Yale OS 030 EBB801

SERVICE MAINTENANCE
MANUAL
Models
For
OS 030 EB
(B801)
NA00733
Parts Contact
For Service &
Part No - 524139078
Handling Corp. June 1999
Yale Materials
1400 Sullivan Drive
Caller No. 12011
Greenville, NC 27834-2011
Yale
Industrial Trucks USER INFORMATION
EXPLANATION OF MODEL CODE
MODEL FAMILY
OS - Order Selector
SS - Straddle Selector
RATED CAPACITY
030 - 3,000 Lbs.
SPECIAL DESIGNATION
As Assigned
DESIGN SERIES
A - B - C - D etc.
MANUFACTURING SOURCE
N - North America
OS 030 E B N S 24 S E 089
FULLY LOWERED
MAST HEIGHT
Measured in Inches
_ MAST TYPE
V - Simplex
E - Triplex
__ CONTROL
S - SCR
_ VOLTAGE
24, 36
BATTERY COMPARTMENT
S - 14.6" Small
To verify that this manual is correct for this truck compare the model code, as explained above, with the
nameplate on the truck. Refer to Table of Contents for nameplate location and information. If the model code
in this manual does not agree with the information on the nameplate, contact your Yale industrial truck dealer.
SPECIAL NOTE
This Maintenance Manual contains complete and accurate information available at the time of publication for
the components and systems listed. Yale Materials Handling Corporation reserves the right to make changes
to its product at any time and the possibility exists that later changes are not included in this manual. If your
lift truck is equipped with special options that are not covered in this Maintenance Manual, you should contact
your local Yale industrial truck dealer for additional information.
B
Yale
Industrial Trucks
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 of the desired section, bending the book back and thumbing the pages to the
corresponding tab.
SECTIONS
1 OPERATING INSTRUCTIONS 1
2 GENERAL TRUCK AND LUBRICATION SCHEDULE 1
3 ELECTRICAL SYSTEM I
4 DRIVE UNIT I
5 BRAKE SYSTEM 1
6 STEERING SYSTEM 1
7 STEERING SYSTEM - WIRE GUIDANCE II 1
8 HYDRAULIC SYSTEM 1
9 MAST I
10 BATTERY AND CHARGING SYSTEM 1
11 USER SUPPORT INFORMATION 1
12 ALPHABETICAL INDEX 1
Yale
IndustrialTrucks
SECTION 1
OPERATING INSTRUCTIONS
1
Yale
Industrial Trucks
SECTION 1 - CONTENTS
OPERATING INSTRUCTIONS
DESCRIPTION PAGE NUMBER
MODEL DESCRIPTION 1-1

OPERATING CONTROLS 1-1
SAFETY AND INFORMATIONAL LABELS 1-4
CAPACITY PLATE 1-4
SERIAL NUMBER 1-4
MODEL CODE 1-4
TRUCK WEIGHT 1-4
CAPACITY RATING 1-4
SAFETY LABELS 1-4
OPERATING PROCEDURES 1-7
OPERATOR PRE-CHECKS AND INSPECTION 1-7
OPERATORS DAILY CHECK LIST 1-8
OPERATING PRECAUTIONS 1-9
Yale
IndustrialTrucks OPERATING INSTRUCTIONS
MODEL DESCRIPTION
The Yale OS 030 EB electric lift truck has a 3,000 lb. lifting
capacity and is specially designed for order picking. The power
source is a 24 volt battery. The operator's platform is elevated
with the load. This allows accurate fork positioning and order
picking operations. The lift truck can be operated from the
standing position with the operator facing either direction.
NOTE: Throughout this manual the terms left, right, front and
rear relate to the viewpoint of an operator standing in the truck
facing the steer/drive tire.
The control handle allows the use of one hand to control

a>'
forward and reverse travel as well as lift and lower.Thevariable C3
CD
lift/lower control allows the operator the option of varying the lift
and lower speeds. The drive motor is stationary to prevent
flexing and wear of the power cables. An electrically released,
spring applied brake is also provided. Yale Hi-Vis Triplex masts
provide excellent visibility for these models.
Before attempting to operate this lift truck, carefully read and

understand these operating procedures. Make sure the lift
truck is in proper operating condition. Be sure all safety devices O
such as the overhead guard and the tether line and belt are in
place and properly secured. The operator should always wear
the tether line and belt when operating this unit.
No additions, omissions, changes, or modifications should be NA00734

madethatwill affect compliance to the stated requirements or in
any way minimize the effectiveness of the safety devices. -
Figure 1-1 OS030EB Truck
OPERATING CONTROLS
The numbers and letters in the following descriptions are to be lift function will be disallowed at this point. Continued
used for component identification. See Figure 1-2 through 1-8. operation with the LEDs flashing can damage the battery,
motors or the contactors. The battery indicator will
1. The Instrument Panel includes a Battery Indicator/Hour- automatically reset when a charged battery is connected.
meter, a Steering Indicator Gauge, a Battery Power Discon¬ The battery indicator functions only when the key switch is
nect, a Slack- Chain Warning Light and the Key Switch. On lift in the ON position.
trucks that have optional Wire Guidance, a rocker switch and a
The Battery Indicator/Hourmeter electronically records lift
red light will also be on the instrument panel. The instrument
truck hours whenever travel or lift functions occur. A liquid
panel is located between the steering wheel and the traction
display crystal (LCD) is used to show the current
controller.
hourmeter reading. The hourmeter utilizes an internal
A. The Battery Indicator/Hourmeter illuminates a light battery to retain the current hourmeter reading when the lift
emitting diode (LED) bar to display the battery state of truck battery is disconnected. The internal battery is not a
charge. Two red, three yellow and five green colored LEDs serviceable part and is designed to last for the life of the
are arranged from left to right for a total of 10 bars. The far Battery Indicator/Hourmeter. Hours are displayed
right LED indicates a charged battery. The far left LED whenever the lift truck battery is connected.
indicates a discharged battery. When a properly charged
B. The Steering Indicator Gauge allows the operator to
battery is installed in the lift truck, the green LED at the far
see the current position of the lift truck steer tire. The
right of the scale is illuminated. As the battery's state of
Steering Indicator Gauge uses red arrow shaped LED's to
charge decreases, LEDs to the left are successively
provide a visual display of the steer tire position.
illuminated. The illuminated LED moves from right to left
and the colors change from green to yellow to red as the C. The Battery Disconnect Switch is the red knob located
battery discharges. The red LED second from the far left on top of the instrument panel. When the knob is
will flash indicating a nearly discharged battery. The depressed, power will be shut off to all circuits throughout
battery should be charged at this time. If the last two LEDs the forklift except for the hourmeter. Turning the key switch
are alternately flashing, the battery MUST be charged. The to the start position restores power.
1-1
Yale
Industrial Trucks OPERATING INSTRUCTIONS
NA00480
ÿ
Figure 1-3 - Directional Control and Horn
3. The Horn Switch is located on the control handle. Push the
horn button to sound the horn.
4. Brake Pedal - The brake is applied when the pedal is re¬

leased. The brake is released when the pedal is depressed.
NA00479 This brake can stop the truck abruptly and is used primarily as a
parking brake. The normal method for stopping this lift truck is
-
Figure 1-2 Instrument Panel
plugging.
D. The Slack Chain Warning Light will let the operator
know when the platform or the forks will not lower because
of an obstruction. Raise the forks untilthe chain is taut and
the light goes off.
E. The Wire Guidance rocker switch controls the
optional wire guidance function. The rocker switch and the
red light are both ON when the guidance system is ON.
Pushing the switch button to the ON position as the lift
truck approaches the guide wire energizes the guidance
system to seek the guide wire. During the SEEK mode the
light will flash and the alarm will sound. A steady light with
no alarm indicates that the guidance system is in the RUN Figure 1-4 - Brake Pedal
mode. The alarm will sound and the light will flash if the
guide wire signal is lost. 5. The Steering Wheel is equipped with a spinner knob. The
on-demand electronic power steering draws power on an as
F. The Key Switch is a three position switch. The first
needed basis.
position is OFF (marked O). The second position is RUN.
The third position is START. The key automatically returns
to the second position after it is released from the start
position.
2. The Control Handle is a multifunctional grip for lifting and

lowering the forks, as well as forward and reverse travel. Push
the control handle in the desired direction of travel. The amount
of control movement determines the speed of travel. The con¬
trol is spring loaded and will automatically return to the neutral
(off) position when released. The two rocker switches in the NA00189
control handle allow the forks to be lifted or lowered. Both
switches will automatically return to the neutral position when Figure 1-5 - Steering Wheel
released. The operator can change the direction of travel while
the lift truck is moving by moving the control handle to the oppo¬ 6. The lift truck is equipped with optional Side Rails which
site direction of travel. The lift truck will come to a stop, unless must be lowered into position for lift truck operation. The Side
the control handle is released, and accelerate in the opposite Rails have electric interlock switches which deactivate drive
direction. This action is called "plugging" and is the normal and hoist functions when they are not in the lowered position.
method of stopping the lift truck.
1-2
Yale
7. The Pallet Clamp will automatically engage the pallet. The i

\ WARNING: Make sure Manual Lowering Valve is
Pallet Clamp Release is a foot pedal on the operator compart¬ X|\ completely closed before lift truck operation.
ment floor. Unintentional mast lowering may occur if the valve
is not closed.
A
WARNING: Before using the manual lowering
feature, make sure there are no obstructions which
would prevent the platform or forks from lowering.
10. The Operating Manual is sent with the lift truck and is lo¬
cated in the container on the drive unit cover. 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.
Part No. 520679601
OPERATING MANUAL
NA00737
Operating Instructions
Service Instructions
Figure 1-6 - Release Pedal and Pallet Clamp User Support Information
MODELS: OS030BD
8. An Amber Flashing Light is mounted on the drive unit cov¬ SS 030 BD
er. The light will flash anytime the key is in the ON position. OS 030 EB
Yale
FOR DRIVER S USE

Figure 1-7 - Flashing Light DO NOT REMOVE FROM TRUCK
STORE IN CONTAINER IN OPERATOR'S COMPARTMENT
READ THIS MANUAL BEFORE OPERATING TRUCK
9. The Manual Lowering Valve, located in the drive motor
compartment is manually operated to lower the operator's plat¬
form. Turn the manual lowering knob clockwise to open the
valve. Turn the knob counterclockwise to close the valve.
Figure 1-8 - Operating Manual
1-3
Yale
SAFETY AND INFORMATIONAL LABELS

Safety and informational labels are located in conspicuous This lift truck meets all applicable mandatory requirements of
locations on this lift truck and should be strictly adhered to. ANSI B56.1, Safety Standard for Powered Industrial Trucks, at
These safety and informational labels must be replaced the time of manufacture. In addition, these lift trucks are
immediately if missing or defaced. Labels will vary with type of classified by Underwriters' Laboratories, Inc. for the type
lift truck and equipment installed. Refer to the Parts Manual for designation shown on the UL plate. Consult the (UL) Index of
part number of labels. Classified Products.
CAPACITY PLATE
Familiarize yourself with the information contained on the Truck Model No.
capacity plate which is located on the operator's platform.
Type
Capacities and warnings contained on this capacity plate must Serial No.
be strictly followed. Information on this capacity plate is as Battery Type Volts
Max. A.H. (6 Hour Rate)
follows: Truck Weight Less Battery lb
Truck Weight With Battery
Serial Number lb
Allowable Battery Weight Range
1. MODEL CODE
This is an identification number assigned to this particular lift lb To lb 2. SERIAL NUMBER
Outrigger Overall Width In
truck and should be used when ordering service parts or when Wheelbase in 3. TRUCK WEIGHT
requesting any information from your Yale industrial lift truck 4. CAPACITY RATING
dealer. The serial number has eleven alpha/numeric A WARNING I
characters and is stamped on the lift truck frame and on the TRAINED OPERATORS AND
MECHANICS ONLY
capacity plate. Read all caution rules and
instructions before operating o
servicing ihis truck.
DO NOT OVERLOAD rj"
Model Code Capacity ratings for evenly 'T|"
distributed and laterally L
centered loads, with mast
An explanation of the model code is located on Page B of this vertical. Tiuck equipped as
specified on this plate. ÿ-L,
manual.
Truck Weight Dim C

Load
This is the approximate weight of the lift truck without a load on

the forks. This weight plus the weight of the load to be moved
must be considered when operating on elevated floors,
elevators, etc.
Capacity Rating
This rating shows the maximum capacity of this lift truck with
relation to load centers and fork heights (see diagram on Figure 1-9 Capacity Plate -
capacity plate). Personal injury and damage to the lift truck can
occur if the capacity rating is exceeded.
SAFETY LABELS
Definitions of the safety labels used on the motorized lift trucks are listed below:
/j\ WARNING /j\ CAUTION

WARNING: Identified by an Orange Label, hazards or CAUTION: Identified by a Yellow Label, hazards or
unsafe practices which MAY result in personal injury or unsafe practices which MAY result in minor personal
death. injury, product or property damage.
1-4
Yale
The reader may find any or all of the following labels used inthis publication. An understanding of their use, as follows, will aid
the reader:
NOTE:
/\\ WARNING: Directs attention to unsafe practices An advisory procedure, practice, condition, etc., which is
which could result in personal injury or death if essential to emphasize.
proper precautions are not taken.
A CAUTION: 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.
The following Warning to the Operator is a label and must be on the lift truck:
A WARNING
8. Stabilize Your Load-Load pallet evenly within the
dimensional limits of the pallet. Do not handle unstable or
loosely stacked loads. Before lifting, be sure load is centered
and forks are completely under load.
FOR YOUR SAFETY AND THE SAFETY OF OTHERS
9. Never Overload-Do not overload truck, check nameplate
1. Know Your Truck-Do not operate this truck unless you
for load weight and load center information.
have been trained and authorized to do so. Read all warnings
and instructions in the Operator's Manual and on this truck, or
10. Avoid Sudden Movement-Start, stop, travel, steer and
obtain from the plant Safety Director or the local Yale
brake smoothly. Use special care when traveling without load
representative.
as the risk of overturn is greater.
2. Check your Truck-Truck should be checked daily before
being placed in service. If found to be in need of repair,
11. Care on Ramps-Do not operate on grades whenthe load
engaging means is elevated above 12" (300 mm). Do not turn
defective or in any way unsafe it should be reported
on grades. Travel on grades with load or load engaging means
immediately to the proper authority andthetruck removed from
upgrade.
service until it has been restored to safe operating condition.
12. Eyes Ahead-Before moving platform or truck, look
3. Protect Yourself- Before operating truck, make sure the
forward, backward, upward and downward to be certain of a
body belt and lanyard are securely fastened. Chain and side
clear path of travel.
rails must be in position and secured.
13. When Elevating-Elevate platform only to order pick, pick
4. Keep Inside-Operate truck from designated operating
up or stack a load. Watch out for obstructions, especially
position. Never place any part of your body into the mast
overhead. Check clearances.
structure or outside the truck.
14. Watch People-Do not allow anyone to stand or pass
5. No Riders-Carry no passengers. The operator's platform
under load or lifting mechanism.
is designed for and must be used by the operator only.
15. Emergency Switch-All power circuits will be cut off
6. Pickup Pallet or Platform-Be sure pallet or platform is
when emergency switch is activated.
securely attached or stable on forks. If pallet is used, position
forks to the outer edges to minimize the possibility of tipping.
16. Shut Down Completely- Before getting off truck,
neutralize travel controls, fully lower lifting mechanism. When
7. Secure Pallet or Platform-lf truck is equipped with a
leaving truck unattended also shut OFF power.
pallet, be sure the pallet is securely clamped. If truck does not
have a pallet or pallet clamp, be sure supplementary platform is
Failure to comply with these warnings
securely attached. Restraining means should be used by the
will create an unreasonable risk
personnel on the pallet or supplementary platform.
of injury to yourself and others.
1-5
Yale
Industrial Trucks OPERATING INSTRUCTIONS
1. LABEL, OPERATOR WARNING *

2. LABEL, MAST WARNING
3. PLATE, OVERHEAD GUARD
4. LABEL, MANUAL LOWER
5. LABEL, FORK WARNING
6. LABEL, ACCELERATOR/LIFT
7. LABEL, WARNING
8. LABEL, MANUAL LOWERING
9. PLATE, UL
10. PLATE, BATTERY
11. SERIAL NUMBER, CAPACITY PLATE
12. SERIAL NUMBER, FRAME
* TEXT OF OPERATOR WARNING

LABEL BEGINS ON PAGE 1-5.
CXXXXXXXWi
Cleaalfted by
Yale
Underwriter* Laboratories Inc.®
A* to Fire and
O
Truck Model No.
Type
Yale n MOVING MAST SECTIONS.
KEEP HANDS CLEAR OF THIS AREA
THIS TRUCK 18 TO BE EQUIPPED WITH

A BATTERY MEASURING
Serial No.
ÿ1/2 In ÿ1/2 In
Electric Shock Hazard Only
TVoe I I Industrial Truck 1
C=]
1
Battery Type
Max. A H.
Volts
(6 Hour Rate)
Truck Weight Less Battery lb
- 0 In • 0 In
No. 1 . 1 C=1 Truck Weight With Battery
Yale Materials HandUng Corporation lb
Q O Allowable Battery Weight Range
lb To lb
10
Outrigger Overall Width in
Wheelbate in
TRAINED OPERATORS ANC

MECHANICS ONLY
Read all caution rules and
A
Manual Low*ring
of Operator Platform.
instructions betore operating
servicing this truck INSTRUCTIONS
Valva Loeatad inaida
Thia Compartment.
DO NOT OVERLOAD
Capacity ratings for evenly 'i
distributed and laterally
centered loads, with mast
%
T 1
OPERATOR PLATFORM
MANUAL LOWERING VALVE
vertical Truck equipped as
specified on this plate J
J. Rotate valve knob clockwise to lower platform.
Attachment #
Fully rotate valve knob counterclockwise
lb
Dim A
Lo»d
Canter
in
Dim B
Fork
Haigni
In
Dim C
In
/ before raising platform.
lb In In in A WARNING DO NOTOPERATE THIS TRUCK UNTIL YOU HAVE

DO NOT REMOVE THIS GUARD FAILURE TO COMPLY WITH THESE • Been trained and qualified
_
lb in In in
TMe erwbaee awidarwddMt— wOli praicdaale REQUIREMENTS WILL CREATE AN • Read the operator* manual attached to truck
Me cpwaer ban Mng atyeaa. bet cewl piaect
agWWavwyf II I f ÿ!. REPLACE M *— ajit lb In In UNREASONABLE RISK OF INJURY • Read all caution ruiee attached to truck
• Checked the namepiata tor capacity
TO YOURSELF AND OTHERS.
SS5073400.D 1 • Checked the truck daily for proper operation and had al defects corrected
Figure 1-10 - Serial Number, Nameplate and Label Locations
1-6
Yale
OPERATING PROCEDURES
Read and understand the Operating Manual attached to the lift If you are unsure of the classification of the area you wish to
truck. Notify your supervisor if the manual is not available. enter, ask your supervisor before entering.
Know your lift truck. Do not operate this lift truck unless you are Do not remove overhead guard unless specifically authorized
trained and authorized to operate this lift truck. to do so.
Do not operate this lift truck with wet or greasy hands. Make sure that fork length is at least 2/3 of load length. Carry
the load flush against the lift truck.
Do not operate this lift truck if it needs repair, if it is unsafe, or if it
might contribute to an unsafe condition. Remove the key and Allow no one under or near the load or mast. Do not put any part
report the condition to the proper authority. of your body into the mast area or between the mast and lift
truck.
If the lift truck becomes unsafe in any way while you are
operating it, stop operating the lift truck and immediately report Watch that your loaddoes not exceed the capacity rating of the
the matter to the proper authority. lift truck. The lift truck capacity is posted on the nameplate.
Only specifically authorized and qualified persons should make Do not handle unstable or loosely stacked loads.
repairs and adjustments to the lift truck.
Never allow anyone to ride on your lift truck and never allow
Be certain that your lifttruck is the correct fire safety type forthe anyone other than a qualified professional to operate your lift
area in which you are working. The proper type designation for truck.
this lifttruck is shown on the model code, on the nameplate, and
the Underwriter's Laboratories, Inc. (UL) plate. An area of use Refer to the lubrication section in this manual for the
label is required on the lifttruck if it is used in areas classified as recommended hourly service intervals. Regular attention atthe
hazardous. Use only lift trucks approved for use in those areas. specified time will pay dividends in maximum efficiency and
longer life of the lift truck.
OPERATOR PRE-CHECKS AND INSPECTION

Before each shift, every 8 hours, it is the operator's 5. Check hydraulic hoses for leaking, chafing, cuts or rein¬
responsibility to carry out the following checks and inspections. forcement showing through the outside of the hose.
Basic maintenance information and the Recommended 6. Make sure chains are not damaged or kinked. Check for
Schedules of Maintenance are included in this manual, which is excess slack or mistracking on the sheaves.
shipped with this lift truck.
7. Make sure all latches are adjusted (if necessary) and fas¬
For more detailed maintenance information see the tened.
Maintenance Manual for this model.
8. Operate brake, hydraulic controls and steering. Make sure
1. Make sure overhead guard, tether line/belt and all other all controls operate correctly and return to their proper posi¬
safety devices are attached. tions. See section on Operating Controls for detailed descrip¬
tions.
2. Make sure all capacity, safety and informational plates or
labels are attached. This lifttruck is not considered safe to use 9. Inspect condition of wheels and tires.
without a legible, properly filled out nameplate. Contact Yale
Materials Handling Corporation or your local dealer for Yale in¬ 10. Inspectforksfordamage. Makesuretheforksarecorrectly
dustrial lift trucks if the nameplate is not present and legible. attached and locked in their proper position.
See label page for label and plate locations.
11 . Test horn, lights, gauges and meters. Make sure they work
3. Inspect lift truck for any damage that might have occurred correctly.
during the previous shift.
12. Make sure unusual noises are investigated immediately.
4. Inspect lifttruckfor any signs of external leaking of the bat¬
tery, steering system or hydraulic system.
1-7
Yale
Industrial Trucks operating instructions
NOTE: This Daily Check List is available for the Operator. Some items on this list may not be applicable to your truck. This
convenient check list is in tablet form and can be ordered through your Yale Industrial Truck Dealer. Form Number 944-6418-A.
OPERATOR'S DAILY CHECK LIST
Yale
Industrial Trucks
Daily pre-shift inspection is an
OSHA requirement. We recommend
that you document these
inspections have been made.
Electric Truck
Record of Fluid Added

Date Operator Battery Water
Truck Number Model Number Hydraulic Oil
Department Serial Number
Shift Drive Hourmeter Reading Lift Hourmeter Reading
SAFETY AND OPERATIONAL CHECKS (Prior to each shift)

Have a qualified mechanic correct all problems (O.K.ÿ) Need Maintenance
Leaks - Hydraulic Oil, Battery

Tires - Condition and Pressure
Forks, Top Clip Retaining Pin and Heel - Check Condition
Load Backrest - Securely Attached
Hydraulic Hoses, Mast Chains and Stops - Check Visually
Finger Guards - Attached
Overhead Guard - Attached
Safety Warnings - Attached (Refer to Parts Manual for Part Numbers)
Internal Checks:
Battery - Check Water/Electrolyte Level and Charge
Hydraulic Fluid - Check Level
Drive Unit Fluid - Check Level
Operator's Compartment:
Operating Manual - In Container
Nameplate - Attached and Information Matches Model, Serial Number and Attachments
Battery Restraint System - Adjusted and Securely Fastened
Seat Belt, Buckle and Retractors - Functioning Smoothly
Brake Fluid - Check Level
Controls (Turn Truck On) Unusual Noises Must Be Investigated Immediately:
Accelerator Linkage - Functioning Smoothly
Service Brake - Functioning Smoothly
Parking Brake - Functioning Smoothly
Steering Operation - Functioning Smoothly
Drive Control - Forward/Reverse - Functioning Smoothly
Tilt Control - Forward and Back - Functioning Smoothly
Lift and Lowering Control - Functioning Smoothly
Attachment Control - Operation
Horn and Lights - Functioning
Gauges: Hourmeter/Battery Discharge Indicator - Functioning
Form 944-6418-A (5/93)

© Copyright 1993 Yale Materials Handling Corporation
1-8
Yale
OPERATING PRECAUTIONS
Keep hands, feet and other parts of your body inside the Operate lift truck under all conditions at a speed that will permit
designated operator's compartment. Parts of your body it to be brought to a stop in a safe manner.
outside the lift truck can be injured when passing obstructions.
These lift trucks are designed for use on smooth, hard floors
Do not permit passengers to ride on the lift truck. with minimal grades.
Observe and comply with instructions concerning floor Operate a loaded lift truck with the load upgrade. Operate an
loadings. Knowthe weight of your lift truck and load combined. unloaded lift truck with the lifting mechanism downgrade.
Lift truck weight information is located on the nameplate.
Do not push loads with the lift truck.
Travel with the load lowered. Do not elevate the load except
during stacking. Observe all traffic regulations, including authorized plantspeed
limits. Under normal traffic conditions, keep to the right.
The operator can change the direction of travel while the lift Maintain a safe distance from the lift truck ahead
truck is moving by moving the direction control lever in the (approximately three lift truck lengths), and keep the lift truck
opposite direction. The lift truck will come to a stop and then, under control at all times.
unless the control handle is released, accelerate in the
opposite direction. This is called plugging. Watch out for pedestrians at all times. Do not
drive up to anyone standing in front of an object.
Look in the direction of travel and keep a clear view of the path
of travel. Yale lift trucks are not intended for use on public roads.
If visibility is impaired and you must operate the lift truck in When leaving the lift truck unattended, lower the lifting
reverse, look in the direction of travel. mechanism, shut OFF power and remove key. Chock wheels if
the lift truck is parked on an incline.
Start, stop, travel, steer and brake smoothly. Slow down for
turns and on uneven or slippery surfaces that could cause lift Report all accidents involving personnel, building structures
truck to overturn or slide. and equipment to the proper authority.
Watch clearances around forks. The driver must be aware that Check all gauges and indicator lights for correct operation.
the forks can sometimes extend beyond the load. This may Frequent reading of the instrument panel should become a
cause the forks to hit an object or lift another load. habit.
Watch out for any obstructions, especially those overhead. "HANDLE WITH CARE." Avoid any abrupt moves. Be a
Check clearances. professional.
Do not run over objects on the roadway surface as lift truck Follow the Recommended Schedules of Maintenance.
stability and steering may be adversely affected. Maintain your lift truck for dependable and economical
operation.
When approaching cross aisles, slow down, sound horn and
keep to the right side of aisle.
1-9
NOTES
1-10
Yale
IndustrialTrucks
SECTION 2
GENERAL TRUCK AND LUBRICATION SCHEDULE

Yale
IndustrialTrucks
MAINTENANCE 2-1
SAFE MAINTENANCE PROCEDURES 2-1
BATTERY OPERATION 2-2
BATTERY INSTALLATION 2-2
WATER ADDITIONS 2-3
CLEANING 2-3
CHARGING THE BATTERY 2-3
CHANGING THE BATTERY 2-3
FORKS 2-4
TETHER LINEAND BELT 2-4
PALLET CLAMP 2-4
HOW TO PUTA LIFT TRUCK ON BLOCKS 2-5
HOW TO RAISE THE DRIVE/ STEER TIRE 2-5
HOW TO RAISE THE LOAD WHEELS 2-5
LUBRICATION INSTRUCTIONS 2-6
EVERY 8 HOURS 2-7
EVERY 350 HOURS 2-7
EVERY 2000 HOURS 2-8
YALE WARRANTY INFORMATION 2-8
RECOMMENDED SCHEDULES OF MAINTENANCE 2-8
HYDRAULIC OILS 2-13
GEAR OILS 2-14
GREASE 2-15
ANTI-SEIZE LUBRICATING COMPOUND 2-15
TIRES AND WHEELS 2-16
HOW TO CHANGE THE DRIVE/STEER TIRE 2-16
HOW TO CHANGE THE LOAD WHEELS 2-16
HOW TO MOVE A DISABLED LIFT TRUCK 2-17
HOW TO TOW THE LIFT TRUCK 2-17
PRECAUTIONS FOR TRUCKS IN STORAGE 2-17
PRECAUTIONS FOR BATTERIES IN STORAGE 2-18
FASTENERS 2-19
INTRODUCTION 2-19
THREADS, NOMENCLATURE 2-19
STRENGTH IDENTIFICATION 2-19
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION SCHEDULE
MAINTENANCE
SAFE MAINTENANCE PROCEDURES 9. When necessary to work with mast in a raised position,
install a safety chain to restrain moving parts. Connect moving
Your Yale industrial truck, as manufactured, meets all the appli¬
parts to a part that does not move.
cable mandatory requirements of ANSI B56.1 Safety Standard
for Powered Industrial Trucks.
10. Brakes, steering mechanisms, control mechanisms,
warning devices, guards and safety devices should be
All standard trucks conform to the Underwriters' Laboratories
inspected regularly and maintained in a safe operating
requirements for the Type Designation shown on the name-
condition.
plate. The truck is also equipped with certain safety devices as
standard equipment. For example, all high lift trucks are
11. All parts of the lift mechanism and frame members should
equipped with an operator's overhead guard.
be carefully and regularly inspected and maintained in a safe
operating condition.
No additions, omissions or modifications should be made that
will affect compliance to the above requirements or in any way
12. All hydraulic systems should be regularly inspected and
reduce the effectiveness of the safety devices.
maintained in conformance with the maintenance schedules.
Lift cylinders , valves and other similar parts should be checked
The following instructions have been prepared for your safety
to assure that "drift" has not developed to the extent that it would
and the safety of your fellow workers during maintenance op¬
create a hazard.
erations and should be strictly followed. Carefully read and un¬
derstand the maintenance procedures before attempting to re¬
13. Special trucks or devices designed and approved for
pair the truck. When in doubt of any maintenance procedure,
hazardous area operation should receive special attention to
contact your local Yale industrial truck dealer.
ensure that maintenance preserves the original condition of the
special operating features.
1. Powered industrial trucks may become hazardous if
maintenance is neglected. Therefore, adequate maintenance
14. Modifications and additions which affect capacity and safe
facilities, personnel and procedures should be provided.
truck operation should not be performed by the customer or
user without the manufacturer's prior written approval.
2. The Recommended Schedules of Maintenance should be
Capacity, operation and maintenance instruction plates, tags or
used as a guide for inspection of the truck.
labels should be changed accordingly.
3. Only qualified and authorized personnel should be
15. Capacity, operation and maintenance instruction plates,
permitted to maintain, repair, adjust and inspect the truck.
tags and labels should be maintained in legible condition.
4. The work area should be properly ventilated. Keep shop
16. The truck should be kept in clean condition to minimize fire
clean and floor dry.
hazards and facilitate detection of loose or damaged parts.
5. Avoid fire hazards and have fire protection equipment
17. Checking the performance of the truck or attachments
present. Do not use an open flame to check level of electrolyte.
should be conducted in an authorized safe clearance area.
Do not use open pans of fuel or flammable cleaning fluids for
cleaning parts.
18. Always use Yale replacement parts to be sure they are
interchangeable with the original parts and are of a quality
6. Raise the lift truck only if it is on a solid level floor.
equal to that provided in the original equipment.
Disconnect the battery. Use solid one piece blocks or other
positive truck positioning devices to support the truck. Chock
You should also be familiar with additional maintenance safety
the wheels to prevent movement of the truck.
instructions contained in the following publications:
7. Before removing any component from the truck, such as
counterweights, mast assembly, drive unit, etc., make sure that
1. ANSI B56.1 - Safety Standard for Powered Industrial
Trucks
the lifting mechanism and slings are of the proper capacity and
in good condition.
This booklet can be obtained from:
8. When working on the hydraulic system, be sure the truck is
Society of Mechanical Engineers
turned off, battery is disconnected, mast is lowered and the
345 E. 47th Street
hydraulic pressure is relieved in hoses and tubes.
New York, NY 10017
2-1
Yale
-
2. ANSI/NFPA 505 Type Designations, Area of Use, the electrolyte is low, replace it with electrolyte of the same spe¬
Maintenance and Operation of Powered Industrial Trucks cific gravity as found in other cells of the battery. Replace the
vent caps and give the battery a refreshing charge of three (3) to
This booklet can be obtained from: six (6) hours or continue the charge untilthere is no increase in
specific gravity for three hydrometer readings taken at one hour
National Fire Protection Assoc. intervals. The normal fully charged specific gravity is 1.280 to
Batterymarch Park 1.290 at 77°F.
Quincy, MA 02269
3. Code of Federal Regulations Title 29, Chapter XVII,

Section 1910.178 (OSHA) Powered Industrial Trucks
This booklet can be obtained from:
Superintendent of Documents
U.S. Government Printing Office
Washington, DC
BATTERY OPERATION
Batteries are rated in ampere hours and are selected to perform
a specific workload within an established period of time. Figure 2-1 - Checking Specific Gravity with a Hydrometer
Changing the workload or the time period could result in exces¬
sive discharging, thus shortening battery life. Limit discharging Hydrometer readings and experience will disclose the frequen¬
of battery so that specific gravities do not go below 1.140 to cy of charge intervals under these circumstances. A battery
1.100. If truck operation results in only partial discharges (50% should always be recharged immediately following a complete
or less) and specific gravities are 1.210 to 1.220 or more at the discharge. Permanent damage may result if the battery is al¬
end of a shift, recharging may be deferred and the battery used lowed to remain in a discharged condition.
for another shift providing the workload is not expected to in¬
crease. Table 2-1 - Specific Gravity Temperature Corrections
SPECIFIC
GRAVITY ELECTROLYTE CORRECTION CORRECT
BATTERY INSTALLATION READING TEMPERATURE POINTS VALUE
/\ CAUTION: The battery must fit the battery
1.210 31° C (87° F) + 0.003 1.213
/ I\ compartment correctly. Use spacers to preventthe
battery from moving horizontally in the battery 1.210 27° C (80° F) + 0.001 1.211
compartment. Make sure that the battery voltage and weight
are correct as shown on the nameplate. 1.210 25° C (77° F) + 0.000 1.210
1.210 18° C (64° F) -0.004 1.206

Remove the vent caps from each cell and determine whether
the electrolyte level in all cells is at least halfway between the + 0.001 for each 1.7° C (3° F) from the 25° C (77° F)
element protector and the bottom of the cell cover vent well. If Base Value Degrees C + 17.8 x 1.8 = Degrees F.
Table 2-2 - Battery Specifications
MAXIMUM BATTERY
VOLTAGE MAXIMUM BATTERY SIZE BATTERY WEIGHT
COMPARTMENT SIZE
Width x Length x Height Width x Length x Height Minimum/Maximum
371 x 986 x 787 mm (14.6 x 38.8 x 31 in) 24 365 x 986 x 782 mm (14.38 x 38.8 x 30.8 in) 681/953 kg (1501/2101 lb)
371 x 986 x 787 mm (14.6 x 38.8 x 31 in) 36 365 x 986 x 782 mm (14.38 x 38.8 x 30.8 in) 704/953 kg (1550/2100 lb)
/\ WARNING: The battery must fit the battery NOTE: Maximum tolerances are +0 and -13 mm ( + 0 and
11\ compartment so that the battery restraint system - 0.5 in) for the size of the battery compartment. The battery
will operate correctly. Use the spacers designed to specification chartshows the maximumsize tolerances thatwill
preventthe battery from moving more than 13mm (0.5 in) in any permit the battery to still fit into the battery compartment.
horizontal direction.
2-2
Yale
A CAUTION: Disposal of batteries must meet local

environmental regulations.
1. Be sure the charger is turned off before touching the
charger cable. Attempting to disconnect the cable while the
charger is operating may result in damage to the cable end and
injury to you.
WATER ADDITIONS
2. If the charger is still on when you begin your shift, report
this condition to your supervisor, the battery may not have
LOW LEVEL received the proper charge.
HIGH LEVEL
3. When you are sure the charger is off, disconnect the
battery from the charger. Before connecting the battery lead to
the truck receptacle, make sure the truck controls are in neutral
and that the connector is firmly in place.
When recharging afully discharged battery, the starting charge

FILL AND VENT TUBE rate may be 3 to 5 times higher than the finish charge rate indi¬
cated on the battery nameplate.
PLATE PROTECTOR
The charge rate should taper down to the finish charge rate by
Figure 2-2 - Proper Water Level the time the battery is 85% charged and may be even lower
when fully charged. High "on charge" temperatures orfrequent
Maintain the electrolyte levels halfway between the plate pro¬
tector and the bottom of the fill and vent tube but never below need for water additions are indications of overcharging. Con¬
sult your Yale industrial truck dealer on specific charging prob¬
the plate protector or higher than the bottom of the fill and vent
lems. For complete charging instructions, refer to the manual
tube. Add only distilled or approved water. Check electrolyte
supplied with the battery charger.
level daily, prior to charging on at least one cell and weekly on
all cells.
CHANGING THE BATTERY
/\ WARNING: To prevent personal injury and
/ I\ unexpected battery movement, the battery must /\ WARNING: To prevent personal injury and
CJLJ be level when it is moving. Before removing the
iI\ unexpected battery movement, the battery must
be level when it is moving. Make sure the battery
battery to check the electrolyte levels, make sure the battery
stand is on a level surface and is aligned and adjusted as
stand is on a level surface and is aligned and adjusted.
described in the following procedure:
CLEANING 1. Make sure the key is in the OFF position. Disconnect the
battery. Move the connector and cables so that they will not be
Examine the battery case for damage and leaking .The battery
damaged when the battery is moved.
can bewashed off with water if dusty. Keep vent caps in place. If
electrolyte has accumulated on top, wash with a neutralizing
2. Remove the battery restraint panel.
solution of soda and water (one pound of baking or commercial
soda ash to one gallon of water) .Follow with a rinse using clear
water. The top of the battery should be kept clean and dry. Keep
3. Align the battery stand with the battery so that the end of
vent caps in place during use and charging. Remove vent caps
the stand is againstthe rollerframe. Adjustthe capscrew legs of
the battery stand so that the tops of the rollers are the same
only to observe levels, make water additions, take tempera¬
height as the bottom of the battery.Adjust allfour capscrew legs
tures or take specific gravity readings with a hydrometer.
of the stand so that the rollers are level. Stand on the base of the
battery puller and pull the battery onto the battery stand.
/\ CAUTION: Keep vent plugs in the cells at all
/ I\ times, except when taking hydrometer readings,
(ÿJLoJ adjusting specific gravity and electrolyte levels,
troubleshooting or reassembling a repaired cell.
CHARGING THE BATTERY

A WARNING: Batteries are heavy. Use care to
avoid injury.
4. If the battery is lifted, use a spreader bar and crane to lift

the battery from the battery stand.
The storage battery which powers your lift truck will normally be
placed on charge after each shift. If you are responsible for con¬
necting and disconnecting the truck to the charger, followthese /\ WARNING: Make sure the capacity of the crane
instructions'. / 1\ and the spreader bar is greater than the weight of
the battery. The weight of the battery is normally
shown on the battery case. The maximum battery weight is
2-3
Yale
shown on the lift truck capacity plate. The spreader bar must NOTE: Your company, industry and government safety
not be made of metal or it must have insulated straps. regulations should be reviewed to help reduce accidents and
damage to equipment.
5. Before installing the battery, make sure the battery is
cleaned and painted.
FORKS
6. When a replacement battery is installed, make sure the WARNING: Do not try to lift a fork without a lifting
battery fits the battery compartment. Use spacers to prevent device. On some trucks the forks can weigh up to
the battery from moving more than 13 mm (0.5 in) in any 180 kg (400 lb) each.
horizontal direction.
WARNING: Never work under a raised carriage
7. Make sure the weight of the replacement battery is within or forks. Lower the carriage or use chains on the
the maximum and minimum weights shown on the nameplate. mast weldments and carriage so they cannot
move. Make sure the moving parts are attached to a part that
8. The battery must be installed so that the battery connector does not move. See SAFETY PROCEDURES WHEN
will connect to the lift truck connector without pulling on the WORKING NEAR THE MAST, Page 9-4 for specific
cables. instructions.
NOTE: Complete information relating to the care and 1. Checkthattheforktipsarealignedwithin13mm(0.5in)of

maintenance of batteries can be found in the literature shipped each other. Do not try to correct alignment of the fork tips by
with the battery. bending the forks. Use shims to align the fork tips.
2. Inspect forks for cracks and wear. Never repair damaged

BATTERY forks by heating or welding. Forks are made of special steel
ROLLERS using special procedures. Replace damaged forks. Always
BATTERY STAND replace forks in pairs.
RATCHET LOCK LEVER
BATTERY PULLER 3. Replace any damaged or broken parts that are used to
keep the forks locked in position.
Figure 2-4 - Checking the Forks

TETHER LINE AND BELT
Figure 2-3 - Changing the Battery WARNING: The tether line is specially made to
WARNING: If a different size battery is installed in lessen the shock of a fall. Do not substitute other
the lift truck, the battery spacers must be changed. types of rope.
See the parts manual for the correct battery spacer
arrangement. 1. Inspect the tether line for wear, cuts or damage. Inspect
the clips for cracks and proper operation.
/\ WARNING: If the lifttruck has been operated with
2. Inspect the belt for cracks, cuts or wear. The operator must
11\ a low battery, check the contactors for welded
contacts before a charged battery is connected. fasten the belt snugly with the "D" ring in the center of the back.
The circuit will not reset and lift truck operation cannot be
controlled if the contacts are welded. To check the contacts, PALLET CLAMP
see the Maintenance Manual for this truck.
Check for correct operation of the pallet clamp. Put an empty
pallet on the forks .With the forks raised so that the pallet is sup-
2-4
Yale
ported by the forks, stand on the corners of the pallet farthest used to raise the lift truck. Make sure that the jack or other lift
from the operator's platform. Some movement may occur, but truck has a capacity of at least 2/3 the total weight of the lift truck
the boardunderthe opposite fork must not raise enough to con¬ as shown on the nameplate.
tact the fork.
3. Raise the lift truck only enough to suspend the drive/steer
tire. Install blocks under the front of the frame to support the lift
HOW TO PUT A LIFT TRUCK ON BLOCKS
truck.
WARNING: The lift truck must be put on blocks for
some types of maintenance and repair. The How to Raise the Load Wheels
removal of the following assemblies will cause
1. Release the brake pedal to apply the brake. Put blocks on
large changes in the center of gravity:S mast, drive axle and
both sides (front and back) of the drive/steer tire to prevent
battery.
movement of the lift truck.
WARNING: Put the lift truck on blocks only if the
2. Use an overhead crane andweb sling underthe outriggers
surface is solid, even and level. Make sure that any
at the mast, to raise the load wheels. Another lift truck can also
blocks used to support the lift truck are solid, one
be used to raise the outriggers. Make sure that the crane and
piece units. Put blocks in front and back of the tires to prevent
sling or other lift truck has a capacity of at least 2/3 the total
movement of the truck.
weight of the lift truck as shown on the nameplate.
How to Raise the Drive/Steer Tire
3. Raise the outriggers only enough to suspend the wheels.
1. Put a block on each side (front and back) of the loadwheels Install blocks under the outriggers at the front of the wheels to
to prevent movement of the lift truck. support the lift truck.
2. Use a special low clearance hydraulic jack under the front

frame to raise the drive/steer tire. Another lift truck can also be
2-5
Yale
EXPLODED VIEW
1. DRIVE/STEER WHEEL BLOCKING THE LOAD WHEELS
2. LOAD WHEEL
3. STOP BLOCK <n n> I
4. SUPPORT BLOCK
3 2ÿ 3
Figure 2-5 - How to Put the Lift Truck on Blocks
LUBRICATION INSTRUCTIONS
/\ WARNING: Yale industrial trucks are equipped /\ WARNING: The service intervals referred to in
/ I\ with certain safety devices as standard equipment; II\ these lubrication and maintenance instructions are
for example: overhead guards, tether line and belt, based on normal operating conditions. If you have
mast screens, etc. If for any reason these safety devices are a light duty or low operating hour application, the maximum
removed when thetruck is being serviced, adjusted, repaired or service interval should not exceed 90 days. If the vehicle is
overhauled, these safety devices must be properly reinstalled operated in areas of high contamination such as dust, corrosive
before testing or operation of the truck. Failure to comply with vapors, etc., the service interval must be decreased from the
this warning could result in serious injury to the mechanic recommended hours. Have a qualified Yale mechanic inspect
and/or the operator. the truck and repair any problems.
/\ CAUTION: Never use steam to clean the The following maintenance instructions are for standard mod¬
/ 1\ electroniccontrolorelectricalparts. Industyareas, els. Trucks used for special applications may be equipped with
CJLJi use low pressure airto blowthe dust off the control. extra lubrication fittings, covers, special oils, etc. Consult your
In oily or greasy areas, use a mild solution of detergent and nearest authorized Yale industrial truck dealer when servicing
water, or denatured alcohol to wash the control. Then blow the these models.
control completely dry with low pressure air.
2-6
Yale
Refer to both the Recommended Schedules of Maintenance EVERY 350 HOURS

and these Lubrication Instructions when inspecting, lubricating
Apply lithium base, multi-purpose No. 2 grease with a high
and servicing these models. Read and observe all safety and
pressure gun to the following fittings. Clean lube fittings
operational precautions described in this manual before per¬
before and after lubricating.
forming any work on this truck. Refer to the appropriate charts
in this section for the oils and grease that are recommended for
Location of Lube Fittings No. of Fittings
use on these models.
1. Master Drive Unit Bearing 2
EVERY 8 HOURS
2. Platform Thrust Rollers - Platform 4
Perform all 8 hour safety and operational checks as described
in the Recommended Schedules of Maintenance located in this Apply lithium base, multi-purpose No. 2 grease to the
section. Hydraulic oil and battery levels should be at their full following surfaces:
marks. Add recommended fluids and oils as required. A certain
amount of water loss in battery cells is normal. Always replace 3. Mast Sliding Surfaces
water at the end of a charge. Use approved tap or distilled wa¬
ter. Apply engine oil (SAE 30) to the following friction points:
4. Hose and Wire Sheaves - Mast Take-up
5. Drive Unit Compartment Door Hinges
6. Pallet Clamp and Linkage - Elevate Platform
7. Side Rails - (pivoting option)
8. Steering Spinner Knob
9. Battery Retainers
10. Lift Chains - Wipe off all old oil using a clean cloth, then use
compressed air to blow off chains. With a clean brush, apply
SAE 30 weight oil to the full Jength of chain. Oil must penetrate
chain joints.
11. Drive Unit Steer Chains - Refer to Step 10.
12. Drive Wheel Lug Nuts
13. Load Wheel Axle Bolts
14. Hydraulic Oil Level - The sight gauge is visible through a

hole in the door of the drive unit compartment. The surface of
the oil is atthe center of the window of the sight gauge when the
hydraulic tank is filled to the correct level. The platform must be
lowered for a correct indication. If the oil is above or below the
window of the sight gauge, open the door to check the level.
Add hydraulic oil, if necessary. DO NOT OVERFILL.
2-7
Yale
EVERY 2000 HOURS

15. Hydraulic Oil Filter - Remove Hydraulic Oil Cover Plate
Assembly to access filter. Replace the hydraulic oil filter,
located in the drive unit compartment, at each oil change.
16. Hydraulic System - There is no drain plug in the hydraulic

tank. The hydraulic tank is drained at the supply hose. Put a
shallow pan with a capacity equal to the hydraulic system of the
truck (hydraulic tank capacity 32 litres, 8.5 gallons) under the
end of the hose. Disconnect the hose and drainthe oil. Pourthe
oil into a suitable container and discard in accordance with local
regulations. Clean the hydraulic tank with solvent and dry with
compressed air. Connect the hose to the tube and tighten the
hose clamp. Fill the tank with hydraulic oil (hydraulic tank
capacity 32 litres, 8.5 gallons). Raise and lower the mast to
expel air from hydraulic system.
NA00201
Figure 2-6 - Lubrication Locations
YALE WARRANTY INFORMATION

A Yale Warranty Statement is provided with each new Yale in¬ solved with your Yale industrialtruck dealer, you may request a
dustrial truck. To maintain your Yale Warranty in good standing review of your problem by contacting the Yale Regional Service
you must follow the Recommended Schedules of Maintenance Representative.
and perform the daily operational and safety checks and main¬
tenance functions described in this manual. All new Yale trucks will be shipped with an Operating Manual.
Standard Parts Manuals, Special Parts Manuals and Mainte¬
If you require a warranty repair you must contact your Yale in¬ nance Manuals are also available from your Yale industrial
dustrialtruck dealer for warranty service during the periods out¬ truck dealer for a nominal charge.
lined in the Warranty Statement. Your Yale industrial truck deal¬
er has complete details on which components are covered and For the optimum in professional repair and maintenance, we
the types of repairs that are warrantable. When in doubt about recommend your Yale industrial truck dealer's factory trained
your warranty coverage, be sure to contact your Yale industrial mechanics for Yale service and a Yale Maintenance Agree¬
truck dealer. If you have a warranty problem that cannot be re¬ ment.
RECOMMENDED SCHEDULES OF MAINTENANCE

(ALL MODELS)
Although the following Recommended Schedules of Mainte¬ Be certain this schedule is read thoroughly and all operations
nance are intended for use with all Electric Narrow Aisle lift are followed. If in doubt of any procedure or component to be
truck models, not all models are equipped with all the items inspected, adjusted and lubricated, or if the truck is specially
listed in this schedule. equipped and used for special applications, consult your near¬
est authorized Yale industrial truck dealer for assistance.
THE OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA)

REQUIRES THAT THE USER EXAMINE THE TRUCK BEFORE EACH SHIFT TO BE SURE IT IS IN SAFE WORKING ORDER.
2-8
Yale
LEGEND
A - Every 8 Hours X - Visually Inspect, Test and Adjust as Required
B - Every 350 Hours O - Drain and Fill
C - Every 2000 Hours R - Replacement
IR - Initial Replacement
CO - Complete Overhaul NA-794
SAFETY AND OPERATIONAL CHECKS (Prior to each shift)
Only the 8 hour checks are to be performed by the operator.
Have a qualified mechanic correct all problems in accordance with A B c
appropriate YALE maintenance instructions.
Leaks - Hydraulic Fluid X
Tires - Condition X
Forks, Top Clip Retaining Pin and Heel - Condition X
Load Backrest - Attached X
Hydraulic Hoses, Mast Chains and Stops - Check Visually X
Finger Guards - Attached X
Overhead Guard - Attached X
Safety Labels - Attached (Refer to Parts/Operating Manual for Locations) X
Internal Checks:
Battery - Water/Electrolyte Level and Charge X
Hydraulic Tank Fluid Level - Dipstick X o
Operator's Compartment:
Operating Manual - In Container X
Nameplate Attached - Information Matches Model, Serial Number, Attachments X
Battery Restraint - In Place X
Brake Fluid - Check Level X 0
Controls: (Turn Truck On) Immediately Check Noises that are not Normal
Accelerator Linkage - Operates Correctly X
Brake - Operates Correctly X
Steering Operation - Operates Smoothly and Correctly X
Drive Control, Forward/Reverse - Operates Correctly X
Tilt Control - Operates Smoothly and Correctly X
Lift and Lower Control - Operates Smoothly and Correctly X
Reach Control - Operates Smoothly and Correctly X
Attachment Control - Operates Smoothly and Correctly X
Horn - Operates Correctly X
Lights - Operate Correctly X
Gauges:
Hourmeter - Operates Correctly X
Battery Indicator - Operates Correctly X
Instrument Monitors - Operates Correctly X
2-9
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION SCHEDULE
NOTE: The following inspections and necessary corrections are the responsibility of the user.
LUBRICATION CHECK: Use compressed air to clean and inspect for damage. A B C
Lubricate - Chassis (All Fittings) X
All Linkage X
Friction Surfaces on Mast X
Friction Surfaces on Attachment X
Lift Chains - Clean and Lubricate X
Wheel Bearings - Clean and Repack with Grease X
Brake Fluid (Master Cylinder) X 0
Hydraulic Oil Filter Element IR R
Hydraulic Tank Breather X R
Differential Oil Level X 0
HYDRAULIC SYSTEM CHECK: A B C

