . . . . . 3-20
PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . 3-64
SteeringAngle Control Board . . . . . . . . . . . . 3-64
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Lift Pump Control Board . . . . . . . . . . . . . . . . 3-69
Bypassingthe Lift Pump Control Board . . . 3-71
ACCELERAT0R . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Removal ............................. 3-72
Installation ............................ 3-72
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . 3-73
KEY SWITCH ............................ 3-73
INSTRUMENTPANEL .................... 3-73
Standard InstrumentPanel . . . . . . . . . . . . . . 3-74
MOTOR MAINTENANCE- GENERAL . . . . . . 3-75
BRUSHAND COMMUTATOR INSPECTION . 3-75
NORMAL COMMUTATOR SERVICE . . . . . . . . 3-77
COMMUTATOR PROBLEMS . . . . . . . . . . . . . . 3-78
BRUSH REPLACEMENT, DRIVE AND
HYDRAULIC PUMP MOTORS . . . . . . . . . . . . . 3-80
Traction Motor Removal . . . . . . . . . . . . . . . . 3-82
Hydraulic Pump Motor Installation . . . . . . . . 3-83
Power Steering Pump Motor . . . . . . . . . . . . 3-83
3-83
Traction Motor ........................ 3-83
Traction Motor Installation. . . . . . . . . . . . . . . 3-83
MOTOR REMOVAL AND INSTALLATION . . . .

7. 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 Installation3-85
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
TRACTION MOTOR REPAIR . . . . . . . . . . . . . . 3-85
COMMUTATOR REPAIRS . . . . . . . . . . . . . . . . . 3-85
TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
. Damaged Field and Armature . . . . . . . . . . . 3-87
Short-Circuit in an Armature Winding . . . . . 3-88
Short-Circuitin 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 DIAGRAMSAND 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
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5-
1
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . 5-1
SERVlCE BRAKE ADJUSTMENT . . . . . . . . . . . . 5-
1
REMOVAL-SERVICE BRAKE PADS . . . . . . . . . . 5-
1
INSTALLATION-SERVICEBRAKE PADS . . . . . . 5-1
REMOVAL-SERVICE BRAKE CALIPER . . . . . . . 5-2
INSTALLATION-SERVICEBRAKE 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-PARKINGBRAKE 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
PARKINGBRAKELEVERASSEMBLY-
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
TROUBLESHOOTING ...................... 5-9
Section 6
TRAIL AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
POWER STEERING SYSTEM . . . . . . . . . . . . . . . 6-4
General . . . . . . . . . . 6-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
STEER AXLE ASSEMBLY . . . . . . . . . . . . . . :. . . . 6-3
. . . . . . . . . . . . . . .
STEERING WHEEL AND COLUMN
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
. . . . . . . . . . 6-5
Installation .............................. 6-6
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Installation ............................ 6-14
Disassembly .......................... 6-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Remove Air from the System . . . . . . . . . . . . 6-14
Check the Operation . . . . . . . . . . . . . . . . . . . 6-15
Steering Pressure ..................... 6-15
POWER STEERINGCYLINDER . . . . . . . . . . . 6-14
CHECKS AND ADJUSTMENTS . . . . . . . . . . . . 6-14
TROUBLESHOOTING .................... 6-16
Section 7
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
HOIST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
TILT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
AUXlLlARY FUNCTIONS .................... 7-1
Third Function Location . . . . . . . . . . . . . . . . . . . 7-1
Fourth FunctionLocation . . . . . . . . . . . . . . . . . 7-1
HYDRAULICOIL TANK ..................... 7-1
SPECIFICATIONS .......................... 7-2
HydraulicTank .......................... 7-2
Power Steering Pump .................... 7-2
Hoist Pump ............................. 7-2