Lift, Tilt, Reach and Power Steer Cylinders for Leaks and Correct Operation X
Tilt Cylinder Rod End Adjustment X
Hydraulic Pump for Noise and Operation X
Power Steer Pump for Noise and Correct Operation X
Hydraulic Control Valve for Leaks and Correct Operation X
Relief Valve Settings X
All Hoses, Tubing and Fittings for Wear and Leaks X
Attachment - Correct Operation X
Attachment Cylinder for Leaks X
General Leaks X
Accumulators X
DRIVE UNIT CHECK: A B C

Brake Adjustment X
Brake Drums and Linings for Wear X
Electric Motor and Drive Train Mounting Bolts (Torque to Specifications) X
Wheel Bolts or Nuts (Torque to Specifications) X
Wheel Brake Bolts (Torque to Specifications) X
Mast and Trunnion Cap Bolts (Torque to Specifications) X
2-10
Yale
ELECTRICAL SYSTEM CHECK: A B C

Clean all Controls X
Interlock Switches - Check Operation X
Accelerator Switch and Potentiometer - Check Operation X
Electronic Card - Check Operation X
Time Delay - Check Operation X
Direction Switch - Check Operation X
Drive Resistor (Magnetic Control) - Check Operation X
Valve Lift and Tilt Switches - Check Operation X
All Motors - Clean with Compressed Air X
All Motors - Check Brushes and Springs X
All Motors - Check Power Wire Terminals X
Battery Box and Connectors - Neutralize and Clean X
Battery Condition - Physical and Electrical X
All Wire Connections X
Contactors - Tips and Wire Connectors X
-
MAST - CARRIAGE ATTACHMENT CHECK: A B C
Mast and Carriage Safety Stops X
Mast Flange Wear X
Mast Rollers and Wear Plugs X
Carriage Rollers and Wear Plugs X
Chain Anchors X
Chain for Wear or Cracks (Use Wear Indicator 5180968-69) X
Pallet/Forks/Platform (Visual) X
Forks (See Note 2) X
Attachment - Sliding Surface Wear X
Attachment - Rotating Parts and Torque Bolts X
GENERAL CHECK: A B C
Steering - King Pins and Knuckles - Tightness X
Steering - Tie Rods and Wheel Alignment X
Steering - Drag Links X
Steering - Bellcrank X
All Bolts, Nuts, Cotter Pins, Etc. X
Overhead Guard and Load Backrest - Cracks, Mounting, Etc. X
Articulation Adjustment X
2-11
Yale
Industrial Trucks general truck and lubrication schedule
ROAD AND LOAD TEST TRUCK: At initial installation and after every maintenance inspection or repair. Test the rated load in
a clear area (See Notes 3 and 4). Report any questionable functions or unusual noises.
Steering
Brake System
Horn, Lights
Emergency Disconnect
Drive Power - Acceleration
Mast - Verify All Stops are Installed and Limit Switches are Functioning Properly
Lift - Full Lift and Lower (Do not tilt forward) (See Note 3)
Tilt - With Load Lowered Operate Full Forward and Backward (See Note 4)
Attachment - Operate all Functions
NOTES: 4. With a rated load at 609.6 mm (24 in) load center, checktilt
cylinder, if equipped, for drift. Tilt drift must not exceed 25.4 mm
1. Tires - Condition affects stability, safety and load capacity (1 .0 in) in 2 minutes, oil at 26° C (79° F). RefertoService Bulletin
that can be handled safely. SE-1077 for procedure to measure hydraulic drift.
2. Use Magnaglo or equivalent Fatigue Crack Detector to test 5. The presence of hydraulic fluid on cylinder rods and fittings
forks. Referto Service News Bulletin SE-643 for Procedure on does not necessarily indicate a leak.
Field Testing Load Forks. The Bulletin also defines minimum
acceptable fork tine thickness due to wear.
6. Recycle all waste oils.
3. With the mast vertical and with a rated load at 609.6 mm
(24in) load center, check lift cylinder drift. Lift drift must not
exceed 25.4 mm (1 .0 in) in 2 minutes, oil at 26° C (79° F). Refer
to Service Bulletin SE-1077 for Procedure to Measure
Hydraulic Drift.
A »\
*
CAUTION: Disposal of lubricants and fluids must
meet local environmental regulations.
To obtain more information on the above reference Service Bulletin, contact your nearest authorized Yale industrial truck dealer.
2-12
Yale
HYDRAULIC OILS
YALE PART NUMBER 5143618-00 0032570-00
Type For All Hydraulically Actuated Equipment
Ambient Air Temp. Normal Freezer
0° to + 110° F 0° to -60° F
Anticipated Ambient Air Temp. Range
(-18° to + 44° C) (-18° to -52° C)
Actual Useable Operation Oil Temperature Range + 18° to + 148° F -55° to +65°F
(-8° to +65° C) (-49° to +18° C)
ASTM Viscosity Grade Number/Index (Ret.) S-215/92 Minimum S-75/200 Minimum

Pour F Maximum
0
- 20° F ( — 29° C) -75° F (-60°C)
MIL - Specifications MIL - H-5606
APPROVED SOURCES
American (Amoco) Rykon Number 21 No Product

Atlantic Richfield/Arco Duro AW-46 No Product
Burmah-Castrol Hyspin AWH-46 No Product

Chevron Oil Company Chevron AW Hyd. Oil 46 Aviation Hyd. Fluid A
Cities Service (Citco) Pacemaker XD-20 No Product
Exxon Nuto H 46 Univis J-43
Fiske Brothers Lubriplate HO-1 No Product
Gulf Harmony 48AW No Product
Houghton & Company Hydro Drive HP 200 No Product
Keystone (Pennwalt) KLC Number 5 No Product
Mobil Oil Co. (Mobil) DTE 25 AERO-HFA
Pennzoil Oil Co. Pennzoil AW 46 No Product
Phillips Petroleum Magnus A-215 No Product
Shell Tellus 46 Aeroshell Fluid 4
Solene Ind. Lubricant H 205-B No Product
Sun Oil Co. (Sunoco) Sunvis 821 WR No Product
Texaco Rando HD-46 Aircraft Hyd "BB"

Valvoline Oil Co. Anti-Wear Number 20 No Product
Field Personnel Note: The hydraulic oils listed above are approved YALE Materials Handling Corporation sources that meet or
exceed the specifications annotated. The use of hydraulic oils other than the suppliers and products listed above is unauthorized.
2-13
Yale
GEAR OILS
YALE PART NUMBER 3101530-34 3101530-38
Application Standard Application Special Application
SAE Grade 80W-90 75W-90

Type Multi-Purpose EP Multi-Purpose EP
Base Oil Conventional Petroleum Synthetic
MIL-Spec. No. MIL-L-2105C MIL-L-2105C

API Service Classification GL-5 GL-5
-15° to + 100° F As low as -60°F (-51°C) Primarily
(-26° to + 38° C) intended for cold storage and/or arctic
Anticipated Ambient Air Temp. Range Most Yale lift truck operations will fall conditions; can be used as high as
within this + 90°F ( + 32°C). Note: This oil is a
temperature range. synthetic formulation.
APPROVED SOURCES
Burmah-Castrol HYPOY C80W/90 No Product

Century Hulburt, Inc. No Product No Product
Chevron Universal
Chevron No Product
Gear Lube 80W/90
Exxon Gear Oil

Exxon No Product
GX 80W/90
Mobil Mobilube HD 80W/90 Mobilube SHC 75W/90
Pennzoil Pennzoil MP 4092 No Product
Philube SMP No Product

Phillips 66
Gear Oil 80W/90
Solene Lub., Inc. Solene Gear Oil #905 No Product
Sunfleet GL-5 No Product

Sun
Gear Lube 80W/90
Unocal MP Gear Lube No Product
Union 76
LS 80W/90
Field Personnel Note: The gear oils listed above are approved YALE Materials Handling Corporation sources that meet or
exceed the specifications annotated. The use of gear oils other than the suppliers and products listed above is unauthorized.
2-14
Yale
GREASE
YALE PART NUMBER 1500318-02
Application STANDARD Multi-Purpose
Type and Compound High Grade Lithium Soap, 2% to 4% micronized molybdenum disulfide additive
and refined high grade mineral oil.
NLGI Grade 2
Dropping Point (Minimum) + 171° C ( + 340° F)
Base Oil Viscosity (SUS) 75 @ + 100° C ( + 210° F) (Minimum)
Nominal Operating Temperature Range -35 to +121° C (-30to +250° F)
Identification Container must be plainly marked with supplier's product identification
APPROVED SOURCES
American Oil Company Molylith Grease #2

Ashland Oil, Inc. Special Moly Grease
Atlantic Richfield Co. Rocolube Moly D
BP Oil International Ltd. BP Energrease LMS 22 or Energrease L21M
Castrol Spheerol LMM
Chevron USA, Inc. Chevron Moly Grease 2
Citgo Lithoplex 2
Elf Grease M0S2 Special
Engen Ltd. Engen Grease SP
Exxon Beacon Q-2
FINA Oil Company Marson LM2
Gulf Gulflex Moly Grease
Mobil Oil Corporation Mobilgrease Special
Shell Oil Corporation Lithall MDS Grease
Sinclair Oil Corporation Litholine EP Molylith Grease
Sun Oil C&rporation Prestige Moly Grease M3
Texco, Inc. Molytex PE 2 (Code 1922)
Total NV Total Multis MS
Field Personnel Note: The greases listed above are approved YALE Material Handling Corporation sources that meet or
exceed the specifications annotated. The use of greases other than the suppliers and products listed above is unauthorized.
ANTI-SEIZE LUBRICATING COMPOUND
YALE PART NUMBER 3101562-30

APPROVED SOURCES
Loctite Corporation 76764
Bostik - Division of Emhart NSBT - 16
Permatex - Subsidiary of Loctite 80208
2-15
Yale
TIRES AND WHEELS To change the drive tire, the wheel must be pressed out of the
rim. The correct tools, equipment and press ring must be used
1 . Check the tires for damage. Inspect the tread and remove
for each size wheel. A press that has a capacity of approxi¬
any objects that will cause damage.
mately 36,000 kg (80,000 lb) is required to press the wheel out
of the rim. Tires should be changed by authorized personnel
2. Smooth any cuts or tears to prevent further damage.
that have the proper tools, equipment and experience.
Check for bent or damaged rims. Check for loose or missing
parts. Remove any wire, straps or other material that may have
wrapped around the axle.
1. PRESS RING
2. OLD TIRE
3. NEW TIRE
Figure 2-7 - Inspecting Tires 4. WHEEL HUB
How to Change the Drive/Steer Tire Figure 2-8 - Position Tire on Wheel
Standard tire sizes are listed for drive/steer and load wheels.
For trucks equipped with special tires consult your nearest au¬ How to Change the Load Wheels
thorized Yale industrial truck dealer. WARNING: For correct operation of the wire
guidance system, all load wheels must always be
Raise the rear of the lift truck as described in How to Put a Lift replaced at the same time.
Truck on Blocks. Remove the wheel nuts that fasten the drive/
steer wheel to the hub. Slide the wheel out from under the lift Raise the loadwheels as described in How to Put a Lift Truck on
truck. Use the reverse procedure to install the wheel. Tighten Blocks (How to Raisethe Load Wheels) . For easier installation,
the wheel nuts to 136 N«m (1 00 Ibf. ft.) torque after installation. remove and install one load wheel at a time.
CAUTION: If the wheels have been removed and The load wheel bearings are prelubricated, double sealed ball
installed, check all wheel nuts after 2 to 5 hours of bearings. They do not require lubrication for the life of the bear¬
operation. Tighten the nuts in a cross pattern to ing. No shimming is required.
136 N«m (100 Ibf. ft.) torque value. When the nuts stay tight for
eight hours, the interval for checking the torque can be
extended to 350 hours.
Table 2-3 - Tires and Wheels
TIRE AND WHEEL SIZES
MODELS DRIVE TIRES LOAD WHEELS
SS030EB 13.5 x 5.5 x 8 - Polyurethane Rubber 6x3 - Single Poly
2-16
Yale
A
HOW TO MOVE A DISABLED LIFT TRUCK WARNING: If the brake has been manually
released, put a "DO NOT OPERATE" tag on the
A f \ WARNING: Use extra care when towing a lift

truck if there is a problem with any of the following:
steering wheel.
Never lift a disabled lift truck unless the lift truck must be moved
and cannot betowed. The lift truck used for lifting the disabled
1. Brakes do not operate correctly.
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
2. Steering does not operate correctly.
center equal to half the width of the disabled lift truck. See the
nameplate of the disabled lift truck for the approximate total
3. Tires are damaged.
weight. The forks must extend the full width of the disabled lift
truck. Centerthe weight ofthe disabled lifttruck on the forks and
4. Traction conditions are bad.
be careful not to damage the underside of the lift truck.
5. If the lift truck must be towed on a steep grade.
PRECAUTIONS FOR TRUCKS IN STORAGE
Poor traction can cause the disabled lift truck or towing vehicle
Complications can arise as a result of improper handling of
to slide. Steep grades will increase the required brake effort.
trucks during periods of storage. The main areas of concernare
the: electric motors, hydraulic components and electric truck
Remember! There may be problems with more than one of
batteries.
the above areas of the truck. Do nottow the lift truck if you have
not identified all problem areas.
Before placing truck in storage, choose an area which is clean,
dry and free from airborne contaminants.
HOW TO TOW THE LIFT TRUCK
When parking the truck, chock the wheels. The forks should be
/\ WARNING: If there is no electrical power the fully lowered. For safety and increased usable floor area re¬
I f \ brakes will be applied and the steering motor will move the forks and tag them with the truck serial number. Coat
LhJ not operate. The lift truck cannot be steered if the all exposed portions of cylinder rods with fresh high grade SAE
steering motor does not operate. DO NOT tow the lift truck if
30 or 40 weight engine oil.
there is no electrical power.
Electric trucks should be stored without batteries. Therefore
1. The towed lift truck must have an operator.
you will have to provide a fully charged battery for the period of
this exercise.
2. Depress the brake pedal during towing to release the
brake.
All hydraulic cylinders should be cycled several times each
month to keep the seals active and to coat the interior walls with
3. Tow the lift truck slowly.
oil. Actuate each cylinder, in both directions, untilthe stops are
reached. With the power OFF, actuate eachcontrol buttonto re¬
4. Raise the forks approximately 12 inches (30 cm) from the
lieve hydraulic pressure.
surface. Install a chain to prevent the mast from moving.
Prior to operating the truck, make a visual inspection for any
5. If another lift truck is used to tow the disabled lift truck, that
leaks or signs of deterioration. Check the fluid level in the hy¬
lift truck must have an equal or larger capacity than the disabled
draulic tank and brake master cylinder. Take corrective action if
lift truck. Install an approximate half capacity load on the forks
necessary.
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.
Operate the truck for a short period of time each month. Electric
Keep the load as low as possible.
drive motors must be exercised to keep them free of rust and
contamination caused by condensation built up over periods of
If the lift truck must be moved without electrical power, the
inactivity. Operate the truck with the motor at its normal temper¬
brake can be manually released. There are three holes with
ature for at least five minutes.
1/4-20 UNC threads in the back plate. Install capscrews in the
holes. Usethe capscrews to pushthe armature plate awayfrom
When the truck is returned to service, it should be given the
the friction disc.
350- hour inspection shown in the Recommended Schedules
of Maintenance found in this manual.
2-/7
Yale
PRECAUTIONS FOR BATTERIES IN STORAGE a. Give equalizing charge prior to placing new batteries in
storage. Used batteries are to be fully charged and allowed to
Batteries should be placed on a wooden pallet and stored in a
balance for approximately three more hours.
dry, moderately cool area. Lead acid batteries will slowly "self
discharge" over a period of time due to their chemical make-up .
b. Neutralizeand clean the battery. Clean with a solution of 16
If the self discharge is left uncontrolled, excessive sulfating can
ounces of baking soda ash in one (1) gallon of water.
occur which is difficult to reduce and may damage the plates.
c. Store in a cool, dry location.
A discharged battery with a specific gravity of 1.100 will freeze
at + 18°F. Afully charged battery with a specific gravity of 1.280
d. Check each cell in the battery at least once every 30 days
will freeze at - 87 ° F. This "self discharge" is due to a chemical
and boost charge when specific gravity falls below 1.240.
reaction, therefore, that chemical reaction can be accelerated
by heat resulting in a more rapid "self discharge". The rate of
e. Protect batteries from ambient contamination.
discharge can amount to an average of about 0.001 point drop
in specific gravity per day.
If a greasy film forms on the top of a battery, it is acid and must
be neutralized with a solution of 16 ounces of baking soda ash
The following procedure should be followed when placing a
in one (1) gallon of water.
battery in storage or when not in operation for more than 30
days.
2-18
Yale
FASTENERS
INTRODUCTION The number of threads per inch for inch fasteners may either be
shown as UNC (Unified National Coarse) or UNF (Unified Na¬
Threaded fasteners like bolts, nuts, capscrews, and studs are
made to specifications that describe the mechanical strength tional Fine). Metric fasteners show the thread pitch.
and hardness of the fastener. A fastener used in a design ap¬
A capscrew will have the following description:
plication isselected according to its specifications. Yale Mate¬
rials Handling Corporation buys parts from many countries.
Partsthat are purchased must be to Yale standards. There are
Table 2-4 - Capscrew Description
several standards used by these countries in the manufacture INCH METRIC
of threaded fasteners. Many of these fasteners are similar, but
cannot be used as a direct replacement. To make sure that you 1/2x13 UNCx 1-1/2 M12x1.75x50
have the correct fastener, orderfasteners and parts through the
Yale Parts Distribution Center, Danville, IL. < X CO o X Q > X on X O
A = Shank Diameter A = Thread Size
Service persons must use replacement fasteners that havethe
same specifications. Fasteners made to each specification B = Number of Threads B = Pitch
have identification marks for that specification. This specifica¬
Per Unit of Length C = Length
tion is commonly called "Grade" for SAE standards and "prop¬
erty class" for metric standards. This section describes the C = Type of Thread
identification of some common fasteners.
D = Shank Length
The metric system used by Yale Materials Handling Corpora¬
tion is described as SI (Le Systeme d'Unites orthe International
STRENGTH IDENTIFICATION
System of Units, also called SI in all languages). The SI system
of measurement is described in ISO Standard 1000, 1973. A The most common property classes for metric fasteners are 8.8
conversion table of common measurements is shown in and 10.9. The property class is marked with a number on the
Table 2-12. head of the capscrew or on a nut. Property classes lessthan 8.8
are often not marked. Grades for inch bolts go from 2 to 8.
Grade 2 fasteners normally do not have any marks. The follow¬
THREADS, NOMENCLATURE ing tables show the marksthat identify the grades and property
The thread design is specified by a series of numbers and let¬ classes for different fasteners.
ters for inch and metric fasteners. See Figure 2-9. The diame¬
ter of the shank of the fastener is shown first in the series [M12 = CAUTION: When fasteners must be replaced,
12 mm, M20 = 20 mm (1/2 = 1/2 inch, 3/4 = 3/4 inch)]. the new fasteners must be of the same strength or
greater than the original fasteners. The new
The length of the shank is often indicated as part of the descrip¬ fasteners must also be the correct size.
tion of a fastener. This length is shown in inches for inch fasten¬
ers and in millimetres for metric fasteners. NOTE: Identification marks are according to bolt strength.
The higher the number or the increase in the number of marks
indicates increased bolt strength.
1.0 in
"13 THREADS 1/2x13 UNC - THREAD
-X/Wwvwvww (DIA. x NO. OF THREADS PER INCH)
U.S.
flWWIWWFM" DIA.
METRIC lilililllUl:
k— 1-75 -J M12 x 1.75 mm - THREAD
| mm | (mm DIA. x THREAD PITCH mm)
Figure 2-9 - Thread Design
2-19
Yale
Table 2-5 - Bolts and Screws

INCH FASTENERS METRIC FASTENERS
TYPE OF FASTENER STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
* MARKINGS NOT REQUIRED * MARKINGS NOT REQUIRED
4.6* 4.8* 5.8* 8.8
.4 .8.
6
5.2
r T 9.8 10.9 12.9
v/ \j
HEX. HEAD BOLTS AND MARKINGS FOR

CAPSCREWS SIZE M5 AND
LARGER
-f 5
HEX. HEAD FLANGE SCREWS

©
SAME AS ABOVE
12 - POINT FLANGE SCREWS
-3T\ 10.9 12.9

MARKINGS NOT REQUIRED
10.9 12.9
HEX. SOCKET HEAD
CAPSCREWS
4.8* 9.8
5.1
ff 4.8, .9.8,
SEMS
2-20
Yale
Table 2-6 - Studs and Nuts

TYPE OF FASTENER STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
* MARKINGS NOT REQUIRED * MARKINGS NOT REQUIRED
4.6* 4.8* 5.8* 8.8

5* 5.2*
9.8 10.9 12.9

MARKINGS
FOR SIZE
8.1 M5 AND
STUDS LARGER
OR
OPTIONAL GEOMETRIC SYMBOLS

FOR SIZES M5 THRU M11 ONLY.
HEX. NUTS OR
o o o
5 8 9 10 12
CCD MARKINGS NOT REQUIRED rrgn mm irsn cejb rren
HEX. SLOTTED NUTS
5 8 9 10 12
HEX. FLANGED NUTS
2-21
Yale
-
Table 2-7 Torque Nuts
TYPE OF FASTENER
STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
OR
ALL METAL PREVAILING

TORQUE NUTS
F G
OR
ALL METAL PREVAILING OR

TORQUE FLANGE NUTS
2-22
Yale
-
Table 2-8 Torque Nuts with Nylon Inserts
TYPE OF FASTENER
STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
OR
a
NYLON INSERT
PREVAILING
TORQUE NUTS

NYLON INSERT
PREVAILING
TORQUE NUTS
2-23
Y&fe
IndustrialTrucks
1/4
5/16
5/16
3/8
3/8
7/16
7/16
1/2
1/2
9/16
9/16
5/8
5/8
3/4
3/4
7/8
7/8
1
1
1
1-1/8
1-1/8
1-1/4
1-1/4
1-3/8
1-3/8
1-1/2
1-1/2
NOTES:
1.
2.
3.
4.
2-24
Marking
SAE Grade
Size (in)
1/4
Thread
20
28
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
14
7
12
7
12
6
12
6
12
Dry
6
6
11
12
20
23
30
35
50
55
70
80
100
110
175
195
165
185
250
270
340
350
400
500
550
660
740
870
980
No Mark
2
> £'3—
7
8
9
15
17
24
25
35
40
55
60
75
85
130
145
Table 2-9
Lub.
125 430
140 470
190
200
260
270
300
380
420
490
560
650
730
Dry
8
10
17
19
30
35
50
55
75
90
110
120
150
170
260
300
640
700
750
800
880
1120
1240
1460
1680
1940
2200
3 Marks
5
ÿ
Lub.
6
7
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
580
600
660
840
920
1100
1260
1460
1640
Dry
12
14
25
25
45
50
70
80
110
120
150
170
220
240
380
420
600
660
900
1000
1030
1280
1440
1820
2000
2380
2720
3160
3560
6 Marks
8
- General Guide to Torque Values
Lub.
9
10
18
20
35
35
55
60
80
90
110
130
170
180
280
320
460
500
680
740
785
960
1080
1360
1500
1780
2040
2360
2660
15
28
30
48
55
77
86
Socket Head
Dry
13
118
132
170
189
235
267
417
467
672
741
1006
1125
1230
1283
1425
1600
1800
2382
2708
2800
3000
1960 Series
Lub.
127
141
176
200
313
350
504
562
756
833
883
966
1066
10
11
20
22
36
41
58
65
89
99
1200 2162
1350 2660
1782
2033
2100
2260
Dry
16
18
33
36
58
65
93
104
142
160
205
228
283
320
501
559
707
778
1060
1190
1702
1908
4177
4700
-
12 Pt. - Flanged
<u>
ÿ
1936 & 60 '
Series
The term lub. includes the application of high stress lubrication to the fastener, and fasteners that have a cadmium plating.
Dry values include screws that only have a thin film of oil to prevent rust.
The torque values are minimum. Values to 20% higher are permitted.
Fasteners with zinc plating must have a 10% higher torque than dry value.
Lub.
106
120
153
171
212
240
376
420
530
584
795
892
1276
1431
1621
1995
3133
3525
12
14
25
27
44
49
70
78
—
Yale
Table 2-10 - General Guide to Torque Values

Grade JIS F4T ISO 8.8 or JIS F8T ISO 10.9 or JIS F11T ISO 12.9
Marking
o o
None 8.8 or F8T or 8T
©
10.9 or F11T or 11T
© 12.9
Size Pitch N«m Ibf ft N*m Ibf ft N*m Ibf ft N«m Ibf ft
M4 0.7 — — 2.9 2 4.1 3 4.9 3.5
M5 0.8 — 6 4 8.5 6 10 7
M6 1.0 4.3 3 10 7 14 10 17 12
M8 1.25 10 7 25 18 35 25 41 30
M8 1.0 10 7 27 20 38 28 45 33
M10 1.5 20 15 49 35 69 50 83 60
M10 1.25 20 15 52 38 73 53 88 64
M12 1.75 35 25 86 62 120 87 145 105

M12 1.25 35 25 95 69 135 98 160 116
M14 2.0 57 41 135 98 190 137 230 166

M14 1.5 57 41 150 108 210 152 250 181
M16 2.0 88 64 210 152 295 213 355 257

M16 1.5 88 64 225 163 315 228 380 275
M18 2.5 — — — 405 300 — —

M20 2.5 172 124 41 0 297 580 420 690 499
M20 1.5 172 124 460 333 640 463 770 557
M24 3.0 297 215 710 514 1000 723 1200 868
M24 2.0 297 215 780 564 1100 796 1300 940
M30 3.5 591 427 1450 1049 2000 1447 2400 1736
M30 2.0 591 427 1600 1157 2250 1627 2700 1953
NOTES:
1. Reduce the torque values approximately 20% when high stress lubrication is applied to the fastener, or fasteners that have a
cadmium plating.
2. Dry values include screws that only have a thin film of oil to prevent rust.
3. The torque values are minimum. Values to 20% higher are permitted.
4. Fasteners with zinc plating must have a 10% higher torque than dry value.
5. Marking not required on M5 and smaller fasteners.
2-25
Yale
IndustrialTrucks general truck and lubrication schedule
Table 2-11 - Recommended Maximum Torque Values for Hydraulic Fittings* _
JIC FLARED TYPE AND SAE SWIVEL ADAPTER UNIONS

STRAIGHT THREAD O-RING FITTINGS
MAXIMUM TORQUE N*m (Ibf ft) MAXIMUM TORQUE N*m (Ibf ft)
DASH THREAD DASH PIPE SIZE
SIZE SIZE SWIVEL NUT LOCKNUT SIZE FEMALE PIPE MALE PIPE
-2 5/16"-24 8(6) 8(6) -2 1/8"-27 18 (13) 16(12)
-3 3/8"-24 8(6) 8(6) - - - -

-4 7/16"-20 14(10) 11 (8) -4 1/4"-18 27 (20) 34 (25)
-5 112"-20 20 (15) 14(10) - - - -

-6 9/16"-18 27 (20) 18 (13) -6 3/8"-18 34 (25) 54 (40) .
-8 3/4"-16 41 (30) 28(21) -8 1/2"-14 64 (47) 73 (54)
-10 7/8"-14 54 (40) 456 (33) - - - -

-12 1-1/16"-12 95 (70) 65 (48) -12 3/4"-14 114(84) 106(78)
-14 1-3/16"-12 108 (80) 76 (56) - - - -

-16 1-5/16"-12 122 (90) 85 (63) -16 1"-11-1/2 175 (129) 152 (112)
-20 1-5/8"- 12 163 (120) - -20 1-1/4"-11-1/2 206 (152) 209 (154)
-24 1-7/8"-12 178 (131) - -24 1-1/2"-11-1/2 206 (152) 286(211)
-32 2-1/2"-12 407 (300) - -32 2"-11-1/2 407 (300) 407 (300)
NOTE: Values shown are for zinc plated fittings. Values for cadmium plated fittings may vary slightly, but not enough to be of
any appreciable difference.
*Torque Values furnished by Air-Way Manufacturing Co., Olivet, Michigan
2-26
Yale
IndustrialTrucks general truck and lubrication schedule
Table 2-12 - Conversion Table for Metric and English Units

MULTIPLY BY TO GET MULTIPLY BY TO GET
AREA
inches2 (in2) X 6.452 = centimeters2 (cm2) centimetres2 (cm2) X 0.155 = inches2 (in2)
feet2 (ft2) X 0.093 = meters2 (m2) metres2 (m2) X 10.764 = feet2 (ft2)
LINEAR
inches (in) X 25.4 = millimeters (mm) millimetre (mm) X 0.039 = inches (in)
feet (ft) X 0.305 = meters (m) metre (m) X 3.281 = feet (ft)
yards (yd) X 0.914 = meters (m) metre (m) X 1.094 = yards (yd)
miles (mi) X 1.609 = kilometers (km) kilometre (km) X 0.621 = miles (mi)
MASS
ounces (oz) X 28.35 = grams (g) grams (g) X 0.035 = ounces (oz)
pounds (lb) X 0.454 = kilograms (kg) kilograms (kg) X 2.205 = pounds (lb)
tons (2,000 lb) X 907.18 = kilograms (kg) kilograms (kg) X 0.001 = tons (2,000 lb)
tons (2,000 lb) X 0.907 = metric ton (t) metric tonne (t) X 1.102 = tons (2,000 lb)
POWER
horsepower (hp) X 0.746 = kilowatts (kW) kilowatts (kW) X 1.34 = horsepower (hp)
PRESSURE
pounds/in2 (psi) X 6.895 = kilopascal (kPa) kilopascal (kPa) X 0.145 = pounds/in2 (psi)
pounds/in2 (psi) X 0.007 = megapascal (MPa) megapascal (MPa) X 145.04 = pounds/in2 (psi)
TEMPERATURE
("Fahrenheit -32) X 0.56 = "Celsius (C) ("Celsius x 1.8) + 32 = "Fahrenheit
TORQUE
pound inches (Ibf in) X 0.113 = Newton meter (N«m) Newton metre (N«m) X 8.851 = pound inches (Ibf in)
pound feet (Ibf ft) X 1.356 = Newton meter (N»m) Newton metre (N«m) X 0.738 = pound feet (Ibf ft)
VELOCITY
miles/hour (mph) X 1.609 = kilometer/hour (km/h) kilometre/hr (km/h) X 0.621 = miles/hour (mph)
VOLUME
inches3 (in3) X 16.387 = centimeters3 (cm3) centimetres3 (cm3) X 0.061 = inches3 (in3)
inches3 (in3) X 0.016 = litres (I) litres (I) X 61.024 = inches3 (in3)
quarts, U.S. (qt) X 0.946 = litres (I) litres (I) X 1.057 = quarts, U.S. (qt)
quarts, U.S. (qt) X 0.83 = quarts, Imp. (qt) quarts, Imp. (qt) X 1.205 = quarts, U.S. (qt)
gallons, U.S. (gal) X 3.785 = litres (I) litres (I) X 0.264 = gallons, U.S. (gal)
gallons, U.S. (gal) X 0.83 = gallons, Imp. (gal) gallons, Imp. (gal) X 1.205 = gallons, U.S. (gal)
ounces (oz) X 29.57 = milliliter (ml) milliliter (ml) X 0.034 = ounces (oz)
2-27
NOTES
2-28
Yale
IndustrialTrucks
SECTION 3
ELECTRICAL SYSTEM
Yale
IndustrialTrucks
DESCRIPTION
GENERAL
RELAYS-GENERAL
SECTION 3
TRANSISTOR MOTOR CONTROLLER

OPERATION
ACCELERATOR POTENTIOMETER
ADJUSTMENTS
REPLACING CONTROLLER
TROUBLESHOOTING
RELAYS-REMOVE AND INSTALLATION

TESTING DIODE BLOCK
REPLACING DIODE BLOCK
- CONTENTS
ELECTRICAL SYSTEM
CHECKS, ADJUSTMENTS AND REPAIRS

CHECKING CONTACTOR COIL
CHECKING TRANSISTOR CONTROLLER
CHECKS WITH CONTROLLER INSTALLED
CONTACTOR AND ELECTRICAL PANELS-

CHECKS AND ADJUSTMENTS
CONTROL AND POWER FUSES
CONTACTORS-GENERAL
TESTING CONTACTORS
CONTACTOR-REMOVE AND INSTALL
CONTACTOR-DISASSEMBLY AND ASSEMBLY
TESTING POWER STEERING SOLENOID

REPLACING POWER STEERING SOLENOID
TROUBLESHOOTING ACCELERATOR SWITCH

INSTRUMENT PANEL REMOVAL AND INSTALLATION
KEY SWITCH-REMOVAL AND INSTALLATION
POWER DISCONNECT SWITCH-REMOVAL AND INSTALLATION
STEERING INDICATOR GAUGE-TESTING
STEERING INDICATOR GAUGE-REMOVAL AND INSTALLATION
VOLTMETER (STANDARD) -REMOVAL AND INSTALLATION
.
PAGE NUMBER
3-1
3-2
3-3
3-9
3-9
3-9
3-9
3-12
3-12
3-13
3-13
3-19
3-19
3-19
3-20
3-21
3-22
3-26
3-26
3-26
3-26
3-27
3-27
ACCELERATOR POTENTIOMENTER-REMOVAL AND INSTALLATION . . 3-28
FORWARD AND REVERSE SWITCHES-REMOVAL AND INSTALLATION 3-29
LIFTAND LOWER SWITCHES-REMOVAL AND INSTALLATION 3-29
......
3-29
3-31
3-31
3-31
3-31
3-32
3-32
.....
BATTERY DISCHARGE INDICATOR-REMOVAL AND INSTALLATION ... 3-32
BATTERY DISCHARGE INDICATOR-
RESET AND DISCHARGE ADJUSTMENTS
SLACK CHAIN INDICATOR LIGHT-REMOVAL AND INSTALLATION
FOOT SWITCH-REMOVAL AND INSTALLATION
LOOSE CHAIN SWITCH-REMOVAL AND INSTALLATION
3-32
3-32
3-32
3-33
(Continued on following page)

Yale
Industrial Trucks
SECTION 3 - CONTENTS (Continued)

ELECTRICAL SYSTEM
LIMIT SWITCH-REMOVAL AND INSTALLATION 3-33

DRIVEAND HYDRAULIC PUMP MOTORS 3-34
CAUSES OF MOTOR FAILURE 3-35
MOTOR TESTS 3-36
DRIVE MOTOR INSPECTION 3-37
DRIVE MOTOR BRUSH-REMOVAL AND INSTALLATION
(MOTOR INSTALLED) 3-38
DRIVE MOTOR BRUSH HOLDER-REMOVAL AND INSTALLATION
(MOTOR INSTALLED) 3-38
DRIVE MOTOR-REMOVAL AND INSTALLATION 3-38
DRIVE MOTOR-DISASSEMBLY AND ASSEMBLY 3-38
HYDRAULIC PUMP AND POWER STEERING MOTORS-
MAINTENANCE INSTRUCTIONS 3-41
BRUSH REPLACEMENT-HOIST PUMP MOTOR 3-41
HOIST MOTOR-REMOVAL AND INSTALLATION 3-41
HOIST MOTOR-DISASSEMBLY AND ASSEMBLY 3-41
POWER STEERING MOTOR-REMOVAL AND INSTALLATION 3-43
BRUSH REPLACEMENT-POWER STEERING MOTOR 3-43
POWER STEERING MOTOR-DISASSEMBLY AND ASSEMBLY 3-43
WIRING DIAGRAMS AND SCHEMATICS 3-45
WIRING SCHEMATIC 3-46
WIRING DIAGRAM 3-49
OPTIONS DIAGRAM 3-52
WIRING SCHEMATIC - WIRE GUIDANCE 3-53
WIRING DIAGRAM - WIRE GUIDANCE 3-56
OPTIONS DIAGRAM - WIRE GUIDANCE 3-59
NOTES
Yale
IndustrialTrucks ELECTRICAL SYSTEM
GENERAL
This section describes the electrical system used on the WARNING: Before performing any adjustments,
OS30EB lift truck. Procedures are outlined for the service procedures, or parts replacements that
maintenance, adjustments and repairs that may be required require physical contact with electrical
when sen/icing this truck. The electric brake is outlined in components or wiring, DISCONNECT THE BATTERY,
Section 5 andthe control module and electrical components of DISCHARGE THE INTERNAL CAPACITOR, AND JACK THE
the steering system are covered in Section 6 of this manual. DRIVE WHEEL UP OFF THE FLOOR. Properly block the
truck.
The drive control of the OS30EB lift truck is a Curtis Transistor
The capacitor in the transistor controller can hold an electrical
Motor Controller, also known as a MOSFET System.
charge after the battery is disconnected. To prevent electrical
shock and injury, discharge the capacitor before inspecting or
repairing components in the drive unit compartment. Wear
safety glasses. To discharge the capacitor, first disconnect the
battery. Then connect an insulatedjumper wire betweenthe B+
and B- terminals (Figure 3-11) of the transistor controller.
CONTACTOR
PANEL
CONTROL
MODULE
ÿELECTRIC
BRAKE
HYDRAULIC
PUMP MOTOR
DRIVE MOTOR
STEERING
MOTOR
NA00396
Figure 3-1 - Drive Unit Compartment
3-1
Yale
TRANSISTOR MOTOR CONTROLLER capacitors are connected between the B+ and B- terminals in
the controller to prevent electrical noise from entering the logic
This section describes the operation , checks, repairs and and causing errors.
troubleshooting of the Curtis PMC 1204X series motor
controller. This transistor motor controller is used to control the The logic of the controller also checks the following functions:
operation of some 12 or 24 volt electric lift trucks.
a. Checks the temperature and gives both low and high
temperature thermal protection to the controller.
The description of the current flow in the electrical circuits in this
section uses the "Conventional Theory of Current Flow". This b. Electrically checksthat an operatorfollows the correct
theory describes the current as flowing from positive to starting sequence to help prevent unexpected operation.
negative . An electric lift truck uses a two-wire electrical system. This function is called "Static- Return-To-Off" (SRO).
There is no common ground through the frame. Both the
c. Electrically checks the traction circuit for
positive supply and the negative return currents flow through
malfunctions, This function prevents lifttruck operation if a
wires and cables. There must be a minimum resistance of
failure is sensed.
50,000 ohms between the electrical circuits and the frame of
the lift truck. d. Checks the current in the motor circuit and
automatically decreases the motor voltage to reduce the
The controller for the traction system uses digital logic. Digital current and prevent damage. The plugging circuit is also
logic uses transistor to operate like very fast switches. The controlled for smoother operation.
transistors are controlled by electrical gate pulse. Electrical
noise is high voltage pulses caused by momentarily operating Additional information showing how the motor controller is
other electrical devices. Digital logic can not understand the electrically connected in the lift truck is shown on the Wiring
difference between control pulses and electrical noise. Filter Diagrams and Schematics located at the rear of this section.
Figure 3-2 - Transistor Motor Controller
3-2
Yale
OPERATION contacts causes the motor armature to rotate in one direction.

The other set of contacts causes the motor armatureto rotate in
A motor controller for an electric lift truck must give a fine speed the opposite direction. Other contactors used for control
control to thetraction motor by making a variation in the applied functions on the lift truck only have one set of contacts because
voltage. This controller uses solid-state electronic devices to a forward and reverse operation is not required. An example is
permit efficient control of the applied voltage. the hydraulic pump motor contactor.
A motor controller must also generate a high current flow in the Contactors are used to energize and deenergize motors, but
traction motor while keeping a low current draw from the cannot control the speed. The transistor motor controller
battery. A battery is less efficient at a high current draw. A applies battery voltage in short, fast pulses to a DC motor to
battery will not give all its electrical power at a high current draw. control the speed. Howthis circuit controls the speed of a motor
The traction motor is a series wound motor that generates with pulses is described in this section.
torque. This torque is proportional to the current moving
through the motor. The speed of the motor is controlled only by The direction and speed control operates the FWD/REV switch
the mechanical load connected to the motor. The motor will to energize the direction contactor. The control also supplies
accelerate until the mechanical load compares equally to the the speed input to the motor controller.
torque. If the current through the motor is increased, the torque
will increase.The increased torque will give a higher speed with
the same mechanical load.
The two functions look like a problem of opposite needs. Howa ARM
solid-state electronic controller balances those needs with
efficiency is described in this section.
MOTOR CONTROLLER
FIELD
This motor controller controls the speed of the traction motor. 1
The direction of rotation of the motor is controlled by the
Forward/Reverse switch and contactors. See Figure 3-3,
Figure 3-4 and Figure 3-5. The controller is sealed in an
aluminum case and has no parts that can be repaired or
replaced. The complete unit must be replaced if correct
troubleshooting methods show that the unit is defective.
The controller uses external contactors to control the direction 1. BATTERY

of rotation of the traction motor. Contactors are electrical 2. TRACTION MOTOR ARMATURE
switches that use an electromagnet to operate the power
3. TRACTION MOTOR FIELD
contacts of the switch. A small electric signal is used to
energize the electromagnet to close the power contacts and
4. REVERSE CONTACTOR CONTACTS
control the large current flow needed for the motor circuit. The 5. FORWARD CONTACTOR CONTACTS
electromagnetic field in the coil moves the armature against 6. FETs SWITCH
spring pressure to close the power contacts. When the coil is
deenergized, the spring pressure moves the armature and Figure 3-3 -Basic Traction Motor Circuit
opens the contacts. When a spring holds the contacts of a
switch open, the switch is called normally open (NO). If the BASIC CONTROLLER OPERATION
switch spring holds the contacts of switch closed, the switch is
called normally closed (NC). This transistor motor controller has a power section and a logic
section with solid-state electronic circuits that control the
There are two contactor that control the direction of rotation of operation of a DC motor. The speed of DC motors is controlled
the traction motor. Each direction contactor has two sets of by the average applied voltage. The higherthe average applied
contacts on the same plunger assembly. Each contactor has a voltage, the faster the motor will rotate. If a switch is put in the
set of NO contacts and a set of NC contacts. When one set of traction motor circuit (see Figure 3-3), and the switch is
contacts is closed, the other set of contacts must be open . This changed to OFF and ON quickly (see Figure 3-7), the traction
arrangement prevents a wrong sequence of closed contacts motor will rotate. As the ON time increases, the speed of the
that could cause a short-circuit. This arrangement of motor increases. As the OFF time increases, the speed of the
contactors also permits current flow through the motor field in motor decreases, The speed of the motor can be controlled
either direction. See Figure 3-4 and Figure 3-5. One set of using this principle.
3-3
Yale
THE FIELD EFFECT TRANSISTOR (FET)
A FET is a solid-state device that operates like a very fast

switch. Transistors are electronic devices that permit electricity
to flow in only one direction. See Figure 3-6. A transistor
FORWARD permits electricity to flow easily from the anode to the cathode.
ROTATION A FET is a transistor that has an additional element called a
gate.
CURRENT
FLOW
NA00399
Figure 3-4 -Current Flow through The Field In The

FORWARD Direction
This controller uses and electronic device called a Field Effect

Transistor (FET) to generate the rapid ON and OFF pulse
times. It has no moving parts.The FETs are turned on and off by
the logic circuits in the controller to act as the switch. Several
power FETs are connected in parallel to carry the necessary
motor current.
REVERSE
ROTATION
1
T ! F,EL0 ! "T" F
II m 1 i
1-rt TF 1.
2.
BATTERY
TRACTION MOTOR
3. FETs SWITCH
CURRENT 4. FET CATHODE
FLOW 5. FET ANODE
NA00400
6. FET GATE
7. POSITIVE SUPPLY THROUGH MOTOR
8. NEGATIVE GATE SIGNAL
Figure 3-5 -Current Flow through The Field In The
REVERSE Direction
9. NO GATE SIGNAL
10. NO POSITIVE SUPPLY (FETs OPEN)
NA00401
-
Figure 3-6 Transistor Control
3-4
Yale
A FET will only permit current flow when there is a negative selected speed, a direct change in the ratio of FET ON TIME to
voltage of the source, a positive voltage at the drain AND a FET OFF TIME also occurs. The voltage for maximum speed
positive signal voltage applied to the gate. A FET will permit changes the ratio to pulses with the maximum ON TIME, to
electricity to flow from the anode to the cathode as long as there produce a maximum average motor voltage. See Figure 3-7.
is the signal voltage at the gate. The FET ON time is the same The pulse rate (15 kHz) stays the same for all speeds.
as the gate pulse ON time as shown in Figure 3-7. The FET
stops conducting when the signal voltage is removed from the
TIME
gate.
When FETs are used as a switch:

GATE PULSES A. LOW SPEED
a. The FETs are ON when electric current flows through CONSTANT FREQUENCY (SHORT "ON"
them (gate signal). BATTERY
ON ON ON ON
TIME>
TIME TIME TIME TIME
VOLTS —
b. The FETS are OFF when electric current cannot flow
OFF OFF OFF OFF
through them (no gate signal). TIME TIME TIME TIME
0-10% AVERAGE
MOTOR VOLTS
A MOTOR CIRCUIT THAT OPERATES WITH PULSES ZERO I (SPEED)
VOLTS FETs PULSES
Figure 3-6 is part of a schematic that shows the controller and
FETs in a traction circuit. When a signal is applied to the gate of
the FETs, the FETs are ON and current flows from the battery TIME
through the motor.
When the gate signal is removed, the FETs are changed to P y

GATE PULSES
u u B. HALF SPEED
(EQUAL "ON"
CONSTANT FREQUENCY AND "OFF-
OFF. The battery voltage is applied to the motor in pulses. The ON ON ON ON TIMES)
pulses of energy through the FETs to the motor are very fast BATTERY (TIME TIME TIME TIME
VOLTS
(15,000 on/off cycles per second). The motor cannot follow
each pulse,butthe motor runs smoothly onthe average voltage
50% AVERAGE
generated by the ON and OFF times. Figure 3-7 shows the
average motor voltage applied to the traction motor. The length
of the ON TIME of the pulses changes the average motor ZERO
ÿ MOTOR VOLTS
(SPEED)
voltage. As the ON TIME of each pulse increases (OFF TIME VOLTS FETs PULSES
decreases) ,the average motor voltage increases.This change
in the ratio of ON TIME to OFF TIME of the pulses is called
pulse width modulation. TIME
The control circuit has an oscillator and a pulse width

modulator. The oscillator generates a saw tooth waveform at a
3
GATE PULSES
constant frequency of 15 ,000 cycles per second (15 kHz) . The CONSTANT FREQUENCY
--
pulse width modulator uses this saw tooth waveform to ON ON ON ON
BATTERY TIME TIME
generate a pulse output that can be smoothly changed from a VOLTS
TIME TIME
TO 100%
l
full ON to a full OFF condition. This pulse output is used by the
gate driver circuit to turn the FETs on and off. The pulse width C. HIGH SPEED
modulator controls the ON and OFF times of the FETs through
the gate driver. The ratio of ON TIME to OFF TIME sets the ZERO
_ (LONG "ON"
TIME)
average motor voltage and the motor speed, VOLTS FETs PULSES
NA00402
The accelerator potentiometer, at the speed control of the lift
truck, produces a voltage that changes as the operator sets the Figure 3-7 - Average Motor Voltage
speed of operation. This voltage is an input to the controller and
the pulse width modulator. As the voltage changes with the
3-5
Yale
BEGINNING CONDITIONS AS THE SWITCH IS CLOSED

SWITCH
ON \\\ .
1 LARGE CURRENT FLOW FROM BATTERY THROUGH
\\\ INDUCTOR.
\\\
I\ 1
!m*! II >
2. INCREASING MAGNETIC FIELD GENERATES
v\\ /,'/
Wv /
//
// REVERSE VOLTAGE WITHIN INDUCTOR.
ÿ3
M- 3. REVERSE VOLTAGE DECREASED CURRENT
THROUGH INDUCTOR. CURRENT ENERGY
CHANGED TO ENERGY IN MAGNETIC FIELD.
''i , |i i
I1 |'
CONSTANT CONDITIONS AFTER SWITCH IS CLOSED
j'l
1
FOR A SHORT TIME PERIOD.
II
1I
I
'1 1
"
! i1 '!
i1
1. VOLTAGE AND CURRENT FLOW IS THE SAME IN
1
"
11 ALL PARTS OF THE CIRCUIT.
+4 J\ 2. MAGNETIC FIELD IS CONSTANT.
ENDING CONDITIONS AS THE SWITCH IS OPENED.

SWITCH
OFF v i
//V 1. DECREASING MAGNETIC FIELD GENERATES

w\ III
1,1
',1
11
1
' VOLTAGE WITHIN INDUCTOR.
\V v
2. DECREASING MAGNETIC FIELD GENERATES
vV-A>. CURRENT FLOW IN ORIGINAL DIRECTION.
NA00403
Figure 3-8 - Inductance

INDUCTION CURRENT FROM THE MOTOR to the amount of current flow through it. At slower speeds, the
OFF times are longer. When the FETs are OFF, the decreasing
When a DC motor is controlled by a pulsed circuit, the magnetic
magnetic field generates a voltage and current in the motor;
field in the armature and field windings is continuously
This current is often called the "flyback current". The Flyback
increasing and decreasing. Thefields increasewhen voltage is
applied (ON TIME) and decreases when the voltage is Diode permits the currentto flow through the field and armature
again to do work. At slower speeds, the motor current is part
removed (OFF TIME). The voltage causes an increasing
battery current and part "flyback current'. There is less battery
current flow through the windings to make the increasing
current used for the specific torque requirement. High current
magnetic field. When the voltage is removed, the decreasing
draw from the battery is to be avoided, if possible, because it is
magnetic field causes current to flow in the same direction
less efficient. At higher speeds, the OFF time is less, so that
through the windings. See Figure 3-8. This increase and
less induction current ("flyback current") is generated. Most of
decrease of the magnetic field is lost energy for doing work
the motor current must come from the battery at higher speeds.
unless the controller is designed to use this energy. A Flyback
Diode (sometimes called a Freewheel Diode) is inthe controller However, the torque and current requirements are also usually
less.
circuit for this purpose.
The Flyback Diode permits the current, from the decreasing The graph in Figure 3-9 shows the typical induction current
magnetic field, to flow through the field and armature again to
during equal ON and OFF times of the FETs.
do work. The torque of a series DC motor is directly proportional
3-6
Yale
INDUCTION
CURRENT
PEAK MOTOR
CURRENT
AVERAGE
I— BATTERY
CURRENT
I T'MC>
a 1. BATTERY
2. MOTOR ARMATURE
3. MOTOR FIELD
4. CONTROLLER
5. FETs (NOT "ON")
6. FLYBACK DIODE
Figure 3-9 -Induction Motor Current

PLUGGING current allowed. The plugging adjustment can be changed as
Plugging is a method of stopping an electric lift truck by needed for application.
changing the direction of current flow within the field of the
traction motor. The Direction/Speed control must be moved for
travel in the opposite direction of present travel. Plugging is
actuated when reversing occurs at the direction switch. The
direction contactors will change to the opposite positions and
reverse the current flow from the battery through the motor
field. The motion of the lift truck drives the traction motor
armature to make the motor operate as a generator. This
additional "generator" current (armature current) adds to the
current flow through the field to reverse the motor at an even
faster rate. Unless the control circuit provides a way to slow this
change of direction, the lift truck will stop very quickly. The plug
diode in the control circuit prevents the lift truck from stopping
too quickly. While the motor is acting as a generator, the plug
diode prevents this "generator current" from adding to the field
current. The control circuit lets all of the plugging current flow
from the armature through the plug diode, then flow with the
battery current through the armature again. This reduces the
effect of the induction current.
During plugging the pulse rate is also reduced from 15 kHz to 1
kHz. The controller regulates the pulse widths of the pulses to
1. BATTERY ARM
ai
4. CONTROLLER
the motor field for the correct amount of plugging. The
2. MOTOR ARMATURE 5. PLUG DIODE
accelerator circuit is also set to a low speed so the normal
acceleration in the opposite direction will occur. The plugging 3. MOTOR FIELD NA00405
adjustment on the controller changes the amount of motor field

Rgure
_ piugging Current Circujt
3-7
Yale
CONTROL CIRCUIT LOW VOLTAGE PROTECTION FUNCTION

The control circuit has operator inputs from the key and brake This function protects the controller and the battery. The
switches (terminal 1) as well as the accelerator potentiometer controller will not operate correctly if there is not a minimum
(terminals 2 & 3). The circuit also has internal inputs from the voltage from the battery. The battery current drain increases as
power circuit for thermal protection, plugging sensing, low the battery voltage decreases. Too large a battery drain will
voltage protection and motor current (current limit). The control damage the battery. If the battery voltage is low, the control
circuit uses these inputs to regulate the ON TIME pulses to the circuit will decrease the ON TIME of the pulses to decrease the
FETs for speed control, current limit and plugging strength. current drain. The battery can still operate the lifttruckto move it
for battery charging or replacement.
STATIC-RETURN-TO-OFF (SRO) FUNCTION
POWER CIRCUIT
The control circuit includes a function to prevent the operation
of the lift truck if the starting sequence is not correct. This The power circuit is controlled by the control circuit. The
function uses the inputs to the control circuit to make sure the complete power circuit is inside the controller and has the
operator is ready to operate the controls. The starting following parts:
sequence follows:
The Field Effect Transistors
a. Turnthe key switch to the ON position. The key switch
The Freewheel Diode
supplies the battery voltage to the brake switch.
The Plug Diode
b. Close the brake switch. Battery voltage is now The Filter Capacitors
supplied to the control circuit. The Temperature Sensor
c. Rotate the Direction/Speed control in the desired
The parts in the power circuit cannot be replaced by users.
direction of travel to select travel direction and speed.
Cables connect the battery and traction motor to the power
circuit at the controller power terminals "B + ", "A2", "M-" and "
If step c is done before both steps a and b are complete, the lift
B-". All of the traction motor current flows through the power
truck will not move in either direction. The control circuit must
circuit of the controller.
get battery voltage through both the key and brake switches
before it gets a speed signal from the accelerator
potentiometer. If the starting sequence is not correct, the AUXILIARY SECTION
control circuit will not send a gate pulse to the FETs for traction
The auxiliary circuit is also contained within the controller. The
motor current.
components that make up the auxiliary section are not
replaceable.
The SRO function also prevents the lift truck from going to full
speed operation because of a malfunction in the accelerator
The auxiliary section accepts all user control inputs, provides
circuit. A closed circuit in the accelerator circuit normally
outputs and monitors and controls the logic and power section
senses a full speed signal by the controller. If this malfunction
of the controller. A 1 2V regulator powered by B + provides the
exists, the SRO function will prevent the start of traction pulses.
power for all the auxiliary section circuits.
If the malfunction occurs during normal operation, the control
circuit senses an accelerator potentiometer input of more than The controlled inputs are:
7000 ohms (open circuit) and stops traction pulses. The circuit Key switch and interlocks
will returnto normal operation after the malfunction is repaired. Directional switches
Static return to off
THERMAL PROTECTION FUNCTION The output provided is:
There is a sensor to sense the heat within the controller Forward/Reverse contactors
housing. If the controller gets too hot or too cold for correct
Controllers with SRO (Static return to off) must be properly
operation, the control circuit will reduce the ON TIME of the
sequenced to enable the controller and allow it to operate. The
pulses to decrease the current to protect the controller. The lift
key switch input must be turned on before the forward or
truck will still operate at a slower speed to permit it to be moved
reverse input is engaged to allow the control logic to turn on the
to a location out of the work area. The controller can then return
controller. If the key switch input is turned on atthe same time or
to a normal operating temperature.
laterthanthe forward or reverse input, the controller will notturn
on.
3-8
Yale
A proper turn-on sequence will enable the logic section of the CHECKING CONTACTOR COIL
controller, allowing the controller to respond to the accelerator
Check the Forward or Reverse contactor coil with an
input. This will turn on the forward/reverse contactor driver and
ohmmeter. A suppressor diode is connected across the coil
provide the proper output to the selected directional contactor.
terminals. The diode will cause the ohmmeter to indicate a
If a fault is detected, or if the logic boards power supply is out of
range, the controller and the contactor driver will not be allowed
difference in resistance in one direction. Reversethe probes of
the ohmmeter to the opposite terminals and measure the
to operate even if a valid turn on sequence is initiated.
resistance. Use the highest resistance indication. Replace the
coil if the resistance readings are a short circuit in both
The bypass contact driver will turn on the bypass contactor
directions or if there is an open circuit in, both directions. Make
when the accelerator demand level reaches 90 % for at least
sure the coilwires are connected again to the correct terminals.
one second. The contactor will turn off instantly when the
Refer to Contactors-General within this section.
accelerator demand is less than 90 %.
Both the forward/reverse and bypass contactor drivers are CHECKING TRANSISTOR CONTROLLER
protected against short circuits.
The controller Is protected against operation with a low battery.
Controller output is slowly decreased as battery voltage
CHECKS, ADJUSTMENTS, AND REPAIRS decreases. The battery can be low if an operator notices slower
operation or less power. This operation is not a defect of the
There are several checks that can be made that check for
transistor controller. Make sure all checks are done with a fully
correct operation of the system. There are only three external
charged battery.
adjustments and no internal adjustments for the transistor
controller.
NOTE: The following checks must be done in the order they are
listed because some steps depend on conditions set in
NOTE: These checks require voltmeter with a meter
previous steps.
movement. Most digital meters will not operate correctly for
some of these checks. Specific checks require additional
equipment. CHECKS WITH CONTROLLER INSTALLED
1. Raise the drive/steer wheel as described in the Operating
A
_« WARNING: Disconnect the battery and separate
Manual or the PERIODIC MAINTENANCE section of the
I \ the connector before opening the drive unit
Service Manual.
compartment or inspecting or repairing the
electrical system. If a tool causes a short circuit, the high
2. Make sure the battery is fully charged.
current flow from the battery can cause an injury or parts
damage.
3. Make a physical check that battery negative is connected
to the B - terminal of the controller. Connect the negative meter
The capacitor in the transistor controller can hold an electrical
lead to the B - terminal,
shock and injury, discharge the capacitor before inspecting or
4. Check for battery positive voltage at the B+ terminal of the
controller and the cable T2 terminal of the Reverse contactor. If
there is no battery positive voltage, check the cables between
battery. Then connect an insulated jumper wire betweenthe B +
battery positive and the two terminals. If the cables are not
and B- terminals (Figure 3-11) of the transistor controller.
defective, the controller can be defective.
Some checks require the battery to be connected. Do not
5. Make sure the key switch is in the OFF position and
connect the battery untilthe procedure tells you to connect the
remove the wires 29 and 26 from terminals 1 and 2 of the
battery. Make sure the drive wheel is raised to prevent truck
controller. Do not disconnect the resistor between terminals 1
movement and possible injury. Raise the drive wheel as
and 2. Check for an open circuit (at least I megohm) between
described in the Operating Manual or the PERIODIC
the wires with the Direction/Speed control in the Neutral
MAINTENANCE section of the Service Manual.
position. If an open circuit is not obtained, check to see that the
accelermeter pot is centered. Check for approximately 1000 to
2250 ohms with the control in either full speed position. Check
for at least one megohm between each wire and the lift truck
frame. If any of the resistance readings are wrong, check the
wiring to the accelerator potentiometer and check the
adjustment of the FWD/REV switch. Connect wire 29 to
terminal 1 and wire 26 to terminal 2.
3-9
Yale
6. Connect the voltmeter positive lead to the controller B + 8. Disconnect the cable from the controller A2 terminal. Use
terminal. Connect the voltmeter negative lead to the controller the ohmmeter to check for a diode between the A2 and B+
M - terminal. Move the key to the ON position and close the terminals. There must be a high resistance in one direction and
brake switch. Check for zero or near zero volts. Move the a low resistance with the meter leads reversed. If there is a low
Direction/Speed control for full speed travel. Check for full or high resistance in both directions, the diode is defective. If
battery voltage. the readings are correct and the motor does not operate, there
is a short in the motor circuit, Check for a short at the motor
7. If there is notfull battery voltage, the controller is detective. cables or directional contactors. If the cables and contactors
If there is battery voltage and the motor does not operate, are good, the motor has a short.
disconnect the battery connector and discharge the internal
capacitor. The correct procedure to discharge the capacitor is
described in the WARNING at the beginning of this section.
KEY SWITCH INPUT

F/R CONTROLLER OUTPUT
STATIC-RETURN TO OFF
NOT USED
FWD. INPUT
.INPUT
TERMINAL 1
TERMINAL 2 NA00406
Figure 3-11 - Battery Indicator Voltage Selection
3-10
Yale
IndustrialTrucks electrical system
SEQUENCE OF OPERATION
The sequence of operation chart describes a complete cycle of the transistor traction chart.
Key switch to the "ON

position.
Brake switch is closed. Gate Driver of Control Circuit Gate Driver sends OFF pulse
sends ON pulse to FETs to FETs gate. OFF TIME
gate. ON TIME (pulse width) (pulse width) set by rest of
set by Accel. Pot. signal. time remaining in one cycle
at 15 kHz.
Control Circuit has battery
positive. Circuit checks for no
signal from Accel. Pot.
Power pulse to traction motor

FETs ON for time of gate ON circuit ends.
Direction/Speed Control pulse.
rotated for slow forward
travel.
Induction current flows

through Flyback Diode and
FWD/REV switch forward
traction motor.
contacts close. Accel. Pot. Power Pulse to traction motor
signal to Control Circuit. circuit.
Forward contactor energized. Control Circuit repeats cycle.

NO contacts close and NC
contacts open.
NA00407
Figure 3-12 - Sequence of Operation
3-11
Yale
ACCELERATOR POTENTIOMETER the potentiometer slightly without moving the pinion gear.
Temporarily tighten the setscrew. Rotate the pinion gear
NOTE: The direction switch must be correctly adjusted before
the accelerator potentiometer can be checked. The accelerator and check the two readings as in Step 3. The pinion gear
must always be in the neutral position after each check.
potentiometer must be adjusted after each installation.
Continue to repeat this step until the two readings are
within 10 %. Make certain the match marks are in
A
WARNING: Disconnect the battery connector to
alignment.
prevent operation of the hydraulic system or
electrical shock and possible injury. d. Carefully tighten the setscrew to 0.06 to 0.11 N*m
(0.56 to 0.94 lbf in) torque without moving the pinion gear
The operator platform can move abruptly and cause an injury from the neutral position. Make sure that the setscrew is
when any Lift or Lower buttons are accidentally pushed. Fully also tightened to hold the potentiometer so that the body
lower the operator platform. Remove the key from the key cannot rotate.
switch and install a tag on the instrument panel stating "DO
NOT OPERATE".
e. Do Step 6c to check that the adjustment is still correct.
If necessary, do Step 6c and 6d again until the checks in
1. Disconnect the battery so that the battery connector is
Step 3 are correct after the setscrew is tightened to the
correct torque value.
completely free.
f. Connect the electrical connectors, install and fasten
2. Remove the capscrews that fasten the accelerator panel the instrument panel cover.
to the cowl. Disconnect electrical plug X-1 .
3. Use an ohmmeter to check the resistance of the ADJUSTMENTS

accelerator potentiometer. Check the resistance at the WARNING: Disconnect the battery and separate
electrical plug connector. Check between wire 26 andwire 28 at / 1\ the connector before opening the drive unit
the connector. Slowly move the direction/speed control forward compartment or inspecting or repairing the
travel and check for a resistance reading of 5K (4500 to 5500) electrical system. If a tool causes a short circuit, the high
ohms as the forward switch just makes contact. Check that the current flow from the battery can cause an injury or parts
reading decreases smoothly with no flat areas or infinity damage.
readings as the direction/speed control is moved to the
maximum position. Do the checks again for the reverse The capacitor in the transistor controller can hold an electrical
direction, The two resistance readings must be equal within charge after the battery is disconnected. To prevent electrical
10% when each switch makes contact. When the shock and injury, discharge the capacitor before inspecting or
direction/speed control is moved to the maximum position, the repairing components in the drive unit compartment. Wear
ohmmeter reading must be 200 ohms or less, in either safety glasses. To discharge the capacitor, first disconnect the
direction. battery. Then connect an insulated jumper wire betweenthe B +
and B - terminals (Figure 3-11) of the transistor controller.
4. If all of the checks of Step 3 are correct, the accelerator
potentiometer is good and correctly adjusted. Connect the Some checks require the battery to be connected. Do not
electrical connectors. If there were flat areas or infinity connect the battery until the procedure tells you to connect the
readings, the potentiometer must be replaced. If the resistance battery. Make sure the drive wheel is raised to prevent truck
readings were smooth, but the values were not correct, adjust movement and possible injury. Raise the drive wheel as
the potentiometer as described in Step 6 of this procedure. described in the Operating Manual or the PERIODIC
MAINTENANCE section of the Service Manual.
5. If the potentiometer does not need adjustment or
replacement and no other parts will be checked, connect The controller has three adjustments: Braking (plugging),
electrical plug X-1 and install the accelerator cover. Current Limit and Controlled Accleration. The plugging
adjustment adjusts the maximum ratethatthe lifttruck will stop.
6. To adjust the potentiometer, do the following steps: The Direction/Speed control can be moved to the maximum
a. Match mark the gear mounted on the potentiometer
speed position from stop or a slow travel speed. The controlled
acceleration adjustment allows adjustment of the maximum
and the directional/speed control handle.
rate of acceleration. The current limit control limits the motor
b. Remove the two pan head screws retaining the current to a preset maximum.
potentiometer support to the mounting bracket.
c. Connect an ohmmeter as in Step 3. Loosen the
setscrew that fastens the pinion gear to the shaft of the
potentiometer. Hold the potentiometer in the mount
position. The setscrew normally holds the potentiometer in
the mount position. Use a screwdriver to turn the shaft of
3-12
Yale
ADJUSTING PLUGGING The capacitor in the transistor controller can hold an electrical
Turning the braking (plugging) adjustment clockwise will charge after the battery is disconnected. To prevent electrical
increase the plugging effect and stop the lift truck in a shorter shock and injury, discharge the capacitor before inspecting or
distance. Turning the adjustment counterclockwise will
decrease the plugging effect. The traction motor brushes have
a faster wear rate when the control is set for the shortest battery. Then connect an insulated jumper wire betweenthe B +
stopping distance (maximum Plugging). More heat is also
generated at this maximum setting,
Some checks require the battery to be connected. Do not
connect the battery until the procedure tells you to connect the
ADJUSTING ACCELERATION battery. Make sure the drive wheel is raised to prevent truck
Turning the controlled acceleration adjustment clockwise will movement and possible injury. Raise the drive wheel as
increase the acceleration rate. Turning the adjustment described in the Operating Manual or the PERIODIC
counterclockwise will give a slower rate of acceleration. The MAINTENANCE section of the Service Manual.
traction motor brushes have a faster wear rate when the control
is set for the maximum acceleration rate. More heat is also REPLACING CONTROLLER
generated at this maximum setting.
Make an identification and disconnect the wires and cables
from the controller. Remove the mounting screws and remove
ADJUSTING CURRENT LIMIT the controller. Installthe replacement controller on the lift truck.
Turning the current limit adjustment counterclockwise will lower Connect the wires and cables to the same terminals as
the current limit. This setting is factory set at the maximum 400 identified during the removal procedure.
amps. Lowering this adjustment may cause the truck to have
limited starting torque and may not run at top speed when fully CAUTION: When replacing the controller, make
loaded. certain to replace it with one having the same
voltage as the one being replaced.
WARNING: Disconnect the battery and separate
the connector before opening the drive unit TROUBLESHOOTING
compartment or inspecting or repairing the
electrical system. If a tool causes a short circuit, the high This section describes the most common faults that can occur
current flow from the battery can cause an injury or parts
in trucks with the CURTIS TRANSISTOR CONTROLLER.
damage. Followthe General Procedures to make sure that maintenance
problems give the correct troubleshooting results. Follow the
General Procedures andthen use the fault procedure that best
describes the problem.
CURRENT LIMIT ADJUST

(CCW = LOWER CURRENT LIMIT)
PLUG CURRENT ADJUST ACCELERATION RAMP ADJUST
(CW = HIGHER PLUGGING CURRENT) (CW = FASTER ACCELERATION)
2:
iz:
IE
ÿ1
NA00408
Figure 3-13 - Controller Adjustment Locations
3-13
Yale
/\ WARNING: Disconnect the battery and separate 2. The electric lift truck has a two-wire system. The frame
/ 1\ the connector before opening the drive unit must not be a common electrical path, Check for 50,000 ohms
CmLhI compartment or inspecting or repairing the or more between each terminal of the battery connector for the
electrical system. If a tool causes a short circuit, the high lift truck and a clean connection on the frame. Remove any
current flow from the battery can cause an injury or parts circuit paths between the controller and the frame of the lift
damage. truck. Carbon dust in a motor or other parts can cause a circuit
path. Check for additional equipment that is causing a circuit
The capacitor in the transistor controller can hold an electrical path to the frame.
shock and injury, discharge the capacitor before inspecting or 3. Check for voltage between each terminal ofthe connector
repairing components in the drive unit compartment. Wear that fastens to the battery and a clean connection on the frame.
safety glasses. To discharge the capacitor, first disconnect the Normally there is some small voltage between the battery and
battery. Then connect an insulated jumper wire betweenthe B + the frame even if the resistance is very high. The small voltage
and B - terminals (Figure 3-11 ) of the transistor controller. is normally less than 30% of the battery voltage. A higher
voltage can indicate a dirty battery or a battery with a defect.
Some checks require the battery to be connected. Do not Clean the battery and battery compartment as necessary,
connect the battery untilthe procedure tells you to connect the
battery. Make sure the drive wheel is raised to prevent truck 4. Visually check for parts or wires that are loose or
movement and possible injury. Raise the drive wheel as damaged.
described in the Operating Manual or the PERIODIC
MAINTENANCE section of the Service Manual. NOTE: The correct meter polarity is necessary for the checks.
The voltage checks are made between the point indicated in
1. Check the specific gravity of the battery. If the specific is the troubleshooting chart and battery negative. Connect the
less than 1,260, the battery is not fully charged or has a defect. meter negative to battery negative.
A fully charged battery has a specific gravity of 1 .270-1 .290. A
discharged battery has a specific gravity of approximately NOTE: Make an identification of any wires before you
1.130. disconnect them. The wires must be connected correctly after
checks or repairs.
3-14
Yale
FAULT NUMBER 1. ONE DIRECTIONAL CONTACTOR WILL NOT CLOSE
Possible causes:
•• Direction switch is defective
Defective (open) wire(s) in circuit
control
•• Contactor defective power steering

coil is
Also check disconnect module, contactor
switches defective key.
coil, Fuse 6, limit or
Check that the direction switch closes. 1.0.1 The direction switch closes. Check FWD or
REV contactor coil and wire 10 at contactors.
Only REV contactor will close. Check for 1.1.1 Voltage at wire 6 wiring is defective.
battery voltage at wire 6 of directional switch
with both switches in neutral position.
1.1.2 No voltage at wire 6. FWD or REV switch,
wiring or FWD contactor coil is defective.
NA00409
3-15
Yale
FAULT NUMBER 2. DIRECTIONAL CONTACTOR WILL NOT CLOSE FOR OPERATION IN EITHER DIRECTION
Possible causes:
••Battery not connected
Control fuse is defective
••
Pump motor fuse is defective
Battery voltage is low
••
Wires in circuit are open
Key switch or brake switch is defective
•Transistor controller is defective
2.0 Check for battery voltage on the positive wire 2.0.1 Battery voltage at positive wire. Check for an
of the control fuse. open control fuse.
2.0.2 No battery voltage at positive wire. Connect

battery or check wiring between battery and
fuse.
2.1 Check for battery voltage at wire 3 terminal of 2.1.1 Battery voltage at wire 3. Check for defective
key switch. key.
2.1.2 No voltage at wire 3. Wire 3 or connections

are defective.
2.2 Key switch closed. Check for battery voltage 2.2.1 Battery voltage at wire 9. Check for defective
at wire 9 at brake switch. brake switch.
2.2.2 No voltage at wire 9. Check for defective wire.
2.3 Brake switch closed. Check for battery 2.3.1 No voltage at wire 11. Check for defective
voltage at wire 11. wire 11 or defective brake switch.
2.4 Check for defective wire 23 to FWD/REV 2.4.1 Wire 23 not defective. Check for defective
contactors. contactor coils.
NA00410
3-16
Yale
FAULT NUMBER 3. LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. THE DIRECTIONAL CONTACTORS
CLOSE NORMALLY. NO POWER WHEN DIRECTION/SPEED CONTROL IS MOVED.
Possible causes: •Traction fuse is defective

••Open circuit between motor and contactors
Power contacts of direction contactor are defective
••Accelerator potentiometer is defective or needs adjustment
Drive motor is defective
••
Defective (open) traction motor cables
Transistor controller is defective
3.0 Check traction fuse. 3.0.1 If fuse is defective, replace fuse with one of
the correct value.
3.0.2 If fuse is not defective, go to 3.1.
3.1 Check for battery voltage between B+ and B- 3.1.1 No battery voltage. Check cables between
terminals of controller. battery and terminals.
3.1 .2 Battery voltage. Go to 3.2.
3.2 Check for battery voltage at M- terminal of 3.2.1 No battery voltage at M-. Cables to armature
direction contactors. of traction motor, motor brushes or motor
armature are defective. Motor brushes or
cables are defective. Replace or repair. Motor
brushes and cables are not defective.
Armature is open, replace motor.
3.2.2 Battery voltage. Go to 3.3.
3.3 Check for battery voltage at A2 terminal of drive 3.3.1 No battery voltage at A2. Check power
motor with directional contactor energized. contact of directional contactor, cable A6 and
drive motor field (F3 to F4) Repair or replace
defective contactors, cable or motor.
3.3.2 Battery voltage. Go to 3.4.
3.4 Check for battery voltage between B+ and M- 3.4.1 No battery voltage at M-. Check power at
terminals of controller. directional contactor and cable. Repair or
replace defective T2 contactor or cable.
3.4.2 Battery voltage. Replace defective PM

controller.
NA00411
3-17
Yale
FAULT NUMBER 4. DIRECTIONAL CONTACTORS CLOSE, LIFT TRUCK ACCELERATES TO FULL SPEED IMMEDIATELY.
Possible causes:
••Accelerator potentiometer is defective or
Transistor controller defective
is
needs adjustment
4.0 Check that accelerator potentiometer is wired 4.0.1 Potentiometer is wired correctly. Check that
correctly. See the DIAGRAMS section of the wire 16 or 18 voltage varies as speed control
Service Manual. is moved. (Should read 2.7 volts at start to 7
volts at full speed.)
4.0.2 Voltage does not change. Adjust or replace

potentiometer.
4.1 Voltage varies. Check for short-circuit of wires 4.1.1 Wires are not defective. Replace controller.
16 and 18.
NA00412
3-18
Yale
CONTACTOR AND ELECTRICAL PANELS-CHECKS AND

ADJUSTMENTS
NOTE: NEVER make adjustments if the system or components
are operating correctly.
WARNING: Do not operate a lift truck that needs LIFT CONT

f \ adjustment or repairs. Report the need for
I
adjustment or repairs immediately. If adjustment or CONTACTOR
repair is necessary, put a "DO NOT OPERATE" tag on the
instrument panel. Remove the key from the key switch,
Some of the checks and adjustments are done with the battery CONTACTOR PANEL
connected. Never have any metal on your fingers, arms or
neck. These metal items can accidentally make an electrical
connection and cause an injury.
/\ CAUTION: Correct meter polarity is necessary

J I\ for some checks. Meter correct positive is
LJLJ indicated as (+). Meter correct negative is
indicated as (-)
Use a meter with a minimum rating of 20,000 ohms per volt to

make measurements. Most digital voltmeters are good.
NOTE: To perform the following component tests or to replace ELECTRICAL PANEL

any of the components, the drive unit compartment doors must NA00413
be opened and the drive unit compartment cover must be

removed. Refer to Section 2.
Figure 3-14 - Fuse Locations
CONTROL AND POWER FUSES
CONTACTORS - GENERAL
In an electric truck wiring circuit, contactors are used to perform
All the fuses used on the OS30EB are located in the electrical the task of "Making" or "Breaking" the main power circuits for
compartment. Remove the cover over the electrical different functions, such as the drive motors, hydraulic pumps,
compartment for access. The condition of some fuses can be power steering pumps, etc. Contactors are basically remote
checked by looking at them. Other fuses do not change in looks control switches for high current applications and serve several
and must be checked with an ohmmeter. Disconnect the purposes. First, they allow the truck to use shorter cables for
battery before checking fuses. the high current carrying power circuits, resulting in less
resistance and better efficiency. Second, they allow the use of
The power fuses, traction circuit (FU1) and pump motor (FU2) lighter gauge wire for the control circuits (such as directional
are on the contactor panel, next to the pump contactor. The switches, accelerator switches, etc.) by separating the control
steering gear motor fuse FU3 is located on the electrical panel and power circuits. This creates great cost savings in lighter
adjacent to the contactor panel. Control fuse FU4 is located on duty components, safer designs (by removing high electrical
the contactor panel, immediately above the pump contactor. currents from areas of possible operator contact), reducing
The fuse for the BDI or the voltmeter, FU5 is also on the heat and power losses, and creating less maintenance
contactor above FU4 and the pump contactor. An additional problems by reducing current in the controls.
control fuse FU6 is located on the electrical panel adjacent to
FU3. Sizes of the fuses are as follows: The contactor uses a low amperage current from the control
FU-1 Power Fuse (Traction Circuit) 300A switch to energize a magnetic coil. This coil then creates a
FU-2 Power Fuse (Pump Motor) 500A magnetic force that draws the contact arms together, closing
FU-3 Steering Gear Motor 35A the circuit for the high amperage current, allowing it to flow
FU-4 Control Fuse 10A through the contactor.
FU-5 BDI or Voltmeter 10A
FU-6 Control Fuse 15A
3-19
Yale
Industrial Trucks ELECTRICAL SYSTEM
When the control switch is opened it stops the flow of current to MAINTENANCE OF CONTACTOR ASSEMBLIES
the magnetic coil, and a return spring opens the contact arms.
As mentioned before, contact tips must be checked frequently.
Because of tho arcing that occurs during closing and opening of
Burn marks are a normal condition created by arcing as the tips
these high current contact arms, contact tips made of precious
open. Extremely worn or pitted tips should be replaced,
metals or alloys are used to prevent welding of the tips. Also,
preferably in pairs. Rapid wearing of tips could be caused by
contactors are designed with an "over travel" feature. The
one or more of the following conditions:
connection between the coil armature (which provides the
actual motionthat closes the tips) andthe contact tips is always
1. Operating truck on a low-charged battery.
a spring dampened connection. The coil armature actually
travels farther than what is required to close the tips, andthis 11
2. Pushing loads, creating high current draw.
over travel" compresses the armature spring.
3. Allowing contactors to drop out while under heavy load
This squeezing or wiping action prevents the tips from
conditions, such as negotiating a steep ramp.
bouncing as they close. This bouncing would cause arcing of
the tips, creating high spots, which could concentrate any
4. Faulty spike suppressors.
further arcing in one spot, welding the tips together. Because of
this arcing, contact tips should be frequently checked for wear.
5. Improper contact tip adjustment.
Two basic types of contactor assemblies are used in industrial
When replacing tips, make sure the new tips have the same
truck electrical circuits. For forward or reverse operation,
amp carrying capacity and are direct replacements for the
single-pole, double-throw contactors are used. This means
original tips. Also avoid using cheap substitutes. Contactor
there is a pair of normally open tips and a pair of normally closed
assemblies are designed to give a wiping action or squeezing
tips. "Normally Open" means that the tips are open when NO
action as the normally open tips come into contact. This helps
current is applied to the magnetic coil. The 1-A and pump
to prevent welding and bouncing ofthetips. On most contactors
contactors use a single-pole, single-throw arrangement,
there is a specified gap setting for the normally open tips and
meaning that there is only one pair of normally open tips.
normally closed tips.
NORMALLY CLOSED NORMALLY OPEN

TESTING CONTACTORS
1/ /\ WARNING: Parts of this procedure require
/|\ working on the truck with full electric current
present. Do not wear any rings jewelry, or a watch
while working around the contactor panel. Whenever manually
closing a contactor with the power connected, use a properly
Figure 3-15 - Schematic Symbols insulated tool.
1. Jackupthedrivewheelofthetrucksothatclearofthefloor.
SPIKE SUPPRESSION
Block the chassis up in this position and remove the jack.
Voltage spikes occur each time the contactor coils are
deenergized. To control these spikes, various devices are A CAUTION: Never operate the drive motor at full
used. On the OS30EB truck the spike suppression used is a /f\ speed for more than a few seconds without a load
diode and resistor in series mounted externally across the (such as when the drive wheels are up off the floor) .
contactor coil. These spike suppressors prevent damage to the A series-wound DC motor will continue to accelerate
electrical circuit and extend contact tip life. indefinitely until it exceeds its designed maximum RPM, at
which point it will self-destruct.
2. Check the condition of the battery. If it is not fully charged,

recharge or replace the battery with a fully charged battery
before continuing.
3. Visually check to see if contactor closes when circuit is

energized. If contactor closes, skip to Step 9. If contactor does
not close, proceed to Step 4.
3-20
Yale
4. Check for batteryvoltage atthe contactor coil. Connectthe Set the voltage scale of the meter to the lowest range higher
positive lead of the meter to the positive side of the coil. To than battery voltage (50 volt range for 24 volt battery, etc.). On
eliminate any false readings caused by other components forward and reverse contactors, a reading of zero volts with the
(such as a driver module connected on the negative side of the contactor open should be obtained, thenthe meter should jump
coil circuit), connect the negative meter lead to battery as the contactor closes and immediately drop to zero or close to
negative. Close all switches required to energize the contactor zero. This is the voltage drop across the contactor. On pump
coil and observe the meter reading: contactors, you should read battery voltage across the
contactor with the tips open, and it should drop to zero or near
a. No Voltage: Open circuit in control circuit wiring to
zero volts as the lips close.
contactor.
b. Low Voltage: High resistance in control circuit wiring A high voltage drop (2 volts or more) across the tips indicates
to contactor. poor contact or high resistance. Check for burned or worn tips,
incorrect size or mis-matched tips, and for incorrect gap
c. Full Battery Voltage: No problem with control
settings on those contactors with adjustable point gaps.
circuit-problem is probably in contactor. Proceed with test.
5. Check at the contactor for loose, broken, or corroded CONTACTORS

connections at the contactor.
The "FORWARD" and "REVERSE" contactor assembly
controls the direction of current flow through the traction motor.
6. Check the mechanical function of the contactor. Use a
The contactor is a heavy-duty switchthat opens and closes the
properly insulated tool, such as an electrician's screwdriver, to
power circuit. The traction circuit has a "FORWARD" and
manually close the contactor tips. Check for looseness or
binding of the moving parts of the contactor. The contactor
"REVERSE" contactor assembly. Each contactor assembly
has the following parts: two sets of normally open (NO)
should move freely, but the parts must not be so loose that the
contacts, two sets of normally closed (NO contacts and a coil.
movement is sloppy.
The coil is an electromagnet that moves the NO contacts to the
closed position against spring pressure. The coil is in the
7. Visually checkthe condition of the tips for pitting, burning,
control circuit. The contactor tips are in the traction circuit. A
or wear.
suppressor is connected to each coil.
8. Checkthe ohm value of the contactor coil. Disconnectthe
When a contactor coil is energized, the normally open (NO)
leads from one side of the coil and connect an ohm meter
contacts close and the normally closed (NO) contacts open.
across the coil. Reverse the ohm meter leads and check in the
Current flows through the traction motor field in one direction
opposite polarity (since spike suppressors onsome coils make
when the "FORWARD" contactor is energized and in the other
them polarity sensitive). Compare the ohm reading against the
direction when the "REVERSE" contactor is energized. This
ohm value for the type contactor being tested. Ohm values for
action gives direction control to thetraction motor. The contacts
G.E. contactors readings that vary from these values may be
normally have a long service life because the current flow
caused by:
through the contacts is stopped before the contacts open. The
FETs are "OFF" before the contactor coil deenergized.
Reading Cause
High Resistance: Corrosion or a burnt coil CONTACTOR-REMOVE AND INSTALL
Infinite Resistance: Open coil A WARNING: Disconnect the battery and separate
11\ the connector before opening the drive unit and
Low Resistance: Shorted or burnt coil compartment or inspecting or repairing the
electrical system, If a tool causes a short circuit, the high
No Resistance: Shorted coil current flow from the battery can cause an injury or parts
damage.
9. If the contactor closes but the truck does not work properly,
check the electrical function of the high current section of the The capacitor in the transistor controller can hold an electrical
contactor (the tips and bus bars). With the truck battery charge after the battery is disconnected. To prevent electrical
connected andall switches closed, connect a volt meter across shock and injury, discharge the capacitor before inspecting or
the high current terminals of the contactor. repairing components in the drive unit compartment. Wear
battery. Then connect an insulatedjumper wire betweenthe B +
3-21
Yale
Some checks require the battery to be connected. Do not 1. Remove the contactor as described in CONTACTOR
connect the battery until the procedure tells you to connect the REMOVE AND INSTALL.
battery. Make sure the drive wheel is raised to prevent truck
movement and possible injury. Raise the drive wheel as 2. Make an identification of the buss bars for correct
described in the Operating Manual or in Section 6 of this installation. Remove the buss bars and nuts that fasten the
Manual. fixed contacts.
Make sure the battery is disconnected and the capacitor in the 3. Remove the two screws that fasten the covers for each
controller is discharged. The correct procedure to discharge contactor. Remove the cover of each contactor. Do NOT lose
the capacitor is described in the WARNING, Make an the plunger springs.
identification of the wires and cables and disconnect them from
the contactor assembly. Remove the mounting screws and 4. Replace the four fixed contacts in the contactor covers.
replace the contactor assembly. Install the mounting screws
and reconnect wires and cables as removed. 5. Remove the two plunger assemblies and movable
contacts and replace the three fixed contact bars. Replace the
contacts of the plungers.
CONTACTOR DISASSEMBLY AND ASSEMBLY
NOTE: If both the contacts and coil of a contactor will be 6. If a coil will be replaced, remove the cover base. Remove
replaced, replace the complete contactor as described in the screws that fasten the coil frame to the mount bracket.
REPLACING THE CONTACTOR. Do only the parts of the Remove the coil and frame. Remove the bushing part of the
procedure necessary to replace the defective parts being plunger and the armature cap from the coil. Installthese parts
replaced. on the replacement coil.
NOTE: All of the contacts for each contactor must be replaced 7. Install the coil and frame on the mount bracket.
at the same time if any contact requires replacement.
8. Install the cover base, fixed contact bars and plungers on
The contactor contacts are made of special silver alloy. The the coil frame. Make sure both springs are on both plungers.
contacts will look black and rough from normal operation, This
condition does not cause problems with the operation of the lift 9. Install the covers and electrical bars on the covers as
truck. Cleaning is not necessary. DO NOT USE A FILE ON THE removed during disassembly.
CONTACTS. DO NOT LUBRICATE THE CONTACTS.
Replace the contacts when the silver alloy is worn away to the 10. Install the contactor assemblies on the lift truck as
base support metal. Replace the contactor parts as follows: described in REPLACING COMPLETE CONTACTOR,
3-22
Yale
ITEM DESCRIPTION
1 Screw-Top Cover
2 Hardware Kit
3 Top Cover
4 Return Spring
5 Moving Contact
6 Fixed Contact
7 Insulator
8 Coil and Frame w/Bracket
9 End Cap
Figure 3-16 - Forward and Reverse Contactors

3-23
Yale
ITEM DESCRIPTION
1 Fixed Contact
2 Moving Contact
3 Top Cover
4 Screw-Top Cover
5 Return Spring
6 Coil and Frame
7 End Cap
8 Auxiliary Contact Kit
Figure 3-17 - Pump Contactors

3-24
Yale
ITEM DESCRIPTION
1 Fixed Contact
2 Moving Contact
3 Top Cover
4 Screw-Top Cover
5 Return Spring
6 Coil and Frame
7 End Cap
Figure 3-18 - Main Contactor

3-25
Yale
RELAYS-GENERAL
The 24", 60", 150", 212", and 10° , relays form a logic network to 5. Install the wires on the relay.
enable traction and limit speeds under varying height and
steering conditions, the 1.2 mph speed limit is achieved by 6. Install the drive unit compartment cover, close the drive
switching a 2.7K ohm resistor in series with the throttle pot unit compartment doors and reconnect the battery.
circuit. The 2.2 mph speed limit is achieved by switching a 6.8K
ohm resistor in parallel with the 2.7K ohm resistor, effectively 7. Test the truck for proper operation.
switching 1,9K ohm in series with the throttle pot.
TESTING DIODE BLOCK
Traction is enabled by a logic network of the 10° , 150", and 212"
relays, with the logic network connecting the EPS brake output
If the diode block is suspected of not functioning properly, the
to the traction enable pin of the Curtis/PMC traction controller.
diode block should be tested for continuity.
10° Relay - The 10° relay is part of the logic networks
Use an ohm meter and test for low resistance between wires 75
mentioned above. The 10° relay coil is energized by the EPS
and 76.
controller when the steer tire is within 10° maximum of straight
travel
Reverse the leads. The reading on the ohm meter should read
24" Relay - The 24" relay is part of the logic networks infinity.
mentioned above. The 24" relay coil is energized by the 24 inch
proximity switch when the fork elevation is 24" or below.
REPLACING DIODE BLOCK
60" Relay - The 60" relay is part of the logic networks
mentioned above. The 60" relay coil is energized by the 60 inch 1. Open the drive unit compartment doors. Disconnect the
proximity switch when the fork elevation is 60" or below. battery. Remove the drive unit compartment cover
2. Identify and remove the wires from the diode block.
mentioned above. The 150" relay coil is energized by the 150
inch proximity switch when the fork elevation is 150" or below.
3. Remove the mounting screws.
On trucks with maximum fork height below 150", the relay coil is
energized by a jumper which replaces the 150" proximity
4. Mountthe replacement diode block on the electrical panel.
switch.
Install the mounting screws.
mentioned above. The 21 2" relay coil is energized by the 21 2 5. Install the wires on the diode block.
inch proximity switch when the fork elevation is 21 2" or below.
On trucks with maximum fork height below 21 2", the relay coil is 6. Install the drive unit compartment cover, close the drive
energized by a jumper which replaces the 212" proximity unit compartment doors and reconnect the battery.
switch.
7. Test the truck for proper operation.
RELAYS-REMOVAL AND INSTALLATION
1. Open the drive unit compartment doors. Disconnect the

battery. Remove the drive unit compartment cover.
2. Tag and remove the wires from the relay.
3. Remove mounting screws.
4. Mountthe relay on the electrical panel. Installthe mounting

screws.
3-26
Yale
TESTING POWER STEERING SOLENOID 2. Identify and remove the wires from the solenoid.
If the solenoid is suspected of not functioning properly the 3. Remove the capscrews retaining the solenoid on the
solenoid should be tested for shorts. electrical panel.
Identify and disconnect all the wires. Use an ohm meter to test 4. Assemble the replacement on the electrical panel.
for resistance across the secondary terminals. A reading of 50
ohms ± 10% should be obtained. If the ohm meter reads either 5. Install the wires on the solenoid.
zero ohms or infinity the solenoid must be" replaced.
6. Install the drive unit compartment cover, close the drive
unit compartment doors and reconnect the battery.
REPLACING POWER STEERING SOLENOID
1. Open the drive unit compartment doors. Disconnect the

7. Test the truck for proper operation.
battery. Remove the drive unit compartment cover
COIL RESISTANCE
50 OHMS
±10%
TIPS NOT SERVICEABLE

(TOTALLY ENCLOSED CASE)
GAP NOT ADJUSTABLE
SINGLE POLE -
SINGLE THROW NA00419
Figure 3-19 - Power Steering Solenoid
3-27
Yale
BDI OR STEERING EMERGENCY KEY

VOLTAGE INDICATOR DISCONNECT SWITCH
GAUGE / , / ÿ
SLACK
CHAIN
LIGHT
LIFT AND
LOWER
CONTROL
DIRECTION/
SPEED
CONTROL
HORN
SWITCH
NA00742
Figure 3-20 - Instrument Panel Arrangement
ACCELERATOR POTENTIOMETER-REMOVAL AND 6. Remove the setscrew retaining the gear on the
INSTALLATION potentiometer shaft and remove the potentiometer. The gear
will come off as the potentiometer is removed.
WARNING: The operator platform can move
abruptly and cause an injury when any Lift or 7. Install a new potentiometer into the opening of the
Lower buttons are accidently pushed. Fully lower potentiometer support. Align the potentiometer with the
the operator platform, remove the key from the key switch and locating pin on the support. The gear must be held betweenthe
install a tag on the instrument panel stating "DO NOT supports so that the gear is placed on the potentiometer shaft
OPERATE". as the potentiometer is installed.
Disconnect the battery connector to prevent operation of the 8. Move the gear so that the match marks are aligned. Install
hydraulic system or electrical shock and possible injury. the setscrew to retain the gear on the potentiometer.
1. Disconnect the battery. 9. Install the potentiometer support. Adjust the accelerator
potentiometer. Refer to ACCELERATOR POTENTIOMETER
2. Remove the four capscrews that fasten the instrument ADJUSTMENT.
panel cover to the cowl.
10. Connect electrical plug X-1 .
3. Match mark the gear mounted on the potentiometer and
the direction/speed control handle. 11 . Install the instrument panel cover.
4. Disconnect electrical plug X-1 . 12. Connect the battery and test the operation of the truck.
5. Remove the two pan head screws retaining the

potentiometer support to the mounting bracket.
3-28
Yale
FORWARD AND REVERSE SWITCHES-REMOVAL AND LIFT AND LOWER SWITCHES-REMOVAL AND
INSTALLATION INSTALLATION
1. Disconnect the battery. 1. Disconnect the battery.
2. Removethe four capscrews retainingthe instrument panel 2. Disconnect electrical plug.

to the cowl.
3. Remove the two pan head screws retaining the shaft
3. Disconnect electrical plug X-1 . support to the mounting bracket.
4. Remove the two pan head screws retaining the 4. Disassemble the switch, either lift or lower from the shaft
potentiometer support. support, Identify and disconnect the electrical wires.
5. Disassemble the switch, either forward or reverse, from 5. Installthewirestothe properterminals. Installthe switch in
the potentiometer support. Identify and disconnect the the shaft support,
electrical wires.
6. Installthe shaft support on the mounting bracket. Check to
6. Install the wires to the proper terminals. make certain that the gears are properly aligned.
7. Install the potentiometer support. Check the accelerator 7. Connect the electrical plug.
potentiometer adjustment. Refer to ACCELERATOR
POTENTIOMETER ADJUSTMENT. 8. Install the instrument panel cover.
NOTE: The only adjustment forthe forward or reverse switches 9. Connect the battery and test the operation of the truck.
is the neutral position of the pinion gear. The position of the
pinion gear is set during replacement or adjustment of the
accelerator potentiometer.
8. Connect the electrical plug X-1 .

9. Install the instrument panel cover.
10. Connect the battery and test the operation of the truck.
TROUBLESHOOTING - ACCELERATOR SWITCH

SYMPTOM ANALYSIS CORRECTION
Handle is free and does not return to Broken return spring likely. Replace return spring.
center.
Device Binds. Mounting screws too tight. Loosen mounting screws just enough to
eliminate binding.
Operating characteristics different in Potentiometer not centered. Center potentiometer.
forward and reverse.
Snap switch contacts welded or poor a. Contact material worn too thin. a. Replace switch.
switch life. b. No coil Suppression. b. Replace contactor coils.
Replace switch.
Lack of speed control. a. Faulty potentiometer. a. Replace potentiometer.
b. PMC control problem. b. Check for loose connections.
Then check PMC control for problem.
Switch contacts do not make, break or a. Contact worn or welded a. (See Snap Switch Contacts Welded.)
carry load properly. b. Replace cam.
b. Cam may be deformed.
3-29
Yale
ITEM DESCRIPTION
1. CONTROL HANDLE
2. HANDLE WELDMENT
3. ROLL PIN
4. WASHER
15 16 U 5. NYLON BEARING
6. BRACKET
7. WASHER
8. HEX HEAD BOLT
9. SHAFT
10. SCREW
11. POTENTIOMETER
12. BRACKET
13. SCREW
14. GEAR-SPUR
HORN SWITCH
15. GEAR-SPUR
16. PIN-SPRING
ACCEL
17. WASHER
18. SPRING RETURN
19. CAM
n 20.
21.
22.
PIN-SPRING
BUSHING
STANDOFF
23. NUT PLATE
#5191146-00 24. INSULATOR
25. SWITCH
26. PLATE SPACER
Figure 3-21 - Gear Tooth Contact Pattern
3-30
Yale
HORN SWITCH-REMOVAL AND INSTALLATION 6. Connect the battery.