8. Section 7
Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . 7-2
HOIST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Installation . . . . . . . . . . . . . . . . . . .
Disassembly-Seal Replacement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
DESCRIPTIONAND OPERATION . . . . . . . . . . . .8-1
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Mast Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Descriptionand Operation . . . . . . . . . . . . . . . . 8-3
TWO STAGE MAST WITH FULL FREE LIFT . . . 8-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
TWO STAGE MAST WITH LIMITED FREE LIFT 8-3
THREE STAGE MAST WITH FULL FREE LIFT . 8-7
SAFETY PROCEDURESWHEN WORKING
NEAR THE MAST . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
MAST REPLACEMENT ..................... 8-9
MAST REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Removal, Standard Carriage . . . . . . . . . . . . 8-10
Removal, Sideshift Carriage . . . . . . . . . . . . . 8-12
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Installation,Standard Carriage . . . . . . . . . . . 8-12
CARRIAGES ............................ 8-10
Section 8
Installation.Sideshift Carriage . . . . . . . . . . . 8-12
MASTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Disassembly Procedures for the Two Stage
Mast with Limited or Full Free Lift . . . . . . . . 8-14
Disassembly Procedures for
8-17
the Three Stage Mast . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . 8-19
Assembly of the Two Stage Mast
with Limited and Full Free Lift . . . . . . . . . . . 8-20
Assembly of the Three Stage Mast
with Full Free Lift . . . . . . . . . . . . . . . . . . . . . . 8-20
Mast Installation . . . . . . . . . . . . . . . . . . . . . . . 8-21
Removalof the Main Lift Cylinders . . . . . . . 8-21
Removalof the Free Lift Cylinder . . . . . . . . 8-22
Disassembly of a Lift Cylinder . . . . . . . . . . . 8-22
8-22
Installationof the Main Lift Cylinders . . . . . . 8-24
Installationof the Free Lift Cylinder
Installationof Header Hoses for
Two Stage Mast with Limited Free Lift . . . . 8-26
Installationof Header Hoses for
Two Stage Mast with Full Free Lift . . . . . . . 8-27
Installationof Header Hoses for
Three Stage Mast with Full Free Lift . . . . . . 8-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Cleaning ............................. 8-34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Check the Lift Cylinders for Leaks . . . . . . . . 8-34
Check the Tilt Cylinders for Leaks . . . . . . . . 8-34
Adjust the Tilt Cylinders . . . . . . . . . . . . . . . . . 8-34
Adjust the Lift Chains . . . . . . . . . . . . . . . . . . . 8-35
Adjust the Mast . . . . . . . . . . . . . . . . . . . . . . . . 8-36
Adjust the Carriage .................... 8-36
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Assembly of a Lift Cylinder . . . . . . . . . . . . . .
HEADER HOSE ARRANGEMENTS . . . . . . . . 8-25
TILT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . 8-33
CHECKS AND ADJUSTMENTS . . . . . . . . . . . . 8-34
TROUBLESHOOTING .................... 8-38
Section 9
BATTERYAND CHARGING SYSTEM-
GENERAL ................................. 9-1
SAFETY TIPS FOR HANDLING
INDUSTRIALTRUCK BATTERIES . . . . . . . . . . . . 9-1
LEADACID BATTERIES . . . . . . . . . . . . . . . . . . . . 9-2
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Chemical Reaction ....................... 9-3

9. Section 9
HOW TO SELECT THE BATTERY . . . . . . . . . . . . 9-4
Voltage of a Battery . . . . . . . . . . . . . . . . . . . . . . 9-4
Battery Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Cleaning the Battery ..................... 9-6
Adding Water . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Hydrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Battery Temperature . . . . . . . . . . . . . . . . . . . . . 9-7
Types of Battery Charges . . . . . . . . . . . . . . . . .9-8
Methods of Charging . . . . . . . . . . . . . . . . . . . . . 9-8
CHARGING THE BATTERY . . . . . . . . . . . . . . . . .9-8
Troubleshooting the Charger . . . . . . . . . . . . . .9-9
Section 9
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
WHEN ORDERING PARTS . . . . . . . . . . . . . . . . 10-1
TECHNICAL PUBLICATIONS . . . . . . . . . . . . . . 10-1
PARTS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
OPERATING MANUAL .................... 10-1
OPERATOR TRAINING . . . . . . . . . . . . . . . . . . . 10-1
SERVICE TRAINING COURSES . . . . . . . . . . . 10-1
SERVICE TRAINING MATERIALS . . . . . . . . . . 10-1