1. Disconnect the battery.
KEY SWITCH-REMOVAL AND INSTALLATION
2. Remove the four capscrews that fasten the instrument
1. Remove the instrument panel. See INSTRUMENT
PANEL-REMOVAL AND INSTALLATION.
3. Disconnect the electrical plug X-1 .
2. Identify and disconnect the electrical wires to the switch.
4. Remove the four capscrews that fastens the horn switch
3. Remove nut retaining the key switch to the instrument
cover.
panel.
5. Disassemble the switch from the mounting bracket.
4. Remove the key switch.
Identify and remove the electrical wires.
5. Install key switch. Make certain the switch is properly
6. Install the switch on the mounting bracket and install the
aligned before tightening the retaining nut.
wires to the proper terminal.
6. Connect the wires to the proper terminals.
7. Install horn switch cover.
7. Install the instrument panel. See INSTRUMENT PANEL
8. Reconnect electrical plug X-1
REMOVAL AND INSTALLATION.
9. Install instrument panel cover on the cowl.
POWER DISCONNECT SWITCH-REMOVAL AND
10. Reconnect battery. Turn on key and test the horn switch INSTALLATION
for proper operation.
--
INSTRUMENT PANEL-REMOVAL AND INSTALLATION
2. Identify and disconnect the electrical wires to the power
INSTRUMENT PANEL disconnect switch.
T BATTERY SLACK CHAIN
I INDICATOR KEY SWITCH LIGHT
-13M- 3. Remove the switch from the instrument panel.
14
4. Install the switch.
STEERING SI
O
POWER 5. Connect the wires to the proper terminals.
INDICATOR CD O, DISCONNECT
CD LU I
X-14 SI 6. Install the instrument panel. See INSTRUMENT PANEL

<8 REMOVAL AND INSTALLATION.
KT-n-lV 10G 13M
105 13E
NA00422
STEERING INDICATOR GAUGE-TESTING
The steering indicator gauge can betested usingthe schematic
Figure 3-22 - Instrument Panel Schematic and chart below.
SIGNAL INPUT CHAR T
2. Remove the four capscrews that fasten the instrument

B*>\
/
TERM. I
+DC 90*
60*
RIGHT
RIGHT
r
*
1. 25 VOLTS
I.66 VOLTS
ÿ _ TERM. 2
COM 30* RIGHT = 2.08 VOLTS
3. Remove the four screws that fasten the instrument panel 0* STRAIGHT = 2.5 VOLTS
TERM. 3
to the cowl. s
? ARM 30* LEFT = 2.91 VOLTS
60* LEFT = 3.33 VOLTS
4. Align the instrument panel on the cowl and install the
capscrews. -> -
90* LEFT = 3.75 VOLTS
Figure 3-23 Test Steering Indicator Gauge

NA00423
5. Install the instrument panel cover.
3-31
Yale
STEERING INDICATOR GAUGE REMOVAL AND BATTERY DISCHARGE INDICATOR-RESET AND

INSTALLATION DISCHARGE ADJUSTMENTS
1. Remove the instrument panel. See INSTRUMENT 1. With a screwdriver rotate both Reset and Discharge
PANEL-REMOVAL AND INSTALLATION. adjusting screws counterclockwise until completely stopped.
2. Identity and disconnect the wires. 2. Rotate Reset screw clockwise untilslot in screw is aligned
with area "B".
3. Remove the nuts and lockwashers retaining the indicator
gauge to the instrument panel. 3. Rotate Discharge screw clockwise until slot in screw is
aligned with area "L".
4. Install the gauge on the instrument panel. Make certain the
gauge is properly aligned.
5. Install the wires on the proper terminals.
6. Install the instrument panel. See INSTRUMENT PANEL

VOLTMETER (STANDARD)-REMOVAL AND RESET <e y DISCHARGE

INSTALLATION NA00424

2. Identify and remove the wires.

Figure 3-24 - Reset and Discharge Settings
3. Remove the nuts and washers retaining the gauge to the
instrument panel. SLACK CHAIN INDICATOR LIGHT-REMOVAL AND
INSTALLATION
4. Installthe gauge on the instrument panel. Make certainthe
gauge is properly aligned.
PANEL- REMOVAL AND INSTALLATION.
5. Install the wires on the proper terminals.
2. Identify and disconnect the wires.
6. Install the instrument panel. See INSTRUMENT
3. Remove the light assembly from the instrument panel.
4. Install light into instrument panel.
BATTERY DISCHARGE INDICATOR
(OPTIONAL) - REMOVAL AND INSTALLATION 5. Connect the wires to the proper terminals.
6. Install instrument panel. See INSTRUMENT PANEL
2. Disconnect the fifteen-pin plug.
FOOT SWITCH-REMOVAL AND INSTALLATION
3. Disassemble the hex, nuts and washers holding the
1. Remove the cover of the foot switch assembly.
retaining bracket. Remove bracket and gauge from the
instrument panel.
2. Installlabels on the wires of the switch so thatthe wires can
be correctly connected during installation. Remove the wires
4. Make certain that the reset and discharge adjustments
from the switch terminals.
have been made. Install the gauge in the instrument panel.
3. Remove the screws that fasten the switch in the housing
5. Connect the fifteen-pin plug.
and remove the switch.
6. Install the instrument panel, See INSTRUMENT
4. Installthewires as labeled during removal. Installthe wires
on the same terminals of the replacement switch and installthe
switch in the housing. Install the cover.
3-32
Yale
6. Connect the wires to the switch terminals as marked

during removal.
SWITCH
BRACKET
|
i
I
ÿ
= >\ -SWITCH
CHAIN
Z7* =
§
ÿ Vr 1 ANCHOR
1. SWITCH ASSEMBLY
2. MOUNT SCREW s
ÿ l l \
)
1/ NA00426
Figure 3-25 - Foot Switch

LOOSE CHAIN SWITCH-REMOVAL AND INSTALLATION
The loose chain switches are at the chain anchors on the mast
Figure 3-26 - Loose Chain Switch
side of the operator platform.
LIMIT SWITCH-REMOVAL AND INSTALLATION
WARNING: To replace the loose chain switches, /\ WARNING: The operator platform can move
/ 1\ the operator platform must be raised to provide / 1\ abruptly and cause an injury when any Lift or
UJLJ access. The lowering of the operator can cause an Lower buttons are accidentally pushed. Fully lower
injury. The operator platform must have a support or a chain to the operator platform, Removethe key from the key switch and
prevent the operator platform from lowering. install a tag on the instrument panel stating "DO NOT
OPERATE".
1. Raise the operator platform for access to the loose chain
1. Raise and block the mast and operator platform high
switches. Block the operator platform or use chains to prevent
enough to gain access to the 24 inch limit switch located on a
the operator platform from lowering. The chains must be
bracket welded to the bottom of the mast, The 150 inch limit
fastened to the operator platform and to a part of the mast that
switch is located on a bracket welded to the right side of the
can not move.
mast (as viewed from the operator platform) approximately 4ft.
from the floor, It is not necessary to raise the mast to remove
this switch.
3. Install labels on the wires for correct connection during 2. Remove the top cover and open the compartment doors.
installation. Remove the wires from the switch terminals.
3. Disconnect the battery. Disconnect limit switch connector.
4. Remove the nuts that fasten the switches to the bracket
and remove the switches. 4. Loosenand remove hex nut retaining switch on the front of
the bracket. Remove the switch from bracket.
5. Install the replacement switch on the bracket. Attach the
switch to the switch bracket. Adjust the switch to provide proper 5. Reverse above procedure to assemble and install.
contact of the cam to the chain anchor. Repeatthe operation for
the second switch. 6. When installing the limit switch, the distance between the
target and the sensor should be 0.10 inches.
3-33
Yale
DRIVE AND HYDRAULIC PUMP MOTORS

Routine Maintenance
1. Periodically blow out all motors with clean, dry

compressed air.
2. Check for oil or dirt in motor.
3. Check bearings for retention of lubricant.
4. Check to make sure pole pieces are tight.
5. Inspect brushes. Brushes must be replaced when they are
£>•
I
worn to one halt their original length. When replacing brushes,
make certain ALL brushes are changed and properly seated.
Brushes must be able to move freely. Make sure they are not
too tight in the brush holders.
6. Visually inspect the commutator. Commutator should be

smooth, with a rich chocolate brown color.
7. Never run the motor at full speed for more than a few
seconds without a load (such as with the drive wheels raised off
the floor). A series wound DC motor will continue to accelerate
until it exceeds its designed maximum RPM, and self-destruct.
Figure 3-27
NA00427
- 24" Limit Switch A I\

WARNING: Make sure motor covers, if used, are
replaced before operating truck.
8. When ordering motor parts, be sure to state both model

and serial numbers of truck, model number of motor and
voltage.
Preventive Maintenance
Preventive maintenance on electric motors is recommended to

be performed at 200-hour intervals under normal operating
conditions.
Under heavy duty, dusty and dirty conditions, preventive

maintenance on electric motors must be performed more
frequently, depending on the conditions andthe environment in
which the electric truck is running.
Proper electric motor preventive maintenance win aid in

detecting many problems before they become serious.
Maximum performance from electric motors and reduced

maintenance costs can beobtained by performing the following
periodic preventive maintenance checks-which can be
performed on motors while in the truck.
1. Disconnect battery while checking electrical connection.
NA00428
2. Open cover for access to drive motor.
3. Open cover for access to hydraulic pump motor.

Figure 3-28 - 150" Limit Switch
3-34
Yale
Cleanliness CAUSES OF MOTOR FAILURE

Overload
Electric motors must be kept clean and dry internally and
externally; free of dust, dirt, grease, oil, chemicals, moisture,
water, carbon dust, and metallic chips. Blow off contamination
Motors have a specific rating of voltage and current at which
they are designed to operate. Should a motor be subjected to a
with compressed air. If internal oil or grease contamination is
severe overload for substantial periods of time, overheating will
present, the motor should be disassembled and the individual
result. Pushing loads, working on ramps of too steep a grade,
parts washed in a suitable cleaning solvent.
and attempting to lift loads greater than the capacity of the truck
are just a few overload conditions. The end result of this
Connections
overheating is the throwing out of solder in the commutator
riser, and bearing failure due to excessive heat. Also thrown or
Check every screw, bolt, and nut for tightness. Especially
lifted commutator bars may occur, or insulation breakdown may
check the pigtails of the brushes, the brush holders, power lead
connections, and field jumper connections.
occur.
Shock Loading
Discoloration and Burn Marks
Shock loading can result from severe (stiff) plugging of the drive
Discoloration and burn marks usually indicate that the motor or
motor. This will cause excessive current draw, as the motor at
certain components of the motor have been overheated -due
the time of plugging is at stall point. Breaking of the armature
to stalled conditions, loose connections, insulation
shaft could result from plugging.
break-down, or contamination. If signs of overheating are
present, determine the cause and perform necessary repairs.
Short in Field Coils
The commutator should be smooth, free of burn marks, and
have a chocolate brown color. Inspect the brushes, the brush
A short in the field coil or coils causes excessive current draw,
holders, the brush springs, and the insulation for discoloration.
again resulting in too much heat. When the truck runs faster
than normal, but with little or no torque, it is an indication of a
Brushes
short in the field coils.
Brushes should be inspected to make certain they are not worn
to less than one half original length. The brushes must be free to
Short in Armature
move in the brush holders and should not have too much
A shorted armature or coils will increase the current draw. A
clearance. Check the brush springs for proper tension. If the
visual inspection of the commutator will show burn marks on
brushes have to be replaced, use only specified brushes for a
the commutator bars connected to the shorted coil or coils.
specific motor.
Short Brushes
Commutator
Short brushes cause arcing on the commutator and excessive
Check that carbon dust and other foreign matter is not caked on
heat. In addition to brush replacement, turning and
the undercut mica between the copper bars.
undercutting of the commutator may be all that is required,
provided the damage is not too great. Check for damage from
The mica separators should be below the segment face. There
shunts hitting the commutator.
should not be any thrown solder from the armature risers.
Check that the brazed connections are not loose.
High or Low Commutator Bar
If grease, oil, or corrosive materials are present, wipe clean with
a cloth and wash with soap and water. Clean up the surface of
When one of the bars is protruding above or lying below the
normal diameter of the commutator, the result is excessive
the commutator with a commercially available commutator
brush wear and arcing of the brushes. Usually a clicking sound
stone if necessary. Take the necessary steps to prevent
will be heard when armature is rotating.
reappearance.
Open Circuit
Bearings
An open circuit in the field or armature coils of the motor.
Check bearings for noise and rough spots while the armature is
rotating. Inspect the bearings for damaged seals. Only original
Low Battery Voltage
equipment sealed bearings with high temperature lubricants
should be used if replacement is required. Do not be misled by
Low voltage causes excessive current draw and increased
identifying numbers on the bearings. The high temperature
heating. Also, accelerated brush wear may occur.
lubricant is not specified in the identification number.
3-35
Yale
Eccentricity of Commutator A motor drawing excessive current can usually be identified by

two dark burn marks on the commutator 90° or 180° apart, if a
Eccentricity of commutator causes rapid brush wear, excessive motor draws too much current due to excessive ramp
sparking of brushes, and increased heating. operation, pushing loads, or being stalled, heat damage will
occur.
Over-Speeding
Current draw is measured with a shunt type amp meter in series
Over-speeding of the motor by operating with no load (drive with the motor. The meter should be capable of reading 600
wheels off floor) for more than 30 seconds, or pushing ortowing amps. A 600 amp shunt meter suitable for this purpose is
of the truck at more than 5 mph will result in failure of the available through your Yale Dealer under part number
armature, 5180968-26. Since current draw is measured with the shunt
meter wired in series with motor circuit, you must "break" the
circuit to insert the meter, This will require disconnecting the
MOTOR TESTS
main power cable to the motor and connecting the meter in line
When testing electric motors for grounds and shorts in the at this point. In most cases this will require the use of a jumper
truck, disconnect armature and field leads from the motor. Use cable between the meter and the truck terminal post. This
an ohmmeter, RX 10 or RX 100 scale, to check for grounds or jumper should be made up from the same type and gauge cable
shorts in the motor. as the power cable it is replacing, and should be kept as short
as practical.
The ohmmeter should indicate:
Meter Connections for Current Draw Tests
1. A closed circuit between the armature terminals.
Meter connections for current draw tests must be made in the
2. A closed circuit between the field terminals. primary power circuit for the motor being tested. This can be
done in several ways. First, some battery cable adapters are
3. Infinity between the motor housing and the armature available so that you can unplug the battery connection, insert
terminals, with meter on high resistance scale. the adapter, and plug the battery connections into either side of
the adapter. The meter is then connected to the adapter. A
4. Infinity between the armature and the field terminals second variation of this is disconnecting the main power lead
(series wound motors only). from the battery connector at the main fuse and connecting the
meter in series at this point. Both of these methods allow you to
If ohmmeter readings are obtained that indicate a problem, check the current draw of virtually any motor in the truck from
further checks should be made by a qualified electric motor one point. You must, however, be careful that you don't readthe
repairman to find the problem and make the necessary repairs. current for more than one motor. For instance, if measuring
drive motor current, you must isolate the power steering motor
Excessive Current Draw (if equipped) by either disconnecting the power steering relay,
or by inserting an insulator between the power steering relay
Excessive current draw is usually caused by shorts in the contactors. If you do not do this, you will be reading both the
system allowing current to follow paths that weren't intended. power steering and drive motor currents at the same time.
Sometimes excessive current draw can be caused by
mechanical malfunctions such as worn bearings, misaligned WARNING: If operating a truck with the power
parts, improper lubrication, and light brake adjustments. Other steering motor disconnected, be aware that
factors include operator misuse such as operating on steep steering effort may be greatly increased and
grades, overloading thetruck and pushing loads. The condition steering response may be decreased accordingly. Operate the
of the battery can contribute greatly to excessive current draw. truck only in a test area requiring little or no maneuvering.
When the battery charge and voltage are low, more current is
needed to perform the same task. Since the power required to A third method would be to connect the meter directly to the
move a load is Power = Volts x Amperage, as the battery motor power cable. Be sure to pick up the power circuit at a
voltage goes down, the amperage must increase to maintain point where both the armature and field coils are included.
power.
Excessive Resistence
Measuring Current Draw
Excessive resistance is usually caused by loose or corroded
When troubleshooting the electrical system of a battery terminal connections, poor solder joints and dirty or corroded
powered industrial truck, you will need to know the specified contacts. Incorrectly sized wiring and poor crimp connections
current draw of the motor being tested as well as the actual of terminals can also cause excessive resistance.
current draw during the test. It a motor draws too much current,
excessive heat is created, resulting in damage to the When too much resistance exists in a circuit, overheating and
commutator, brushes, armature, and related components. sluggish or erratic operation will occur .
3-36
Yale
The best way to rest for excessive resistance is to measure the stoning, clean grease and oil from the commutator using a cloth
voltage drop across the suspected component or wire. A wire, saturated with a suitable solution. After stoning, the
fuse, switch or contact tip should have very little or no voltage commutator should be smoothed with a very fine grade of
drop. Therefore, by checking voltage drop, it can bedetermined sandpaper, and then polished by using the back of the paper.
if resistance is too high by a highvoltage drop. A voltage drop of When the commutator is too rough or eccentric to be stoned
0.10 to 0,30 volts is acceptable. A higher reading indicates down, it is advisable to turn the commutator on a lathe.
excessive resistance.
4. Undercut the mica using one of the several types of
Brush Springs undercutting tools available on the market. Undercutting is
usually done to a depth of 0.047 inches. It is recommended to
The brush springs should be inspected visually. If the springs slightly bevel the segment corners.
are found to be broken or discolored, they must be replaced. Be
certain to replace the springs with the recommended spring 5. A commutator that is badly grooved should be ground or
listed in the parts manual. turned the same as for roughness or eccentricity. After the
commutator has been conditioned, make sure that it is
completely cleaned out by suction (preferred) ,or by blowing out
DRIVE MOTOR INSPECTION
with clean, dry compressed air.
1. Check commutator for grounds, shorts, or uneven wear.
2. Check bearings; replace if worn or damaged. RIGHT WAY

Using undercutting tool
3. Check field coils. removes all traces of insulator
along the conducting slots.
4. Check brush holder/assembly.
INSULATOR
5. Replace lock nuts on each end of armature shaft. CONDUCTOR
Preparation of Drive Motor Commutator WRONG WAY

Using hacksaw may leave
A ridges of insulator along the
1. In order to ensure the best possible operation from edges of the conducting slots,
newly-fitted brushes, the commutator should be in good
condition. INSULATOR
V causing arcing, chatter, and
rapid brush wear.
Check the commutator for:

CONDUCTOR NA00429
I
a. Dirt or other foreign matter.
Figure 3-29 - Undercutting Commutator
b. Eccentricity: Fitting Motor Brushes (Motor Removed)
0.002 inches max. runout from shaft - Motors up to 7.312 1. Care taken to ensure the best possible commutator and
inches Diameter. brush running conditions, mechanical and otherwise, will pay
dividends along improved commutation.
0.003 inches max. runout from shaft - Motors larger than
7.312 inches Diameter 2. Brushes of different qualities should never be run together
on the same commutator. Using brushes of improper
c. High or low bars, roughness or burning.
compound, or brushes otherthan those originally specified and
d. High mica. manufactured for a specific motor, will cause commutator
damage.
e. Grooving of commutator.
3. Before installing brushes, inspect the brush holders inside
If any of the above conditions exist, they should be remedied as
and out for burned spots. Make sure that the brush pigtails are
follows:
properly secured in the brushes, and that the brushes move
freely in the brush holders.
2. Clean the commutator by holding a piece of dry canvas or
other hard non-linting material, which is wound around and
4. Fit the new brushes to the commutator surface by using a
securely fastened to a piece of wood, against the commutator.
strip of fine sandpaper placed between the face of the brush
and the commutator (sand surface against brush).Use several
3. If the eccentricity or roughness is not too great, it may be
one direction strokes of the sandpaper, pulled in the direction of
possible to polish the commutator with one of the several
the commutator rotates with the forward direction of the truck
varieties of dressing stones available on the market. Before
(drive motor), and in the direction in which the commutator
3-37
Yale
rotates while hoisting (hoist pump motor). Only the pressure of DRIVE MOTOR-REMOVAL AND INSTALLATION
the brush should be on the sandpaper when it is fitted in this
matter. Make sure that the complete surface of the brush rides
on the cleaned-up surface of the commutator.
2. Open drive unit compartment.
5. Following the installation of new brushes, the motorshould
3. Tag and disconnect power cables to the motor and the
be blown out with clean, dry compressed air.
wires to the electric brake.
DRIVE MOTOR BRUSH-REMOVAL AND INSTALLATION 4. Remove bolts mounting the motor to the drive unit.
(MOTOR INSTALLED)
5. Remove the drive motor with the brake assembly in place
1. Disconnectbattery.andopendriveunitcompartmentdoor.
using a sling and proper lifting equipment. Refer to Section 5 of
this manual for brake disassembly.
2. Remove screws securing motor cover plates, if equipped.
CAUTION: Be sure to cover the drive unit opening
3. Note position of brush and wire assemblies before
so that debris does not enter it.
removing. When installing brush set, be certain to place brush
set and wires in same position as removed.
6. Reverse the procedure to install the drive motor.
4. Loosen screw and washer securing brushwire to terminal .
Remove brush springs and brush set.
DRIVE MOTOR- DISASSEMBLY AND ASSEMBLY
5. Reverse above to install. Refer to Fitting Brushes 1. Clean and punch mark (or scribe) brake assembly, drive
paragraph in this section. and commutator end heads, and motor field ring housing to
simplify assembly of the motor.
DRIVE MOTOR BRUSH HOLDER-REMOVAL AND
INSTALLATION (MOTOR INSTALLED) 2. Remove brushes and brush spring assemblies.
1. Disconnect battery, and open drive unit compartment door. 3. Remove elastic stop nut and gear and shims, if necessary,
using a socket and impact wrench.
2. Remove Brush assemblies (Refer to brush removal
section). NOTE: When same motor pinion or gear is used, replace shim
or shims in same position as removed. When a new gear set
3. Scribe motor field ring housing and commutator end head is used, refer to Drive Unit Section 4 for gear setting.
to make certain end head is installed in same position as
removed. 4. Remove screws securing commutator end head. Remove
end head. It may be necessary to use a pullerto remove. Do not
4. Tag and disconnect drive motor wires from terminals on force, or damage to the end head may result.
end head.
5. Remove screws securing drive end head. Tap end head
5. Remove hex head screws securing end head to field ring. loose using a plastic hammer and remove, complete with
armature.
6. Remove end head assembly.
IMPORTANT: Be extremely careful not to damage the field
NOTE: It may be necessary to use a puller to start the end head coils, pole pieces or armature when removing.
off the bearing when removing. Do not force, or damage to the
end head may result. 6. Remove the oil seal and the outer snap ring retaining the
armature shaft. Remove the inner snap ring retaining the end
7. Remove screws securing brush holder assembly to end head.
head. Inspect all parts for wear or damage, and replace when
necessary. 7. Separate drive end head from armature. The bearing end
head will come off with the bearing. It may be necessary to use
8. Reverse above to install. Be sure the new brush holders a puller to remove. Do not force, or damage to the end head
are rigid, not sloppy, and there are no loose rivets. may result.
NOTE: Do not drive on end head when installing. Lightly tap 8. Remove screws securing brush holder assembly to
using a plastic hammer. commutator end head. Remove brush holder assembly.
3-38
Yale
9. Remove bearings from end heads if necessary. Refer to

Apply Locite 609 (Yale 501702906) to this
Inspection.
surface after snap ring has been installed.
10. Replace field coils when necessary, refer to Inspection.
11. Install a snap ring into the slot provided in the armature
shaft.
12. Carefully apply Loctite 609 (Yale 501702906) to the area

above the snap ring when the commutator bearing will be
installed. The Loctite 609 will fill the gap between the bearing
>—
and the shaft.
13. Install the bearing on the shaft. There should not be any
force against the snap ring when the bearing is installed. The NA00430
snap ring is used to locate the bearing.
Figure 3-30 - Commutator End of Armature Shaft
CAUTION: Make certain that none of the Loctite
NOTE: LOCTITE 609 TAKES APPROXIMATELY 10
609 is allowed to get onto the armature or in the
MINUTES TO SET UP AND 24 HOURS TO FULLY CURE.
bearing . Wipe off any excess after the bearing is
installed.
14. Continue to assemblethe motor in the reverse steps of the
disassembly. Install a new elastic stop nut to secure the motor
pinion gear.
3-39
Yale
26
24
18
Figure 3-31 - Drive Motor
3-40
Yale
HYDRAULIC PUMP AND POWER STEERING MOTORS- 3. If mechanical or electrical failure occurs, first check for
MAINTENANCE INSTRUCTIONS proper electrical connections, fusing, or unusual binding of
mechanical load. Starting and accelerating torques of D.C.
Vendor supplied pump motors are generally used where
motors are considerably higher than the full load torque of the
smaller pump requirements are found. Typical vendor supplied
motor. Care should be taken to prevent damage to driven
motors include those from General Electric, Ohio Motor, etc.
machinery as a result of the higher starting and accelerating
Service requirements are similar for all DC motors, but several
torques. Perform motor tests as outlined in this section.
differences should be observed.
1. Some vendor supplied motors require removal of the BRUSH REPLACEMENT- HOIST PUMP MOTORS
commutator end head to replace the brushes (see following
1. Disconnect battery. Open the drive unit compartment
procedure).
doors. Remove the drive unit compartment top cover.
2. Many vendor supplied motors have an integral cooling fan
2. Remove the cover from the commutator end head.
on the armature shaft. This means that the armature can only
be removed through the drive end of the motor, since the fan
3. Remove the brush springs and remove the brushes.
would interfere with the field coils if you try to remove it through
the commutator end.
4. Inspect brushes for excessive wear.
3. Some smaller motors, particularly power steering motors,
5. Reverse steps above to assemble.
are of the permanent magnet type. This means that the field
coils are replaced with permanent magnets. These require two
special considerations when being serviced: HOIST MOTOR-REMOVAL AND INSTALLATION
a. Only service these motors in clean areas, since the 1. Disconnect the battery.
magnets will attract any ferrous metal particles once the
armature is removed. Foreign objects will destroy the 2. Remove the pump mounting bolts.
motor if not removed.
3. Move the hoist pump away from the motor.
b. Since the permanent magnets exert a relatively
strong pull on the armature shaft, keep your fingers clear of
4. Identify and remove the power cables.
possible pinch points when removing or installing the
armature.
5. Remove the four hex, head screws securing the hoist
motor to the truck frame.
4. Do not attempt to press the armature shaft out of the
armature on vendor supplied motors withoutfirst checking your
6. Reverse the steps above to install the motor.
service parts manual. Some motors do not have a separate
serviceable armature shaft, and attempting to press the shaft
out will destroy the armature. HOIST MOTOR-DISASSEMBLY AND ASSEMBLY
1. Punch mark end heads and frame to ensure correct
5. Never run a pump motor for more than a few seconds
placement of end heads when reassembling the motor.
without the pump attached and connected. Series wound DC
motors, without a load, will continue to accelerate indefinitely
2. Loosen screw securing cover band and slide off band.
until they exceed their designed maximum RPM, at which point
they will self-destruct. Remove brush springs and brushes.
3.
GENERAL INFORMATION 4. Remove two screws and nuts securing the stator and
commutator end head together. Remove the cap screws and
1. Lubrication - Pre-lubricated ball bearings are supplied. nuts retaining the drive end head and the commutator end head
Replace only with original equipment. Press only on the inner to the stator. Carefully remove the commutator end head.
race when installing bearings on shaft. Remove brush ring and brushes.
2. Motor brushes need periodic inspection and replacement 5. Remove drive end head. Remove the armature from the
as wear indicates. Brush wear is greatly influenced by stator.
individual application, so it is recommendedthatthe brush wear
be checked often to determine future required inspection. IMPORTANT: Be extremely careful not to damage the field
When the brushes are worn to half their original length, they coils, pole pieces or armature when removing.
should be replaced.
3-41
Yale
14
13
10
ITEM DESCRIPTION
1 Drive End Head
2 Bearing
3 Snap Ring
4 Field Coil Kit
5 Fan
6 Armature Assembly
7 Brush
8 Brush Spring
9 Brush Box and Plate
10 Lead Arm Kit
11 Bearing
12 Wavey Washer
13 C.E. Head
14 Brush Cover Plate
Figure 3-32 - Master Drive Unit Parts

3-42
Yale
6. If field coil must be replaced, remove pole shoe screws and 2. Match mark the commutator end head and the stator
terminal screws, if necessary, and remove field coils. assembly.
7. Inspect all components and the brushes. Replace as 3. Remove the socket head thru bolts. Remove the
necessary. Refer to BRUSH REPLACEMENT in this section. commutator end head and bearing.
8. Using compressed air, blow out motor. Thoroughly clean 4. Remove the brushes. Inspect the brushes and springs.
and replace any worn parts.
5. Reverse the above steps to assemble.
9. Reverse steps above to assemble. Make sure armature
turns freely with a few thousandths end play.
POWER STEERING MOTOR-DISASSEMBLY AND
ASSEMBLY
POWER STEERING MOTOR-REMOVAL AND
1. Remove the power steering motor. See POWER
INSTALLATION
STEERING PUMP-REMOVAL AND INSTALLATION.
1. Disconnect the battery. Open the drive unit compartment
doors. 2. Mark both end heads and stator assembly to ensure
proper alignment at assembly. Remove the socket head thru
2. Remove, identify and disconnect the power cables. bolts and remove commutator end head and bearing.
3. To service the power steering pump, remove the mounting 3. Loosen hex screws and washers retaining the brushes.
screws and nuts retaining the motor to the speed reduction Remove the brush set and brush spring. Check nuts and
gear bolt. Remove the motor from the truck as a complete unit. jumper bar from terminals.
4. Reverse the above steps to install the motor. 4. Remove drive end head and bearing.
5. Removebrush ring assembly. Remove armature and shaft

BRUSH REPLACEMENT-POWER STEERING MOTOR
assembly from stator assembly.
CAUTION: These motors should be
/f\ disassembled in an extremely clean area free of 6. Use compressed air to clean armature, stator and end
any ferrous metal chips as the magnet pole pieces heads. Inspect all components. Replace all defective or worn
will attract them and cause serious damage to motor. parts.
7. Reverse above steps to assemble.

1. Disconnect battery. Open drive unit compartment doors.
Remove the drive unit compartment cover.
3-43
Yale
DESCRIPTION
1. ARMATURE
2. FAN
3. BOLT
4. DRIVE END PINION
5. FAN COVER
6. BEARING
7. KEY
8. ROLL PIN
9 STATOR
10. COMMUTATOR END HEAD
11. BRUSH SET
12. NUT
13. SPRING WASHER
14. RETAINING RING NA00433
Figure 3-33 -Steering Motor-W/O Wire Guidance
3-44
Yale
STEERING MOTOR
NA00713
Figure 3-34 -Steering Motor-W/ Wire Guidance
3-45
Yale
FOR ALL NOTES SEE SHT 3
FUSE 5
-H ,0AII
BAT DISC SW RESISTOR
II 10A l|-12(3) 76(73)

START 33 OHM 25W
10| RLY
NC Q
S2 SI
FWD REV
K1-12
ARM I 5
BLACK
FREEWHEEL DIODE
M PLUG DIODE
«
P.M.C
CONTROL
CONTROL
CIRCUITY
FILTER CAP CONN
It
CONN SMART STEER
OPTIONAL
T1 28 27
87
: ir 3
30
60" RLY
4ÿ6
31 6: :=
S
26
©I Y to ~
_
—150" RLY
J_ I TRACTION POT
111
524138283
Sheet 1 of 7
Figure 3-35 - Wiring Schematic Revision 0
3-46
Yak)
IndustrialTrucks
ELECTRICAL SYSTEM
0NC NO-,
LqX,c°m COMo-ÿoNO
SIDE RAIL LF SW
O F> S,DERA,LRTSW
- «- 110 -» - «-
TO OPT EQUIP
SEE SHT 3
10 10 31 10 56 35 32
YELLOW GREEN
K o £ NC O J
o q6 2
NO/ £ NC/
QNO o
° i op 2
31 56
31 10 35
1 V| 1 1 'ÿ
r |,.s| ? i1 f 1i ? i
<D 1 1
'
J1 | J2
db933/1
BATTERY
INDICATOR
• (f) 13 33
w
o
>
ir
©I
I
T
U_ U_ LL J_ I J_ 1_ L
13 13 13 13
TO OPT EQUIP
II I J_ SEE SHT 3
524138283
Sheet 2 of 7
Figure 3-35 - Wiring Schematic (Continued) Revision 0
3-47
Yale
GENERAL NOTES:
• ALL PARTS ARE SHOWN IN THE NORMAL POSITION

FOR THE FOLLOWING CONDITIONS;
WIRE 40 NEAR 0.0 VOLTS ABOVE 24".
ISO" PROXIMITY SWITCH TARGETED AT ISO" OR BELOW
• CONNECTOR
B.O.I 933/1
X19B MUST BE CONNECTED TOGETHER
• WHEN
HOUR METER - HIDDEN
OPTIONAL HOUR METER IS NOT USED SECURE
• UNIT STOPPED. WIRE 42 NEAR BATTERY VOLTAGE AT 150" OR BELOW. FOR PROPER OPERATION OF B.D.I 933/1. CONNECTOR X9 TO A MAIN WIRE HARNESS BRANCH.
• OPERATOR PLATFORM IS FULLY LOWERED.
WIRE 40 NEAR 0.0 VOLTS ABOVE 150". FOR PIN AND WIRE LOCATION ON BDI 933/1 SEE
• PROXIMITY LIMIT SWITCH
• STEERING IS SET FOR STRAIGHT TRAVEL.
ENLARGED VIEW ON SHT 7.
•• OPERATOR IS OFF THE UNIT.
WITH BATTERY DISCONNECTED.
E. FAST LOWER CAN ONLY BE ACHIEVED WHEN PLAIFOKM IS
ABOVE 24" ELEVATION. • STEERING
TRUCKS WITH 212* OR 272" PROXIMITY LIMIT SWITCH:
REMOVE AND DISCARD JUMPER ASSEMBLY ATTACHED TO
• BROKEN LINES ARE FOR OPTION ONLY.

|"P>
TOR PROPER OPERATION OF STEERING CONNECTORS CONNECTOR X212 ON PROXIMITY SENSOR HARNESS.
• ALL UNUSED TERMINALS AND CONNECTORS MUST

BE SECURE TO A MAIN WIRE HARNESS BRANCH.
FOR PROPER TRUCK OPERATION FOLLOWING STEPS
MUST BE TAKEN:
"C". "R" AND T MUST BE CONNECTED AS FOLLOWS:
MULTI TURN STEERING - CONNECT CONNECTOR "C" WITH T.
CONNECT CONNECTOR X212 OR X272 TO A RESPECTIVE
PROXIMITY LIMIT SWITCH.
• ALL CONNECTORS ARE DRAWN FROM FRONT VIEW

AND ARE ENLARGED FOR CLARITY.
• B.D.I 933/1
CONNECTOR X19B MUST BE CONNECTEDTOGETHER
-
SMART STEER CONNECT CONNECTOR "C" WITH "R". TRUCKS WITH OUT 212" OR 272" PROXIMITY LIMIT SWITCH:
JUMPER ASSEMBLY MUST BE CONNECTED TO CONNECTOR
NOTES: FOR PROPER OPERATION OF B.D.I 933/1. • SIDE RAILS
WHEN OPTIONAL SIDE RAIL SWITCHES ARE NOT USED
X212 WHEN THERE IS NO 2127272" PRXIMITY LIMIT SWITCH.
MODEL OSEB FOR PIN AND WIRE LOCATION ON 8DI 933/1 SEE SWITCH WHEN USED. REF.
WIRES 10V-110 AND 25B-110 MUST BE CONNECTED TOGETHER
[T> 24" PROXIMITY SWITCH TARGETEO AT 24" OR BELOW. ENLARGED VIEW ON SHT 7. WITH JUMPER 2 AND 3 AS SHOWN ON SHEET 2 AND 6.
WIRE 40 NEAR BATTERY VOLTAGE AT 24" OR BELOW. NA00051
524138283
Sheet 3 of 7
Figure 3-35 - Wiring Schematic (Continued) Revision 0
3-48
Yale
IndustrialTrucks
ELECTRICAL SYSTEM
TO SHT 5
212-/272 76(73)
RELAY
RELAY
DIODE-D2
rWD REV
23A— CONTACTOR
S3 33
iILLL 13(38)
PART OF
PROX SENSOR
HARNESS
13A| 10J 8 |1OA | 76 | 6A 12 |13B| 13 |13V

10 23 6 10CJ 32 I 8A| 35 I 14 |l3Dll3F
10J 56 12 L 17 26 30
FRONT VIEW OF BOTH CONTACTORS

IS SHOWN FOR PURPOSE OF
CLARIFYING WIRING CONNECTIONS
NA00052
524138283
Sheet 4 of 7
Figure 3-36 - Wiring Diagram Revision 0
3-49
Yale
FROM SHT 4
q.
212" PROXIMITY
LIMIT SWITCH
®-,\ OPTIONAL
3[
OAB lss<f]
loi
TTN P
ÿU-
C5 I
H
El<3
CONN X272
TO BE USED
WITH 272"
PROXIMITY SWITCH
><
STROBE LIGHT
11321 40 J 10L|10K
1
41 10L 1
13Z| 13Y
38 p
[1OH j 10J
0J 1 13
J(13XJ13Y
t 13X| 39 |l0j|l0K <-> 7
ÿHisa
w
¥ z a:
- BLACK -
mm X9
— RED - V cHES
57, 57A
EPS III (5
---
13R-
STEER HOUR METER
MOTOR HIDDEN
O ON OPTIONAL
J®. K1 II! O LIM- K3
O ERROR
o error
1 Tt
*1 1
—— 1
CONNECTOR K2 CONNECTOR K3 BRAKE SOLENOID
TRACTION
MOTOR
524138283
Sheet 5 of 7
Figure 3-36 - Wiring Diagram (Continued) Revision 0
3-50
YaleIndustrialTrucks
ELECTRICAL SYSTEM
HOUR METER ACC/RF

CONN X23 FOR FAN SWITCH
BATT/HM) FOR SLACK BATTERY
ACCESSORY WHEN USED 24V SHOWN KEY SWITCH
JUMPER 2 GUIDANCE CHAIN DISCONNECT SW JUMPER
SEE SHT 7 (OPTIONAL)
SWITCH LIGHT
WHEN USED
17 10S 13E
FOR FOR
GUIDANCE GUIDANCE
SONALERT LIGHT
WHEN USED WHEN USED
48 (+)
13K (•)
OPERATOR COMPORTMENT
LEFT SIDE FAN RIGHT SIDE
RAIL SWITCH OPTIONAL RAIL SWITCH
(WHEN USED) (WHEN USED)
FOR OPTIONAL SMART

STEER SEE SHT 7
TRACTION
POT
BLUk
BLU ORN
ÿ >
W
YfcL BLK BLU
BLU RED RED
BLK
BLK YEL
BLU
HED 6Rf? BRN
BLK
—
Bl U
I I
-
I 1
YEL ORN BRN
FED, RED
J:
if
ORN BRN YEL
BLK BLU BLK
RED 'brn
RED
BLK BLU
CONN X2 AND X3
ARE PART OF
21 COND COIL
ASSY
HORN SW
CONN X1 AND X7
ARE NOT USEO
ON THIS MODEL
NC NO C SLACK CHAIN SLACK CHAIN C NONC

SWITCH #2
FOOT BRAKE
SWITCH
524138283
Sheet 6 of 7
Figure 3-36 - Wiring Diagram (Continued) Revision 0
3-51
Yale
FOR ALL NOTES SEE SHT 3 TO

MAIN PLATFORM HARNESS
ACCESSORY CONNECTION
SEE SHT 6
CONN X23
BATTERY INDICATOR GAGE
•m- 13 -
CONNECT TO WIRE 10 AND 13
t
ON MAIN PLATFORM HARNESS
SEE ACCESSORY CONNECTOR
X23
uj
S i§ ii
FOR
A
FOR
HYDRAULIC POT ACCELERATOR POT
AND HORN SWITCH FWD-REV SWITCHES
HEATER FREEZER MODIFICATION

12 VOLT
RIGHT SIOE
FAN AND LIGHTS
PACKAGE
(RIGHT SIDE TYPICAL AS SHOWN)
REAR VIEW OF BDI 933/1
00 00 00
I— PURPLE
-
- WHITE
BLUE
-GREEN-
spot\
f
- -1-ÿ -j- r"~
i
PURPLE ÿ PURPLE
1 2 314 567
V LIGHT J o 9 oo 999
LIGHT AND FAN

SWITCHES 2 I J2
- ORANGE
<E
X19B
ÿ
RED-FAN
c BDI 933/1 WITH LIFT INTERRUPT
f LAMP N.
ORANGE -
ORANGE -
LAMP
f
SMART STEER
FOR OPTIONAL MULTI TURN SEE SHT 6
12 VOLT FAN, SPOT LIGHT AND LAMP WITH CONVERTER
LEFT SIDE WIRING SHOWN RIGHT SIDE IS TYPICAL
524138283
Figure 3-37 - Options Diagram Sheet 7 of 7
Revision 0
3-52
YaleIndustrialTrucks ELECTRICAL SYSTEM
FOR ALL NOTES SEE SHEET 3

HI lOA Ih
HI io* IF
ACCEL
POT
SllTlTiTlWTlTi'
-TRAM
ARMjS
CONTROL
LOGIC
ARM) £
CC +
LlI ~ s-
CD
----
----
21 -J-
ig-l.
I—
~
MDU POT
GUIDANCE
P.M.C.
CONTROL z 5
STEER DIR
INDICATOR
-156-
NA00483
524138283
Sheet 1 of 7
-
Figure 3-38 Wiring Schematic - Wire Guidance Revision 0
3-53
Yale
<3 E>
FROM SHT 1
NA00462
524138283
Sheet 2 of 7
Figure 3-39 - Wiring Schematic - Wire Guidance (Continued)
Revision 0
3-54
Yale
cc GREEN=
k WHITE ÿ=
w BLK FAN =
g PINK =
"~ BLUE «=
PURPLE «=
CIRCUIT ISTYPICAL FOR LEFT AND RIGHT SIDE LIGHTS AND FAN ASSEMBLY
FROM SHT 2
NA00463
524138283
Figure 3-40 - Wiring Schematic - Wire Guidance Sheet 3 of 7
Revision 0
3-55
Yale
FOR ALL NOTES SEE SHT 3 TO SHT 5
76(73)
STUD
/- 13C
,3Eÿÿ LIFTCONT
/ÿ 13D
FWD REV
TRAM CONTACTOR
MODULE
CONN X 14
IS PART OF
PROX SENSOR HARNESS
y13A 10J 8 I10AI 76 6A 12 13B 13M3V 39 40 13V

10 23 6 10D 32 8A 35 14 13DH3F 6A 32 20
10J 156 8 29
57B 13F 10D
PLUG DETECT MOOULE
CONN X2E AND X3E

ARE PART OF
21 COND CABLE ASSY
CONN X4E
IS PART OF
57313
8 COND CABLE ASSY
FRONT VIEW OF BOTH CONTACTORS

IS SHOWN FOR PURPOSE OF
CLARIFYING WIRING CONNECTIONS
NA00464
524138283
Sheet 4 of 7
Figure 3-41 - Wiring Diagram - Wire Guidance Revision 0
3-56
Yale
CjESkb FOR ALL NOTES SEE SHT 3

BATTERY
IQÿICÿIAP] 212" PROXIMITY
LIMIT SWITCH
OPTIONAL
(•)
<+>
CONN X272
TO BE USED
WITH 272"
PROX SWITCH
150" PROXIMITY
LIMIT SWITCH
OPTIONAL
<?EDi
u
40 10L 10K STROBE LIGHT
38 10H 10J 13XH3AC

39 10J 10AC
60- PROXIMITY
LIMIT SWITCH
24- PROXIMITY
LIMIT SWITCH
o ' 52 P
"<K
Ti
ÿ Iÿ "z
18.18A I 16
2Pl] 5P2 I
E3SSE1
cHjIEEJ 05
V
15 36
18 16
HOUR METER
HIDDEN
OPTIONAL
—|reo]w!ÿrn|bikJ ii |b'u<Jgr'n|wht|heo|
-{REojjÿRNÿBLKj o ÿBLkJ GRn|wHt|rEo|
B10 BRAKE SOLENOID :

-J
106 103 28B 29 29 28 103 106
EB 102 ]|.[ ÿ
102
'
68 101 104 105 5 105 104 101 8
Mi
STEER MOTOR
@(ÿ-F4-
I 105| 8B| 28B| 57 I 28
if|grn BLKfT JJJJJ jJjJj j)j]

101 103 29
RED
N JiJ
GRN RED
BLKjwHTj GL
NA00465
524138283
Figure 3-42 - -
Wiring Diagram Wire Guidance (Continued) Sheet 5 of 7
Revision 0
3-57
Yale
(BATT/HM)
(OPTIONAL)
[(ÿ)(•)]
(WHEN USED)
(ENLARGED FOR CLARITY)
(WHEN USED)
gall
BLU /flST
ÿ4 kL
— - _ — -
EO "t1 r
w 9A i , 5A |
o TU
NA00466
524138283
-
Figure 3-43 Wiring Diagram - Wire Guidance (Continued) Sheet 6 of 7
Revision 0
3-58
Yale

TO
MAIN PLATFORM HARNESS
ACCESSORY CONNECTION MAIN PLATFORM HARNESS
SEE SHT 6 SEE SHT 6
CONN X23
WIRE #35
BATTERY INDICATOR GAGE
ÿ1
CONNECT TO WIRE 10AND 13
y
A<sl ON MAIN PLATFORM HARNESS
SEE ACCESSORY CONNECTOR
< s?
5 8
£ t as
S H
P
.-X FOR
HYDRAULIC POT
,_J
FOR
ACCELERATOR POT
- -
10AC 13AE
—
8LK
ÿ
•
AND HORN SWITCH FWD-REV SWITCHES
ÿ
ÿ
13AC ÿ ÿ
10AE - RED
12 VOLT HEATER FREEZER MODIFICATION

CONVERTER
TO
RIGHT SIDE
|3 FAN AND LIGHTS
a PACKAGE
(RIGHT SIDE TYPICAL AS SHOWN) REAR VIEW OF BDI 933/1
ÿ
ÿ D ÿÿ
—-
PURPLE
• BLUE
WHITE -
GREEN -
SPOT
• PURPLE -f— Q O—j- PURPLE - -R
3(4 5 S
yLIGHT ODOO
LIGHT AND FAN

u. 13B oi
SWITCHES 35—'
10E— L32 |J2
ÿ£=
31A-
— <T]
BDI 933/1 WITH LIFT INTERRUPT
TO MAIN HARNESS
SEE SHT 6
/ LAMP \
ÿ
•
WHITE
WHITE
-K_
-\ÿ°
-yA -ORANGE -
-ORANGE -
STEER POT TRIM POT
\
-f
LAMP
WHITE O O—j-ORANGE - SELF CENTERING STEER
FOR OPTIONAL MULTI TURN
12 VOLT FAN. SPOT LIGHT AND LAMP WITH CONVERTER

SMART STEER
LEFT SIDE WIRING SHOWN RIGHT SIDE IS TYPICAL
FOR OPTIONAL MULTI TURN SEE SHT 6
NA00461
524138283
-
Figure 3-44 Options Diagram -Wire Guidance Sheet 7 of 7
Revision 0
3-59
NOTES
3-60
Yale
IndustrialTrucks
SECTION 4
DRIVE UNIT ]
Yale
Industrial Trucks
DRIVE UNIT
GENERAL 4-1
DESCRIPTION 4-1
REPAIR 4-1
REMOVAL 4-1
DISASSEMBLY 4-2
ASSEMBLY 4-4
BEVEL PINION SHAFT INSTALLATION 4-4
BEVEL GEAR INSTALLATION 4-6
CHECKS AND ADJUSTMENTS 4-8
BACKLASH AND TOOTH CONTACT PATTERN 4-8
AXLE SHAFT BEARING CLEARANCE 4-8
TRUNNION BEARING 4-9
INSTALLATION 4-9
TROUBLESHOOTING 4-12
Yale
IndustrialTrucks DRIVE UNIT
GENERAL
This section has a description and the repair and adjustment 5. Disconnect the wires to the brake assembly.
procedures for the parts of the master drive unit (MDU). The
final drive ratio of the MDU used in the OS EB model is 14.9:1. 6. Make an identification mark on the motor housing and the
Thetraction motor, steering and brake repair procedures are in frame weldment for correct motor alignment during installation.
separate sections. The main parts of the MDU are the case, Remove the six capscrews and lockwashers retaining the
pinion (motor) and large gear set, the pinion and spiral bevel flange of the traction motor to the MDU upper housing.
gear set, bearings, and the axle and wheel. The large ball
bearing for steering is part of the upper housing of the MDU. /\ WARNING: The traction motor is heavy. Be sure
/|\ that all lifting devices (hoists, cables, chains,
The traction motor fastens to an adapter ring that is attached to slings, etc.) are suitable and of adequate capacity
the lift truck frame. This adapter ring is part of the large ball to lift the traction motor. The traction motor can weigh
bearing and allows the MDU to turn on the axis of the traction approximately 40 kg (85 lbs).
motor. The traction motor does not turn with the MDU.
7. Use a sling around the traction motor and an overhead
NOTE: The manufacturer recommends draining and refilling crane to carefully lift the traction motor. Do not damage thedrive
the drive unit oil afterthe first 500 hours of useon all new trucks . gear on the motor shaft or the brake assembly on the top of the
See Section 2 - LUBRICATION INSTRUCTIONS. motor. Position the motor on its side so that the gear and the
brake assembly are not damaged.
DESCRIPTION
8. Loosen the locknut at the chain anchor for the steering
Six capscrews fasten the large ball bearing and MDU to the chain. Remove the capscrew at the chainanchor. Putamarkon
frame. The bearing lets the MDU turn for steering. There is a the MDUforthe location of the pinthat fastens the chain anchor
small helical pinion on the motor armature shaft. This pinion to the sprocket. Remove the pin. Carefully remove the chain
turns a large helical gear attached to the bevel pinion shaft in anchor and chain from the sprocket.
the MDU. The bevel pinion shaft turns the bevel gear attached
to the axle shaft to turn the drive wheel. The brake is fastened to /\ WARNING: The lift truck is heavy. Be surethatall
the top end of the motor shaft to stop rotation of the shaft. The / 1\ lifting devices (hoists, cables, chains, slings, etc.)
brake action works through the gears to stop the unit. ChJ are suitable and of adequate capacity to lift the lift
truck. The lifttruck can weigh approximately 3541 kg (7800 lbs)
REPAIR empty.
9. Carefully put a sling under the lift truck frame. Position the
REMOVAL
sling near the MDU on the mast side of the MDU. Attach the
A CAUTION: The capscrews used to fasten the

Master Drive Unit (MDU) and traction motor are all
metric. Do not damage them using the wrong tools .
sling so that it will not slip when the lift truck is raised. Do not
damage the guidance sensor if the lift truck has wire
guidance.
A
1. Move the steering wheel so that the drive wheel is in a WARNING: If the MDU falls, it can cause an
position for straight travel. injury. Hold the MDU vertical to prevent it from
falling.
2. Disconnect and remove the battery. See Section 2 -
GENERAL TRUCK AND LUBRICATION, CHANGING THE 10. Remove the six capscrews and lockwashers that fasten
BATTERY. the adapter ring and MDU to the frame or axle plate.
3. Open the drive unit compartment doors. Fasten the doors 11. Holdthe MDUand raise the lifttruckframe so thatthe MDU
so that they are fully open. Put a pan under the MDU drain plug is free. Carefully lower the MDU to the floor and move the MDU
and remove the drain plug. Afterthe oil has completely drained, from under the lifttruck. Lower the lifttruckframe onto blocks.
installthe drain plug. Tighten the drain plug to 22 N*m (16 Ibf ft)
torque.
4. Tag and disconnectthe power cables ofthe traction motor.

Fastenthe cables in a location to prevent damage during motor
removal.
4-1
Yale
A
DISASSEMBLY
CAUTION: Be careful not to damage the threads
See Figure 4-1 and Figure 4-2.
or splines on the axle shaft.
A
CAUTION: Failure to completely straighten the
NOTE: The bevel gear is secured to the axle shaft using
staked portion ofthe nut priorto removal can cause
Loctite® 270. It may be necessary to use a welding torch to
damage to the shaft threads.
heat the bevel gear to 100 to 120° C (212 to 248° F) to free the
bevel gear from the axle shaft.
A CAUTION: The capscrews and nuts used on the

MDU are all metric. Do not damage them using the
wrong tool.
NOTE: Before disassembling the drive unit make certain the

6. Use a strap wrench or place a wood wedge under the
helical gear to keep the gear from rotating. Remove the nut
retaining the helical spur gear. Use a gear puller to remove the
helical gear from the pinion shaft. Carefully remove the pinion
work area is clean and all the necessary tools are available.
shaft and bearing cone from the lower housing. Use a plastic
The nuts retaining the drive axle and upper gear on the pinion
hammer, if necessary. Remove the spacer bushing from the
shaft are staked in place and the staked portion must be
pinion shaft.
completely removed before attempting any disassembly.
7. Use a copper mandrel and a plastic hammer to drive the
1. Remove the wheel nuts and the drive/steer wheel.
axle shaft out ofthe lower housing. Remove the bevel pinion out
ofthe lower housing.
2. Remove the nine capscrews that fasten the lower housing
to the upper housing. Remove the four capscrews inside the
upper housing. See Figure 4-1 . There are also two capscrews
inside the case that are secured with washers and nuts on the
opposite side ofthe upper housing. Make certain to remove the
capscrews, lockwashers and nuts before attempting to
separate the upper housing from the lower housing.
3. The upper housing is retained to the lower housing with

two dowel pins. Use a plastic hammer against the lower portion
of the upper housing to separate the upper housing from the
lower housing. Carefully slide the upper housing for clearance
betweenthe upper housing and helical gear. Removethe upper
housing.
/\ CAUTION: The helical gear and pinion shaft

w i\ assembly can only be removed afterthe bevel gear
ÿÿÿ3 and axle shaft have been removed from the drive
unit lower housing.
4. Remove the capscrews retaining the drive unit cover.

Remove the drive unit cover.
5. Install two wheel nuts onto the wheel bolts. Position a

piece of wood or bar between the nuts to hold the drive axle
stationary while removing the special capscrew retaining the
bevel gear to the axle shaft. Remove the special capscrew (24
mm) and the special washer.
A WARNING: If the MDU falls, it can cause an

injury. Hold the MDU vertical to prevent it from
falling.
1.
2.
3.
UPPER HOUSING
CAPSCREWS INSIDE TOP CASE
HOUSING
/\ WARNING: Toxic vapors may be generated by 4. CAPSCREWS
f I\heating the axle shaft to remove the Loctite .
5. DOWEL
CmLbJ Wear a protective mask during this operation. Use
gloves to remove the bevel gear if it has been heated.
Figure 4-1 - Separating Upper and Lower Housing
4-2
Yale
Industrial Trucks drive unit
1. TRACTION MOTOR 51. WHEEL/TIRE ASSEMBLY

2. CAPSCREW 52. LUG NUT
3. LOCKWASHER
4. NUT
5. LOCKWASHER g
6. PINION
7. O-RING
8. CAPSCREW
9. LOCKWASHER
10. CHAIN BLOCK 9.
11. CAPSCREW
12. NUT 17
13. CHAIN TENSIONER
14. CONNECTING LINK
15. CHAIN
16. CAPSCREW
17. CENTERING RING
18. CAPSCREW
19. WASHER
20. NUT
21. CAPSCREW
22. CAPSCREW
23. CAPSCREW
24. DOWEL PIN
25. PINION GEAR
26. LOCKNUT
27. HELICAL GEAR
28. BEARING
29. SHIMS ,52 /
30. DRAIN PLUG J /
31. SEAL RING
32. CAPSCREW
-v
1 ///)}%] '
33. COVER I lIlUol Jj 35/4
34. AXLE SHAFT I Ij I /6
((aCIM/q//
35. WHEEL BOLT
36. BEARING
37. SHIMS
/
38. SEAL RING
39. THREAD PROTECTION SEAL 11ÿ_ ÿ
40. CAPSCREW | (
41 • DISK
42. RING GEAR AND PINION SHAFT
12 i
43. BEARING
44. SHIMS fp 'ÿ14'
45. LOWER HOUSING 13ÿ<1
46. LUBE FITTING U
47. BREATHER VALVE (j4£
48. PLUG -OIL FILL
49. SEAL RING 33 /
50. UPPER HOUSING 31 /
NA00202
Figure 4-2 - Master Drive Unit Parts

4-3
Yale
& CAUTION: Keep all shim sets together and

labeled for correct location and installation during
assembly
ASSEMBLY
/\
/ 1\
WARNING: Cleaning solvents can be flammable
and toxic, and can cause skin irritation. When
using cleaning solvents, always follow the
NOTE: If the bevel pinion and gear set will NOT be replaced,
the same shim sets can be used during assembly. Adjustment recommendations of the manufacturer. Wear eye protection.
will not be necessary.
1. Clean all components thoroughly. Remove all traces of
8. If necessary, remove the bearing cones from the axle
Loctite . Use Loctite® Fast Cleaner No. 706 to remove
shaft, from the bevel gear and from the bevel pinion shaft. To Loctite from the lower housing in the area where the thread
remove the bearing cone from the axle shaft it is necessary to protecting shield had been located. Spray the cleaner from a
cut the bearing cage, then open the cage and remove the distance of approximately 30 cm (0.50 in), while holding the can
rollers. Use a puller to remove the cone from the axle shaft. upright. Allow the cleaner to work, then thoroughly remove the
dissolved dirt from the lower housing using a clean cloth. Spray
9. Remove the bearing shield from the lower housing using a the surface with the cleaner again and allow to air dry.
plastic hammer. See Figure 4-3.
2. Check all parts for damage or cracks. Replace all worn or
10. If necessary, remove the motor nut, lockwasher, bevel damaged parts. When assembling the drive unit use all new
pinion and key from the motor shaft. Remove the O-ring from stake nuts, O-rings and seals.
the motor.
/\ CAUTION: The axle and gear assemblies are
11\ installed and removed several times during this
procedure. Becarefulduringinstallationsothatthe
bearing seal is not damaged.
NOTE: The helical pinion and gear and the bevel pinion shaft
and bevel gear are matched sets and MUST be replaced as
sets. When replacing the gear sets, always replace thetapered
roller bearings. The inner bearings and outer races MUST be
from the same manufacturer. Lubricate the bearings with clean
transmission oil prior to assembly.
NOTE: Assembly of the drive unit requires the use of a

standard micrometer, torque wrench and a dial indicator. The
use of other special tools is recommended by the manufacturer
of the drive unit.
NOTE: The large ball bearing is part of the upper housing.

The upper housing and the ball bearing are replaced as a unit.
Bevel Pinion Shaft Installation

See Figure 4-2, Figure 4-5 and Figure 4-7.
Figure 4-3 - Removing Bearing Shield
This procedure has the necessary steps needed to install the
11. Remove the wheel bolts from the axle shaft, using a bevel pinion shaft. All of these steps are necessary if a
hydraulic press, if necessary. replacement bevel pinion shaft and gear set or a replacement
lowercase are needed. Normally, it is not necessary to replace
12. If necessary, remove each of the bearing cups. Use a the lower case or helical gear set.
puller or copper mandrel and a plastic hammer. Do NOT
damage or lose the shims between the cups and the bore in the If the original bevel gear set will be installed in the same lower
case. Keep each set of shims together and separate from the case, use the original shim sets (x) and (y). Installthe shim sets,
other sets of shims. Put a label on each set so that the sets can bearing, bevel pinion shaft, helical pinion and gear and special
be installed in the correct position during assembly. Measure nut. Check the bearing clearance as described in Step g.
the distance between the edge of the case and the inner seal
ring at the axle bore. The replacement seal ring MUST be If only the bevel gear set is replaced, use the number (*) to find
installed in the same position as the old seal. Remove the seal the correct shim set (x). If the new number is smaller than the
ring. old number, remove shims. If the old number is larger, add
shims. Add or subtract shims equal to the difference between
the numbers. Do NOT use damaged or distorted shims.
4-4
Yale
EXAMPLE: Install the bevel pinion shaft as follows:

The old number 74.25 minus the new number 74.15 will
a. Make a bushing to fit the bore for the lower pinion shaft
make removing shims 0.1 mm (0.004 in) thick necessary.
bearing. The bushing O.D. will be 51.5 mm (2.03 in).
Bushing (2) must be 67.5 mm (2.66 in) long.
If this method of finding the correct set is used, it is NOT
necessary to do Steps b. through d. Do Steps a. and e. through b. Install the bushing in the bore. To find the correct
9- thickness for shim set "x", it is necessary to know the case
dimension E. To find the case dimension E, use the
Use all of the following Steps to assemble, adjust and install a formula:
NEW bevel pinion (if you do not have one of the above E = L - F + d/2
numbers) or the original bevel pinion shaft in a NEW case. L = bushing length
F = the difference between the bearing bore for the
NOTE: There are two numbers on each of the two parts of the axle and the end of the bushing. See Figure 4-5.
bevel gear set. One number on each part is the set number. d/2 = 44.45 mm (1.75 in)
These numbers MUST bethe same. The other number on the
bevel gear isthe gear clearance number. The other number on c. Measure the dimension F. See Figure 4-5. Subtract
the value F from the length (L) of the bushing and add the
the bevel pinion is the dimension "B" value. Check that the
numbers are correct. value d/2. The result is dimension E.
d. The shim set thickness X for shim set "x" for the lower
bearing is found as shown in Figure 4-5.
X = E -B - T
E = the value found in Step c
B = the number on the end of the pinion shaft
T = the total thickness of the bearing
e. Install the shim set "x" and press the bearing cup into
the bore. Installthe bearing cone and spacer on the pinion
shaft. Install the pinion shaft in the case.
f. Install a piece of wood betweenthe end of the pinion
and the case to holdthe pinion tightly in the bore. Do NOT
install shims or bearing. Measure the distance between
the top end of the spacer andthe bottom of the bore for the
bearing. This is distance C in Figure 4-5.
g. Measure the distance S between the edges of the
bearing cup and cone. If the cup extends below the cone,
the dimension S is negative (subtract). If the cone extends
below the cup, the dimension S is positive (add).
h. Add or subtract (Step g.) dimension Sfrom dimension
C. The result minus 0.02 mm (0.001 in) isthe dimension X
or the thickness of shim set "y" for the top bearing.
X (in mm) = C + or - S - 0.02 mm.
i. Installthe shim set "y", the bearing cup, bearing cone,
helical gear and special nut. Use a press to install the
bearing cup.
1. UPPER PINION BEARING RACE j. Use a strap wrench or a piece of wood to keep the
2. LOWER PINION BEARING RACE helical gearfrom turning and tighten the nutto 100 N«m (74
3. INNER AXLE SHAFT BEARING RACE Ibf ft) torque. Do NOT use a punch to lock the nut at this
4. OUTER AXLE SHAFT BEARING RACE time.
5. UPPER PINION BEARING SHIMS
6. LOWER PINION BEARING SHIMS
7. INNER AXLE SHAFT SHIMS
8. OUTER AXLE SHAFT SHIMS
9. INNER SEAL RING
10. BEARING SHIELD
Figure 4-4 - Bearing and Shim Location

4-5
Yale
Bevel Gear Installation 5. Carefully install the axle assembly in the case. Install the
bevel gear on the axle assembly using the M16 capscrew and
special washer.
1. Use a press to install the wheel bolts.
6. Prevent the axle from turning. Tighten the M16 capscrew
to 245 N«m (332 Ibf ft) torque. Tighten the special nut at the
NOTE: When installing the wheel bolts, make certain that the
large gear to 60 N«m (44 Ibf ft) torque.
flat side of the bolt collars face the center of the wheel shaft.
7. Check and adjust the backlash, tooth contact pattern and
2. Install the seal ring on the wheel shaft. Installthe cone on
bearing clearances BEFORE continuing. See CHECKS AND
the axle shaft.
ADJUSTMENTS.
NOTE: Afterthe proper backlash has been obtained, grease
the seal ring and fill the outer bearing cone using Shell Alvania 8. After the proper backlash and tooth contact pattern has
R3 grease prior to assembly. been established, remove the bevel gear, the bearing cups,
and the axle assembly.
3. Install the cone on the bevel gear using a press.
9. Coat the seat of the thread protecting seal with Loctite No.
4. Do NOT install the inner seal ring untilthe bearing preload
270. Press the shield on the lower housing as far as possible.
has been adjusted. Install the original shims under both the Thinly coat the radial shaft seal with Loctite® No. 574. Install
inner bearing cup and the outer bearing cup. Use a press to the inner seal into the lower housing. The inner seal, when
install both bearing cups in the case. properly installed, should be 1.8 + 0.5 mm (0.071 +0.02 in)
below the bottom edge of the outer bearing bore. See
NOTE: Do NOT use damaged or distorted shims. Figure 4-6. Fillthe inner seal ring andthe cone on the axle shaft
with Shell Alvania R3 grease.
SHOWN WITH BEARING AND SHIMS INSTALLED
1. BEVEL PINION SHAFT

2. SPACER
3. SPECIAL BUSHING
4. LOWER CASE
5. LOWER BEARING
6. SHIM SET "X"
7. SHIM SET "Y"
8. UPPER BEARING
9. BEARING CUP
10. BEARING CONE
DIMENSION "B" (mm) ON END OF BEVEL PINION SHAFT
Figure 4-5 - Installing Bevel Pinion Shaft

4-6
Yale
capscrew and special washer. Tighten the M16 capscrew to

245 N«m (332 Ibf ft) torque.
NOTE: If the tapped holes in the bottom of the lower housing

extend through the housing, it is recommended that the
capscrews are completely sealed with Loctite® to prevent oil
from leaking from around the threads.
11. Use Loctite® 574 on the cover. Apply one drop of Loctite
243 on each of the cover capscrew threads. Install the cover.
Tighten the cover capscrews to 9.5 N*m (7 Ibf ft) torque.
12. Use Loctite® 574 to installthe upper housing on the lower

housing. Make sure the upper housing is aligned correctly and
use a punch to installthe two dowels, if removed. See Step 3 of
the DISASSEMBLY procedure. Install the capscrews to retain
the upper housing to the housing. Tighten the 8 mm capscrews
to 23 N«m (17 Ibf ft) torque. Tighten the 10 mm capscrews to 46
1.8 + 0.5 mm - N*m (34 Ibf ft) torque. Install the alien head capscrews andthe
(0.071 +0.02 washers and nuts. Tighten the nuts to 23 N»m (17 Ibf ft) torque.
NOTE: To replace the drive tire on the wheel, the wheel must
be pressed out of the tire rim. See Section 2 - HOW TO
Figure 4-6 - Inner Seal Installation CHANGE THE DRIVE/STEER TIRE.
10. Install the shims, outer bearing cup and the axle shaft.
Apply Loctite® 270 to the internal splines of the bevel gear. 13. Install the wheel and the lug nuts. Tighten the nuts in a
Installthe bevel pinion on the axle shaft. Remove any excess cross patternto one-half the torque value specified in Section 2.
Loctite from the bevel gear using a clean cloth. Installthe M16 Tighten the lug nuts again using the cross pattern to obtain the
proper torque.
15. COVER
16. DRAIN PLUG
17. THREAD PROTECTION SEAL
18. INNER SEAL
19. SHIMS
20. BEARING
21. AXLE SHAFT
22. WHEEL BOLT
23. HELICAL PINION
1. LOCKNUT
2. HELICAL GEAR
3. BEARING
4. SHIMS
5. LOWER HOUSING
6. SHIMS
7. BEARING
8. BEVEL PINION GEAR
9. DISK
10. CAPSCREW
11. SHIMS
12. BEARING
13. BEVEL PINION SHAFT
14. CAPSCREW
Figure 4-7 - Installing Bevel Gear Set
4-7
Yale

Backlash and Tooth Contact Pattern Axle Shaft Bearing Clearance
See Figure 4-8 and Figure 4-11. See Figure 4-9.
CAUTION: The axle and gear assemblies are CAUTION: The axle and bevel gear assemblies
installed and removed several times during this are installedand removed severaltimes during this
procedure. Be careful during installation of the axle procedure. Be careful during installation of the axle
so that the bearing seal is not damaged. so that the bearing seal is not damaged.
This backlash is the clearance between the teeth of the bevel The correct bearing clearance for the bevel pinion and bevel
gear and the teeth of the pinion. Use a dial indicator to measure gear is marked on the edge of the bevel gear. The adjustment
the clearance. See Figure 4-8. Put the dial indicator in a range is ± 0.03 to 0.07 mm (± 0.001 to 0.003 in). Carefully
position so that the sensor touches a tooth of the bevel gear. install the axle assembly and bevel gear in the case. Use the
Install a wood wedge under the large gear atthe top of the MDU original shims under the special washer. Tighten the capscrew
to keep the gear and pinion from moving. Move the bevel gear to 100 N*m (74 Ibf ft) torque.
in the direction away fromthe sensor of the dial indicator. Adjust
the dial indicator for a zero reading. Move the gear toward the Remove the capscrew and special washer. Measure the
dial indicator and read the backlash. The backlash must be 0.1 thickness of the shim set. Use a soft hammer to tap the end of
to 0.15 mm (0.004 to 0.006 in). the axle to move it approximately 1 mm (0.04 in). Add 0.1 mm
(0.004 in) of shim to the shim set. Installthe special washer and
capscrew again. Tighten the capscrew as before.
1. SPIRAL BEVEL GEAR
2. DIAL INDICATOR Use a dial indicator to measure the bearing clearance. See
3. WOOD WEDGE Figure 4-9. Putthe dial indicator in a position so that the sensor
touches the flat surface of the special washer on the spiral
bevel gear. Make a mark on the gear as a measurement point.
Move the bevel gear in one direction (approximately 180 )
while pushing on the gear. Adjust the dial indicator for a zero
reading at the measurement mark. Move the gear in the
opposite directionwhile pulling on the gear. Read the clearance
on the dial indicator at the measurement mark. If the clearance
is not as shown on the edge of the gear, adjust the clearance.
Add or remove shims between the special washer and the gear
for the value marked on the edge of the gear. There will be no
noticeable clearance when the adjustment is correct, but it will
be possible to rotate the axle by hand.
11411
1. SPIRAL BEVEL GEAR
2. DIAL INDICATOR
3. SPECIAL WASHER
,
ljN>
Figure 4-8 - Checking Backlash
If the backlash is too much, the bevel gear must move toward
the pinion. If the backlash is not enough, the bevel gear must
move away from the pinion. The bevel gear is moved in the
correct direction by adding or removing shims under the
bearing cup. The shims for the shim set are available in the
following thicknesses: 0.1 mm, 0.1 5 mm, 0.3 mm and 0.5 mm.
The tooth contact pattern must also be correct. Remove the

wood wedge and check the tooth contact pattern as shown in
Figure 4-11 . Adjust the position of the bevel gear for the best
tooth contact pattern and the correct backlash.
Figure 4-9 - Checking Bearing Clearance

4-8
Yale
Trunnion Bearing INSTALLATION

The transmission upper housing must be replaced if: WARNING: The lift truck is heavy. Be sure that all
lifting devices (hoists, cables, chains, slings, etc.)
a. The sealed cover plate on the trunnion bearing has
are suitable and of adequate capacity to lift the lift
separated.
truck. The lift truck can weigh approximately 3541 kg (7800 lbs)
b. Thetrunnion bearing is difficult to turn or binds. It is not empty.
possible to replace the outer race and/or balls.
1. Carefully put a sling under the lift truck frame on the mast
c. The maximum bearing clearance is exceeded.
side ofthe MDU. Do not damage the guidance sensor if the
lift truck has wire guidance.
To check the bearing clearance, clamp the upper housing onto
a level assembly table. Installthree eye bolts intothe outer race
2. Lift the frame for clearance to slide the MDU under the
ofthe trunnion bearing. Rotatethe bearing severaltimes. Install
frame. Temporarily install blocks under the frame to prevent
a cable in each eye bolt.
lowering.
Position three dial gauges on the trunnion bearing and set the
3. Move the MDU into approximate alignment under the
gauge dials to "zero". Mark the position of one dial gauge on the
frame.
trunnion bearing with a marking pen. See Figure 4-10.
4. Holdthe MDU inthe vertical positionthrough the hole inthe
Using a lifting device and a spring balance, raise the upper
housing with approximately 50 kg (110 lb) of force. Rotate the
plate. Do NOT put any part of your body between the MDU and
the frame or axle plate. Carefully raise the frame and remove
trunnion bearing several times and position at the mark again.
the blocks. Carefully lower the frame and align the capscrew
The recommended maximum bearing clearance is 0.03 mm
holes in the large ball bearing, adapter ring and the frame.
(0.0012 in). If the bearing clearance is more than the
recommended clearance, the trunnion bearing and upper
5. Installthe six capscrews and lockwashers that fasten the
housing must be replaced.
adapter ring and MDU to the frame. Use a cross pattern to
slowlytighten the capscrews to approximately 25 N«m (34 Ibfft)
torque. Make sure the large ball bearing and adapter ring are in
the correct position around the complete circumference. Use
the cross pattern to tighten the capscrews to 68 N*m (50 Ibf ft)
torque.
WARNING: The traction motor is heavy. Be sure

that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capacity
to lift the traction motor. The traction motor can weigh
approximately 40 kg (85 lbs).
6. If the pinion gear on the motor shaft was removed, install

the key, gear, lockwasher and nut. Tighten the nutto 54 N»m (40
Ibf ft) torque. If an impact wrench is used, make sure it does not
tighten the nut to more than the correct torque.
7. Install a new O-ring on the motor using O-ring lubricant.
8. Use an overhead crane and a sling to lift thetraction motor.

Carefully align and lower the traction motor onto the MDU
adapter ring. Do NOT damage the pinion gear on the motor
shaft, the large gear ofthe MDU or the brake assembly. Make
sure that the motor is aligned properly before lowering it intothe
upper housing.
9. Install the three capscrews and lockwashers. Tighten the

capscrews to 20 N«m (15 Ibf ft) torque.
10. Connect the power cables to the motor terminals.

Figure 4-10 - Checking Trunnion Bearing
11. Connect the wires to the brake assembly.
4-9
Yale
12. Make sure the MDU is in the position for straight travel with grease. A dry bearing will take approximately 55 g (0.12 lb) of
the tire to the left of the case (facing MDU). Carefully install the grease to fill the bearing completely.
steering chain. Use the pin to install the chain anchor on the
adapter ring. Usethe capscrew to fasten the two chain anchors 14. Lower the lift truck to the floor. Fill the MDU to the level/fill
together. Adjust the steering chain and steering potentiometer. plug using the recommended oil listed in Section 2. Add the oil
See Section 6 - STEERING SYSTEM and Section 3 - slowly. The oil must go through the bearings to the lower part of
ELECTRICAL SYSTEM for additional information. the MDU. Fill until the oil just starts to run out. Install the plug
and tighten to 22 N«m (17 Ibf ft).
13. Lubricate the large ball bearing using the recommended
grease listed in Section 2 and adding the grease through both 15. Close the drive unit compartment door. Install and connect
fittings. Slowly rotate the MDU while filling the fittings with the battery.
4-10
Yale
ADJUSTMENT OF CORRECT CONTACT PATTERN OF

GEAR TEETH
STEP 1. Apply gear-marking compound to
about 12 teeth of the ring gear.
CORRECT CONTACT PATTERN
STEP 2. Apply a small amount of resistance to
the drive wheel and rotate the pinion
gear using a wrench. Rotate the pinion
gear so the ring gear makes one revo¬
lution.
STEP 3. Check the tooth contact pattern on the

ring gear. Checkthe pattern on the side
of the tooth where the pinion teeth ap¬
ply the force.
WRONG CONTACT PATTERN
HIGH NARROW CONTACT

If the pattern shows the pinion gear is too far
from the center of the ring gear, an adjustment
in the direction of the arrows is necessary.
<= Adjust the thickness of the shim sets as
T described in the assembly procedure.
LOW NARROW CONTACT

If the pattern shows the pinion gear is too close
to the center of the ring gear, an adjustment in
the direction of the arrows is necessary. Adjust
the thickness of the shim sets as described in
the assembly procedure.
SHORT HEEL CONTACT

If the pattern shows the pinion gear is too close
T
P to the center of the ring gear, an adjustment in
the direction of the arrows is necessary. Adjust
the shim sets at the ring gear as described in the
assembly procedure.
p
SHORT TOE CONTACT If the pattern shows the pinion gear is too far
from the center of the ring gear, an adjustment
in the direction of the arrows is necessary.
Adjust the shim sets at the spiral ring gear as
€
T
described in the assembly procedure.
Figure 4-11 - Gear Tooth Contact Pattern
4-11
Yale
IndustrialTrucks drive unit
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE
Lift truck will not move Traction motor not operating
Damaged gears or bearings

Master drive unit makes noise There is not enough lubricant or the wrong lubricant has been
used
Dry or damaged bearings
Wrong bearing or gear adjustment
Worn or damaged gears

Oil leaks at the housing cover Housing cover is not sealed or properly seated
Capscrews not sealed off or not tightened to specified torque

Oil leaks at the wheel shaft Shaft seal incorrectly mounted or damaged
Surface of axle shaft damaged
Oil leaks at the filler plug or drain plug Dirt between sealing ring and housing
Plugs not tightened to specified torque

Oil leakage between lower and upper housings Sealing surface not sealed off
Capscrews not tightened to specified torque

Oil leaks in motor compartment Too much oil in transmission
Breather defective
Traction motor seal defective
Banging noise at helical gears Teeth on the helical gear or helical pinion damaged
Ringing noise Helical gear and pinion running without lubrication

Grinding noise Bearing preload or backlash not properly adjusted
Trunnion bearing difficult to turn, binds or exceeds maximum The centering ring has separated and dirt has penetrated into
clearance the bearing
Cage segments are damaged
Deformation of the balls or ball races
Bearing not properly lubricated
4-12
Yale
IndustrialTrucks
SECTION 5
BRAKE SYSTEM
Yale
IndustrialTrucks
BRAKE SYSTEM
GENERAL 5-1
DESCRIPTION AND OPERATION 5-1
BRAKE SWITCH 5-1
ELECTRIC BRAKE-REMOVAL AND DISASSEMBLY 5-2
ELECTRIC BRAKE ADJUSTMENT 5-2
ELECTRIC BRAKE-ASSEMBLY AND INSTALLATION 5-2
BRAKE SWITCH-REMOVE AND REPLACE 5-3
TROUBLESHOOTING 5-4
Yale
IndustrialTrucks BRAKE SYSTEM
GENERAL
This section provides the description and repair procedures for

the electric brake assembly.
DESCRIPTION AND OPERATION
The electric brake is installed on the top of the drive motor. The
brake assembly has a coil, a mounting flange, an armature, a
hub, and rotor, with two function surfaces. The coil is fastened
to the housing of the drive motor. The hub is installed on the
shaft of the drive motor. The rotor is installed between the
armature and mounting flange. The rotor engages the
armature and mounting flange, and rotates with the shaft of the
motor.
When the operator releases the brake switch on the operator

platform by removing his foot, the brake is automatically
applied. When the brake is applied, springs push the armature
plate against the rotor and push the rotor against the mounting
flange. The operator must engage the brake switch to release
the brake. The brake switch energizes the coil. The coil pulls
the armature away from the rotor.
Several conditions can cause application of the brake because

the brake is used on several different units. These are the
conditions that apply the brake:
• Brake switch is released.

• Key switch is turned to OFF.
• Power disconnect circuit is activated.
• The automatic shutoff circuit is activated.
• A lift chain is slack (slack chain switch activated).
©
• A side gate is up (side gate switch activated).
BRAKE SWITCH
The brake switch assembly is located in the floor of the 1. MOUNTING FLANGE
operator's platform. 2. ROTOR
3. HOLLOW SPACER
NOTE: If the lift truck must be moved without battery power, 4. ARMATURE
the brake can be manually released. There are two holes with 5. SPRING
1/4-20 UNC threads in the back plate. Install capscrews in the 6. HUB
holes. Use the capscrews to push the armature plate awayfrom 7. COIL
the friction disc.
8. WASHER
9. CAPSCREW NA00204
WARNING: When the brake is manually
released, put a "DO NOT OPERATE" tag on the
steering wheel.
Figure 5-1 - Electric Brake
5-1
Yale
ELECTRIC BRAKE-REMOVAL AND DISASSEMBLY 1. Loosen the three capscrews that secure the brake
assembly to the mounting flange.
AI
1.
\ WARNING: Disconnect the battery connector
before starting any repairs.
2. Turn the hollow spacers clockwise two or three
revolutions.
Disconnect the battery connector.
3. Using a measuring device between the coil and armature,
set the air-gap slightly smaller than the desired air-gap, .010 in.
2. Disconnect the wiring harness connector from coil
(.25 mm) by turning the capscrews clockwise.
connector.
NOTE: The air-gap adjustment is made when turning the
3. Removethethree capscrews and washers that secure the
capscrews, not the hollow spacers.
brake to the mounting flange.
4. Turn the hollow spacers counterclockwise until they are
4. Carefully remove the coil, springs, armature, rotor, hub,
snug against the mounting flange. The air-gap should now be at
and hollow spacers from the mounting flange.
the desired .012 in. (.3 mm).
5. Remove the mounting flange from the motor.
5. Check that the final setting is correct.
6. Use adhesive sealant on the capscrews.
NOTE: Acceptable adhesive sealants include those below:

Loctite Corporation No. 290
Felt-pro Inc. Pro-Lock
Saf-T-Lok Chemical Corp. Saf-T-Lok S90
7. Tighten the three capscrews. Torque to 33 Ibf (45 N-m).
8. Connect the wiring harness connector to the coil

connector.
9. Connect the battery connector.

c
CM 1. MOUNTING FLANGE
Y—
ELECTRICAL BRAKE-ASSEMBLY AND INSTALLATION
O 2. ROTOR
3. HOLLOW SPACER 1. Install the mounting flange on the motor.
4. ARMATURE
5. SPRING 2. Install the key and hub on the motor shaft.
6. HUB
3. Install the washer and nut. Torque the nut to 80 Ibf
7. COIL
(12 N*m). Loosen the nut to the first alignment position and
8. WASHER install a new cotter pin.
9. CAPSCREW
NA00205 4. Install the springs between the coil and armature.
Figure 5-2 - Electric Brake 5. Install the hollow spacers through the armature engaging
the screw holes in the coil. Turn the hollow spacers clockwise
two or three revolutions.
ELECTRIC BRAKE-ADJUSTMENT
Newbrakes are preadjusted atthe factory to the correct .012 in. 6. Place the three washers on the capscrews and installthem
(.3mm) air-gap (distance between coil and armature). See through the coil into the hollow spacers.
Figure 5-2. As the brakes wear, the air-gap will increase.When
the air-gap reaches two or three times the specified value, it 7. Install the brake assembly onto the mounting flange.
should be adjusted. The air-gap should also be adjusted
whenever the rotor replaced. 8. Make the air-gap adjustment. See Electrical Brake
Adjustment.
5-2
Yale
BRAKE SWITCH-REMOVE AND REPLACE the switch. Put labels on the wires. Make sure the labels
accurately describe the connections on the switch. Disconnect
the wires and remove the switch.
WARNING: Disconnect the battery connector
before starting any repairs
When a switch is installed, connect the wires according to the
labels. Figure 5-3 shows typical connections. If necessary, see
The brake switch assembly is in the floor of the operator's the wiring diagrams found in Section 3.
platform. Remove the cover of the assembly to get access to
1. SCREW 5. NUT
2. COVER 6. SWITCH ASSEMBLY
3. SPRING 7. SPRING
4. SCREW NA00722
Figure 5-3 - Brake Switch
5-3
Y&to
IndustrialTrucks brake system
TROUBLESHOOTING
The brake will not release. The battery is discharged.
The battery is not connected.
The wires to the brake assembly are not connected.
The wires to the brake switch are not connected.
The brake switch has a defect.
The brake assembly is not adjusted correctly.

The automatic shutoff circuit has applied the brake.
The brake will not stop the lift truck. The brake is not adjusted correctly.
The friction disc is worn or damaged.
There is oil or grease on the friction disc or brake plates.
5-4
Yale
IndustrialTrucks
SECTION 6
STEERING SYSTEM
Yale
IndustrialTrucks
STEERING SYSTEM
GENERAL 6-1
DESCRIPTION 6-1
CHECKS AND ADJUSTMENTS 6-1
GENERAL 6-1
CHECKS 6-1
DIPSWITCHES 6-2
LED INDICATORS 6-2
CHECKING THE STEERING SYSTEM
FOR CORRECT OPERATION 6-3
CHECKING SLOW TRAVEL SPEED 6-3
CHECKING HIGH LIFT TRACTION SHUTOFF 6-3
ADJUSTMENTS 6-3
GENERAL 6-3
TACH GENERATOR STEERING SYSTEM 6-4
TACH GENERATOR ADJUSTMENT 6-4
SENSITIVITY ADJUSTMENT 6-4
FEEDBACK POTENTIOMETER ADJUSTMENT 6-5
SMART STEERING SYSTEM 6-5
COMMAND POTENTIOMETER ADJUSTMENT 6-5
FEEDBACK POTENTIOMETER ADJUSTMENT 6-6
STEERING CHAINADJUSTMENT 6-7
REPAIR 6-7
TACH GENERATOR STEERING SYSTEM 6-7
TACH GENERATOR REPLACEMENT 6-7
SMART STEER STEERING SYSTEM 6-7
COMMAND POTENTIOMETER REPLACEMENT 6-7
FEEDBACK POTENTIOMETER REPLACEMENT 6-8
ELECTRONIC CONTROL MODULE REPLACEMENT 6-8
STEER MOTOR ASSEMBLY AND STEERING CHAIN
REPLACEMENT 6-8
TYPICAL OPERATING VOLTAGES 6-9
Yale
IndustrialTrucks STEERING SYSTEM
GENERAL operator input. The Electronic Control Module processes the

This section contains procedures for adjustment, repair and signal to a scertain the steer angle selected by the operator.
troubleshooting of the Electric Power Steering System. The The feedback potentiometer is connected to the steer motor.
system controls the steer motor used to turn the Master Drive The feedback potentiometer provides a signal to the Electronic
Unit. The lift truck is steered by turning the Master Drive Unit. Control Module that corresponds to the position of the master
drive unit.
There are three Electric Power Steering Systems available: the
standard system called Tach Steer Generator Steering System The signal from the command potentiometer (or tach genera¬
(TGS), the optional Smart Steering System and the Wire tor) andthe signal from the feedback potentiometer are sent si¬
Guidance Steering System. This section covers the standard multaneously to the Electronic Control Module. If the master
TGS System and the optional Smart Steering System only. drive unit is not at the operator-selected angle, the Electronic
Control Module provides electrical output to the steer motor.
NOTE: This section is NOT applicable to lift trucks with the
optional Wire Guidance Steering System. See SECTION 7 The steer motor is coupled to the master drive unit with a
WIRE GUIDANCE for checks, adjustments, and repairs to the sprocket and chain. The electrical output to the steer motor
steer system of trucks equipped with the Wire Guidance causes the motor to rotate the sprocket and chain and turn the
Steering System. master drive unit. As the master drive unit approaches the se¬
lected angle, the signal from the feedback potentiometer
DESCRIPTION changes to instruct the Electronic Control Module to slow and
then stop the rotation of the steer motor.
The Electric Power Steering system is comprised of the
following components:
a. Steering handle (Smart Steer System) or steering
wheel (TGS System) General
b. Command potentiometer (Smart Steer System) orthe Do not make adjustments to a properly operating steering
tach generator (TGS system) system.
c. Feedback potentiometer
d. Steering system wire harness WARNING: Do not operate a lift truck that needs
e. Electronic Control Module (ECM) adjustments or repairs. Report the need for
f. Lift truck battery adjustments or repairs immediately. If adjustment
g. Steer motor or repair is necessary, put a "DO NOT OPERATE" tag in the
h. Steering sprocket and chain operator's area. Remove the key from the key switch.
The TGS system has a steering wheel coupled to a belt-driven WARNING: Some of the checks and adjustments
tach generator. The steering wheel does NOT automatically re¬ are done with the battery connected. Never have
turn to the center position. any metal on your fingers, arms or neck. During
some checks or adjustments, the operator must move the lift
The Smart Steering System has a steering handle that returns truck. The person doing the adjustments must make the
to the center position when released. The handle moves 100° adjustments with the system energized. Make sure the
each side of center for the full range of steering control. operator does not move the lift truck to cause an injury.
The steering wheel and tach generator for the TGS system are
located in the operator's compartment. The steering handle CHECKS
and command potentiometer for the Smart Steer system are lo¬
Three test points are provided for adjustment of the Electronic
cated in the operator's compartment. The Electronic Control
Control Module. TP1 is the feedback potentiometer input
Module and steer motor are in the motor compartment beside
adjusted by P2. TP2 is NOT used in the tachometer steering
the master drive unit. The feedback potentiometer is connected
system. TP3 is the analog and logic common. Light Emitting
to the steer motor below the steer sprocket. The steering chain Diodes (LEDs) 1 through 5, located on the Electronic Control
connects the steer sprocket at the gear motor to the sprocket of Module circuit board, are used to indicate system faults.
the master drive unit. The Electronic Control Module is also lo¬
cated in the steer motor compartment.
The command potentiometer attached to the steering handle
provides a signal to the Electronic Control Module correspond¬
ing to the operator input. Similarly, the tach generator coupled
to the steering wheel on the optional TGS system provides a
signal to the Electronic Control Module corresponding to the
6-1
Yale
Industrial Trucks STEERING SYSTEM
Dipswitches LED Indicators
A CAUTION: The dipswitches are factory-set and

should not need to be adjusted.
If the Electronic Control Module (ECM) is replaced or the

The Electronic Control Module continuously monitors the
steering system. Problems detected by the Electronic Control
Module are indicated by 5 LEDs. See Figure 6-2. These
vehicles equipped with electric steering systems are designed
to stop automatically when a fault occurs. The brake relay,
settings of the dipswitches are inadvertently changed, see located in the Electronic Control Module, applies the brake to
Figure 6-1 to set the position of the dipswitches to the factory stop the vehicle if a fault condition is detected.
settings.
On trucks equipped with the optional TGS steer system, an

-
Table 1 LED Indicators
adjustment can be made to the settings of dipswitches 5, 6, and LED 1 on (green) Controller active
(with motor clicking sound)
7 to alter the sensitivity of the tach generator input scaling, if
desired. Refer to Tach Generator Steering System - Sensitivity LED 2 on (red) Left limit reached
Adjustment in the ADJUSTMENTS section.
LED 3 on (red) Right limit reached
LED 4 on, LED 5 off Error in sensor circuit

Error in controller or motor
LED 4 off, LED 5 on
circuit
SET SWITCH 8 FOR LED 4 on, LED 5 on Error in controller

RTC STEER
Supply contactor fault or
voltage on emergency
LED 4, LED 5 off, and LED brake coil (the controller
1 on (with no sound from must remain off for a mini¬
SET SWITCH 8 FOR motor) mum of 2 seconds before a
TACH STEER
new startup to avoid an er¬
ror condition)
Figure 6-1 Dipswitches - Factory Settings
6-2
Yale
IndustrialTrucks steering system
O o
LED'S
DIPSWITCHES TEST POINTS POTENTIOMETERS
RE 1 TP3TP2TP1 P2 PI P3
M1
O
M2
11 1213 10 11 12 13 14 15 16 17
Figure 6-2 - Electronic Control Module
Checking the Steering System for Correct Operation Checking High Lift Traction ShutOff
The Electronic Control Module check includes checks for the 1. Instructthe operator to raisethe platform above 3810 mm
command potentiometer and the feedback potentiometer. (150 in).
1. Open the motor compartment door. Movethe key switch to 2. The traction system should NOT operate with the operator
the ON position and push the foot switch. platform above 3810 mm (150 in) unless the truck is equipped
with the high lift travel-enable option. If the unit is so equipped,
2. Make sure the battery has a corrected specific gravity of at check that the traction system operates normally EXCEPT
least 1.250. To check the system for correct operation, move when the steering is set for 7° or more from center and the
the steering handle or steering wheel from a full left turn position operator platform is above 3810 mm (150 in) . If the steering is
to a full right turn position. The master drive unit should move set for more than 7° and the operator platform is above 3810
85° to 95° in each direction from straight travel. mm (150 in), the traction system should NOT operate.
3. If the master drive unit moves less than 90° ±5°) in either ADJUSTMENTS
direction, the steering is incorrectly adjusted or may have a
General
mechanical problem. Refer to ADJUSTMENTS.
NOTE: This section is NOT applicable to lift trucks with the
4. Check that the master drive unit moves through the full optional Wire Guidance Steering System. See STEERING
rangeof rotation infive seconds or less. The lift truck must be on -
SYSTEM WIRE GUIDANCE II SECTION 7 for checks and
smooth concrete with a fully charged battery and no load. adjustments to the Wire Guidance Steering System.
5. If the master drive unit requires greater than 5 seconds to Make sure the battery has a corrected specific gravity of at least
move through the full range of rotation, check for a mechanical 1.250. Movethe lift truck to an open area where it can be driven
problem or defective Electronic Control Module. in a straight line for a distance of at least 9 metres (30 ft).
Checking Slow Travel Speed NOTE: Do not make adjustments to a properly operating
steer system. The following adjustments must be done in the
NOTE: The slow travel speed is checked during the
adjustment procedure. Refer to ADJUSTMENTS.
order specified. Do not move the steering wheel or handle after
it has been accurately centered unless instructed to move it in
the following procedures.
6-3
Yale
DRIVE
BELT
NA00663
Figure 6-3 - Tach Generator Steering

TACH GENERATOR STEERING SYSTEM Table 2 - Sensitivity Adjustment
Switch 5, 6, and 7 closed Maximum Sensitivity
Tach Generator Adjustment
Switch 6 and 7 closed,
The tach generator is located at the steering mechanism in the switch 5 open
instrument panel. Remove the screws at the top of the instru¬ Switch 5 and 7 closed,
ment panel. Tilt the panel to the open (down) position for access switch 6 open
to the tach generator.
Switch 7 closed, switch 5 (Factory Setting)
The tach generator does not require adjustment. Check the and 6 open
drive belt for proper alignment and verify that the belt is not ex¬ Switch 5 and 6 closed,
cessively worn. Replace as required. See Figure 6-3. switch 7 open
Switch 6 closed, switch 5
Sensitivity Adjustment and 7 open
WARNING: Changing the sensitivity setting of the Switch 5 closed, switch 6

and 7 open
tach generator steering system alters the amount
of operator effort required to steer the truck. Notify Switch 5, 6, and 7 open Minimum Sensitivity
all affected operators that the truck may steer differently before
operation. Use caution to avoid injury.
The sensitivity of the TGS steering system is adjusted by

changing the position of dipswitches 5, 6, and 7. Do not change
any other dipswitches. See Table 2.
6-4
Yale
Feedback Potentiometer Adjustment

1. Center the drive tire for straight travel.
2. Refer to Figure 6-5 to identify the feedback potentiometer.
Unplug the connector from the feedback potentiometer.
3. Measure the resistance between wires 16 and 17. Mea¬

sure the resistance between wires 17 and 18.
4. Adjustthefeedback potentiometer untilthe resistanceval¬
©
ues measured in Step 3 are equal (± 50 ohms). Adjust the po¬
tentiometer by loosening the retaining nut and moving the po¬
tentiometer body to attain the desired resistance readings. ©
Tighten the retaining nut without moving the potentiometer
body.
5. Attach the plug removed in Step 2 to the feedback poten¬ ©
tiometer. Set the key switch to the "ON" position.
6. Measurethe voltage across TP3 and TP1 on the Electron¬
ic Control Module circuit board by inserting the negative probe
into TP3 andthe positive probe in TP1 .Adjust potentiometer P2
on the Electronic Control Module circuit board to a value of 0
Volts DC (± 0.05 VDC).
A WARNING: During the following check, the

operator must move the lift truck. Use caution to
avoid injury.
7. Operate the lift truck in a straight line for at least 30 feet,

1.
2.
3.
STEERING WHEEL
TACH STEER ASSEMBLY
TACH STEER BRACKET
4. SPACER
making corrections with the steering wheel as necessary to
keep the truck traveling in a straight line. At the end of the 30
5. TIMING BELT
feet, do not touch the steering wheel. Adjust potentiometer P2 6. STEERING SHAFT
again as described in Step 6. 7. STEERING KNOB ASSEMBLY
8. SPROCKET NA00651
8. Repeat this procedure a minimum of 3 times to insure ac¬
curate potentiometer adjustment. -
Figure 6-4 Tachometer Steering
SMART STEERING SYSTEM 4. Adjust the command potentiometer until the resistance
values measured in Step 3 are equal (±50ohms). Adjustthe po¬
Command Potentiometer Adjustment tentiometer by loosening the retaining nut and moving the po¬
tentiometer body to attain the desired resistance readings.
The command potentiometer is located at the steering mecha¬ Tighten the retaining nut without moving the potentiometer
nism in the instrument panel. See Figure 6-4. Remove the body.
screws at the top of the instrument panel. Tilt the panel to the
open (down) position for access to the potentiometer. 5. Attach the plug removed in Step 2 to the command poten¬
tiometer.
1. Set the key switch in the "OFF" position.
6. Set the key switch to the "ON" position.
2. Unplug the connector from the command potentiometer.
See Figure 6-4. 7. Measure the voltage across TP3 and TP2 on the Electron¬
ic Control Module circuit board by inserting the negative probe
3. Use an ohmmeter to measure the resistance between into TP3 andthe positive probe in TP2. Referto Figure 6-2. Ad¬
wires 19 (black) and 20 (green). Measure the resistance be¬ just potentiometer P1 on the Electronic Control Module circuit
tween wires 20 (green) and 21 (white). board to a value of 0 Volts DC (± 0.05 VDC).
6-5
Yale
Feedback Potentiometer Adjustment 12. Draw a straight line between the first and last marks. The
center mark must be within 76 mm (3 in) of the line. If the center
A CAUTION: Make sure the Smart Steering

command potentiometer is properly adjusted
before adjusting the feedback.
1. Centerthetireandsteerhandleforstraighttravel. Afterthe
mark is within this specification, P2 is correctly adjusted. If the
mark is NOT within the specification, adjust P2 until the trial is
successful.
drive tire and handle are centered, do not adjust the steer
handle again until specifically instructed to do so in this
procedure.
2. Refer to Figure 6-5 to identify the feedback potentiometer.

Unplug the connector from the feedback potentiometer. MOTOR
3. Measure the resistance between wires 16 and 17.