10. SECTION 1
1 OPERATING INSTRUCTIONS

11. OPERATING INSTRUCTIONS
CONTENTS
FORKADJUSTMENT ............................................... 1-4
GENERAL ......................................................... 1-1
HOW TOPUTA LIFT TRUCK ON BLOCKS ........................... 1-12
HOW TO RAISE THEDRIVE TYRES ................................. 1-13
HOW TO RAISE THE STEERING TYRE .............................. 1-13
HOW TO TOW THELIFT TRUCK ..................................... 1-12
MODEL AND CONTROL INFORMATION .............................. 1-7
InstrumentPanelA (STANDARD) ................................... 1-10
Instrument Panel B (OPTIONAL) .................................... 1-70
Instrument Panel C (OPTIONAL) .................................... 1-10
1.
11
MOVING A DISABLED LIFT TRUCK .................................. 1-12
OPERATOR PRECAUTIONS ......................................... 1-2
OPERATING PROCEDURE .......................................... 1-3
OPERATOR PRE-CHECKSAND INSPECTION ......................... 1-3
PRECAUTIONS FOR BATTERIES IN STORAGE ....................... 1-14
PRECAUTIONS FOR TRUCKS IN STORAGE ......................... 1-13
SAFENAND INFORMATIONALLABELS .............................. 1-2
SAFETYAND OPERATIONALCHECKLIST ............................ 1-5
SAFE MAINTENANCEPROCEDURES ............................... 1-11
SHUT DOWN PROCEDURE ......................................... 1-4
TemperatureIndicator Lamp ........................................

12. OPERATINGINSTRUCTIONS
GENERAL
Before attempting to operate this truck, carefully read and
understand these operating procedures.
Makesurethetruck is inproper operating condition. Besure
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 relatetotheviewpoint 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. Informa-
tion 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
asix digit number preceded by a letter and isstamped onthe
truck frame and on the name plate.
2.
located on the back of the front cover of this manual.
Model Code - An explanation of the model code is
3. Truck Weight - This is the approximate weight of the
truckwithout a loadonthe forks.This weight plusthe weight
ofthe loadto be moved must be consideredwhen operating
on raised floors, lifts, etc.
4. Capacity Rating -This ratingshows 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
locationsonthistruckandshouldbestrictlyfollowed. Check
the name plateof each truck beforeoperation.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 locationfor all labels. The location of the labels
is also shown in Section 2, GENERAL TRUCK AND
LUBRICATI0N.
This truck meetsall applicablemandatory requirementsand
safety standardsfor 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 inanyway minimizetheeffectiveness ofthe
safety devices.
I
~~
1 5
I :
I i
NOTICE TO USER
The U S A OccupationalSafety and HealthAct of 1970an
other national safety codes requirea new plate d this unit 03 2
equipped other than 8s stated on plate Obtain the correcl
plale from your authoriseddenier
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 IndustrialTruck Dealer.
Capacities and Cautions
Contained on the Name
plate Must be Strictly
Followed.
2 3 1
Figure 1-1 - Name Plate
1-1

13. 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.
HAZARD INTENSITY LEVEL
-
1
-
1
1
-
1
DANGER: Identified by a Red Label,
immediate hazards which WILL result in
severe personal injury or death.
WARNING: Identified by an Orange Label,
hazards or unsafe practices which MAY result in
personal injury or death.
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 I
An advisory procedure, practice, condition, etc., which is
essential to emphasize.
Directs attention to hazards or unsafe practices which may
result in minorpersonal injury,product or propertydamage 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.
Directsattentionto unsafe practices andfor existing hazards
whichWILL resultinsevere personal injuryor 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.
WARNING: Use special care when travelling
without a load as THE RISK OF
AOVERTURNING 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.
Reportall 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.
1-2