Measure the resistance between wires 17 and 18.
4. Adjust the feedback potentiometer until the resistance

values measured in Step 3 are equal (±50 ohms). Adjust the
potentiometer by loosening the retaining nut and moving the
potentiometer body to attain the desired resistance readings. MOTOR
Tighten the retaining nut without moving the potentiometer MOUNTING
body. BRACKET
5. Attach the plug removed in Step 2 to the feedback

potentiometer.
6. Set the key switch to the "ON" position.
NOTE: If there are no steering changes within a 10 second CHAIN

period, the Electronic Control Module removes power to the
steer motor. To restore power to the steer motor, cycle the key
from the "ON" position to the "OFF" position, and then back to
the "ON" position. SPROCKET
7. Measure the voltage across TP3 and TP1 on the

Electronic Control Module circuit board by inserting the
POTENTIOMETER
negative probe into TP3 and the positive probe in TP1 . See
MOUNTING
BRACKET
Figure 6-2. Adjust potentiometer P2 on the Electronic Control
Module circuit board to a value of 0 Volts DC (± 0.05 VDC).
A
WARNING: During the following check, the
operator must move the lift truck. Use caution to
FEEDBACK
avoid injury.
POTENTIOMETER
8. Operate the lift truck in a straight line for at least 30 feet,
without touching the steer handle. Adjust potentiometer P2 FL1179
again as necessary to ensure the lift truck travels in a straight
line within 152 mm (6 in.) in 9 meters (30 ft.). Figure 6-5 - Motor Mounting Assembly
9. To verify thatthe lifttruck is traveling in a straight line, install
a pointer at the center of the front (master drive unit end) of the
lift truck. Make a mark on the floor under the point of the pointer.
10. Operate the lifttruck straightforward 5 meters (15 ft). Make

a mark on the floor under the point of the pointer.
11. Operate the lifttruck straight forward 5 more meters (15 ft) .
Make another mark on the floor under the point of the pointer.
6-6
Yale
STEERING CHAIN ADJUSTMENT ure the clearance betweenthe straight edge andthe chain. The
clearanceshould not exceed3.3 mm (0.13 in). See Figure 6-6.
1. Disconnect the battery connector. Open the motor com¬
partment doors. 4. Tighten the adjustment nut atthe master drive unit sprock¬
et to obtain a maximum clearance of 3.3 mm (0.13 in) between
2. Position a straight edge (e.g. a thin piece of rigid material) the chain and straight edge. Do NOT tighten the chain to a
against the steering chain between the sprockets. Make sure clearance of less than 1.3 mm (0.05 in).
the chain is tight on the opposite side of the sprockets.
5. Close and fasten the motor compartment doors.
3. Push on the chain at a point approximately halfway be¬
tween the sprockets with aforce of 9 to 12 kg (20-25 lbs) . Meas¬
(0.05 to 0.13
1.3 to 3.3 mm
1. MOTOR SPROCKET
2. MDU
3. STEERING CHAIN
4. STRAIGHTEDGE
5. ADJUSTING BOLT
6. ADJUSTING NUT
-
Figure 6-6 Steer Chain Adjustment
REPAIR 7. Installthetach generator mounting brackettothe newtach
generator.
TACH GENERATOR STEERING SYSTEM
8. Insert the tach generator in place and install the tach
Tach Generator Replacement generator drive belt.
1. Disconnect the battery connector. 9. Install the capscrews, washers, and nuts that retain the
tach generator mounting brackettothe steering wheel bracket.
2. Remove the screw that fastens the steering wheel to the
shaft of the steering mechanism. Remove the steering wheel. 10. Connect the wire harness to the tach generator.
3. Remove the screws atthe top of the instrument panel. Tilt 11. Install the instrument panel and connect the battery
the instrument panel to the open position for access to the connector.
parts.
SMART STEER STEERING SYSTEM
4. Disconnect the wire harness to the tach generator.
Command Potentiometer Replacement
5. Remove the capscrews, washers and nuts retaining the
tach generator to the steering wheel bracket. 1. Disconnect the battery connector.
6. Remove the tach generator drive belt. 2. Remove the screw that fastens the steering handle to the
shaft of the steering mechanism. Removethe steering handle.
6-7
Yale
3. Remove the screws at the top of the instrument panel. Tilt Electronic Control Module Replacement
the instrument panel to the open position for access to the
parts.
1. Disconnect the battery connector and open the motor
compartment door.
4. Remove the capscrews that fasten the steering
2. Disconnect the wire harness plugs to the Electronic
mechanism bracket to the back of the instrument panel.
Control Module.
5. Remove the setscrew that fastens the shaft of the
3. Prevent the Electronic Control Module from falling while
command potentiometer to the steering shaft. Remove the
removing the mounting capscrews, washers and nuts.
capscrew and nut that fasten the bracket for the command
potentiometer. Remove the bracket and potentiometer.
4. Use caution when handling the Electronic Control Module
Remove the potentiometer from the bracket. Label the
to avoid spreading the heat-transfer grease from the underside
potentiometer wires for correct connections during
of the module to the surrounding areas.
installations.
5. Install heat-transfer grease on the underside of the
6. Install the new command potentiometer, as required.
replacement module and the frame. Install the module on the
Connect the wires of the command potentiometer.
frame panel using the four capscrews, washers and nuts.
7. Install the steering mechanism bracket to the back of the
6. Connect the wire harness plugs.
instrument panel.
7. Refer to ADJUSTMENTS to adjust the potentiometers on
8. Connect all wires disconnected during removal.
the circuit board for proper operation.
9. If the command potentiometer was replaced or the setting
8. Check the position of the dipswitches to be sure the
was changed, adjust the command potentiometer. Refer to
switches are set correctly. Refer to DIPSWITCHES.
ADJUSTMENTS. Tighten the screw that fastens the
potentiometer to the steering shaft.
Steer Motor Assembly and Steering Chain Replacement
10. Close the instrument panel and tighten the screws. Install 1. Disconnect the battery and open the motor compartment
the steering handle on the shaft of the steering mechanism. doors.
tighten the screw.
2. Disconnect the wire harness plug to the feedback
Feedback Potentiometer Replacement potentiometer. Remove the nuts that fasten the feedback
potentiometer bracket to the frame.
1. Position the master drive unit for straight travel.
Disconnect the battery connector.
3. Hold the motor assembly and remove the capscrews, nuts
andwashers that fasten the motor assembly to the frame panel.
2. Open the motor compartment door. Disconnect the
electrical plug for the feedback potentiometer.
4. Carefully tip the top of the assembly away from the panel to
remove the motor and feedback potentiometer bracket out of
3. Loosen the setscrew that fastens the shaft of the
the truck. Do NOT bendthe bracket. Remove the steering chain
potentiometer to the motor assembly. Remove the nut that
from the sprocket and remove the motor assembly.
fastens the potentiometer to the bracket. Remove the
potentiometer.
5. Remove the steering chain from the master drive unit
sprocket as required by pulling the chain anchor pins out of the
4. Set the new feedback potentiometer for mid-range. Install
holes in the sprocket. Clean and lubricate the chain using
the new potentiometer on the bracket. Install the nut to fasten
multi-purpose grease.
the potentiometer, but do not tighten the nut or setscrew.
6. Make sure the master drive unit is aligned for straight
5. Adjust the feedback potentiometer. Refer to
travel. Install the steering chain on the master drive unit
ADJUSTMENTS. Tighten the nut and setscrew without moving
sprocket. Install the pin of the chain anchor in the first hole
the potentiometer body or shaft to avoid changing the setting.
before the axle centerline.
Connect the plug.
7. Install the new motor, sprocket, and feedback
6. Close the motor compartment doors. Connect the battery.
potentiometer assembly. Tighten the capscrews and nuts to 31
N m (23 Ibf ft) torque.
6-8
Yale
8. Adjust the feedback potentiometer. Refer to be within 10% of the values listed in the table. Voltages are
ADJUSTMENTS. measured between the designated test point and TP3
(ground). See Figure 6-8.
TYPICAL OPERATING VOLTAGES
The following table lists typical operating voltages for a

correctly adjusted steering system. Measured voltages should
AMPLIFIED
MDU
FEEDBACK COMMAND
TP1 TP2
SENSOR >6.85
ERROR
DETECTED 6.45
RIGHT
1.8
+ 7° -2.7 4.5 4.3 2.3
CENTER 0.0 0.0 4.2 4.15 2.4
-7° 3.1 3.8 4.0 2.5
LEFT
-3.8 1.8 3.9
SENSOR
ERROR <1.2 3.94
DETECTED
USED ONLY ON
SMART STEER
-
Figure 6-7 Typical Operating Voltages
6-9
Yale
IndustrialTrucks steering system
Q D B7 ÿ ÿÿ
- i II M1 1 2 3 4 5 6 7
m
ÿ>2 3 4 5
TT
6
- -M •
N- - •
10 11 12 13 14 15 16 17
Figure 6-8 - Test Point and Connector Reference

TROUBLESHOOTING

Truck will not move or steer. Battery disconnected
Shutoff has occurred; set key to OFF position, wait two seconds, then set key
to start, then to ON position.
Dipswitch in wrong position. Check dipswitches.
No action when steering wheel is turned. Open circuit in wiring between tachometer and Electronic Control Module or
between feedback potentiometer and Electronic Control Module.
Tachometer defective.
No output from Electronic Control Module to steer motor. Replace Electronic
Control Module.
Power leads defective between Electronic Control Module and steer motor.
Check all power connections.
Feedback potentiometer defective.
Check tachometer input. Test for voltage between K1-4 and TP3 when
tachometer is spun. Test for voltage between K1-6 and TP3 when tachometer
is spun. If voltage is present, Electronic Control Module defective.
Master drive unit out of normal operating range. Jack truck and manually turn
master drive unit within range.
Steer motor defective.
Steering is loose. Steering chain loose. Adjust chain for proper tension.
Truck turns in direction opposite to direction Steer motor leads reversed.
steered.
Tachometer leads reversed.
Feedback potentiometer leads reversed.
6-10
Yale
IndustrialTrucks
SECTION 7
7 STEERING SYSTEM - WIRE GUIDANCE II

Yale
IndustrialTrucks
DESCRIPTION
INTRODUCTION
GENERAL
DESCRIPTION
GENERAL
CHECKS
GENERAL
STEERING SYSTEM
OPERATION MODES
WIRE GUIDANCE
MANUAL STEERING
- WIRE GUIDANCE
HOW TO OPERATE THE WIRE GUIDANCE SYSTEM

CHECKING FOR SHORT-CIRCUITS TO THE FRAME

CHECKS TO THE LIFT TRUCK
AUTOMATIC CHECKS
MANUAL CHECKS
CHECK 01 - OPERATOR CONTROLS
CHECK 02 - STEERING INPUT VOLTAGE
CHECK 03 - MDU POTENTIOMETER COARSE AMPLIFIER
CHECK 04 - MDU CENTERING
CHECK 05 - DIRECTION INPUTS
CHECKS 06 THROUGH 09 - SENSOR LEVELS
CHECK 10 - STEERED END SENSOR BALANCE
CHECK 11 - LOAD END SENSOR BALANCE
CHECK 13 - MEDIUM TRAVEL SPEED
CHECK 14 - SLOW TRAVEL SPEED
CHECKING THE OPERATION OF THE SHUTOFF CIRCUIT
CHECKING THE STEERING AT MAST HEIGHTS
CHECKING THE ECM POWER TRANSISTORS
CHECKING THE STEERING CONTACTOR
ADJUSTMENTS
GENERAL
ADJUSTING RT1 TO THE OPERATIONAL MIDPOINT
ADJUSTING THE STEERING CHAIN CLEARANCE
CENTERING THE STEER TIRE
CENTERING THE MDU POTENTIOMETER
TRAM ADJUSTMENTS
TRAM STEER ADJUSTMENT VERIFICATION
TRAM STEER ADJUSTMENT
ADJUSTING RT2 FOR STRAIGHT TRAVEL
ADJUSTING THE TRAVEL SPEEDS
MEDIUM SPEED
SLOW SPEED
ADJUSTING SENSORS TO LIFT TRUCK CENTERLINE
.
PAGE NUMBER
......
7-1
7-1
7-1
7-2
7-2
7-3
7-3
7-4
7-4
7-8
7-8
7-8
7-8
7-8
7-10
7-10
7-10
7-10
7-10
7-11
7-11
7-11
7-12
7-12
7-12
7-12
7-12
7-13
7-14
7-14
7-14
7-14
7-15
7-16
7-16
7-17
7-17
7-17
7-17
7-18
7-18
7-19
7-20

Yale
IndustrialTrucks

STEERING SYSTEM - WIRE GUIDANCE
REPAIR 7-21
GENERAL 7-21
STEERING GEARMOTOR 7-22
REPLACING THE GEARMOTOR ASSEMBLY
AND STEERING CHAIN 7-22
STEER WHEEL ASSEMBLY 7-25
REMOVAL AND DISASSEMBLY 7-25
ASSEMBLY AND INSTALLATION 7-26
REPLACE GUIDANCE SWITCH, INDICATOR, AND ALARM 7-27
REPLACE THE MDU POTENTIOMETER 7-27
REPLACE THE ECM 7-27
REPLACE THE COMPLETE MODULE 7-27
REPLACE THE LOGIC BOARD SET 7-27
REPLACE THE ECM POWER TRANSISTORS 7-28
REPLACE THE STEERING CONTACTOR 7-30
REPLACE THE SENSORS 7-31
Yale
IndustrialTrucks STEERING SYSTEM - WIRE GUIDANCE II
INTRODUCTION
GENERAL information to the ECM. The slow down and automatic shutoff
feature of the ECM will decrease the lift truck speed or stop the
This section has the description, adjustments, repair and
lift truck if the guidance system cannot sense the signal from
troubleshooting for the optional WIRE GUIDANCE system.
the guide wire. The shutoff circuit will also stop the lift truck if
This system electrically controls a motor to turn the Master
certain steering components malfunction. The guidance switch
Drive Unit (MDU) for steering.
at the instrument panel provides operator control of the
guidance system. A light near the guidance switch and an
See Section 6 STEERING SYSTEM for trucks equipped with
alarm indicate guidance system operation. A steering indicator
the standard EPS STEERING SYSTEM (trucks without wire
gauge shows the position of the steer tire. A tach generator,
guidance).
gear driven by the steering wheel and a tach steer module
provides the steering input signal to the ECM when the lifttruck
Trucks equipped with wire guidance have a means of
is in manual steering.
automatically controlling the steering system and a means of
manually controlling the steering system. Refer to
OPERATION MODES.
The system of automatically steering the lift truck is referred to

as "wire guidance" or "guidance" in this section. The system of
manually steering the lift truck is referred to as "manual
steering" in this section.
NOTE: This lifttruck can be operated with the operator facing

the steer tire or the operator facing the load forks. Throughout
this manual the terms right, left, front and rear relate to the
viewpoint of an operator standing in the truck facing the steer
tire. See Figure 7-2.
NOTE: All mechanical parts of the steering must be in good

conditionand correctlyadjusted for correct guidance operation.
NOTE: The loadwheels MUST BETHE SAME SIZE, in good 11028

condition and the bearings must be lubricated and correctly
adjusted for correct guidance operation.
1. STEERING WHEEL
DESCRIPTION
2. TACH STEER MODULE
The wire guidance system is a system to automatically steer 3. TACH GENERATOR
the lift truck. The system senses a magnetic field from an 4. MULTIPLE CONDUCTOR CABLE
electric signal carried by a guide wire buried in the floor. A wire 5. GUIDANCE SWITCH
driver generates the signal carried by the guide wire. The wire
6. GUIDANCE LIGHT
driver is part of the location installation and operates on AC
power. 7. ALARM
8. TRACTION CIRCUIT
The lifttruck has the following guidance parts: sensors at each 9. ECM
end of the lift truck, an Electronic Control Module (ECM), 10. BATTERY
gearmotor, tach generator, tach steer module, Master Drive 11. STEERING GEARMOTOR
Unit (MDU) potentiometer, guidance light, guidance switch, 12. MDU POTENTIOMETER
guidance alarm, and steering indicator gauge. The guidance 13. MDU AND CHAIN
light, switch, alarm and steering indicator gauge are located on 14. SENSOR (STEER TIRE)
the instrument panel for operator control of the system. See 15. SENSOR (LOAD WHEEL)
Figure 7-1.
There are two sensors. One sensor is at each end of the lift
Figure 7-1 - Wire Guidance
truck. When the lift truck is following the guide wire, each Each sensor is fastened to a bracket located near the floor. The
sensor is directly over the guide wire. The sensors sense the steer tire sensor bracket is on the frame at the drive unit end of
signal from the guide wire and send signals to the ECM. The the lifttruck. The bracket for the load wheel sensor is between
ECM controls the gearmotor rotation, which turns the MDU for the load wheels. The ECM is located in the motor compartment
steering. The MDU potentiometer sends MDU position
7-1
Yale
IndustrialTrucks -
STEERING SYSTEM WIRE GUIDANCE II
above the gearmotor. The alarm, switch, light and steering RIGHT SIGNAL and a LEFT SIGNAL. A total of 4 SIGNALS are
indicator gauge are fastened on the instrument panel. There sent by the 2 SENSORS ASSEMBLIES during "wire guidance"
are control cables that provide the electrical connections operation. The ECM uses the SIGNALS to monitor lift truck
between the operators compartment and the drive unit position in relation to the GUIDE WIRE and to automatically
compartment. steer the lift truck. See Figure 7-2.
The wire guidance system controls the electric power steering

OPERATION MODES
system to steer the lift truck along the guide wire. The operator
Lift trucks equipped with the optional wire guidance system activates the guidance system by pushing the guidance switch
steering control are also capable of manual steering. Manual to the ON position. The guidance system can be activated or
steering is available when the wire guidance switch is in the deactivated at anytime, by pushing the switch ON or OFF. The
"OFF" position. The operator uses a steering wheel mounted in operator must steerthe lift truck close enough to the wire and at
the operator compartment to control the steering when the the correct angle for the system to sense the signal. See
truck is in the manual steering mode. Figure 7-2. If the lift truck is in a position so that the system
senses the signal and the guidance system has been activated,
Wire Guidance the system will automatically find the guide wire.
NOTE: The guidance system must have a signal from the
Manual steering is possible when the guidance system is first
wire driver of the correct amplitude and frequency. The
activated if the system cannot sense a signal. The alarm and
standard frequency is 6,240 to 6,260 Hz with a wire current of
flashing light will both operate during this condition. Steering
76 to 80 ma. The frequency and the wire current can each be
will become automatic when the system is activated and the
differentforeach installation. Make sure thefrequency andwire
sensors can sense a signal. The alarm will stop operating and
current from the wire driver is correct for the sensors on the lift
the flashing light will be continuously illuminated after the lift
truck. See the labels on the sensors. The Yale wire driver has
truck is following the guide wire. The alarm and flashing light will
the frequency and wire current on a label inside the door. See
again operate if the guide wire signal is lost. The system will
the manufacturer for other wire drivers.
then slow the lift truck in two stages to try to sense the signal
again . If the guide wire signal cannot be sensed, the system will
NOTE: A lift truck equipped with "wire guidance" has 1
deenergize the traction circuit and apply the brake.
FRONT SENSOR ASSEMBLY and 1 REAR SENSOR
ASSEMBLY. Each SENSOR ASSEMBLY supplies 2 signals a
O FORWARD
DIRECTION OF TRAVEL
REVERSE
DIRECTION OF TRAVEL
FRONT
(STEER TIRE)
LEFT
SIDE
* RIGHT
SIDE
1. GUIDE WIRE
2. LOAD WHEEL
3. GUIDANCE SENSOR REAR
(LOAD WHEELS)
4. STEER TIRE
Figure 7-2 Operation of the Guidance System

7-2
Yale
IndustrialTrucks -
When the wire guidance switch is ON and the lift truck is guidance light will not be a flashing light, but will remain ON.
following the guide wire, the steering is controlled by the steer The alarm stops making a noise. This is the "automatic mode".
tire sensor signals and load wheel sensor signals. The left and
right signals from each sensor are near equal when a sensor is If the lift truck is moving too fast or is at too sharp an angle, the
centered over the guide wire. If a sensor is not centered over guidance system cannot align the lift truck on the guide wire. If
the guide wire, then the signal from the portion of the sensor this happens, the alarm continues to make noise and the light
which is closest to the guide wire is stronger than the signal continues to be a flashing light. The system will return to the
from the opposite side of the sensor. The left and right sensor "search mode" and it will be necessary to again manually steer
signals become unequal or unbalanced as the center of the the lift truck toward the guide wire.
sensor moves away from the guide wire. During normal
guidance operation, the centerline of the lift truck is centered As the guidance system finds the guide wire, the alarm
over the guide wire. continues to makenoiseandthe light continues to be aflashing
light. The guidance system automatically steers the lift truck to
The wire guidance system receives signals from the system align it over the guide wire ("acquisition mode") .The automatic
sensors and from the MDU potentiometer. The ECM uses the shut-off circuit is not activated and manual steering will not
input signals to keep the lift truck following the path of the wire. operate. The automatic shut-off circuit is activated after the lift
truck is aligned and the alarm stops making noise. This is the
The wire guidance system isdeactivatedandthe operator must "automatic mode". At this time, the light will not be a flashing
manually steer the lift truck when the guidance switch is in the light, but will remain ON.
OFF position.
If the guidance system finds the guide wire but later loses the
Manual Steering signal from the wire, the light is a flashing light and the alarm
makes noise. These conditions occur when the center of the lift
When the wire guidance switch is OFF the steering iscontrolled truck is approximately 32 mm (1.25 in) off the guide wire. If this
by the operator rotating the steering wheel. The steering wheel happens, the system will first slow the lift truck to a maximum
is located in the operator compartment and is connected to a speed of approximately 6.4 km/h (4 mph). If the system still
tach generator. The output from the tach generator goes to the cannotfind the signal, itwill then slow the lift truck toamaximum
tach steer module. The tach steer modulesends a signal to the speed of approximately 3.6 km/h (2.25 mph). These conditions
ECM to move the MDU. occur when the center of the lift truck is approximately 38 mm
(1.5 in) off the guide wire. If the system cannot find the wire to
See Section 6 - STEERING SYSTEM for additional return to the "automatic mode", automatic shut-off occurs.
information on how manual steering works. Refer to These conditions occur when the center of the lift truck is
INTRODUCTION, DESCRIPTION. approximately 44 mm (1 .75 in) off the guide wire. The traction
circuit is deenergized and the brake is applied.
HOW TO OPERATE THE WIRE GUIDANCE SYSTEM
If automatic shut-off occurs, it is necessary to reset the system.
Turn the key switch to the OFF position, then energize the
The operation of the wire guidance system is controlled by the
electrical system of the lift truck for continued operation.
guidance switch. Pushing the switch to the ON position, as the
lift truck comes to the guide wire, energizes the guidance
When a direction change is made in guidance, the light is a
system to find the wire. This is the "search mode" of guidance.
flashing light and the alarm comes on for approximately 1-3
The guidance light is a flashing light, the alarm makes a noise
seconds. During this time the automatic shut-off function is
and the lift truck is automatically limited to "slow speed".
deactivated. This permits the lift truck to make the necessary
steering corrections andthen automatically steer the lift truck in
Forthe system to find the guide wire, the lift truck must be driven
the opposite direction.The guidance system will also adjust for
at a slow speed to the guide wire. The guidance system can find
steer tire sensor or steer tire and load wheel sensor operation
the guide wire at an angle of 30° or less when traveling in the
depending on the direction the lift truck is now traveling.
steertire direction. When traveling in the load wheel direction, it
is necessary to align the lift truck on the guide wire. The lift truck
NOTE: If the guidance switch is in the ON position when the
must be aligned within approximately 44 mm (1.75 in) of the
key is turned to the ON position, the guidance system will
guide wire. See Figure 7-2. Both sensors are used when
automatically operate on guidance. The lift truck will operate on
traveling in the load wheel direction. Only thesteertire sensor is
guidance until the guidance switch is pushed to the OFF
used when traveling in the steer tire direction.
position for manual steering or until automatic shut-off occurs.
There will NOT be automatic steering unless the lift truck is on
When the guidance system first senses the magnetic signal the guide wire.
from the guide wire, it automatically steers the lift truck to follow
the wire. This is the "acquisition mode". The manual steering
will not operate. If the guidance system finds the guide wire, the
7-3
Yalo
IndustrialTrucks -

GENERAL NOTE: If a check or an adjustment takes longer than 10
seconds, it can be necessary to move the steering wheel
A WARNING: Disconnectthe battery by separating slightly. The ECM will remove power from the steering
Xf\ the connector before opening the compartment
cover or inspecting/repairing the electrical system.
gearmotor if there are no steering changes in a 10 second
period. Some checks or adjustments require power to the
If a tool causes a short-circuit, the high current flow from the gearmotor.
battery can cause an injury or parts damage.
NOTE: The checks, adjustments and test procedures in this
/\ WARNING: The capacitor in the SCR controller section are for testing and adjusting the separate components.
/|\ can hold an electrical charge after the battery is The procedures are not in a specific sequence and this
disconnected. To prevent electrical shock and sequence is NOT a troubleshooting sequence.
injury, discharge the capacitor before inspecting or repairing
any component in the rear compartment. Wear safety glasses. /\ WARNING: Many of the checks and adjustments
Make certain the battery has been disconnected. Use a /|\ are done with the battery connected. Never have
screwdriver or jumper wire between the two terminals to any metal on your fingers, arms or neck. During
discharge capacitor C1. some checks or adjustments, the operator must move the lift
truck. The person doing the adjustments must make the
Table 7-2 shows the functions of the different components of adjustments with the system energized. Make sure the
the ECM. Figure 7-4 shows the location of these components. operator does not move the lift truck to cause an injury.
Table 7-1 shows the function and the normal voltage for the
different ECM terminals. Table 7-3 shows display code A CAUTION: The steering chain MUST be correctly
descriptions. /|\ adjusted for the guidance system to operate
correctly AND to make the checks and
NOTE: Do not do any adjustments if the system operates adjustments correctly. Check and if necessary, adjust the
correctly. steering chain. Refer to ADJUSTING THE STEERING CHAIN
CLEARANCE.
A WARNING: Do not operate a lift truck that needs
/f \ adjustment or repairs. Report the need for To read the displays on the ECM circuit board or do the manual
LJLJ adjustment or repairs immediately. If adjustment or checks, you must have access to the ECM. For access, open
repair is necessary, put a "DO NOT OPERATE" tag in the the motor compartment doors and remove the ECM cover. See
operator's area. Remove the key from the key switch. Figure 7-3.
ftL f1
a
ooo op o o o o o o poo
.flm.jTm.
1. ECM COVER 3. LOGIC BOARD SET

2. NUTS AND WASHERS 4. ELECTRICAL PLUGS 5. SPACERS AND WASHERS
Figure 7-3 - ECM and Logic Board

7-4
Yale
The wire guidance system uses the ECM test circuit to check To do some of the tests correctly, the center of the sensors must
for correct operation and adjustment of each part of the system. be directly over the guide wire. The guidance system must have
The test circuit automatically makes some checks during a signal from the wire driver of the correct amplitude and
operation. Other checks can be done manually. These last frequency. The standard frequency is 6,240 to 6,260 Hz with a
checks are usually necessary as part of the adjustment wire current of 76 to 80 ma. The frequency and the wire current
procedures and are found in MANUAL CHECKS and in can each be different for each installation. Make sure the
ADJUSTMENTS of this section. Switch S1 on the ECM circuit frequency and wire currentfrom the wire driver is correct forthe
board, is used to change the manual check mode. Push the sensors on the lifttruck. See the labels on the sensors. The Yale
Mode button to change between checks. The two displays on wire driver has the frequency and wire current on a label inside
the ECM circuit board indicate the results of the checks. See the door. See the manufacturer for other wire drivers. The
Figure 7-3 and Table 7-1 for the locations and functions of the manual tests must be done on a straight section of the guide
parts of the circuit board. The ECM check circuit has 13 manual wire. For other checks the steer tire must be set for straight
checks 01 through 11, 13 and 14. travel. Do not move the steering afterthe steertire has been set
until told to do so in the procedure.
6 7
LEO J j LEO/ /
o PB
l_l l_l (MODE '©0©[r
II II
STICK MDU
PB POT. POT.
IDWN)
D4 CCONN D HOI
RT4
STEER
SENSOR
C4 CCONN C 3CI RT5
LOAO SI S2
SENSOR
<r
ZLd BI2 B3 12380
z5 CONN B
oo
U_l
UPPER ! EPR0M
BIO Bl
n
12 ÿ
a oz
UJ
AI2 A3 Q.
2
CONN A 3
->
UPPER T UJ
**7:
zui
:
AIO
T—U ---
0
At
ÿ 1 -P
15
-J
g
z?
K iE3°E°E 3°B °
X
oo :
o-j :
m
o o 0
UJ
1. ECM CIRCUIT BOARD 15 9. MDU POTENTIOMETER ADJUST RT 2

2. LEFT DISPLAY 10. STEER SENSOR ADJUST RT 4
3. MODE BUTTON 11. LOAD SENSOR ADJUST RT 5
4. RIGHT DISPLAY 12. SWITCHES 1 AND 2
5. UP AND DOWN BUTTONS 13. MEDIUM SPEED ADJUST RT 6
6. LED 1 14. SLOW SPEED ADJUST RT 7
7. STEER BALANCE ADJUSTMENT RT 1 15. TEST POINTS TP1 -TP15
8. LED 2
Figure 7-4 - ECM Logic Board
7-5
Yale
Table 7-1 - Guidance ECM Component Functions

COMPONENT
FUNCTION RANGE*
TESTPOINT
RT1 Steer Balance Pot N/A
RT2 MDU Centering Pot N/A
RT4 Steer Sensor Balance Pot N/A
RT5 Load Sensor Balance Pot N/A
RT6 "Medium Speed" Pot N/A
RT7 "Slow Speed" Pot N/A
S1 Test Switch N/A
S2 Not Used N/A
TP1 5 Volt Supply 4.8 to 5.2 Volts
TP2 14 Volt Supply 13 to 15 Volts
Auto: 2.7 to 4.0 Volts
TP3 Auto/Manual Input Manual 0.0 to 2.2 Volts
Steering Input Signal
TP4
During CW Rotation of Steering wheel Less Than 2.5 to Greater Than 0.1 Volts
Steering Input Signal Approximately 2.5 Volts

TP4 See Steering Input Signal Balance Adjustment for adjustment
Steering Wheel Stationary procedure and specific voltages.
Steering Input Signal
TP4
During CCW Rotation of Steering Wheel Greater Than 2.5 to Less Than 4.9 Volts
Full Left 4.7 to 4.9 Volts
TP5 MDU Coarse Center 2.4 to 2.6 Volts
Full Right 0.1 to 0.3 Volts
23° Left 4.9 to 5.5 Volts
TP6 MDU Medium Center 2.4 to 2.6 Volts
23° Right 0.0 to 0.2 Volts
5.5° Left 4.9 to 5.5 Volts
TP7 MDU Fine Center 2.45 to 2.55 Volts
5.5° Right 0.0 to 0.2 Volts
Right Rear Sensor Signal (Load Wheel) 1.5 to 2.5 Volts Truck Centered on Guide Wire
TP8 See Figure 7-2 1.0 Volts or Less Truck Away Guide Wire
Left Rear Sensor Signal (Load Wheel) 1.5 to 2.5 Volts Truck Centered on Guide Wire
TP9
See Figure 7-2 1.0 Volts or Less Truck Away Guide Wire
Right Front Sensor Signal (Steer Tire) 1.5 to 2.5 Volts Truck Centered on Guide Wire
TP10 1.0 Volts or Less Truck Away Guide Wire
See Figure 7-2
Left Front Sensor Signal (Steer Tire) 1.5 to 2.5 Volts Truck Centered on Guide Wire
TP11
See Figure 7-2 1.0 Volts or Less Truck Away Guide Wire
TP12 Motor Current Variable
TP13 Not Used N/A
TP14 Not Used N/A
TP15 Battery Negative (Common) Signal Common for all Test Points Measurements
NOTE: * FLOOR TO TIRE FRICTION CAN MAKE A DIFFERENCE IN THE READINGS WHEN A CHECK IS REPEATED.
7-6
Yale
IndustrialTrucks -
Table 7-2 - Guidance ECM Terminals

TERMINAL TERMINAL ÿVOLTAGE
OR PLUG OR PLUG FUNCTION OR CONDITION (Use Battery Negative as Common Test Point
TYPE NUMBER for All Measurements)
POWER 1 Battery Positive Battery Voltage
TERMINALS
2 Output to Steering Gearmotor 0.0 to Battery Volts - 2 Volts
(Variable L/R & Rate)
3 Output to Steering Gearmotor 0.0 to Battery Volts - 2 Volts
(Variable L/R & Rate)
4 Battery Negative 0.0 Volts
ECM PLUG A A1 Battery Negative 0.0 Volts
A2 Battery Voltage to Traction and Brake Circuits Battery Voltage
PSC & Brake Sw. Closed
A3 Battery Voltage from PSC Contactor and Brake Battery Voltage
Switches PSC & Brake Sw. Closed
A4 MDU Pot Wiper (Wiper Centered) 2.5 Volts
A5 Signal from Tach Steer Module Approximately 2.5 Volts
NOTE: See Steering Input Signal Balance
(Steering Wheel Stationary) Adjustment for adjustment procedure and
specific voltages.
A6 and A7 Speed Input (Accelerator Pot Wiper) 0.0 to 5.0 volts
A8 MDU Pot Supply Voltage 5 Volts
A9 Steer Pot/Tach Steer Module Supply Voltage 5 Volts
A10 Not Used (2.5 Volt Supply) N/A
A11 Reference Voltage to MDU Pot 0.0 Volts
A12 Reference Voltage to Tach Steer Module and 0.0 Volts
Guidance Switch
ECM PLUG B B1 Reverse Contactor Positive Connection 80% Battery Voltage (Dir. Selected)
B2 Forward Contactor Positive Connection 80% Battery Voltage (Dir. Selected)
B3 Plug Detection Signal 12 to 9 Volts (Start of Plug)
(Momentary Signal) 0 Volts (At End of Plug)
B4 Input from Guidance Switch .5 to 2.5 Volts Off
(Off=Manual) (On=Auto) 0 Volts On
B5 Input from Guidance Switch 0 Volts Off
(Off=Manual) (On=Auto) 12 to 14 Volts On
B6 Guidance Light Signal Approx. 12 Volts Off-10 Volts On
B7 Supply Voltage to Guidance Light and Alarm 12 to 14 Volts
B8 NOT USED N/A
B9 Speed Input (Accelerator Pot Wiper) Below 24" Same as A6/A7
Above 24" Same as A6/A7
B10 Guidance Alarm Signal 12 to 14 Volts Off-5 Volts On
B11 NOT USED N/A
B12 Input from Traction Control Below 24" Same as A6/A7
Above 24" Same as A6/A7
ECM PLUG C C1 Supply Voltage 14 Volts
LOAD WHEEL C2 Right Rear Output Signal on Wire Over 1 Volt and Near Equal to C3 1
SENSOR
C3 Left Rear Output Signal on Wire Over 1 Volt and Near Equal to C2 1
C4 Reference Voltage 0 Volts
ECM PLUG D D1 Supply Voltage 14 Volts
STEER TIRE D2 Right Front Output Signal on Wire Over 1 Volt and Near Equal to D3 1
SENSOR
D3 Left Front Output Signal on Wire Over 1 Volt and Near Equal to D2 1
D4 Reference Voltage 0 Volts
1 With lift truck centered on guide wire.
NOTE: * All voltage readings listed subject to ± 10% variation unless otherwise noted.
7-7
Yale
CHECKS
GENERAL 4. To check for wire connections to the frame, disconnect the
battery so that the connector is completely free and use an
CAUTION: The steering chain MUST be correctly ohmmeterto check the circuits. Checkfor 50,000 ohms or more
adjusted for the guidance system to operate between each terminal of the part of the battery connector on
correctly AND to make the checks and the lift truck and a clean connection on the frame. Make sure
adjustments correctly. Check and if necessary, adjust the there are no electrical connections to the frame of the lift truck.
steering chain. Refer to ADJUSTMENTS, ADJUSTING THE Wires or terminals without insulation can cause these
STEERING CHAIN CLEARANCE. connections. Isolators for circuit boards that are missing,
broken or not installed correctly can also cause these
Checking for Short-Circuits to the Frame connections.
It is important for the correct operation of the guidance system
5. Checkfor voltage between each terminal ofthe connector
that all system components have electrical insulation. There
on the battery and a clean metal connection on the frame ofthe
must be electrical insulation between the frame of the lift truck
lift truck. It is normal to measure some voltage between the
and each component. If a connector, cable, wire or component
battery andthe frame even if the resistance checks are correct.
is making a connection to the frame, a malfunction can occur.
If a voltage is measured, use an ammeter to determine if the
The position of a motor cable can make a magnetic field that
current level is acceptable. Current in excess of 100
can change the sensor signal . Electricalstatic can also cause a
milliamperes can cause a problem.
malfunction. Make sure all cables are installed in the same
position if they were moved for checking or replacement. Make
There can be a voltage on the frame if the battery is dirty or if the
sure all shields are correctly installed and connected. Make
battery has a defect. Clean the battery and battery
sure all insulation and isolators are correctly installed. Repair
compartment as necessary. There can also be a voltage on the
all short-circuits as soon as they are found. Keep the battery
frame if there is carbon dust in the motors. Use dry compressed
and battery compartment clean and painted. Keep all carbon
air to remove the carbon dust from all motors.
dust and dirt removed from the inside of all the motors. Use dry
compressed air.
AUTOMATIC CHECKS
CHECKS TO THE LIFT TRUCK The following paragraphs have a description of the automatic
checks that are done by the test circuit of the ECM. See
1. Move the lift truck away from the guide wire. The area
Table 7-3. There is also a description ofthe numbers on both of
should also be away from any electrical or magnetic fields.
the ECM displays during normal operation. LEDs 1 and 2 will
Connect the negative lead from a digital voltmeter (FLUKE
flash for any of the displays shown in Table 7-3.
MODEL 8060A MULTIMETER or equivalent) to TP15 on
ECM board. Putthe positive lead on terminals TP8, TP9, TP1 0
The logic system ofthe ECM makes internal checks for correct
and TP11. Turn the key switch on. Operate the truck in the
operation. The checks are automatic and occur during manual
forward and reverse directions. The highest reading should be
or automatic steering.
1 volt. If the reading at any of theterminals is over 1 volt, there is
a wire connection to the frame, probably in the traction circuit.
NOTE: When the lift truck is aligned on an energized guide
See Figure 7-4 for TP locations.
wire with the guidance system activated, the guidance system
will automatically steer the lift truck.
2. Do the same tests with the voltmeter as in Step 1. Operate
the hydraulic system and then the STEERING SYSTEM. If the
If the center of the lift truck moves off the guide wire by
reading at any of the test points is over 1 volt, there is a wire
approximately 32 mm (1 .25 in), the guidance system will show
connection to the frame, probably in the hydraulic or steering
a display of "5d 01". LEDs 1 and 2 will flash. The guidance
circuits.
.............
system will limit the lift truck to a maximum travel speed of
"medium speed".
3. Move the lift truck to an area that does NOT have a guide
wire. Turn the steering wheel for a full right or left turn. Activate
The maximum "medium speed" is:
the guidance system. Accelerate the lift truck with the steering
OS030EB 6.1 ±0.5 km/hr (3.8 ± 0.3 mph)
handle or steering wheel still positioned for a full right or left
turn. If the guidance system attempts to steerthe lift truck out of
the turn, there is a traction circuit connection to the frame. The
If the center of the lift truck moves off the guide wire by
connection makes the guidance system operate as if it were on
approximately 38 mm (1 .5 in) , the guidance system will show a
an energized guide wire. This operating condition is usually
display of "5d 02". LEDs 1 and 2 will flash and the guidance
from a high resistance connection. A dirty battery or motor can
system will limit the lift truck to a maximum travel speed of "slow
cause this condition.
speed".
7-8
Yale
Industrial Trucks -
Table 7-3 - Display Code Descriptions "Watchdog" fault has occurred to indicate a possible problem
as a guide to the service person. These faults usually occur
DISPLAY REDUCED SPEED CONDITIONS
only once. The lift truck is operational, but there could be a
5d 01 SLOW TO "MEDIUM SPEED" problem. This display can be caused by a poor connection that
5d 02 SLOW TO "SLOW SPEED" is a good connection most of the time.
DISPLAY STOP CONDITIONS A display of "A5 00" shows that the operator platform is above
A5 00 LIFT HEIGHT OVER MAXIMUM the height where travel is permitted. The traction circuit is
disabled. Lowering the platform below the limit will enable the
A5 01 MDU OUT OF NORMAL RANGE traction circuit.
A5 02 MDU NOT MOVING
A5 03 MDU MOVING WRONG A display of "A5 01" shows that the MDU potentiometer signal
is out of the correct range. This fault can be caused by the
A5 04 STEER SIGNAL OUT OF RANGE following: (1) a poor connection to any of the potentiometer
A5 05 GUIDANCE SW FAULT IN AUTO wires, (2) incorrect adjustment, (3) a defective potentiometer or
A5 06 BOTH FWD & REV IN AUTO (4) the MDU turned beyond the normal range.
A5 10 LOW SENSOR SIGNAL A display of "A5 02" shows that there is no change in the signal
A5 11 LIFT TRUCK OFF GUIDE WIRE from the MDU potentiometer when there should be. This fault
A5 12 HIGH SENSOR RATIO can be caused by a defective steering gearmotor, a
mechanically jammed MDU or a defect in the MDU
A5 13 LOW AVERAGE SENSOR LEVEL
potentiometer or circuit.
A5 14 LOSS OF SENSOR COIL INPUT
A5 30 EPROM CHECKSUM ERROR A display of "A5 03" shows that the signal from the MDU
potentiometer is the reverse of the correct signal.
A5 31 EEPROM CHECKSUM ERROR
dd dd TEST MODE SELECTED This fault is caused by reversed leads to either the MDU
DISPLAY NON-TRACTION CONDITIONS potentiometer or steering gearmotor.
dd 05 GUIDANCE SW FAULT IN MANUAL A display of "A5 04" shows that the steer signal from the tach
dd 06 FWD 8c REV SELECTED AT SAME TIME generator is out of the correct range. This fault can be caused
by the following:
dd 07 LOGIC BOARD NOT TESTED
dd 40 WATCHDOG RESET OCCURED a. A poor connection at the tach generator or tach steer
module.
NOTE: LEDs 1 AND 2 FLASH FOR ALL OF THE ABOVE
CONDITIONS. b. Incorrect adjustment.
c. A defective tach generator or tach steer module.
The maximum "slow speed" is 3.8 ± 0.5 km/hr (2.25 ± 0.3
mph). A display of "A5 05" shows that the signal from the guidance
switch is out of the correct range during the "acquire" or
If the center of the lift truck moves off the guide wire by "automatic" mode. This fault can be caused by a poor
approximately 44 mm (1 .75 in), the guidance system will show connection of the switch wires.
a display of "A5 11". LEDs 1 and 2 will flash and automatic
shut-off occurs. Thetraction system isdisabled and the brake is A display of "A5 06" shows that both the forward and reverse
applied. All of the other "Stop Conditions" shown in Table 7-3 directions have been selected when the guidance switch is in
will either prevent lift truck movement in the guidance mode or the "automatic" mode. This fault is caused by a fault in the
stop the lift truck as just described. direction control switches, switch wiring or switch adjustments.
A display of "dd 05" indicates that there is a fault in the Adisplayof"A5 10"shows that one ofthefour sensor signals is
"manual" circuit of the guidance switch. A display of "dd 06" below the normal range during operation. This fault can be
shows that both forward and reverse directions have been caused by a poor connection or a defective sensor.
simultaneously selected. The lift truck will not operate. A
display of "dd 07" indicates an internal fault. The lift truck can A display of "A5 11" shows that the lift truck is off the guide wire
be operational. Replacement of the logic board is required as previously described.
when "dd 07" is displayed. The "Watchdog" check is an
automatic check that checks for faults that can reset the EGM
during automatic steering. The "dd 40" display indicates a
7-9
Yale
A display of "A5 12" shows that the left-to-right signal ratio of There are no decimal points, so when reading voltages, 4.1
the sensors is out of the correct range. This fault can be caused volts will be indicated as "41" on the right display. Press the
by a poor connection or a defective sensor. Mode button to advance to the next check. You must advance
through the steps in numerical order to get to the check you
A display of "A5 13" shows that the average left/right signal want. Traction or steering power is not enabled in some checks.
from a sensor set has dropped below the necessary level for Setting switch S1 to the "closed" (up) position at any time will
correct guidance operation. This fault can be caused by a return the system to normal operation.
defective sensor or a weak signal from the guide wire.
Adisplay of "A5 14" shows that one ofthe four sensor signals is
Check 01 - Operator Controls
This check checks the operation of the operator guidance
missing. This fault can be caused by an open connection or a
controls. Push the Mode button on the logic board so that the
defective sensor.
left display shows "01". The alarm will make a noise and the
guidance indicator will flash. The right display will show "22"
A display of "A5 30" shows that there is an error in the program
(2.2 volts) or less when the guidance button is in the Manual
memory of the Erasable Programmable Read Only Memory
position. The right display will show "27" to "40" (2.7 to 4.0 volts)
(EPROM) chip. This fault can be caused by a defective EPROM
when the guidance button is in the Automatic position. If any of
or other logic device.
these voltages are not correct, there is a fault in the guidance
switch or associated wiring. Steering and traction operations
A display of "A5 31" shows that there is an error in the
are disabled during this check.
Electrically Erasable Programable Read Only Memory
(EEPROM) chip. This fault can be caused by a defective
EEPROM or other logic device.
Check 02 - Steering Input Voltage
The amplified voltage from the steering input is shown on the
/\ WARNING: An error code "A5 31" can also be right display during this check. Push the Mode button on the
1|\ caused by turning the power off while switch S1 is logic board so that the left display shows "02".
in the "open" (down) position. Then, energizing the
system when switch S1 is in the "closed" (up) position. Turn the The right display will show "24"to "26" with the steering wheel
power off for at least five seconds and then turn the power back stationary. The right display will show a value less than "24" to
on. If the error code still exists, the logic board must be greaterthan "01" (< 2.4 to > 0.1 volts) while the steering wheel is
replaced. being continuously rotated CW. The right display will show a
value greater than "26" to less than "49" (> 2.6 to < 4.9 volts)
Adisplay of"dd dd" shows that switch S1 on the logic card is in while the steering wheel is being continuously rotated CCW.
the "open" (down) position for the check functions. Switch S1 is Voltages below 0.1 volts or above 4.9 volts will cause shut-off.
set to the "closed" (up) position for normal operation. Steering andtraction operations are disabled during this check.
A display of "dd 05" shows that the signal from the guidance Check 03 - MDU Potentiometer Coarse Amplifier
switch is out of the correct range during the "manual" mode.
The amplified voltage from the MDU potentiometer is shown on
This fault can be caused by a poor connection of switch wires.
the right display during this check. Push the Mode button on the
logic board so that the left display shows "03". The right display
A display of "dd 06" shows that both forward and reverse
will show "25" (2.5 volts) with the steer tire positioned for
signals are present at the same time. This fault is normally
straight travel. The right display value decreases as the steer
caused by a malfunctioning forward or reverse switch.
tire is positioned further to the right. The right display value
increases as the steer tire is positioned further to the left. The
A display of "dd 07" shows an internal fault. Replace the logic
right display will show between 01 and 03 (0.1 to 0.3 volts) at a
board.
full right turn. The right display will show between 47 and 49 (4.7
to 4.9 volts) at a full left turn. Voltages above 4.9 volts or below
A display of "dd 40" shows that Watchdog reset has occured
0.1 volts will cause shut-off. Steering and traction operations
as described earlier.
are not disabled during this check.
MANUAL CHECKS Check 04 - MDU Centering

There are manualchecks 01 through 11,13 and 14. Access the This check checks the MDU centering. Push the Mode button
manual checks by setting switch S1 on the logic board to the on the logic board so that the left display shows "04". The
"open" (down) or manual position. See Figure 7-4. The lifttruck system will energize the steering motor to move the MDU to the
electrical system must be energized to make the checks. In the position that the system considers "center" (steer tire
manual mode the display will show "dd dd". The two digits on positioned for straight travel). The right display will show "25"
the left display indicate the step number. The two digits on the (2.5 volts) indicating the MDU is "centered". The MDU can be
right display indicatethe variable value being read or adjusted. adjusted to physical center (straight travel) by adjusting RT2.
7-10
Yale
IndustrialTrucks -
Check 05 - Direction Inputs Push the Mode button on the logic board so thatthe left display
shows "07". Check that Check 07 displays the value for the left
This check checks each direction signal and the zero speed side of the steered end sensor assembly (left front sensor
(plugging) signal. Push the Mode button on the logic board so signal).
that the left display shows "05". The right display will show one
of the displays as indicated inTable 7-4. The left digit of the right Pushthe Mode button on the logic board so that the left display
display will show the presence or absence of the plugging shows "08". Check that Check 08 displays thevalue for the right
signal. The right digit of the right display shows the direction side of the loadend sensor assembly (right rear sensor signal) .
status. The traction and STEERING SYSTEMS are both
operational during this check. Pushthe Mode button on the logic board so thatthe left display
shows "09". Check that Check 09 displays the value for the left
Table 7-4 - Direction/Plugging Inputs side of the load end sensor assembly (left rear sensor signal).
DISPLAY DESCRIPTION
INITIAL DISPLAY BEFORE ANY
00
DIRECTION IS SELECTED FRONT SENSOR FRONT
GUIDE WIRE
LAST DIRECTION SELECTED WAS SUPPLIES
X1 SUPPLIES
STEERED END FIRST LEFT FRONT
SENSOR SIGNAL RIGHT FRONT
SENSOR SIGNAL
LAST DIRECTION SELECTED WAS LOAD
X2
END FIRST
OX NO PLUGGING SIGNAL STEER TIRE
1X PLUGGING SIGNAL WAS PRESENT REAR SENSOR
NOTE: "X" can be a "0", a "1" or a "2".
FORWARD
DIRECTION
EXAMPLES: OF TRAVEL
1. The lift truck was driven load end first and plugged to a LOAD WHEELS
stop. The plugging signal was present (left digit "1") andthe last
direction selected (during plugging) was steered end first (right
digit "1"). The display therefore shows "11". If the lift truck had LOAD WHEELS
been allowed to accelerate after plugging to a stop, the
SUPPLIES SUPPLIES
plugging signal would have been dropped. The display would RIGHT REAR
LEFT REAR
show "01". SENSOR SIGNAL REAR SENSOR SIGNAL
2. The lift truck was driven load end first andcoasted to a stop
(no plugging). The right display will show "02". Figure 7-5 - Direction Orientation
Checks 06 Through 09 - Sensor Levels -
Check 10 Steered End Sensor Balance
Checks 06 through 09 display the values from the sensor input This check checks the balance between the right and left
voltages. See Figure 7-5. With the lift truck centered on the signals of the steered end sensor. The lift truck MUST be in the
guide wire and with Check 10 - Steered End Sensor Balance position so that the SENSOR at the steered end is centered
and Check 11 - Load End Sensor Balance adjusted, checks 06 within 0.2 inch of the energized guide wire and the load end
through 09 should show near equal values on the right-hand sensor is centered within 0.5 inch of the energized guide wire.
display. Steering and traction operations are disabled during Set switch S1 to the "closed" (up) position to allow manual lift
these checks. See Table 7-4 for sensor details. See Table 7-1 truck operation. After the lift truck is centered, set switch S1 to
for sensor values. the "open" (down) position and push the Mode button on the
logic board so that the left display shows "10". If the right-hand
Push the Mode button on the logic board so thatthe left display display does not show "00", the sensor assembly is not
shows "06". Check that Check 06 displays thevalue for the right balanced. The balance can be set by adjusting RT4 for a
side of the steered end sensor assembly (right front sensor display of "00". Steering and traction operations are disabled
signal). during these checks.
7-11
Yale
IndustrialTrucks -
in the steer tire direction. Stop the lift truck and disconnect wire
-
Check 11 Load End Sensor Balance
5P2 from terminal 2 of the power terminal strip on the ECM.
This check checks the balance between the right and left Install tape on the wire to prevent a short-circuit. See
signals of the load end sensor. The lift truck MUST be in the Figure 7-6.
position so that the SENSOR at the load end is centered within
0 .2 inch of the energized guide wire and thesteered end sensor 4. Operate the lift truck at a slow speed on guidance in the
is centered within 0.5 inch of the energized guide wire. Set steer tire direction.
switch S1 to the "closed" (up) position to allow manual lift truck
operation. After the lift truck is centered, set switch S1 to the 5. Check that the lift truck slowly moves off the guide wire. If
"open" (down) position and push the Mode button on the logic the lift truck moves off the guide wire by approximately 32 mm
board so that the left display shows "11". If the right-hand (1 .25 in), the guidance system will show a display of "5d 01".
display does not show "00", the sensor assembly is not LEDs 1 and2will flash andthe guidance system will slowthe lift
balanced. The balance can be set by adjusting RT5 for a truck to a maximum speed of approximately 6 km/h (4 mph). If
display of "00". Steering and traction operations are disabled the lift truck moves off the guide wire by approximately 38 mm
during these checks. (1 .5 in), the guidance system will show a display of "5d 02".
LEDs 1 and 2 will flash and the guidance system will slowthe lift
-
Check 13 Medium Travel Speed truck to a maximum speed of approximately 4 km/h (2 mph). If
the lift truck moves off the guide wire by approximately 44 mm
This check puts the lift truck inthe mediumtravel speed modeto (1 .75 in), the guidance system will show a display of "A5 11".
set the mediumtravel speed. RT6 is adjusted to set the medium LEDs 1 and 2 will flash and automatic shut-off occurs. The
travel speed. The traction and STEERING SYSTEMS are both traction system is disabled and the brake is applied.
operational during this check. Refer to ADJUSTMENTS,
ADJUSTING THE TRAVEL SPEEDS for additional 6. Reconnect wire 5P2 to terminal 2 of the power terminal
information. strip on the ECM.
-
Check 14 Slow Travel Speed Checking the Steering at Mast Heights
This check puts the lifttruck inthe slowtravel speed mode to set 1. Raise the operator compartment to a fork height of:
the slow travel speed. RT7 is adjusted to set the slow travel 3810 mm (150 in) to 5385 mm (212 in)
speed. The traction and STEERING SYSTEMS are both 3810 mm (150 in) to 6910 mm (272 in)
operational during this check. Refer to ADJUSTMENTS,
ADJUSTING THE TRAVEL SPEEDS for additional 2. Set the steering for a right or left turn of more than 7° .
information.
3. Checkthatthe traction system (forward and reversetravel)
NOTE: The EV-100 LX traction motor controller is also used is disabled on all lift trucks.
to control travel speed and traction cutout at 5385 mm (212 in)
and at 6909 mm (272 in). The EV-100 LX traction motor 4. Set the steering for less than a 7° turn (straight travel).
controller has different FUNCTION VALUE SETTINGS for
different lift truck models, different mast heights and different 5. Check that the traction system will operate and that the
travel options. See Section 3 - EV-100 LX MOTOR brake is released.
CONTROLLER, FUNCTION 13 (SPEED LIMIT 3) for
additional information. 6. Raise the operator compartment to a fork height above:
5385 mm (212 in)
Checking the Operation of the Shutoff Circuit 6910 mm (272 in)
1. Move the lift truck to a section of guide wire that has a 7. Set the steering for less than a 7° turn (straight travel).
straight section.
8. Checkthatthe traction system (forward and reversetravel)
2. Energize the guidance system of the lift truck. Make sure will not operate.
the guide wire is correctly energized.
NOTE: OS030EB model trucks with optional "TRAVEL
3. Align the centerline of the lift truck on the guide wire. ABOVE 5385 mm (212 in) WITH 7° RESTRICTED STEER TO
Operate the lift truck along the straight section of the guide wire MFH" will have traction above 5385 mm (212 in) fork height.
7-12
Yale
IndustrialTrucks -
1. TRANSISTOR BLOCK M1 4. PLUG PIN SOCKETS 6. E2