14. OPERATING INSTRUCTIONS
Basic maintenance information and the Recommended
Schedule of Maintenance are in the Operating Manual,
located inthe document holder on the compartment cover.
Also refer to Section 2, GENERAL TRUCK AND
LUBRICAT1ON.
1.
and all other protective equipment is attached.
Make sure overhead guard, load backrest extension,
2. Make sure all capacity,safety and informational plates
or labels are attached. This truck is not considered safe to
usewithout a legible, properlyfilled out nameplate.Contact
Yale Materials Handling Corporationor 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.
during the previous shift.
Inspect truck for any damagethat might have occurred
4. Inspecttruck beforeandafteroperating,for anysigns of
external leaking of the battery, steering system, hydraulic
system, etc.
5.
reinforcement showing through the outside of the hose.
Check hydraulic hoses for leaking, chafing, cuts or
6. Check for mistracking of the hoses on the sheaves.
7 .
8.
Make sure chains are not damaged or kinked.
Make sure mast stops and finger guards are in place.
9.
and fastened.
Make sure bonnet latches are adjusted (if equipped)
10. Operate service and parking brakes, all hydraulic
controls, (lift, tilt and auxiliary, if equipped), accelerator,
shifting linkages andsteering. Makesurethey operatefreely
and return to their proper positions. See section on
OPERATING CONTROLSfor 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. Operatetruck andmakesureallgaugesand metersare
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.
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 ifyouare not inthe operator's seat,which isthe
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. Refertothe Maintenanceand Lubricationsection 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.
Depress accelerator pedal to travel
CAUTION: Operating the drive control in a
situation where the truck will not move will
Adamage the electric motor.
1. Keephands,feet and other partsofyour body insidethe
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. Knowthe 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

15. OPERATING INSTRUCTIONS
5. The operator can change the direction of travel while
the lifttruck is movingby movingthe direction control lever in
the opposite direction. This is called plugging.
6.
the path of travel.
7 .
forks trailing and always look in the direction of travel.
8. Start,stop,travel, steer and brakesmoothly. Slowdown
for turns and on uneven or slippery surfaces that could
cause truck to overturn or slide.
Look in the direction of travel and keep a clear view of
Ifvisibility is impairedbythe load, operatetruck with the
9. Beforeentering trucks or trailers, be certain the brakes
on the truck or trailer are applied and wheel chock(s) are in
place. Iftrailers are notcoupled to atractor, 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 properlysecured. 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 pushfreight 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 beawarethat the forks can sometimes extend beyond
the load. This may cause the forks to hit an object or lift
another load.
13. Watchoutfor obstructions,especiallyoverhead. Check
clearances.
14. Do not runover objectsonthe roadway surface astruck
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. Onslopingsurfaces, higherthan 5 percent (a5ft. riseor
drop in 100ft. of travel), operate loaded truck with the load
facing uphill.Donotturnon an slope. Forstability reasons,a
lift truck must not be driven across a slope.
18. Operate unloaded truck on all grades with the lifting
mechanism downhill.
Q
20. Watch out for pedestrians at
all times. Donot drive upto anyone
standing in front of an object.
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 lifttrucks are not intendedfor 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 loadwill 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 theforks onthefork carriage. Forksshould bespaced
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 andcondition ofstuds at eachend of
the carriage upper fork clip slide. If studs are damaged or
missingthey should be repaired or replacedbeforetheforks
are adjusted.
19. Do not push extra loads with the truck.
1-4