2. TRANSISTOR BLOCK M2 5. C2/E1 7. C1
3. POWER TERMINALS
-
Figure 7-6 Transistor stance Check Points
Checking the ECM Power Transistors NOTE: The specifications values shown in Table 7-5 were
taken using a Fluke Model 8060A Multimeter. Other meters and
1. Disconnect the battery so that the connector is completely
other transistor manufacturers will give different readings
free. Open the motor compartment door and remove the cover
because of internal differences in the meters and transistors.
on the ECM.
When using other meters, compare the resistancevalues of the
transistors being tested to the resistance values of a new
2. Remove the electrical plug at the right side of the logic
transistor of the same manufacturer. Allow a 10% variation for
card.
correct readings. The readings must be within the values
shown in Table 7-5.
3. Use a Fluke Model 8060A Multimeter. Set the multimeter
to do the diode test as described in the Fluke instruction
manual.
4. Connect the meter to each of the locations shown in

Table 7-5. Check for the resistance values listed. If any of the
12 readings for EACH transistor block (M1 AND M2) are not
within the values shown, replace the transistor block that has
the incorrect reading.
7-13
Yale
IndustrialTrucks -
-
Table 7-5 Transistor Resistance Values ADJUSTMENTS
TERMINAL GENERAL
CONNECTIONS RESISTANCE VALUES IN
OHMS CAUTION: The steering chain MUST be correctly
+ - adjusted for the guidance system to operate
correctly AND to make the checks and
B11 C2/E1 80 - 400 adjustments correctly. Check and if necessary, adjust the
steering chain. Refer to ADJUSTING THE STEERING CHAIN
B11 C1 450 - 600 CLEARANCE.
C1 B11 OPEN
NOTE: Make sure the battery has a corrected specific gravity
C1 C2/E1 OPEN of at least 1.250. Do not make any adjustments if the system
operates correctly.
C2/E1 C1 350 - 550
C2/E1 B11 80 - 400 WARNING: Do not operate a lift truck that needs
adjustment or repairs. Report the need for
1 Plug pin socket 4 (M1), pin socket 7 (M2) adjustment or repairs immediately. If adjustment or
repair is necessary, put a "DO NOT OPERATE" tag in the
B22 E2 80 - 400 operator's area. Remove the key from the key switch.
B22 C2/E1 450 - 600
NOTE: The adjustment procedures in this section are for
C2/E1 B22 OPEN adjusting the separate components. The procedures are not in
a specific sequence and this sequence is NOT a
C2/E1 E2 OPEN troubleshooting sequence.
E2 C2/E1 350 - 550
WARNING: Many of the adjustments are done
E2 B22 80 - 400 with the battery connected. Never have any metal
on your fingers, arms or neck. During some
2 Plug pin socket 6 (M1), pin socket 9 (M2) adjustments, the operator must move the truck. The person
doing the adjustments must make the adjustments with the
Checking the Steering Contactor system energized. Make sure the operator does not move the
truck to cause an injury.
The steering contactor is fastened to the Electrical Panel
Assembly in the motor compartment.
Some of the following adjustments are done using the ECM
check circuit. For access to the ECM circuit board, open the
NOTE: Before checking the steering contactor, verify that
motor compartment doors and remove the cover from the ECM.
battery volts is present at wire 3P2. If battery volts is not
See Figure 7-3.
present, check the steering contactor fuse (35 amp) and the
power cables.
ADJUSTING RT1 TO THE OPERATIONAL MIDPOINT
This procedure adjusts the ECM to the steer signal input from
free and open the motor compartment doors.
the tach steer module. See Figure 7-4 for the location of RT1 .
2. Check that wires 10 and 13 are connected to the control
CAUTION: Do not move the steering wheel
terminals of the contactor. Check that cables 3P2 and 4P2 are
unless told to while performing this adjustment
connected to the power terminals. Check that all connections
procedure.
and wires are in good condition.
1. Set switch S1 on the ECM circuit board to the "open"
3. If all connections are good, remove the wires from the
(down) position. With the key switch ON, the displays will show
control terminals. Use an ohmmeter to check for continuity
"dd dd".
between the control terminals. If there is continuity, the
contactor coil is good. If not, replace the contactor. See Section
2. Push the Mode button on the ECMfor a left display of "02".
3 - ELECTRICAL SYSTEM, CONTACTORS for additional
information.
7-14
Yale
IndustrialTrucks -
3. Adjust RT1 for a right-hand display of "25". Mark one side of the screwdriver slot and the face of the
RT1 potentiometer if necessary.
4. Check thatthe right-handdisplay changes to lessthan "25"
b. Turn the RT1 potentiometer counterclockwise,
with the steer wheel being continuously rotated for a right turn.
counting the number of times the RT1 potentiometer is
turned, until the steer motor again starts to pulse (initial
turn on). Make note of the number of revolutions the RT1
potentiometer was turned from Step (a.) to Step (b.).
c. Divide the value calculated in Step (b.) by 2. Record
this value.
d. Adjust RT1 to its operational midpoint by turning the
RT1 potentiometer clockwise from the Step (b.) position, a
number of turns equal to the value calculated in Step (c.).
0
1.3 TO 3.3 mm (0.05 TO 0.13 in)
1. STEERING WHEEL
3072
2. TACH STEER ASSEMBLY
1. REDUCER SPROCKET
3. TACH STEER BRACKET
2. STEERING CHAIN
4. SPACER
3. MDU SPROCKET
5. TIMING BELT
4. ADJUSTING NUT
6. STEERING SHAFT
5. ADJUSTING BOLT
7. STEERING KNOB ASSEMBLY
6. RIGID MATERIAL
8. SPROCKET NA00651
Figure 7-7 - Steering Handle Assembly -

Figure 7-8 Adjusting the Steering Chain Clearance
5. Check the the right-hand display changes to greater than ADJUSTING THE STEERING CHAIN CLEARANCE
"25" with the steer wheel being continuously rotated for a left 1. Disconnectthe battery so that the connector is completely
turn. free and open the motor compartment doors.
6. If any of the readings are not correct, check the tach 2. Operate the steering to find the point where the steering
generator, tach steer module and wiring for normal signals to chain has the least deflection. Rotate the steer wheel to the
the ECM. See Figure 7-7. right (CW) to turn the MDU to the full right turn (CW) position.
Slowly rotate the steer wheel to the left (CCW) to turn the MDU
7. Return switch S1 to the "closed" (up) position for normal to the left (CCW) position and watch the steering chain. The
operation. point of least deflection is the point where the steering chain is
straight or nearly straight between the sprockets.
8. Adjust the RT1 potentiometer to its operational midpoint.
a. Turn the RT1 potentiometer clockwise until the steer 3. Install a thin piece of rigid material on the chain between
motor starts to pulse (initial turn on). Make note of the the sprockets. The material must have a straight edge. Make
position of the screwdriver slot on the RT1 potentiometer. sure the chain is tight on the opposite side of the sprockets.
Measurethe clearance betweenthe bottom of the straightedge
7-15
Yale
IndustrialTrucks -
of the rigid material and the chain. See Figure 7-8. The middle point. Refer to ADJUSTMENTS, CENTERING THE STEER
of the chain must have a clearance of 1.3 to 3.3 mm (0.05 to TIRE for the procedure to center the steer tire.
0.13 in).
Proceed to ADJUSTING RT2 FOR STRAIGHT TRAVEL if the
4. Tighten the adjustment nut at the MDU sprocket for a potentiometer DOES NOT need adjustment.
maximum clearance of 1.3 to 3.3 mm (0.05 to 0.13 in) between
the chain and straight edge. Do NOT tighten the adjusting nut Perform the following Steps (1 .) to (10.) if the potentiometer
for a clearance of less than 1.3 mm (0.05 in). DOES require adjustment.
5. Close and fasten the motor compartment doors. 1. Verify that the steer chain is properly adjusted. Refer to
ADJUSTING THE STEERING CHAIN CLEARANCE.
CENTERING THE STEER TIRE
2. Position the steer tire for straight travel. Refer to
1. Move the lift truck to a safe level area. Turn the key switch ADJUSTMENTS, CENTERING THE STEER TIRE.
off and remove the key.
3. Disconnectthe electrical plug for the MDU potentiometer.
WARNING: Disconnectthe battery by separating Loosenthe nut (5) that fastens the potentiometer to the bracket
Xf\ the connector before opening the compartment
(4).
If a tool causes a short-circuit, the high current flow from the 4. Adjust the MDU potentiometer for mid-range. Compare
battery can cause an injury or parts damage. the resistance measured between wires 16 and 17 with the
resistance measured between wires 17 and 18. The
2. Disconnect the battery and separate the connectors. potentiometer is at the mid-range position when the resistance
readings are equal within 50 ohms. Rotate the potentiometer
3. Open drive unit compartment doors. body for the correct resistance readings.
4. Verify that the steer chain is properly adjusted. Refer to 5. Tighten the nut that fastens the potentiometer to the
ADJUSTING THE STEERING CHAIN CLEARANCE. bracket without moving the potentiometer body. Maintain the
clearance between the bottom of the coupling and the
5. Do not move the steering wheel. Do not use the steering gearmotor housing. See Figure 7-11 . Reconnect the electrical
wheel to position the steer tire for straight travel. Use a large plug for the MDU potentiometer.
screwdriver at the armature shaft of the steering gearmotor to
move the steer tire to the straight travel position. 6. Reconnect the battery and energize the electrical system
of the lift truck.
The steertire is set for straight travelwhen the distance from the
front edge of the steer tire wheel to the frame plate is equal to 7. Set switch S1 on the ECM circuit board to the "open"
the distance from the rear edge of the steer tire wheel to the (down) position. With the key switch ON, the displays will show
frame plate. "dd dd".
6. The MDU potentiometer must now be centered. Do not 8. Push the Mode button on the ECMfor a left display of "03".
reconnect the battery at this time. Refer to CENTERING THE
MDU POTENTIOMETER to complete this procedure. 9. Use RT2 to adjust the right-hand display to "25" with the
steer tire set for straight travel. This will set RT2 to
approximately the mid-range position. Return switch S1 to the
CENTERING THE MDU POTENTIOMETER
"closed" (up) position for normal operation.
This procedure adjusts the ECM to the MDU pot signal. See
Figure 7-11 for the location of MDU potentiometer. 10. Adjust RT2 for straight travel. Refer to ADJUSTING RT2
FOR STRAIGHT TRAVEL
NOTE: This procedure is ONLY NECESSARY afterthe MDU
potentiometer has been replaced, or if the MDU potentiometer The board will be used Hyster or Yale, small or large chassis,
adjustment has been disturbed. The potentiometer must be Guidance or non-W/G, 24V or 36V, and Traction performance
positioned at mid-range with the steer tire positioned for or standard. The board receives the prox switch inputs, as well
straight travel. as a steering input, and outputs signals necessary to invoke
speed limits or inhibit traction.
Adjustment can be checked and the mid-range position of the
potentiometer can be verified by checking for 2.3 to 2.7 volts at
the pot wiper (wire 17) with the steer tire positioned for straight
travel and the system energized . Use TP15 forthe negative test
7-16
Yale
Steering input: switch input is present. If a fault condition occurs, thetechnician

Steering input for wire guided trucks is the feedback pot wiper, can easily check these indicators to verify proximity switch
into a high-impedance comparator input into theTRAM. This function.
can be adjusted for +/- 10°, using two pots on the TRAM.
TRAM ADJUSTMENTS
Proximity inputs:
The proximity switches on a standardtruck are at 24", 60", 150", TRAM Steer Adjustment Verification
and 2127272" heights, and the Traction Performance option
1. Set steer tire straight ahead.
has an additional 120" proximity.
2. Check that Yellow LED on TRAM is on . If it is off, proceed to
There is an input pin to the TRAM which is wired high (in the
"TRAM Steer Adjustment" below.
truck's harness) to indicate when Traction Performance option
(120" proximity) is present.
3. Turn steer tire to 4° Left, as measured between the steer
Faults: tire edge and the front "bumper" of the frame. For RTC trucks,
Since the proximity switches will turn off sequentially (all this may be accomplished by turning the steering input knob,
then inserting a spacer block between the handle return spring
switches use the same target), the TRAM can monitor for
and its stop rod.
"unacceptable" input patterns. If an unacceptable pattern for
-0.4 seconds, the TRAM will fault. Depending on the fault input
4. Check that Yellow LED is still ON. If it is OFF, proceed to
pattern, the TRAM will either inhibit travel or be in "limp home"
mode, allowing 1.2 mph. If a fault occurs long enough to latch,
"TRAM Steer Adjustment" below.
then the fault input condition must be corrected and the
keyswitch recycled to clear the fault. If the truck is in a fault state 5. Turn steertireto 10° Left. Check that Yellow LED is off. If it
is on, proceed to "TRAM Steer Adjustment" below.
which inhibits travel, the truck can usually move into a
"limp-home" mode by lowering the platform to the next
6. Turn steer tire to 4° Right.
proximity switch level.
Speed limits, large chassis: 7. Check that Yellow LED is on. If it is off, proceed to "TRAM
Steer Adjustment" below.
The TRAM uses the three speed limits of the GE EV100LX
card, selectively pulling PA4, PA5, or PA6 down to ground.
8. Turn steer tire to 10° Right. Check that Yellow LED is off,
Speed limits, small chassis: adjustment is not necessary. If it is on, proceed to "TRAM Steer
The throttle wires pass through the TRAM, normally through a Adjustment" below.
5k adjustment pot (for 1.2 mph) .A FET can be actuated to shunt
TRAM Steer Adjustment
around the pot (full speed), and another FET can switch
another pot in parallel to the first, effectively achieving 2.2 mph. 1. Start with steer tire pointed straight ahead. If yellow LED is
off, adjust TRAM Pot RV1 counterclockwise until LED turns on.
Traction Enable/Inhibit: If you reachthe end of travel for RV1 (clicking noise) and LED is
The board receives the traction enable (and brake still off, turn RV2 counterclockwise until LED turns on.
disengaging) signal from the steering controller. This passes
through a high current FET on the TRAM, then supplies the high 2. Turnsteertire10° Left (see step 3 above). If LED is off, turn
side of the forward/reverse contactors (GE controller) or the RV2 counterclockwise until LED turns on.
traction enable line (Curtis PMC controller).
3. Turn RV2 clockwise until LED turns off, then turn 1
Indicators: additional turn clockwise.
There are 3 status LED's:
A green LED indicates that power is on, and the TRAM is 4. Turn steer tire 10° Right. If LED is off, turn RV1
functioning. counterclockwise until LED turns on.
A yellow LED to indicate when steering is within 10° of center. 5. Turn RV1 clockwise until LED turns off, then turn 1
This indicator will work with either Atlas binary input or the additional turn clockwise.
TRAM's internal comparator.
A red LED to indicate a latched fault status. ADJUSTING RT2 FOR STRAIGHT TRAVEL
This procedure adjusts the ECM to the MDU signal for lift truck
There are five LED's corresponding to the 5 proximity switch straight travel. See Figure 7-4 for the location of RT2.
inputs. These will be lighted if the corresponding proximity
7-17
Yale
a _«
I\
CAUTION: Make sure the steering input signal is
balanced and the MDU potentiometer is centered
according to the previous procedures. Refer to AD-
JUSTING RT1 TO THE OPERATIONAL MIDPOINT and CEN¬
TERING THE MDU POTENTIOMETER.
NOTE: If the lift truck cannot be adjusted for straight travel
after performing Steps (a.) through (d.), the MDU potentiometer
may be out of range. Adjust the MDU potentiometer to
mid-range.
POTENTIOMETER.
Refer to CENTERING THE MDU
/\ CAUTION: Make sure the steering wheel is not 3. After the MDU is set for straight travel (Step 2), push the
/ 1\ moved while performing this adjustment Mode button for a left-hand display of "03". The right-hand
procedure. display should show "25" (2.5 volts) with the MDU positioned for
straight travel.
NOTE: Before starting this procedure, find a section of floor
that is smooth and level for approximately 30.5 m (100 ft) . Install 4. Check for the correct range of operation by rotating the
a pointer at the center of the rear (load wheel end) of the lift steering wheel for a full right turn and then a full left turn. The
truck. right display value should decrease as the MDU turns to the
right. The right display will show between 01 and 03 at a full right
1. Turn the key switch on. Set switch S1 on the ECM circuit turn. The right display value should increase as the MDU turns
board to the "open" (down) position. Push the Mode button on to the left. The right display will show between 47 and 49 at a full
the ECM for a left display of "04". The system will energize the left turn. The MDU will move 85 to 95° in each direction from the
steering motor to move the MDU to the position that the system center position.
considers "center". The right display will show "25" (2.5 volts)
indicating the MDU is "centered". To check and adjust the MDU 5. Set switch S1 on the circuit board to the "closed" (up)
to the physical center (straight travel), do Step 2. position for normal operation.
2. Have the operator drive the lift truck in the reverse direction
(load wheel end first). Adjust potentiometer RT2 for straight ADJUSTING THE TRAVEL SPEEDS
travel as described in sub Steps (a.) through (d.). Clockwise NOTE: The EV-100 LX traction motor controller is also used
adjustment of RT2 makes the lift truck turn to the left. to control travel speed above 3810 mm (150 in) and traction
Counterclockwise adjustment makes the lift truck turn to the cutout at 5385 mm (212 in) and at 6909 mm (272 in). The
right. See Figure 7-5 for left and right orientation. EV-100 LX traction motor controller has different FUNCTION
Potentiometer RT2 is correctly adjusted when the lift truck will VALUE SETTINGS for different lift truck models, different mast
travel in a straight line within 152 mm (6 in) in 9.1 m (30 ft). To heights and different travel options. See Section 3 - EV-100 LX
check that the lift truck is moving in a straight line, do the MOTOR CONTROLLER, FUNCTION 11 (SPEED LIMIT 1) and
following procedure: FUNCTION 13 (SPEED LIMIT 3) for additional information.
NOTE: The ECM will remove power from the steering /\ WARNING: Travel speed affects stability. Do Not
gearmotor if there are no steering changes within a 10 second /f\ adjust MEDIUM SPEED or SLOW SPEED beyond
period. If sub Steps (a.) through (d) take longer than 10 wJLJ specifications.
seconds, it will be necessary to cycle the key switch off andthen
on to supply power to the gearmotor and re-select mode 4 Medium Speed
before adjusting RT2. See Step 1.
NOTE: The medium travel speed adjustment RT6 is located
a. Make a mark on thefloor underthe point of the pointer. on the ECM. The "medium speed" is adjusted to
6.1 ± 0.5 km/hr (3.8 ± 0.3 mph)
b. Have the operator drive the lift truck in the reverse
direction for 4.6 m (15 ft). Make a mark on the floor under
the point of the pointer.
NOTE: The numbers in the "()" of the following procedure are
c. Have the operator drive the lift truck in the reverse the item numbers in Figure 7-9.
direction for another 4.6 m (15 ft). Make another mark on
the floor under the point of the pointer. 1. Make sure the battery has a corrected specific gravity of at
d. Draw a straight line between the first and last marks. least 1.250. Make sure that the lift truck has been operated at
The center mark must be within 76 mm (3 in) of the line. If full speed for approximately 10 minutes before checking the
the center mark is within this specification, RT2 is correctly speed.
adjusted. If the mark is NOT within the specification, adjust
RT2 as described in this procedure until the mark is within 2. Find a section of floor that is smooth and level for
the specifications. approximately 30.5 m (100 ft).

(down) position. Push the Mode button for a left-hand display of
7-18
Yale
IndustrialTrucks steering system - wire guidance ii
13". This will set the control card to adjust the maximum
"medium travel speed" for the lift truck.
1
X
1. BEGIN ACCELERATION 5. 10 M (33 FT.) LINE (%)

2. ACCELERATION AREA 6. TIMED DISTANCE RT6 (*)
3. START TIMING LINE 7. 17 M (56 FT.) LINE (*)
4. TIMED DISTANCE RT7 (% 8. STOPPING AREA
% 3.8 km/hr + 0.5 km/hr (2.25 mph ± 0.3 mph) SLOW SPEED
* 6.1 km/kr + 0.5 km/hr (3.80 mph ± 0.3 mph) MEDIUM SPEED NA00754
Figure 7-9 - Checking Lift Truck Travel Speeds

4. Movethe lift truck to the beginning of the approximate 30.5 full speed for approximately 10 minutes before checking the
m (100 ft) distance (1). Put a line on the floor for the starting speed.
point (3). Put a line on the floor at the 17 m (56 ft) (7) distance.
Draw the lines in the center of the 30.5 m (100 ft) distance. The 2. Find a section of floor that is smooth and level for
area at each end is for acceleration and a distance to stop the lift approximately 30.5 m (100 ft).
truck.
5. Have personnel at the start line and at the 17 m (56 ft) line (down) position. Pushthe Modebutton for a left-hand display of
(7) to check the times. "14". This will set the maximum "slow travel speed" for the lift
truck. The correct maximumtravel speed forthe "slow speed" is
Operate the lift truck at full speed and check the total time it 3.8 plus or minus 0.5 km/hr (2.25 plus or minus 0.3 mph).
takes for the lift truck to travel the distance. The lift truck must
travel at full speed for the total time of the distance. 4. Movethe lifttruck to the beginning of the approximate 30.5
m (100 ft) distance (1) .Putlines on the floorforthe starting point
6. If the time is less than 10 seconds the "medium" travel (3) and 10 m (33 ft) (5) distances inthe center of the 30.5 m (100
potentiometer RT6 is set for a speed faster than the specified ft) distance. The area at each end is for acceleration and a
speed. The potentiometer must be adjusted CCW. If the time is distance to stop the lift truck.
more than 10 seconds the potentiometer must be adjusted CW
for a faster travel speed. Adjust the potentiometer in small 5. Have other personnel at the start line (3) and the 10 m (33
amounts and repeat Steps 4, 5 and 6 untilthe speed is correct. ft) line (5) to check the times. Operate the lift truck at full speed
Slow Speed and checkthe totaltime ittakes forthe lifttrucktotravelthe 10m
(33 ft) distance (4). The lifttruck must travel at full speed forthe
NOTE: The numbers in the "( )" of the following procedure are total time of the 10 m (33 ft) distance.
the item numbers in Figure 7-9.
6. If the time is less than 10 seconds, the "slow" travel
NOTE: The slow travel speed adjustment RT7 is located on potentiometer RT7 is set for a speed faster than the specified
the ECM. The "slow speed" for all lift trucks is adjusted to 3.8 speed. The potentiometer must be adjusted CCW. If the time is
± 0.5 km/hr (2.25 ± 0.3 mph). more than 10 seconds the potentiometer must be adjusted
clockwise for a faster travel speed. Adjust the potentiometer in
1. Make sure the battery has a corrected specific gravity of at small amounts and repeat Steps 4, 5 and 6 until the speed is
least 1.250. Make sure that the lift truck has been operated at correct.
7-19
Yale
IndustrialTrucks -
5. Have other personnel at the start line (3) and the 10 m (33 /\ CAUTION: Use a section of guide wire at least
ft) line (5) to check the times. Operate the lift truck at full speed / I\ 30.5 m (100 ft) long. This section must be straight
and check the total time it takes forthe lifttruckto travelthe 10m within 3.2 mm (0.125 in) in 3.05 m (1Oft). The guide
(33 ft) distance (4). The lift truckmust travel at full speed for the wire frequency and current must match the sensors. The
total time of the 10 m (33 ft) distance. standard frequency and current is 6.250 KHz at 78 ma.
6. If the time is less than 10 seconds, the "slow" travel 7. Measure the lift truck width to locate the centerline at each
potentiometer RT7 is set for a speed faster than the specified sensor location. Install vertical pointers atthe centerline. Nylon
speed. The potentiometer must be adjusted CCW. Ifthetime is tie wraps work well for the pointers. The points of the pointers
more than 10 seconds the potentiometer must be adjusted must just clear the floor and be visible during travel.
clockwise for a faster travel speed. Adjust the potentiometer in
small amounts and repeat Steps 4, 5 and 6 until the speed is 8. If necessary, adjust each sensor so that the center of the
correct. sensor is on the centerline and has a floor clearance of 65.09 to
68.26 mm (2.5625 to 2.6875 in).
ADJUSTING SENSORS TO LIFT TRUCK CENTERLINE
9. Move the lift truck so that both pointers are centered over
the guide wire. The steered end sensor must becentered within
/\ CAUTION: Make sure that all of the previous 2.5 mm (0.1 in) of the guide wire. The load end sensor must be
1
1\ adjustment procedures have been completed
correctly. The following adjustments will NOT be centered within 76 mm (3 in) of the guide wire.
correct if the previous adjustments are not correct. THE
FOLLOWING ADJUSTMENTS MUST BE DONE IN THE NOTE: Verify steered end sensor adjustment by measuring
SEQUENCE LISTED. the voltage between the green and white wires of the sensor.
Adjust the sensor left to right and look for the voltage closest to
"0". The truck and guide wire must be energized and sensor
plugs "C" and "D" must be connected. See Figure 7-10.
CORRECT FRONT SENSOR PLUG

GUIDE WIRE
TRUCK CENTERED ON GUIDE WIRE BLACK
GREEN
Left and Right Signals Balanced WHITE
Near 0 Volts Between Green and LEFT RIGHT RED
REAR KEY
White Wires
INCORRECT FRONT SENSOR PLUG

GUIDE WIRE BLACK
Left Signal High Right Signal Low GREEN
WHITE
Voltage Present Between Green ( + ) LEFT RIGHT RED
and White ( - ) Wires REAR KEY
INCORRECT SENSOR PLUG

GUIDE WIRE
BLACK
Left Signal Low Right Signal High GREEN
WHITE
Voltage Present Between Green (-) LEFT RIGHT RED
and White ( + ) Wires REAR KEY
Figure 7-10 - Adjusting Sensors to Centerline

10. Set switch S1 on the ECM circuit board to the "open" end sensor must be centered within 76 mm (3 in) of the guide
(down) position. Pushthe Mode button for a left-hand display of wire.
"10". Connect a digital voltmeter between test points TP1 0 and
TP11 . Adjust RT4 on the circuit board for a voltage reading of NOTE: Verify load end sensor adjustment by measuring the
"0.00" between TP10 and TP11. voltage between the green and white wires of the sensor.
Adjust the sensor left to right and look for the voltage closest to
11. If necessary, move the lift truck so that the loadend pointer "0". The truck and guide wire must be energized and sensor
is centered over the guide wire. The load end sensor must be plugs "C" and "D" must be connected. See Figure 7-10.
centered within 2.5 mm (0.1 in) of the guide wire. The steered
7-20
Yale
IndustrialTrucks -
12. Push the Mode button for a left-hand display of "11". 15. Operatethelifttruck9.1 m (30ft) in the direction of the load
Connect a digital voltmeter between test points TP8 and TP9. wheels. Coast toastop. Do not plug or use the brake to stop the
Adjust RT5 on the circuit board for a voltage reading of "0.00" truck. Check that the load end pointer stays within 13 mm (0.5
between TP8 and TP9. in) of the guide wire. If the pointers are 5 mm (0.2 in) or more to
one side of the guide wire, the steered end pointer AND sensor
13. Set switch S1 to the "closed" (up) position to return the lift must be moved. Measurethe distance that the load end pointer
truck to normal operation. is off the guide wire. Move the steered end pointer and sensor
that same distance towards the opposite side of the guide
14. Push the guidance button on the instrument panel to the wire.
ON position for guidance operation. Operate the lift truck 9.1 m
(30 ft) in the direction of the MDU. Coastto a stop. Do not plug or EXAMPLE:
use the brake to stop the truck. Check that the steered end
pointer stays within 13 mm (0.5 in) of the guide wire. Check that If the load end pointer is 13 mm (0.5 in) to the right side of the
the load end pointer is approximately the same distance from guide wire, move the steered end sensor and pointer toward
the guide wire and on the same side as the steered end pointer. the left side of the guide wire. The steered end sensor and
If the load end sensor is not following in the correct position, the pointer are moved from the original position to the left 13 mm
steered end pointer AND sensor must be moved. Move the (0.5 in).
steered end pointer and sensor so that they are on the same
side and are the same distance from the guide wire. Make sure 16. Do Steps 8 and 9 until both pointers stay on the guide wire
to maintain the correct floor clearance (Step 2) and keep the without any adjustment.
centers of the sensor and pointer on the same centerline.
Repeat this step until the pointers track correctly.
NOTE: If the pointers are 5 mm (0.2 in) or more to one side

of the guide wire, recheck the sensor balance adjustment (Step
10.). Also recheck the MDU potentiometer RT2 adjustment.
Refer to ADJUSTING RT2 FOR STRAIGHT TRAVEL.
REPAIR
See Section 4 - DRIVE UNIT for removal and repair
Af\
WARNING: Disconnectthe battery by separating
the connector before opening the compartment procedures for the MDU.
cover or inspecting/repairing the electrical system .
If a tool causes a short-circuit, the high current flow from the
A ÿ-«
I \
WARNING: The capacitor in the SCR controller
can hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
any component in the rear compartment. Wear safety glasses.
Make certain the battery has been disconnected. Use a
screwdriver or jumper wire between the two terminals to
discharge capacitor C1 .
WARNING: Do not operate a lift truck that needs

11\ adjustment or repairs. Report the need for
adjustment or repairs immediately. Ifadjustmentor
repair is necessary, put a "DO NOT OPERATE" tag in the
operator's area. Remove the key from the key switch.
General
There are repair proceduresfor the following parts: the steering
wheel assembly, the sensors at each end of the unit, the
Electronic Control Module (ECM) assembly, andthe gearmotor
unit. There are also repair procedures for the guidance
components at the instrument panel.
7-21
Yale
STEERING GEARMOTOR NOT bend the bracket. Remove the steering chain (5) from the
sprocket and remove the gearmotor assembly.
Replacing the Gearmotor Assembly and Steering Chain
6. See Figure 7-12 to repair the gear box of the gearmotor
NOTE: Item numbers in ( ) are the item numbers shown in
assembly. Clean and lubricate the gears and bearings using
Figure 7-11 .
Yale multi-purpose grease P/N 1500318-02.
1. Set the steering for straight travel. Refer to
7. If necessary, remove the steering chain from the MDU
ADJUSTMENTS, CENTERING THE STEER TIRE.
sprocket (6) by pulling the chain anchor (7) pins out of the holes
2. Disconnect the battery connector. Open the drive unit
in the sprocket.
compartment doors. Disconnect the flasher-light. Remove the
drive unit compartment cover. 8. If the steering chain was removed, clean and lubricate the
chain using Yale multi-purpose grease P/N 1500318-02.
3. Disconnect the electrical plug for the MDU potentiometer
9. Make sure the steer tire is positioned for straight travel.
(3). Remove the nuts and bolts that fasten the MDU
Refer to ADJUSTMENTS, CENTERING THE STEER TIRE. If
potentiometer bracket (4) to the frame plate (2).
removed, installthe steering chain on the MDU sprocket. Install
the pin of the chain anchor in the first hole before the axle
4. Hold the gearmotor assembly (1) and remove the
centerline (8) as shown in Figure 7-11.
capscrews, nuts and washers that fasten the gearmotor
assembly to the frame plate.
10. Make sure the setscrew (6) for the MDU potentiometer is
aligned as shown in Figure 7-11. Install the sprocket of the
5. Carefully tip the top of the assembly away from the plate to
replacement gearmotor assembly in the steering chain.
rotate the MDU potentiometer bracket away from the frame. Do
7-22
Yale
IndustrialTrucks -
CLEARANCE
4.3 - 8.4 mm
(0.17 - 0.33 n)
1. GEARMOTOR ASSEMBLY 8. FIRST HOLE BEFORE CENTERLINE

2. FRAME PLATE 9. GEARMOTOR SETSCREW
3. MDU POTENTIOMETER MUST BE AS SHOWN
4. POTENTIOMETER BRACKET (FACING YOU WITH STEERING SET
5. STEERING CHAIN FOR STRAIGHT TRAVEL)
6. MDU SPROCKET 0. COUPLING
7. CHAIN ANCHOR 11. COUPLING SETSCREW
Figure 7-11 - Steering Gearmotor and MDU Assembly

7-23
Yale
IndustrialTrucks -
/\ CAUTION: If the gearmotor assembly has the 13. If the MDU potentiometer is not installed, install the
/|\ MDU potentiometer installed, make sure to align potentiometer. Make sure to install the potentiometer so that
CmLbJ the MDU bracket to the frame during installation. there is a clearance as shown in Figure 7-11 . Center the MDU
Do NOT bend the bracket. potentiometer. Refer to ADJUSTMENTS, CENTERING THE
MDU POTENTIOMETER.
11. Holdthe assembly and installthe capscrews , washers and
nuts that fasten the assembly to the frame panel. Tighten the 14. Adjust RT2 for straight travel. Refer to ADJUSTMENTS,
capscrews and nuts to 31 N«m (23 Ibf ft) torque. ADJUSTING RT2 FOR STRAIGHT TRAVEL.
12. Adjust the steer chain. Refer to ADJUSTMENTS, 15. Replace the drive unit compartment cover. Reconnectthe
ADJUSTING THE STEERING CHAIN CLEARANCE. flasher-light. Close and fasten the drive unit compartment
doors. Reconnect the battery.
MOTOR ADAPTER
GASKET
KEY
REDUCER HOUSING
WORM GEAR SET
BEARING CONE
BEARING CUP
LOAD RING
OIL SEAL
SHAFT
COVER
SNAP RING
COVER RING
SPACER
BALL BEARING
PLUG
Figure 7-12 - Gear Box Assembly
7-24
Yale
IndustrialTrucks -
1. STEER KNOB ASSEMBLY

2. STEERING WHEEL
3. SHOULDER BOLT
4. SHAFT-STEER
5. SPROCKET
6. TIMING BELT
7. LOCKNUT-BEARING
8. LOCKWASHER-BEARING
9. BEARING CUP
10. BEARING CONE
11. TACH STEER BRACKET
12. SCREW 18. NUT
13. LOCKWASHER 19. PLATE-TACH MOUNTING
14. TACH STEER ASSEMBLY 20. SCREW
15. CAPSCREW 21. LOCKWASHER
16. WASHER 22. FLAT WASHER
17. WASHER 23. SPACER NA00652
-
Figure 7-13 Steering Wheel Assembly
STEERING WHEEL ASSEMBLY 4. Remove the screw (3) and steering wheel (2) from the
steering shaft (4).
Removal and Disassembly
NOTE: Complete disassembly is ususally not necessary. 5 . Loosenthe sprocket setscrews and remove two sprockets
Remove only the parts necessary to replace the defective part. (5) and timing belt (6) from steering the assembly.
NOTE: The numbers in the "( )" of the following procedure are 6. Remove the bearing locknut (7) and lockwasher (8) from
the item numbers in Figure 7-13. the steering shaft (4).
1. Disconnect the battery connector. 7. Remove the steering shaft (4), two bearing cups (9) and
bearing cones (10) from the steering bracket (11).
2. Remove the console cover from the cowl.
8. Tag and disconnect the wires to the tach steering
3. Remove the steering knob assembly (1) from the steering assembly (14).
wheel (2).
7-25
Yale
9. Remove the four capscrews (12), lockwashers (13) and NOTE: Reversing the tach generator wires will cause reverse
thetach steering assembly (14) from the steering bracket (11). steering.
10. Remove the two capscrews (15), washers (16), washers WARNING: No steering or reverse steering can
(17), nuts (18) and the tach mounting plate (19) from the occur if the Tach Generator connections are not
steering bracket (11). proper! The ECM CANNOT detect these faults and
traction will be allowed.
11. Remove the four capscrews (20), lockwashers (21),
washers (22), spacers (23) and the steering bracket (11) from 5. install the two bearing cups (9), cones (10) and the
the support weldment. steering shaft (4) through the steering bracket (11).
Assembly and Installation 6. Installthe lockwashers (8) and bearing locknut(7) onto the
steering shaft (4).
7. Install the two sprockets (5) and tighten the setscrews.
1. Install the steering bracket (11) onto the support weldment
8. Install the timing belt (6).
with four capscrews (20), lockwashers (21), washers (22) and
spacers (23).
9. Installthe steering wheel (2) onto the steering shaft (4) with
the screw (3).
2. Install the tach mounting plate (19) onto the steering
bracket (11) with two capscrews (15), washers (16), washers
10. Install the steering knob assembly (1) onto the steering
(17) and nuts (18).
wheel (2).
3. Install the tach steering assembly (14) onto the steering
11. Install the console cover onto the cowl.
bracket (11) with four capscrews (12) and lockwashers (13).
12. Connect the battery connector.
4. Connect the wiring to the tach steering assembly (14).
1. INSTRUMENT PANEL
2. BATTERY INDICATOR/
HOURMETER
3. STEERING INDICATOR
4. BATTERY DISCONNECT
SWITCH
5. SLACK CHAIN
6. WIRE GUIDANCE
7. KEY SWITCH
NA00347
Figure 7-14 - Guidance Button, Indicators and Alarm
7-26
Yale
IndustrialTrucks -
REPLACE GUIDANCE SWITCH, INDICATOR, AND 5. Centerthe MDU potentiometer. Referto ADJUSTMENTS,
ALARM CENTERING THE MDU POTENTIOMETER.
NOTE: Removal of each part is usually not necessary.
6. Adjust RT2 for straight travel. Refer to ADJUSTMENTS,
Remove only the parts necessary to replace the defective part.
ADJUSTING RT2 FOR STRAIGHT TRAVEL.
The guidance switch and indicator are located inthe instrument
panel. The alarm is fastened to the front (upright side) of the
7. Close the motor compartment doors and connect the
operator platform.
battery.
the item numbers in Figure 7-14. REPLACE THE ECM
Replace the Complete Module
free. NOTE: Complete disassembly is usually not necessary.
Remove only the parts necessary to replacethe defective part.
2. Remove the screw that fasten steering wheel to the shaft
of the steering mechanism. Remove the steering handle. See Figure 7-15 and Figure 7-16.
3. Remove the screws at the top of the instrument panel. Tilt 1. Disconnectthe battery so that the connector is completely
the instrument panel to the open position for access to the free.
parts.
2. To replacethecomplete module, installtags on thewires at
4. To replacethe switch or indicator, puttags on the wires for the terminal strip for correct connections during installation.
correct connection during installation.Pullthewire terminals off Disconnect the wires from the terminal strip. Disconnect the
the switch or indicator terminals. plugs of the wiring cables.
5. Pushthe switch assembly or indicator assembly out of the 3. Hold the module and remove the capscrews and washers
instrument panel. Push the replacement switch or indicator that fasten the module to the frame plate. Access to the
assembly into the instrument panel. Make sure the words on capscrews is from the traction motor compartment.
the switch are not upside down.
NOTE: Keep the frame area clean to prevent voids between
6. To replacethe alarm, puttags on the alarmwires for correct the power base and the frame panel. Use a piece of plastic to
connection during installation. Remove the bezel nut that cover the silicon grease on the power base or remove the
fastens the alarm and remove the alarm. Install the grease.
replacement alarm and connect the wires as tagged during
removal. 4. Installsilicon grease on the power base of the replacement
module and the frame. Install the module on the frame panel
7. Close the instrument panel and tighten the screws. Install using the four capscrews and the washers.
the steering handle on the shaft of the steering mechanism.
Tighten the srcrew. 5. Install the wires on the terminal strip as marked during
removal. Connect the wiring cable plugs.
REPLACETHE MDU POTENTIOMETER
6. Adjustthe ECM. RefertoCHECKS AND ADJUSTMENTS,
1. Set the steering for straight travel. Refer to ADJUSTMENTS.
ADJUSTMENTS, CENTERING THE STEER TIRE.
Replace the Logic Board Set
NOTE: The logic board for the guidance ECM is actually a
free.
two-piece set. The set MUST be replaced as a single unit.
3. Open the motor compartment door. Disconnect the
NOTE: The logic board does not normally get defects. The
electrical plug for the MDU potentiometer.
logic board can be damaged from a malfunction of the power
base. If the power base has a defect, replace the complete
4. Loosen the setscrew that fastens the shaft of the
module. If physical damage causes a defect in the logic board,
potentiometer. See Figure 7-11. Loosen the upper coupling
replace the logic board set as described in the following
setscrew (11). Remove the nut that fastens the potentiometer
procedure.
to the bracket (4). Remove the potentiometer (3).
7-27
Yale
a
is:
r M oj [5 o o o o o jjjo jojjojjoj
N c A XL
mm
U
Q
1. ECM COVER 3. LOGIC BOARD SET
2. NUTS AND WASHERS 4. ELECTRICAL PLUGS 5. SPACERS AND WASHERS
Figure 7-15 - ECM and Logic Board

CAUTION: The electronic components can be 7. AdjusttheECM. RefertoCHECKS AND ADJUSTMENTS,
damaged by electrostatic discharge. Use a special ADJUSTMENTS.
floor pad to help prevent an electrostatic charge.
ALWAYS remove the electrostatic charge on your body before 8. Install the ECM cover (1) using the nuts and washers (2).
touching electronic components. Connect a static strap to your
wrist and a good earth ground. Follow the directions on the Replace the ECM Power Transistors
package of the component. NOTE: Make sure that the transistor block is defective before
replacing the block. Refer to CHECKS AND ADJUSTMENTS,
NOTE: The numbers in the "()" of the following procedure are CHECKING THE ECM POWER TRANSISTORS.
NOTE: The numbers in the "( )" of the following procedure are
1. Disconnectthe battery so that the connector is completely
free.
2. Remove the nuts that fasten the cover (1) on the ECM. free. Open the motor compartment doors.
Install tags on all the electrical plugs (4) for correct connection
during installation. Remove the nuts that fasten the cover on the ECM.
2.
3. Disconnect the electrical plugs (4). The plugs are at the
3. Disconnectthe electrical plugs from each edge of the logic
edges of the two circuit boards of the set (3).
board set.
4. Removethe spacers and washers (5) that fasten the logic Remove the spacers and washers that fasten the logic
4.
board set (3). Remove the logic board set.
board set. Remove the logic board set.
5. Install the replacement logic board set. Make sure the
5. Use a knife to carefully remove the protective coating on
LEDs are at the top. Install the washers and spacers (5) to
the terminals for the control leads of the transistor block (1) or
fasten the logic board set.
(2) to be replaced.
6. install the electrical plugs (4) on the edges of the logic
board set as marked during removal.
7-28
Yale
IndustrialTrucks -
6. Put tags on the control wires and power leads for correct 11. Connect the control wires to the controlterminals (9) of the
connection during installation. Remove the power leads from transistor block as marked during removal. Use solder and a
the power terminals (3). soldering iron to connect the wires to the terminals. Use pliers
that have a long nose to hold the terminal under the connection
7. Use a soldering iron and pliers that have a long nose to to help keep heat out of the transistor. Do not holdthe soldering
remove the wires from the terminals of the transistor block. Use iron on a terminal too long. The terminal can get too hot and
the pliers to pull eachwire off each terminal as the soldering iron damage the transistors or meltthewire insulation. Make sure to
melts the solder. Do not holdthe soldering iron ona terminal too use enough heat to make a good solder joint.
long. The wire can get too hot and melt the insulation.
12. Connect the power leads to the power terminal (3) as
8. Remove the two screws and lockwashers (8) that fasten marked during removal.
the block (1) or (2) to the heat sink plate. Remove the block.
13. Installthe logic board set, plugs and ECM cover. Close the
9. Put a thin coating of silicon grease on the metal plate on the motor compartment doors.
bottom of the replacement transistor block.
10. Install the replacement block (1) or (2) on the heat sink.
Make sure the block is in the correct position to correctly
connect the control wires. Tighten the screws (8).
1. TRANSISTOR BLOCK M1 6. E2
2. TRANSISTOR BLOCK M2 7. C1
3. POWER TERMINALS 8. MOUNT SCREW AND WASHER
4. PLUG PIN SOCKETS 9. CONTROL TERMINALS
5. C2/E1
-
Figure 7-16 ECM Power Panel
7-29
Yale
IndustrialTrucks -
REPLACE THE STEERING CONTACTOR 3. Remove the capscrews, nuts and washers that fasten the
contactor to the Electrical Panel Assembly. Remove the
NOTE: The steering contactor is fastened to the Electrical
contactor.
Panel Assembly in the motor compartment.
4. Install the replacement contactor in the same position as
the old contactor. Reinstall the capscrews, nuts and washers
free and open the motor compartment doors.
that fasten the contactor to the Electrical Panel Assembly.
2. Put tags on the steering contactor leads for correct
5. Install the contactor leads as tagged during removal.
connection during installation.
BLACK
GREEN
WHITE
5 RED
BLACK
1 GREEN
WHITE
RED
10
I I"
9
12371 UT777777777777T7T7777777T777777TT777771
1. LOAD WHEEL SENSOR 4. TO ECM CONNECTOR 7. WASHER 10. KEY

2. SENSOR BRACKET 5. STEER WHEEL SENSOR 8. NUT 11. PLUG "D"
3. SENSOR CABLE 6. CAPSCREW 9. FLOOR 12. PLUG "C"
Figure 7-17 - Sensor Arrangement
7-30
Yale
IndustrialTrucks -
REPLACE THE SENSORS the steer wheel sensor. Fasten a string or small gauge wire to
the connector plug. The string or wire must be longer then the
NOTE: The replacement sensors must be for the frequency
length of the sensor cable. Carefully pull the cable toward the
of the guide wire signal at the installation. See the decal on the
sensor. Remove the string or wire from the connector plug.
sensor. The standard sensor frequency is 6,250 Hz. The Yale
wire driver hasthe frequency and wire current on a label inside
the door. See the manufacturer of other wire drivers for the
/\ CAUTION: Check the orientation of the old
installation frequency.
/ 1\ sensor position for the replacement installation.
(ÿÿJLaai) The replacement sensor MUST be installed so that
the same side of the sensor is toward the mount surface. The
NOTE: Each sensor must have a cable of the correct length.
replacement sensor MUST ALSO have the cable toward the
New sensors have either a long (load wheel) or short (steer
same side as the old sensor. The guidance system will NOT
wheel) cable. Make sure to choose the sensor with the correct
operate correctly if the sensor is not installed correctly.
cable length during replacement.
5. Remove the two nuts, washers and capscrews that fasten
/\ CAUTION: The electronic components can be
the sensor. Remove the sensor.
1 1\ damaged by electrostatic discharge. Use a special
UJLJ floor pad to help prevent an electrostatic charge.
6. Install the correct replacement sensor as shown in
ALWAYS remove the electrostatic charge on your body before
Figure 7-17. The cable for the loadwheel sensor is longer than
touching electronic components. Connect a static strap to your
the cable for the steer wheel sensor. Make sure to install the
wrist and a good earth ground. Follow the directions on the
correct sensor. If necessary, loosen the capscrews and nuts at
package of the component.
the end of the sensor bracket to align the center mark on the
sensor board. Fasten the sensor so that the floor clearance is
/\ WARNING: To replace the loadwheel sensor, the
66.5 mm (2.63 in). If possible, the center mark on the sensor
/f\ operator platform must be raised to provide
must align with the centerline of the lift truck. Tighten the sensor
access. The lowering of the operator platform or
mount capscrews and nuts to 2.0 to 2.5 N«m (18 to 22 Ibf in).
forks can cause an injury. Use blocks and chains on the mast
and operator platform so that they cannot move. Make sure the
7. Fasten a string or wire used during removal to the
moving parts are attached to a part that cannot move. See
connector plug of the replacement sensor. Carefully pull the
SAFETY PROCEDURES WHEN WORKING NEAR THE
string or wire to get the sensor cable to the ECM. Remove the
MAST, Page 9-4 for specific instructions.
string or wire. Install new cableties at the same locations of the
old cable ties. Install the cable clamp near the sensor.
8. Connect the sensor connector plug to the ECM. Connect
1. Raise the operator platform for access to the load wheel
connector plug "C" (load wheel sensor) to the "C" location.
sensor area between the load wheels. Use blocks and chains
Connect connector plug "D" (steer wheel sensor) to the "D"
on the mast and operator platform so that they cannot move.
location. See Figure 7-18. Connect the battery connector.
Make sure the moving parts are attached to a part that cannot
move. It can be necessary to remove the battery for access to
9. Adjust the ECM for the replacement sensor. Refer to
the cable ties and wires from the load wheel sensor.
ADJUSTMENTS, ADJUSTING SENSORS TO LIFT TRUCK
CENTERLINE.
free and remove the cover for access to the electrical
10. Remove the support or chain and lower the operator
compartment. Discharge the INTERNAL CAPACITOR of the
platform.
traction motor controller using the proper procedure.
11. Install the ECM cover, close and fasten the electrical
/\ CAUTION: The position of motor and other power
compartment door. Install the electrical compartment cover.
/ 1\ cables can change the operation of the guidance
UhJ system. DO NOT change the position of power
NOTE: Do not splice sensor leads. Splicing sensor leads can
cables during the replacement of sensors.
cause erratic guidance operation. Anytime a sensor lead is
damaged, install a complete sensor assembly.
3. Remove all the cable ties and clamps that fasten the
sensor cable. Make a note of the location of each cable tie and
NOTE: When installing new sensors, install new terminal
position of the sensor cable for the installation.
leads. Do not try to use the connector pins from the previous
sensor assembly.
4. Remove the cover on the ECM. Remove plug connector
"C" for the load wheel sensor. Remove plug connector "D" for
7-31
Yale
IndustrialTrucks -
LEO
o O
| | | |
PB
(mooe: j
i i i
PB
(UP)
©G©G
STICK MOU
PB POT. POT.
IDWN)
04 CONN D
u U u
RT4
D STEER
SENSOR
C4 CONN
<! 3 D RT5
L0A0
SENSOR
SI S2
a
ZLU BI2 B3
CONN B
oo
o_i
UPPER ! EPROM
BIO Bf
i XZ i
a:
uj
AI2 A3 a.
2
CONN A 3
UPPER T UJ
111<E AIO Al p- -P J
zS
I 15 sX
OO
O-J o o U|o||o||o| |o||o OHO O
O O
UJ
1. CONNECTOR PLUG "A" 3. CONNECTOR PLUG "C"

2. CONNECTOR PLUG "B" 4. CONNECTOR PLUG "D"
Figure 7-18 - Connector Plug Location
7-32
Yale
IndustrialTrucks steering system - wire guidance ii
TROUBLESHOOTING

Truck will not steer or move. Battery disconnected.
Shut-off has occurred. Set key OFF, START and ON.

No action when steering wheel is turned. Open circuit in wiring between steering Tach Generator and Tach Steer Module.
Check connections and wires.
Open circuit in wiring between Tach Steer Module and ECM. Check connections
and wires.
Steering Tach Generator or Tach Steer Module is defective.
ECM has no output to steering gearmotor. Check logic and power driver circuits.
Power leads between ECM and steering gearmotor are defective. Check con¬
nections and leads 5P2 and 6P2.
Steering gearmotor is defective.
MDU is against stop. Use large screwdriver in end of steering gearmotor arma¬
ture to move MDU away from stop.
Steering is loose. Steering chain is loose. Adjust chain.