16. OPERATINGINSTRUCTIONS
To adjust the forks, raise them a few inches off the floor. Lift
uponthe keeper pinand slidetheforks alongthe 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.
The check listsareavailableintabletformwith50sheets 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 Maintenancewhich should be
used as a guide along with the Lubrication Instructions.
1-5

17. OPERATING INSTRUCTIONS
~~ ~~~~~ ~
Date
Truck Number
NOTE: This Daily Check List is available for the Operator.Some items onthis list may not be applicable to yourtruck.
This convenient check list is in tablet form and can be ordered through your YALE IndustrialTruck Dealer. Form Number
944-641&A.
~
Operator Battery Water
Model Number Hydraulic Oil
Yale
Department
Shift
IndustrialTrucks
Record of Fluid Added
Serial Number
Drive Hour Hoist Hour
Meter Reading Meter Reading
Daily pre-shift inspectionis an OSHA requirement.
We recommendthat you document that these
inspections have been made.
Operator’s Daily Check List
Electric Truck
SAFETY AND OPERATIONAL CHECKS (Prior to each shift)
Have a qualified mechanic correct all problems (0.K.V) Need Maintenance
Leaks - Hydraulic Oil, Battery
ITyres - Condition and Pressure I I I
I I I
IForks, Top Clip Retaining Pin and Heel - Check Condition
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
IOverhead Guard - Attached I I I
ISafety Warnings - Attached (Refer to Parts Manual for Location) I I I
IInternal Checks: I I I
IBattery - Check Water/Electrolyte Level and Charge I I I
IHydraulic Fluid Level - Check Level I I I
I I I
IDrive Unit Fluid Level - Check Level
IOperator’s Compartment: I I I
IOperating Manual - in Container I I I
- Attached and information matches model, serial number and
Form 944-6418-A (5/93)
0 Copyright 1993 Yale Materials Handling Corporation
1-6

18. OPERATING INSTRUCTIONS
MODELAND CONTROL INFORMATION
The ERP/C16-20ATF three wheel electric rider lift trucks
have lifting capacities of 1600 kgs to 2000 kgs (3000Ib 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. ’
No additions, omissions, changes or modifications should
be made that will affect compliance to the previously stated
requirementsor inanyway minimizetheeffectivenessofthe
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 1-3 -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.
with a spinner knob. The horn button is located inthe 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.
Figure 1 4 - Operating Controls
4. Storage Box - The storage box is within easy reachof
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 arethe sametype and colour. Makesure the
voltage of the battery is the same as specified on the name
plate. The halves of the connector must be joined for
operation. Pulluponthe handleto separate the halves ofthe
connector to disconnect the battery.
6. Accelerator Pedal - The accelerator pedal controls the
speed of the truck. To INCREASEtravel speed depress the
pedal. To DECREASE travel speed release the pedal.
7 . Brake Pedal -The largeservice brake pedal is located
for leftor rightfoot operation. Depressthe foot pedalto 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.
2. Steering Column -The steering columnis adjustableto
five tilt positions. The molded steering wheel is equipped
1-7

19. OPERATINGINSTRUCTIONS
Figure 1-5 - Operating Controls
8. Operator Seat - The lever to adjustthe operator's seat
is located between the seat rails. Movethe lever to the left
andslide the seat to the desired position.Releasethe 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
notapplied.When carryingthe maximumpermitted loadthe
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 - DirectionControl 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 - ParkingBrake
1-8

20. OPERATING INSTRUCTIONS
11. LightAssemblies - Rocker switches usedto controlthe
rear light bar assemblies are located on the control lever
cover. Makesure the dualtail, brake and back-up lights are
functioning. Other optional light packages are available for
this truck.
I I I
Figure 1-8 - Light Switch
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 -Steering Column Tilt Lever
13. Lift Control Lever - To raise the forks PULL the hand
lever.To lowerthe forks PUSHthe hand lever.To stop/hold,
move the hand lever to the neutral position. The lever is
spring loaded to the neutral position.
I1 I I I
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.
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
has a detented positionfor usewith attachmentsthat havea
clamping actuation. This lever is actuated by pushing the
lever slightly to the rightandthen 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-clampingaction.Thefourth 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 arespring loadedtothe neutralposition.
Refer to the attachment publication supplied by the
manufacturer for attachment operation.
Symbol varies by attachment
I
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
c. Premium Dashboard Display
1-9

21. 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 chargedbattery.Whenthe needleis
in the yellow segment, the battery voltage is falling off and
when the needlereachesthe red segment,the batterymust
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.
Figure 1-13 - Battery Voltmeter and Hour Meter
Gauges and indicator lamps located on the instrument
panels are described inthefollowing paragraphs.Whenthe
key switch isturned 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.
Thefollowing Indicatorlampsarefound on allthedashboard
displays.
This lamp is illuminated when the parking brake is applied.
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 combinationdashboarddisplay has a batteryindicator
which features a LED (Light Emitting Diode) display of
state-of-charge.OnlytheLEDindicatingthestate-of-charge
is illuminated. At 70% of discharge an LED will flash,
indicating"energyreserve".At 80% of discharge both led's
will alternately flash, indicating "empty". Lift Interrupt will
occur at approximately80% butwill not occurwhilethe lift is
beingoperated.The systemwill automaticallyresetwhen a
charged battery is connected.
I I
Figure 1-14 - Combination Dashboard Display
The hour meter continuallydisplays total operation hours.
The primary function of the hour meter is to determine
maintenance intervals as outlined in the Recommended
Schedule of Maintenancelocated in this manual.
Instrument Panel C (OPTIONAL)
This premiumdashboard 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.
I f, ,
i
I
Figure 1-15 - Premium Dashboard Display
The hour meter function shows the operating time of the
truck. The hour meter indicator lamp is illuminatedfor four
seconds after the lift truck has been turned off. Duringthis
time the operatingtime is displayed on the digital display. If
there is an hourmeterforthe pumpmotoritwill bedisplayed
for another four seconds.
Hour Meter Function Indicator
7-70

22. OPERATINGINSTRUCTIONS
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(approximately80%
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 codeappears
on the dashboard display.
Battery Function Indicator
If this lamp is Illuminated the lift pump or traction motor
brushesareworn and mustbe replaced. lfthetyre andarrow
symbol i
s illuminated the traction motor brushes must be
replaced. If the fork and arrow symbol is illuminatedthe lift
pump motor brushes must be replaced.
[
p
i
]
1
-
8
8
8
1
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 istoo hot. Ifthetyre
and arrow symbol is illuminatedthetraction motoristoo hot.
Allow the motor to cool if the red LED’s are illuminated.
[ - H I E ]
Temperature Indicator Lamp
SAFE MAINTENANCE PROCEDURES
Thistruck meetsallapplicable mandatory requirements and
safety standardsfor powered industrialtrucks at the time of
manufacture.The truck is also equipped with certain safety
devices as standard equipment. For example, all high lift
trucks are equippedwith 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
thatwill affectcomplianceto 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.
Carefullyreadandunderstandthe 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, personneland proceduresshould be
provided.
2. The Recommended Schedule of Maintenance should
be usedas a guidefor 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. Raisethe 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.
tag to the control handle.
Disconnect the battery. Attach a DO NOT OPERATE
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

23. OPERATINGINSTRUCTIONS
11. All parts of lifting mechanisms should be carefully and
regularly inspected and maintained in correct operating
condition.
12. All hydraulicsystemsshouldberegularlyinspectedand
maintained in conformance with the maintenance
schedules. Lift cylinders, valves and other similar parts
should becheckedto ensurethat’ldrift”hasnotdevelopedto
the extent that itwould create a hazard.Seethe ROADAND
LOAD TEST, in Section 2, GENERAL TRUCK AND
LUBRICATI0N.
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 conditionto 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 replacementpartsto besuretheyare
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.
MOVING A DISABLED LIFTTRUCK
WARNING: Use extra care when towing a lift
Atruck if there is a problem with any of the
following:
1.
2.
3. Tyres are damaged
4. Traction conditions are bad
5.
Brakes do not operate correctly
Steering does not operate correctly
If the lift truck must be towed on a steep grade
Ifthe steering pump motor does not operate steering the lift
truck can bedifficult.Poortractioncancausethe disabled lift
truck or towing vehicle to slide. Steep grades will increase
the required brake effort.
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.
counterweights of both lift trucks.
Use a steel towing chain attached to the tow pins in the
Never lift a disabled lift truck unless the lift truck must be
movedand cannot betowed. The lifttruck usedfor liftingthe
disabled truck must havea ratedcapacity equalto or greater
than the weight of the disabled lift truck. The capacity must
befor a load centre equal to halfthe 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 lifttruck 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 lifttruck if you have
not identified all problem areas.
WARNING: Be sure to stay clear of the tow
chain, towing vehicle andthe lifttruckduringthe
towing operation to prevent injury.
WARNING: Travel slowly and do not tow on
grades. NEVER tow the lift truck faster than a
Anormal walking speed. Always tow smoothly
A
without sudden starts or stops.
WARNING: Until repairs are complete keep a
tag on the steering wheel stating - DO NOT
AOPERATE. 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
WARNING: The lifttruck must beput on blocks
for some types of maintenance and repair.The
Aremoval 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.
HOW TO TOW THE LIFT TRUCK
1. The towed lift truck must have an operator.
1-12

24. OPERATINGINSTRUCTIONS
b. Before removing the steering axle assembly or
counterweight, put blocks underthe mast assembly so
that the lift truck cannot tip forward.
Thesurface must besolid, even, and levelwhen the lifttruck
is put on blocks. Makesure that any blocks usedto support
the lift truck are solid, one piece units.
HOW TO RAISE THE STEERINGN R E
1. Applythe parking brake. Put blockson both sides (front
and back) of the drive tyres to prevent movement of the lift
truck.
2. Usehydraulicjacksto 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.
truck. Put blocks under the frame to support the lift truck.
Putthe jacks underthe rear of the frame to raise the lift
NOTE: Some lift trucks have lifting eyes. These lifting
eyes can be usedto raise the lift truck so that blocks can be
installed.
HOW TO RAISE THE DRIVE TYRES
1.
each outer upright.
Put the mast in the vertical position. Put a block under
2.
from the surface.
Tilt the mastfully forward untilthe drivetyres are raised
3. Put blocks under the frame behind the drive tyres.
4.
the steering tyre to prevent movement of the truck.
Put additional blocks on each side (front and back) of
5. Ifthe hydraulic system will not operate, use a hydraulic
jackunderthesideoftheframe nearthefront. Makesurethe
jack has a capacity equal to at least halfthe weight ofthe lift
truck. See the name plate for truck weight.
DRIVETYRES STEERING TYRES
Figure 1-16 - Putting a Lift Truck on Blocks
PRECAUTIONS FOR TRUCKS IN STORAGE stored with forks attachedthe 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
areelectric
motors, hydrauliccomponents andelectrictruck
Electrictrucks should be stored without batteries,therefore
batteries. Electric poweredtrucks can best be protected by
being operated for a short period of time each month.
Before placing
any truck in storage'
area which is 'lean* and free
contaminants.
you will have to provide a fully charged battery for the
exercise period.
All hydraulic cylinders should be cycled several times each
month to keep the seals active and to coat the interiorwalls
with oil. Actuate each cylinder, in both directions, until the
must choose an
airborne
stops are reached. With the power off, actuate each
hydraulic control valve to relieve hydraulic pressure.
When parking the truck chock the Do not use the
hand brake. The mast should be fully lowered and tilted
back. Forsafetyand increasedusableRoorarea removethe
forks and tag them with the truck serial number. If truck is
1-13

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