Truck tries to turn in opposite Gearmotor leads reversed.
direction. (LED 1 and LED 2)
do not illuminate correctly. Steering potentiometer leads reversed.
MDU potentiometer leads reversed.
7-33
NOTES
7-34
Yale
IndustrialTrucks
SECTION 8
8 HYDRAULIC SYSTEM ]
Yale
IndustrialTrucks
HYDRAULIC SYSTEM
INTRODUCTION 8-1
DESCRIPTION 8-1
LIFT PUMP AND MOTOR 8-1
MAST LIFTAND LOWER 8-1
MANUAL LOWERING 8-1
ACCUMULATOR 8-1
FLOW REGULATOR 8-2
FILTER 8-3
TANK 8-3
MAIN LIFT CYLINDERS 8-3
VELOCITY FUSES 8-3
SPECIFICATIONS 8-3
REPAIRS 8-4
LIFT PUMP AND MOTOR 8-4
REMOVAL 8-4
SEAL REPLACEMENT 8-4
INSTALLATION 8-6
HYDRAULIC TANK 8-6
REMOVAL 8-6
DISASSEMBLY 8-6
INSTALLATION 8-6
TROUBLESHOOTING 8-7
Yalo
IndustrialTrucks HYDRAULIC SYSTEM
INTRODUCTION
This section describes the hydraulic system and contains the form. Turn the manual lowering knob clockwise to open the
procedures for adjustment and repair. Aguidefortroubleshoot- valve. Turn the knob counterclockwise to close the valve. See
ing is included at the end of this section. Repair procedures for NO TAG.
the mast and hydraulic cylinders are contained in Section 8.
Section 2 contains the maintenance intervals for servicing the WARNING: Make sure manual lowering valve is
hydraulic oil and hydraulic filter. completely closed before lift truck operation.
Unintentional mast lowering may occur if the valve
is not closed.
DESCRIPTION
The Hydraulic System includes the following major compo¬ WARNING: Before using the manual lowering
nents: feature, make sure there are no obstructionswhich
would prevent the platform or forks from lowering.
• Lift Pump and Motor Assembly
• Electro-Hydraulic Control Valve Accumulator
• Accumulator
• Flow Regulator WARNING: The accumulator is pressurized.
• Filter Never attempt to disassemble it or change the
• Tank precharge. Personal injury can result.
• Main Lift Cylinder (2)
• Velocity Fuses (2) A piston type accumulator is installed in the lift circuit to cushion
the starting and stopping of the operator compartment. The ac¬
Lift Pump and Motor
cumulator is precharged with dry nitrogen to 2.07 MPa (300
The lift pump and motor assembly is located in the drive unit psi). Maximum working pressure of the accumulator is 20.68
compartment. The motor that drives the lift pump will be a 24 MPa (3000 psi). The accumulator is mounted to the manifold
volt or 36 volt motor depending on the truck battery voltage. block. See Figure 8-2.
The lift pump only operates whenthe control handle is moved to

select the lift function. 1. ACCUMULATOR
2. FLOW REGULATOR
Mast Lift and Lower 3. MANIFOLD BLOCK
NA00231
Figure 8-2 - Flow Regulator and Accumulator

Oil enters the accumulator when hydraulic system pressure is
NA00478
greater than accumulator pressure. As the hydraulic oil enters
the accumulator, the nitrogen gas in the accumulator is com¬
Figure 8-1 - Control Handle Operation pressed. Accumulator pressure rises until it is equal to hydrau¬
lic system pressure.When accumulator pressure is equal to hy¬
Rocker switches in the control handleallow the forks to be lifted draulic system pressure, no oil transfer occurs. Oil exits the ac¬
or lowered. The OS030EB model has two switches, one for lift cumulator into the hydraulic system when system pressure is
andthe otherfor lower. The switches will automatically returnto less than accumulator pressure. The transfer of oil in and out of
the neutral position when released the accumulator during the increases and decreases of hydrau¬
lic system pressure reduces abrupt pressure changes in the
Manual Lowering hydraulic system and provides a cushioning effectto the opera¬
tor's compartment and load.
The Manual Lowering Valve, located in the drive motor
compartment is manually operated to lowerthe operator's plat-
8-1
Yale
Service parts are not available for the accumulator. If the accu¬ The flow regulator cartridge is not a serviceable item. It must be
mulator is malfunctioning, it must be replaced as a assembly. replaced if it malfunctions. The flow regulator cartridge is
marked with an arrow which indicates direction of free flow. See
Flow Regulator Figure 8-2. When replacing the flow regulator cartridge, be cer¬
tain that the arrow points toward the mast cylinders.
A cartridge type flow regulator is incorporated in the mast man¬
ifold block to control lowering speed. See Figure 8-2. The flow
regulator allows full flow in one direction and controls flow in the Flow regulators are supplied in different flow ratings depending
opposite direction. The flow of hydraulic oil to the mast is unre¬ on the mast. If replacement is necessary, be sure to install the
stricted and maximum lift speed is allowed. The flow of fluid correct part number.
from the mast back to the tank is controlled and lowering speed
is regulated.
1. FILTER
2. RELIEF VALVE
3. SOLENOID VALVE
4. PUMP MOTOR
5. PUMP
6. CHECK VALVE
7. FLOW REGULATOR
8. ACCUMULATOR
9. LOWERING CONTROL VALVE
10. LIFT CYLINDER NA00662
Figure 8-3 - Hydraulic Schematic

8-2
Yale
Filter The breather, strainer and filter should be serviced in accor¬

dance with the recommended lubrication charts found is Sec¬
The hydraulic filter is located inside the hydraulic oil tank. It is
tion 2.
mounted on the bottom of the return line and incorporates an
integral relief valve.
A sight glass is provided on the side of the tank to check fluid
level. Be sure the operator platform is completely loweredwhen
Table 8-1 - Hydraulic Filter Specifications checking the hydraulic oil level.
Filtration
Flow Capacity Relief Valve Setting
Rating Table 8-2 - Hydraulic System Capacities
18 gpm 103.43 kPa (15 psi) 25 to 30 micron Hydraulic Hydraulic Hydraulic Tank
System Capacity Tank Capacity Working Volume
Tank 34 litre (9 gal) 32 litre (8.5 gal) 30 litre (7.9 gal)
A molded plastic tank is used as the hydraulic reservoir. Open
the drive unit compartment and remove the drive unit cover to Main Lift Cylinders
access the hydraulic tank.
The main lift cylinders are used to elevate the mast. See Sec¬
The molded outlet of the tank is locatedatthe bottom.The top of tion 8 - MAST for additional information.
the tank has an access plate bolted to it. There is a breather/fill¬
er and the tank inlet on the top of the access cover. Unscrew the
Velocity Fuses
breather/filler to expose the fill spout and strainer. The main lift cylinders are each equipped with a velocity fuse.
The velocity fuses are designed to prevent uncontrolled lower¬
ing of the mast in the event of a hydraulic hose or line failure. If
such a failure would occur the velocity fuse would act as a flow
regulator to allow the mast to lower at a controlled rate.
1. TANK
2. FILTER
3. BREATHER/FILLER
4. OUTLET
5. RETURN LINE
FREE FLOW
Figure 8-5 - Velocity Fuse
Af \ WARNING: Never operate a mast with the

velocity fuse disassembled or removed.
Velocity fuses are supplied in different flow ratings depending

on the mast. If replacement is necessary, be sure to install the
correct part number.
.. .. .........
.. .. .. .. ..
SPECIFICATIONS
LIFT PUMP AND MOTOR

Rated Flow (24V) 32 litre/min (8.5 gpm)
@ 2000 RPM
Figure 8-4 - Hydraulic Tank and Filter Assembly Rated Flow (36V)
Rated Maximum Pressure

Operating Speed ............... 28 litre/min (7.4 gpm)
@ 2000 RPM
21 MPa (3046 psi)
50 to 3500 RPM
8-3
Yale
Removal
WARNING: Disconnect the battery by separating
the connector before opening the compartment
cover or inspecting/repairing the electrical system .
If a tool causes a short circuit, the high current flow from the
NOTE: If the motor must be removed, do all the steps of this

procedure. To remove the pump, do Steps 1, 2, 6, and 7.
1. Disconnect the battery and open the front compartment

doors. If the motor must be removed, put labels on the power
cables and disconnect the power cables at the motor.
2. Position a drain pan under the lift pump. Loosen the hose
clamp at the inlet and the hose fitting at the outlet of the pump.
Oil can flow from the hoses when the hoses are disconnected.
Have plugs ready to install in the hoses. Disconnect a hose and
quickly install a plug in the hose. Disconnect the other hose us¬
ing the same procedure. If the motor must be removed, install
plugs on the fittings atthe pumpto prevent dirt from entering the
pump.
WARNING: The lift pump and motor is heavy. Be

sure that all lifting devices (hoists, cables, chains,
TTDI nnr
to lift the lift pump and motor. The lift pump and motor can weigh
approximately 253.6 kg (115 lb).
4
3. Remove the M8 capscrews, washers, and spacers that
fasten the bottom of the motor to the bracket.
4. Make a mark on the top of the motor housing for correct

1. LIFT PUMP MOTOR alignment of the motor during installation. Hold the motor as¬
2. LIFT PUMP sembly to keep it from falling and remove the other M8
3. PUMP INLET (SUCTION) capscrews, washers, and spacers that fasten the motor.
4. PUMP OUTPUT (PRESSURE)
NA00233 5. Use a sling around the pump motor and a crane to lift the
motor and the pump. The crane and sling must have a lifting ca¬
pacity of approximately 45 kg (100 lb). Do not damage the mo¬
Figure 8-6 - Lift Pump and Motor tor terminals or pump fittings.
6. Remove the hydraulic fittings from the pump. Removethe

REPAIRS two capscrews and lockwashers that fasten the pump to the
motor. Slowly remove the pump from the motor.
LIFT PUMP AND MOTOR
Seals that are worn or damaged are the most common cause of NOTE: The recommended maintenance and repairs of the lift
pump repair. The pump bearings, gears and shafts also wear. pump motor is covered in Section 3.
Most service persons do not repair a pump that is worn. The
cost of repairs can be greater than the cost of a new pump. The Seal Replacement
special back-up rings, seals and bushings in the hydraulic WARNING: Be careful when removing or
pump are replaceable. These parts come in the repair kit. The installing snap rings. These snap rings can come
end covers also can be replaced. Replace the pump if other loose during removal or installation with enough
pump parts are damaged. force to cause an injury. Always use the correct snap ring pliers
and wear eye and face protection during removal and
installation.
8-4
Yale
CAUTION: If the pump is held in a vise for NOTE: Some pump housings will show gear marks. These
disassembly, use soft jaws in the vise. Make sure marks are caused by the small clearances between the parts.
the vise does not hold the pump too tightly and Gear marks do not indicate a worn or damaged pump unless
cause distortion of the pump housing. the pump does not operate according to the specifications.
NOTE: Make notes of the locations of the parts and seals 4. If necessary, cleanthe internal parts ofthe hydraulic pump.
during disassembly. There are two types of special back-up Lubricate the parts with clean hydraulic oil as the pump is as¬
rings. Make a note of the location of each type. See Figure 8-7. sembled.
1. Carefully remove the end covers. Make a note of the spe¬ 5. Install the gear and bushing assembly in the pump hous¬
cial back-up ring and seal arrangement. Do not disassemble ing. Make sure each bushing is correctly aligned.
the gear and bushing assembly.
6. Install new bushing seals and special back-up rings, install
2. Carefully remove the bushing seals from the bushings and new housing seals. The correct arrangement is shown in
pump housing. Figure 8-7. Installthe end covers and the special washers and
capscrews. Tighten the capscrews to 46 N«m (34 Ibf ft).
3. Inspectthe pump gear assembly andthe pump housing for
wear and damage. Replace a damaged or worn hydraulic 7. Install a new oil seal on the shaft. Carefully press the oil
pump. seal into the end housing. Install a new snap ring.
11
B—|
-CD
6 16 15
1. SCREW 9. WASHER
2. BEADED TUBE 10. RETAINING RING
3. PRESSURE PLATE SEAL 11. BEARING
4. SEAL 12. SPACER
5. PRESSURE PLATE 13. OIL SEAL
6. SLEEVE BEARING 14. RETAINING RING
7. GEAR 15. DRIVE SHAFT
8. SHEAR PIN 16. IDLER SHAFT ASSEMBLY
NA00482
Figure 8-7 - Lift Pump Disassembled
8-5
Yale
Installation 2. Open the drive unit compartment and remove the drive unit
cover.
WARNING: The lift pump and motor is heavy. Be
/ I\ sure that all lifting devices (hoists, cables, chains,
3. Position a suitable drain pan in the drive unit compartment.
to lift the lift pump and motor. The lift pump and motor can weigh See Table 8-2 for hydraulic tank capacity. Tag all the hydraulic
lines to the hydraulic tank. Disconnectthe suction tube to the lift
approximately 253.6 kg (115 lb).
pump and allow the hydraulic oil to drain out of the tank. Clean
1. Carefully install the lift pump on the motor with the four up any spilled oil. Disconnect the rest of the hydraulic lines to
the tank. Plug the hydraulic lines to prevent dirt from entering
capscrews. Tighten the capscrews to 20 N»m (15 Ibf. ft.).
the system.
2. If the motor was removed, use the capscrews, washers,
and spacers to install the pump and motor on the brackets. Re¬ 4. Remove the capscrew holding the upper tank support
place damaged bushings. See the mount detail in Figure 8-8. bracket. Remove the support bracket. The hydraulic tank can
now be removed by lifting the tank straight up.
Align the lift pump and motor with the mounting holes in the
frame using a lifting device.
Disassembly
3. Clean the fittings and install them on the pump. The pump 1. Remove the breather/filler assembly from the top of the
must have oil for first operation. Before connecting the hydrau¬ tank. Remove the strainer from the fill tube. See Figure 8-4.
lic hoses, fill the pump with clean oil at the outlet fitting.
2. Remove the three capscrews, lockwashers, nuts, flat
4. If necessary, clean the hydraulic hoses. Connect the washers and O-rings retaining the tank cover to the hydraulic
hoses to the inlet and the outlet fittings on the pump. tank. Remove the tank cover, gasket return line and filter from
the tank.
5. Connect the power cables to the motor terminals accord¬
ing to the labels. 3 . Inspect all components for damage and replace any defec¬
tive item.
6. Check the hydraulic fluid level and connect the battery.
Installation
7. Operate the lift truck through all functions. Check for oil
leaks. Check the hydraulic tank for the correct oil level.
1. Locate the hydraulic tank in the lift truck.
2. Install the upper tank support bracket using the capscrew,

washer and nut.
3. Install a new gasket on the hydraulic tank. Align the top

cover assembly with the hydraulic tank and the gasket. Install
the three nuts and lockwashers to retain the top cover to the
tank.
1. PUMP MOTOR
2. BRACKET 4. Install the strainer in the tank cover.
3. BUSHING
5. Removethe plugs from the hydraulic lines. Connect all the
4. SPACER
hydraulic lines to the hydraulic tank.
5. CAPSCREW AND WASHER
6. Fill the hydraulic tank to the recommended level with the
Figure 8-8 - Lower Pump Mount recommended hydraulic oil. See Section 2 - HYDRAULIC
OILS.
HYDRAULIC TANK
7. Install the breather/filler assembly.
Removal
/\ WARNING: Disconnect the battery by separating 8. Remove the drain pan, close the drive unit compartment
/f\ the connector before opening the compartment cover. Connect the battery.
If a tool causes a short circuit, the high current flow from the 9. Operate the lift truck through all functions. Check for oil
battery can cause an injury or parts damage. leaks. Check the hydraulic tank for the correct oil level.
1. Turn the key switch to the OFF position. Disconnect the 10. Close the drive unit compartment and install the drive unit
battery. cover on the lift truck.
8-6
Yale
Industrial Trucks HYDRAULIC SYSTEM
TROUBLESHOOTING

Low hydraulic pressure Pump is worn or damaged
Relief valve needs adjustment
Hydraulic system relief valve opens frequently Relief valve needs cleaning or relief valve is defective
Restriction in the system

The pump noise is not normal Oil in the hydraulic tank is low
Restriction in the inlet hose

Inlet fitting or inlet hose clamp is loose
The bearings or gears are damaged
The housing is damaged
Loose capscrews holding the pump housing together
Loose capscrews in the pump mounting
Pump motor is damaged or worn

The pump has low output The pump is worn
Seals or gaskets are damaged and cause leaks
The fitting at the pump leaks

The pump has leaks Fittings are loose or defective
Loose capscrews holding the pump housing together

Seals are defective
8-7
NOTES
8-8
Yale
Industrial Trucks
SECTION 9
MAST ]
Yale
IndustrialTrucks
MAST
INTRODUCTION 9-1
DESCRIPTION 9-1
TRIPLEX MAST 9-1
OPERATION-TRIPLEX MAST 9-1
SIMPLEX MAST 9-1
OPERATION-SIMPLEX MAST 9-2
OPERATOR'S COMPARTMENT 9-3
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST 9-4
CHECKS 9-5
CHECK MAST OPERATION 9-5
CHECK FOR LEAKS IN HYDRAULIC SYSTEM 9-5
REMOVE AIR FROM HYDRAULIC SYSTEM 9-5
CHECK LIFT CHAINS 9-5
CLEANING AND INSPECTION 9-5
ADJUSTMENTS 9-6
LOAD ROLLERS 9-6
ADJUST WEAR PLUGS 9-7
LUBRICATE CHAINS 9-8
ADJUST CHAINS 9-8
ADJUST PLATFORM LIFT CHAINS 9-8
ADJUST MAIN LIFT CHAINS 9-9
ADJUST WEAR STRIPS 9-9
MAINTENANCE 9-10
OPERATOR'S COMPARTMENT 9-10
REMOVAL 9-10
INSTALLATION 9-11
FORKS 9-12
REMOVAL 9-12
INSTALLATION 9-13
PALLET CLAMP 9-13

Yale
IndustrialTrucks

MAST
TRIPLEX MAST ASSEMBLY 9-13

REMOVAL 9-13
CLEANING AND INSPECTION 9-14
INSTALLATION 9-16
INNER AND SECONDARY MASTASSEMBLIES
REMOVAL AND INSTALLATION 9-17
REPLACE HOSES 9-17
MAIN CYLINDERS 9-17
REMOVAL 9-17
INSTALLATION 9-17
DISASSEMBLY OF A LIFT CYLINDER 9-18
ASSEMBLY OF A LIFT CYLINDER 9-18
LOAD ROLLERS AND WEAR PLUGS
REMOVAL AND INSTALLATION 9-20
TROUBLESHOOTING-MAST 9-21
Yale
IndustrialTrucks MAST
INTRODUCTION
This section contains the removal, installation and adjustment To extend the mast, oil from the main control valve flows to all
procedures fortheTriplex Hi-Vis mast assembly and operator's cylinders at the same time. Platform lift chains connect to the
compartment used on the OS030EBandthe SS030B lift trucks. crossmember of the inner mast weldment, are routed over two
This section includes the required maintenance and repair chain sheaves at the top of the inner mast weldment, and
procedures. A troubleshooting chart is provided at the end of connect at the bottom of the operator's compartment. As the
this section. free main cylinders extends, the chains transfer the lifting
motion to the operator's compartment causing the operator's
The mast is used to vertically raise and lower the operator's compartment to move upward. The main lift cylinder raises the
compartment and the load. The main lift cylinders are installed operator's compartment to the top of the inner mast weldment.
vertically in the mast. The main lift cylinders raise the vertical The main cylinders must raise the operator's compartment, the
frames of the mast. These vertical frames are called mast load on the forks, and the weight of the secondary and inner
weldments. mast weldments.
/\ WARNING: The mast, operator's compartment The two main cylinders control the movement of boththe inner
If\ and their components, are heavy. To help prevent and secondary mast weldment as well as the operator's
ChJI damage or an injury, a lifting device must be used compartment. The base of each cylinder is located by a pin
during all service procedures. installed in the lower crossmember bracket of the outer mast
weldment. The rods of each main cylinder are fastened to the
See Section 2 - GENERAL TRUCK AND LUBRICATION for top crossmember of the intermediate mast weldment with snap
the correct maintenance intervals and inspection procedures. rings. As the cylinders extend, the secondary mast weldment is
raised. A pair of lift chains connect near the top rear of the outer
mast weldment, are routed over sheaves at the top of the
DESCRIPTION
intermediate mast weldment, and connect to the bottom of the
Triplex Mast inner mast weldment. As the secondary mast weldment is
raised, the chains transfer the lifting motion to elevate the inner
The Triplex Hi-Vis Mast assembly has three main vertical
mast and operator's compartment.
frames called weldments. There is an outer mast weldment, a
secondary mast weldment and an inner mast weldment. These
During lowering, the main lift cylinders lower first because they
weldments are assembled so they telescope. The outer mast
support the greater amount of the total load. After the main lift
weldment, attached to the lift truck frame, is stationary and
cylinders have completely retracted, the free lift cylinder
does not move upward nor tilt forward or backward. The
lowers. Each cylinder has a velocity fuse installed in its base to
secondary mast weldment is located between the outer mast
limit the lowering speed of the cylinder. Velocity fuses protect
and inner mast weldments and moves within the outer mast.
the operator and mast in the event of a hydraulic line failure.
The inner mast weldment moves inside the secondary mast
Hoses connect all of the cylinders to a single external lowering
weldment. The operator's compartment moves inside the inner
control valve that regulates the lowering speed under normal
mast weldment.
operating conditions. All oil from the lift cylinders flows through
the lowering control valves to the hydraulic tank. The lowering
The operator's compartment is raised with the two main lift
controlvalve is located inthe manifold attached to the bottom of
cylinders. The mast is extended by two dual stage main lift
the outer mast weldment.
cylinders attached to the secondary mast. These main lift
cylinders control the movement of the secondary mast. Two
main lift chains transfer the force to the inner mast weldment. SIMPLEX MAST
The two-stage mast assembly has two weldments. They are
Hoses connect the two hydraulic cylinders. When the
the inner mast weldment and the outer mast weldment. The
telescopic weldments and the operator's compartment lift a
inner mast weldment has a load roller on each bottom channel
load, forces are put on the mast assembly. To decrease friction
section. The load rollers travel along the channels within the
caused by these forces, load rollers and wear strips are
outer mast weldment. The outer mast weldment has one load
installed between the moving parts. The load rollers travel
roller located at the top of the inside of each channel. The
along the channels within the weldments.
outside channels of the inner mast weldment travel on these
load rollers during channel movement. The load rollers permit
OPERATION-TRIPLEX MAST them to controlthe forces during movement of the mast. These
forces are from the front, back and sides. Wear strips are used
The Triplex mast is designed so that all stages of the mast
to control forces fromfront to back.The wear strips are installed
assembly operate proportionally. Whenthe mast is raisedthree
at the top of the outer mast weldment. The wear strips are on
feet, the secondary mast and inner mast each has elevated one
the inside edge of the channels of the outer mast weldment.
foot. The inner mast and the secondary mast lift at the same
Shims and springs are used under the wear strips to keep the
speed.
correct clearance between the weldments.
9-1
Yale
The two-stage mast assembly has two single-stage main

cylinders that are installed vertically behindeach channel of the
outer mast weldment. The base of the main cylinders fit into
pins that are located in the bottom crossmember of the outer
mast weldment. Lock plates are used to position the main
o
cylinders . These lock plates are bolted to the lower end of each
outer mast channel. Removable supports forthe main cylinders
are bolted to the chain anchor weldments. The rods of each
main cylinder are fastened to the top crossmember of the inner
mast weldment with a snap ring. The inner mast weldment
extends from the outer mast weldment as the cylinder rods
extend. The weight of the weldment or operator platform
causes the cylinder rods to retract.
Two hoist chains control the movement of the operator

platform. The chains fasten to the chain anchor supports that
are welded on each channel of the outer mast weldment. The
chains go up and over the chain sheaves and then connect to
the operator platform. The chain sheaves are installed at the
inside of the channels near the top of the inner mast weldment.
The chains transfer the force from the main cylinders to the
operator platform.
OPERATION-SIMPLEX MAST
As the rods in the main cylinders extend, they move the inner
mast weldment out of the outer mast weldment. Since the
chains are fastened to the inner mast weldment and the
operator platform, the force from the cylinder rods transfer the
lifting motion to the operator platform.
When the cylinder rods retract, the weight of the load,operator

platform, and inner mast weldment pushes the fluid from the
cylinders.The hydraulic fluid flows from the cylinders through
the flow control valve located in the manifold to the hydraulic
tank. Each main cylinder has a velocity fuse installed in its
base. These velocity fuses controlthe lowering speed of a load
if a hydraulic line should break.
NA00743
Figure 9-1 - Triplex Mast
9-2
Yale
Industrial Trucks MAST
Operator's Compartment
The operator's compartment contains the instrument panel and
the controls necessary to operate the lift truck. The operator's
compartment is equipped with an overhead guard and a tether
line and belt for the safety of the operator. The operator's
compartment assembly moves within the vertical channels of
the inner mast weldment. Load rollers keep the operator's
4 compartment aligned between the inner channels of the inner
mast weldment and decrease friction. Load forks are attached
to the bottom of the operator's compartment. The operator is
elevated with the load. There is no load backrest extension.
6
1. MAIN LIFT CYLINDER

2. OUTER WELDMENT
3. SECONDARY WELDMENT
4. INNER WELDMENT
5. MAIN LIFT CHAIN
6. PLATFORM LIFT CHAIN
7. OPERATOR'S COMPARTMENT
NA00386
Figure 9-2 - Operation of the Triplex Mast
9-3
Yale
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures
can be required when repairing or removing the mast.
WARNING: Mast parts are heavy and can move. Distances between
parts are small . Serious injury or death can result if part of the body is hit by
parts of the mast or the operator's compartment.
• Never put any part of the body into or under the mast or operator's compartment
unless all parts are completely lowered or a safety chain is installed. Also make sure
that the power is off and the key is removed.
• Put a "DO NOT OPERATE" tag in the operator compartment. Disconnect the battery
and put a tag or lock on the battery connector.
• Be careful of the forks. When the mast is raised, the forks can be at a height to cause
an injury.
• Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to
ascend to or descend from the raised operator compartment, or to work on the mast.
• Do NOT use blocks to support the mast weldments nor to restrain their movement.
• Mast repairs require disassembly and removal of parts and can require removal of
the mast or operator's compartment.
Follow the repair procedures in this section.
WHEN WORKING NEAR THE MAST ALWAYS:

Lower the mast and operator's compartment assembly NA00744
completely. Make sure that all parts of the mast that move are fully
lowered.
OR
If parts of the mast must be in a raised position, install a safety
chain to restrain the moving parts of the mast. Connect moving
parts to a part that does not move. Follow these procedures:
a. Raisethe operator's compartment to the top of the inner weld-
ment (free lift cylinder is completely extended). Use a 3/8-inch
minimum safety chain with a hook to fasten the top crossmember
of the inner weldment to a crossmember on the operator's
compartment. Putthe hook on the steer tire side of the mast. Make
sure the hook is completely engaged with a link in the chain. Make
sure the safety chain is not slack and does not touch lift chains or
chain sheaves, tubes, hoses, fittings or other parts on the mast.
b. Raise the mast to align the bottom crossmember of the sec¬
ondary weldment with a crossmember on the outer weldment.
c. Use a 3/8-inch minimum safety chain with a hook to fasten the
crossmembers together so that the movable secondary member
cannot lower. Put the hook on the load wheel side of the mast.
Make sure the hook is completely engaged with a link in the chain.
Make sure the safety chain does not touch lift chains or chain
sheaves, tubes, hoses, fittings or other parts on the mast.
d. Slowly lower the mast until there is tension in both safety
chains, return the lift/lower control to the neutral position. Move the
key to the OFF position and remove the key from the key switch.
Disconnect the battery and put a tag or lock on the battery connec¬ NA00745
tor. Install a "DO NOT REMOVE" tag on the safety chains.
9-4
Yale
Industrial Trucks MAST
CHECKS
Check Mast Operation Determine if cylinder is leaking by using gate valves in the
supply lines to both cylinders to isolate the affected cylinder.
WARNING: Pressurized hydraulic oil can be
injected into the body by pressure. Do not try to
4. If the operator's compartment or inner mast does not
locate hydraulic leaks by putting hands on
lower, open the gate valve and check for movement again. If the
pressurized hydraulic components.
operator's compartment lowers when the gate valves are open,
check for leaks in the hydraulic lines and fittings. If no leaks are
1. Check for leaks in the hydraulic system (see below).
found, the electro mechanical control valve can have a defect.
Check the condition of the hydraulic hoses and tubes.
Remove the load from the forks.
2. Slowly raise and lower the mast several times without a
Remove Air from Hydraulic System
load. The mast components must raise and lower smoothly in
the correct sequence. NOTE: When you are removing air from the hydraulic
system, make sure that all of the hydraulic fittings are tight and
NOTE: Some parts of the mast move at different speeds do not leak. Make sure that the level of oil in the hydraulic tank
during raising and lowering. is correct.
3. The weldments andthe operator's compartment assembly Operate all of the mast functions to remove air from the
must lower completely. hydraulic system. Fully extend and retract each cylinder rod.
When the cylinder rod reaches the end of its stroke, hold the
4. Check that the controls for the operator's compartment control handle for approximately two seconds. Repeat the
operate the functions installed on the lift truck. See the symbols procedure as many times as necessary for each cylinder until
by each of the controls and refer to the OPERATING MANUAL the operation of both cylinders is smooth.
for your lift truck. Make sure all of the hydraulic lines are
connected correctly and do not leak. Check Lift Chains
Cleaning and Inspection
Check for Leaks in Hydraulic System
CAUTION: Do NOT use steam to clean the lift
chains, sheaves or load rollers. The sheaves and
bearings are sealed and permanently lubricated.
Do not use compressed air on the bearings. The air can force
pressurized hydraulic components. Check for the location of
the lubricant out of the bearings.
high-pressure leaks by holding a piece of cardboard in front of
the suspected area.
and toxic, and can cause skin irritation. Wear
protection for eyes and skin. When using cleaning
load. Put a capacity (see the Nameplate) load on the forks and
solvents, always follow the recommendations of the
raise and lower the load several times. Lower the load. Check
manufacturer.
for any external hydraulic oil leaks. Repair as necessary.
1. Clean the lift chains using solvent. Inspecttheliftchainsfor
2. On all models, raise the operator's compartment and the
wear or damage. A lift chain becomes longer when it is worn. If a
capacity load one metre (3 ft). Verify that there are no external
lift chain is 3% longerthan a new lift chain, the lift chain must be
hydraulic oil leaks. If the operator's compartment lowers slowly
replaced. Use a chain scale to measure the chains. If a chain
with the lift control in a NEUTRAL positionthere are leaks inside
scale is not available, check the lift chains with the
the hydraulic system. The maximum speed that the operator's
measurements given in Figure 9-3.
compartment is allowed to lower is 50 mm (2 in) in ten minutes
when the hydraulic oil is 30° C (90° F). If the oil temperature is
WARNING: Never replace a partial section of a lift
70° C (160° F), the maximum speed that the operator's
chain. Replace the complete chain. Never replace
compartment can lower is 150 mm (6 in) per ten minutes.
just one chain of a chain pair. Replace both chains.
3. Check the lift cylinders for internal leaks. Remove the load 2. Inspectthe chain anchors and pins. Replace any parts that
from the forks. Install a gate valve in the supply line betweenthe are worn or damaged.
control valve and the mast. Put a capacity load on the forks
again. Raise the operator's compartment one metre (3 ft). 3. Inspect the chain sheaves. Replace any parts that are
Close the gate valve. If the operator's compartment or inner worn or damaged.
mast lowers slowly, the seals in the lift cylinders have leaks.
9-5
Yale
CHECKS
Check Mast Operation Determine if cylinder is leaking by using gate valves in the
supply lines to both cylinders to isolate the affected cylinder.
4. If the operator's compartment or inner mast does not
lower, openthe gate valve and checkformovementagain. Ifthe
pressurized hydraulic components.
operator's compartment lowerswhen the gate valves are open,
check for leaks in the hydraulic lines and fittings. If no leaks are
1. Check for leaks in the hydraulic system (see below).
found, the electro mechanical control valve can have a defect.
Check the condition of the hydraulic hoses and tubes.
Remove the load from the forks.
load. The mast components must raise and lower smoothly in
the correct sequence. NOTE: When you are removing air from the hydraulic
system, make sure that all of the hydraulic fittings are tight and
NOTE: Some parts of the mast move at different speeds do not leak. Make sure that the level of oil in the hydraulic tank
during raising and lowering. is correct.
3. The weldments andthe operator's compartment assembly Operate all of the mast functions to remove air from the
must lower completely. hydraulic system. Fully extend and retract each cylinder rod.
When the cylinder rod reaches the end of its stroke, hold the
4. Check that the controls for the operator's compartment control handle for approximately two seconds. Repeat the
operate the functions installed on the lift truck. See the symbols procedure as many times as necessary for each cylinder until
by each of the controls and refer to the OPERATING MANUAL the operation of both cylinders is smooth.
for your lift truck. Make sure all of the hydraulic lines are
connected correctly and do not leak. Check Lift Chains
Check for Leaks in Hydraulic System
CAUTION: Do NOT use steam to clean the lift
/\ WARNING: Pressurized hydraulic oil can be
chains, sheaves or load rollers. The sheaves and
I
I\ injected into the body by pressure. Do not try to bearings are sealed and permanently lubricated.
ChJ locate hydraulic leaks by putting hands on Do not use compressed air on the bearings. The air can force
pressurized hydraulic components. Check for the location of
the lubricant out of the bearings.
high-pressure leaks by holding a piece of cardboard in front of
the suspected area.
and toxic, and can cause skin irritation. Wear
load. Put a capacity (see the Nameplate) load on the forks and
raise and lower the load several times. Lower the load: Check
manufacturer.
for any external hydraulic oil leaks. Repair as necessary.
1. Clean the lift chains using solvent. Inspecttheliftchainsfor
2. On all models, raise the operator's compartment and the
wear or damage. A lift chain becomes longer when it is worn. If a
capacity load one metre (3 ft). Verify that there are no external
lift chain is 3% longer than a new lift chain, the lift chain must be
hydraulic oil leaks. If the operator's compartment lowers slowly
replaced. Use a chain scale to measure the chains. If a chain
with the lift control in a NEUTRAL position there are leaks inside
scale is not available, check the lift chains with the
the hydraulic system. The maximum speed that the operator's
measurements given in Figure 9-3.
compartment is allowed to lower is 50 mm (2 in) in ten minutes
when the hydraulic oil is 30° C (90° F). If the oil temperature is
WARNING: Never replace a partial section of a lift
70° C (160° F), the maximum speed that the operator's
chain. Replace the complete chain. Never replace
compartment can lower is 150 mm (6 in) per ten minutes.
just one chain of a chain pair. Replace both chains.
3. Check the lift cylinders for internal leaks. Removethe load 2. Inspectthe chain anchors and pins. Replace any parts that
from the forks. Install a gate valve in the supply line between the are worn or damaged.
control valve and the mast. Put a capacity load on the forks
again. Raise the operator's compartment one metre (3 ft). 3. Inspect the chain sheaves. Replace any parts that are
Close the gate valve. If the operator's compartment or inner worn or damaged.
mast lowers slowly, the seals in the lift cylinders have leaks.
9-6
Yale
Ditch ADJUSTMENTS
Total length of WEAR LIMIT
fo J5 20 links (pitch) The maximum The most important item to consider in maintaining the mast
of new chain length of 20 links assembly is to keep the inner and secondary sections centered
fo< 3ÿ1
and level within the stationary channel of the outer mast. The
mm (inch) mm (inch) mm (inch)
mast weldments must be aligned parallel to each other during
12.7 (0.50) 254.0 (10.0) 261.6 (10.3) operation to ensure smooth operation and minimum wear.
15.9 (0.625) 317.5 (12.5) 327.0 (12.88)
19.1 (0.75) 381.0 (15.0) 392.4 (15.45)
The masts are designed with features that provide for normal
25.4 (1.00) 508.0 (20.0) 523.25 (20.6) wear and adjustments to compensate for any wear. Whenever
31.8 (1.25) 635.0 (25.0) 654.1 (25.75)
44.5 (1.75) 889.0 (35.0) 915.7 (36.05) making any adjustments, it is important to take proper
50.8 (2.00) 1016.0 (40.0) 1046.5 (41.2) measurements to insure that the mast components are
centered and level.
Wear plugs, an integral part of the load roller assembly, wear

strips, and adjustable chainanchor pins allowfor alignment and
adjustment of the mast. Always adjust the wear plugs and wear
strips for one weldment before making adjustments on other
weldments.
Load Rollers
Load rollers are found on each mast section. Tapered load
rollers are used on the operator's compartment assembly. Load
rollers allow the mast sections and operator's compartment to
move up and down inside one another smoothly. The mast load
rollers are comprised of a grease-sealed ball bearing and an
adjustable inner wear plug.The tapered load rollers used on the
operator's compartment do not have wear plugs. A snap ring is
12174 used to retain the load roller to the mounting bracket. The
mounting brackets are welded to the mast assembly or
operator's compartment.
Adjustments are made to the load rollers to keep side play to a

minimum and to keep the mast weldments centered within their
respective channels. The mast load rollers are adjusted by the
1. CHAIN WEAR SCALE 5180968-69 adjustment of the wear plugs. Refer to ADJUST WEAR
NOTE: The instructions for measuring chain PLUGS. The tapered load rollers used on the operator's
wear are shown on the chain wear scale. compartment do not have wear plugs and are adjusted using
shims. Refer to OPERATOR'S COMPARTMENT -
INSTALLATION.
Since load rollers contain a grease-sealed bearing, no

lubrication of the roller itself is necessary. However, on the mast
load rollers, the wear plugs come into contact with the central
portion of the mast channel. Therefore, it is necessary to
periodically apply grease to this area. In many applications, dirt
from the environment collects on the greased section of the
masts and creates hardened accumulations of dirt and grease
which interferes with free movement of the rollers. If this
condition is allowed to exist, the rollers will slide instead of roll
up and down in the mast creating flat spots on the roller shell.
Steam clean the mast assembly periodically to remove any dirt

1.
2.
WORN PIN
CRACKS 5.
'
LOOSE LEAVES
67C
accumulation. Apply new grease to all friction areas. Inspect
the rollers for cracks, flat spots or frozen bearings.
3. EDGE WEAR 6. DAMAGED PIN
4. HOLE WEAR 7. CORROSION
Figure 9-3 - Inspect the Lift Chains
9-7
Yale
1. YALE SPECIAL TOOL

5062050-00
1. LOAD ROLLER 2. ADJUSTMENT HANDLE
2. WEAR PLUG 3. WELDMENT
3. STUB SHAFT
4. ELEVATING UPRIGHT Figure 9-5 - Wear Plugs-Adjustment
5. SETSCREW
Proceed until all mast sections have been successfully
6. NUT adjusted and tested.
7. SEALED BEARING
Figure 9-4 - Load Roller and Wear Plug Assembly Adjust the wear plugs as follows:
Adjust Wear Plugs 1. Loosen the jam nut on the wear plug using Yale Special
Tool 5062050-00, available from your Yale lift truck dealer. See
NOTE: Move the lift truck to an area with a smooth level floor Figure 9-5. Raise and lower the mast weldments several times
before making any adjustments to make sure the adjustments to find the point of minimum clearance of the weldment.
are accurate.
2. Adjust the wear plugs to attain zero clearance betweenthe
Wear plugs should be adjusted to provide minimum clearance wear plug and the weldment channel at the tightest point.
between the wear plug and the mast weldment. Loosenthe jam Adjust wear plugs on opposite sides to keep the weldment in
nut on the back side of the wear plug and turn the socket head the center.
setscrew in or out as required. A mast wear plug adjustment
tool is available to make the wear plug adjustment easier. This 3. Adjust the clearance to approximately 0.5 mm (0.02 in) by
tool can be obtained by contacting your nearest dealer. turning the adjustment handle 1/8 turn counterclockwise. Keep
the clearance between the weldments equal on both sides.
Always adjust the wear plugs and wear strips for one mast Keep the weldments parallel to each other.
weldment before making adjustments on other weldments.
4. Tighten each jam nut without moving the setscrew.
WARNING: If a mast section binds or does not
move freely during any adjustments, NEVER WARNING: If a mast section binds or does not
loosen the wear plugs without first raising the mast move freely during any adjustments, NEVER
assembly high enough to remove any slack in the chains. loosen the wear plugs without first raising the mast
Failure to do this may allow for a sudden drop of the binding assembly high enough to remove the slack out of the chains.
mast section and could cause serious injury. Failure to do this may allow for a sudden drop of the binding
mast section and could cause serious injury.
After each section has been adjusted, test the operation of the
mast assembly by raising and lowering the mast assembly 5. Raise and lower the weldments without a load. Check that
without a load. This will aid in determining if the wear plugs have there is minimum clearance, as described in Step 3, with free
been adjusted equally and that the mast does not bind. After movement. If the weldments do not move smoothly, repeat this
each section has been successfully tested without a load, procedure until the wear plugs are properly adjusted.
another test should be done with a load.
6. Repeat Steps 1 through 6 for each weldment.
9-8
Yale
Lubricate Chains (Step 1) is correct. When the tension is equal on both chains,
Clean and inspect the chains before lubrication. Use SAE 30 the chain sheave assembly will be level.
engine oil as a lubricant forthe chains. The recommendationfor
adding lubricant is to remove the chains from the lift truck and 3. Tighten the locknuts.
soak them in oil.
ADJUST CHAINS
J\ WARNING: Mast parts are heavy and can move.
11\ Distances between parts are small. Serious injury
CJLJ or death can result if part of the body is hit by parts
of the mast or the operator's compartment. Never put any part
of the body into or under the mast or operator's compartment
II
unless all parts are completely lowered or a safety chain is
installed. Also make sure that the power is off and the key is
removed. Refer to SAFETY PROCEDURES WHEN
WORKING NEAR THE MAST, Page 9-4.
Adjustments must be made to both main lift chains. Each lift

chain is adjusted at the chain anchor. Chains are adjusted for
the following reasons:
1. Adjustments should be made to the chains to keep the
chains at the proper tension. The chain tension must be the MAIN LIFT
same for each chain ofthe chain set. Chains that havethe same 1. SECONDARY 5. ANCHOR PIN
tension will move the same amount using the same pressure. WELDMENT 6. CHAIN ANCHOR
2. CHAIN SHEAVE 7. LOCKNUT
2. Each lift chain should support an equal load,to prevent too 3. LIFT CHAIN 8. OUTER WELDMENT
much load and wear on one chain of a pair. 4. COTTER PIN 9. ADJUSTMENT NUT
3 . The chain lengths must be equal for each chain set and the NA00294
length must be correct for the mast height.

4. Mast weldments must move in the correct sequence.
Figure 9-6 - Chain Adjustment
NOTE: When the chain adjustments are complete, make
5. The chains must be able to travel freely over chain sure that the cotter pin at the bottom ofthe chainanchor can be
sheaves through the raising and lowering cycle. installed under the adjustment nut. If there is no room to install
Adjust Platform Lift Chains the cotter pin, the chains are too short. Install the correct
chains. Make sure that the locknuts on the chain anchors are
WARNING: Mast parts are heavy and can move. tight against the mount plate. If there are not enough threads
11\ Distances between parts are small. Serious injury on the chain anchor for correct adjustment, new chains are too
or death can result if part of the body is hit by parts long or old chains are too worn. Links can be removed from old
ofthe mast or the operator's compartment. Never put any part chains if the chains are less than 3% longer than the correct
of the body into or under the mast or operator's compartment new chain. Replace old chains that are too long or new chains
unless all parts are completely lowered or a safety chain is that are not the correct length.
removed. Refer to SAFETY PROCEDURES WHEN 4. Check the mast operation. Refer to CHECKS - CHECK
WORKING NEAR THE MAST, Page 9-4. MAST OPERATION, Page 9-5.
1. Raisethe operator's compartment assembly for access to
the chain anchors near the top ofthe free lift cylinder. Install
safety chains. Refer to SAFETY PROCEDURES WHEN
WORKING NEAR THE MAST, Page 9-4. Loosen both
lockouts at the chain anchors to make any adjustments.
2. Check chain tension by pushing on both chains at the

same time. If the tension is not the same, adjust the nuts on the
chain anchors until the tension is the same and the distance
9-9
Yale
Adjust Main Lift Chains NOTE: The wear plugs and lift chains must be adjusted
before the wear strips are checked, replaced, or adjusted.
/\ WARNING: Mast parts are heavy and can move.
II\ Distances between parts are small. Serious injury Check and adjust the wear strips as follows:
or death can result if part of the body is hit by parts
of the body into or under the mast or operator's compartment /\ WARNING: Mast parts are heavy and can move.
/ I\ Distances between parts are small. Serious injury
NOTE: The free lift chains must be adjusted before adjusting
the main lift chains. removed. Refer to SAFETY PROCEDURES WHEN
1. Check the main lift chains for equal tension by pushing on
both chains at the same time. If the tension is not the same, 1. Move the lift truck to an area with a smooth level floor
adjustment is required. The adjustment nuts are at the chain before makingadjustments to insure adjustments are accurate.
anchors near the top of the outer weldment. Raise the operator's compartment to gain access to the wear
strips. Install safety chains as described in SAFETY
2. To adjust the tension, loosen both locknuts at the chain PROCEDURES WHEN WORKING NEAR THE MAST, Page
anchor. Adjust the nuts at the chain anchor until the tension is 9-4.
the same on both sides. Tighten the locknuts.
2. Remove the capscrews, washers, wear strips and shims.
NOTE: When the chain adjustments are complete, make
Replace all worn or damaged parts. One wear strip and one
sure that the cotter pin at the bottom of the chain anchor can be
shim on each side are usually the correct adjustment. There
installed under the adjustment nut. If there is no room to install
must bethe same number of shims underthe wear strip on both
the cotter pin, the chains are too short. Install the correct
sides of the weldment. Equal shims will keep the weldment
chains. Make sure that the locknuts on the chain anchors are
parallel with equal clearance.
tight against the mount plate. If there are not enough threads
on the chain anchor for correct adjustment, new chains are too
long or old chains are too worn. Links can be removed from old
chains if the chains are less than 3% longer than the correct ?-— 1
new chain. Replace old chains that are too long or new chains 6--2
that are not the correct length.
3. Check the mast operation. Refer to CHECKS - CHECK

(t -3
MAST OPERATION, Page 9-5
Adjust Wear Strips

The wear strips and shims are fastened to the lower guide
blocks of weldments that move. The wear strips and shims are
adjusted for the following reasons:
• For minimum clearance to prevent too much side 1. CAPSCREW
US
movement of the weldments. 2. WASHER
3. WEAR STRIP
• To keep the weldments parallel. 4. SHIM
5. WELDMENT CHANNEL
Figure 9-7 - Typical Wear Strip Assembly
3. Use a prybar to move the weldment to install shims for
minimum clearance. Install the shims and new wear strips as
shown in Figure 9-7. Wear strips and shims on the inner
weldment can be used on either side. There are right and left
9-10
Yale
wear strips and shims on the secondary weldments. Remove Removal

the safety chains.
1. Park the lift truck with a minimum oftenfeet of clearance in
front of the truck. Be sure the steer tire is positioned for straight
/\ WARNING: If a mast section binds or hangs up
travel.
/f\ during any adjustments, NEVER loosen the wear
CJLJI plugs without first raising the mast assembly high
2. Raise the operator's compartment until the floor of the
enough to remove the slack out of the chains. Failure to do this
operator's compartment is even with the top of the drive unit
may allow for a sudden drop of the binding mast section and
compartment.
could cause serious injury.
3. Use safety chains to secure the crossmember of the
4. Check that the mast operates correctly as described in
operator's compartment to a crossmember on the outer
CHECK THE OPERATION OF THE MAST at the beginning of
stationary weldment.
this section, Page 9-5.
4. Turn the key to the OFF position, disconnect the battery
NOTE: Refer to Section 2 of this manual for the
and separate the connectors.
recommended maintenance and inspection intervals for the
mast, hydraulic cylinders, forks and operator's compartment.
/f\ Distances between parts are small. Serious injury
MAINTENANCE or death can result if part of the body is hit by parts
/\ WARNING: Lower the lift mechanism completely.
/ 1\ Never allow anyone under a raised operator's unless all parts are completely lowered or a safety chain is
CJLJ compartment or forks. Do not put any part of your installed. Also make sure that the power is off and the key is
body in or through the mechanism unless all parts of the mast
are completely lowered, the key switch is in the OFF position,
and the battery is disconnected.
5. Disconnect the spring holding tension on the wire take-up
assembly and remove the spring from the truck. See
I
I\ Distances between parts are small. Serious injury Figure 9-8.
installed. Also make sure that the power is OFF and the key is
/\ WARNING: Some parts can be damaged by

/ 1\ welding and cause an injury. Get authorization and
CLj instructions from your Yale lift truck dealer before
welding on the mast or operator's compartment.
/\ WARNING: Be careful when removing or

/ I\ installing snap rings. These snap rings are large
LJLJ and can come loose during removal or installation
with enough force to cause an injury. Always use the correct
snap ring pliers and wear eye and face protection during -
Figure 9-8 Wire Take-up Tension Spring
removal or installation.
6. Locate the clamp at the bottom of the mast-side of the
operator's compartment that secures the wire take-up
OPERATOR'S COMPARTMENT assembly to the floor of the operator's compartment. Remove
the bolt that secures the clamp to the operator's compartment
/\ WARNING: Lift chains, hoses and cables can roll and remove the clamp from the truck.
/ I\ over the sheaves to fall and cause an injury if the
ChJ ends are not fastened. Keep control of the ends of
the lift chains, hoses and cables as they are removed. Use wire 7. Position blocks under the operator's compartment and at
to temporarily secure the ends of the lift chains, hoses or both ends of each fork in order to support the weight of the
cables. operator's compartment and forks when lowered.
9-11
Yale
8. Remove the safety chains preventing the mast and 16. Using caution to avoid stretching or snagging any hoses,
operator's compartment from moving. wires or cables, slowly move the truck forward with the traction
control in the operator's compartment until the bottom of the
9. Connectthe battery. Lowerthe operator's compartment on mast is clear of the operator's compartment load rollers.
to the blocks positioned in Step 7. Make sure the operator's
compartment and forks are securely supported at both ends 17. Disconnect the battery and separate the connectors.
and level and stable.
18. Remove the dash cover in the operator's compartment.
10. Support the operator's compartment from above to
19. Disconnectthe two connectors of the wire take-up harness
prevent the operator's compartment from tipping after it is
in the operator's compartment.
removed from the truck. As an alternative, place a load on the
top of the forks, evenly spaced between the blocks, to prevent
20. Remove the two screws securing the wire take-up strain
the operator's compartment from tipping.
relief fitting to the operator's compartment.
11. Disconnect the battery and separate the connectors.
A
WARNING: Care must be taken to adequately
12. Open the drive unit compartment. support the operator's compartment at all times to
prevent tipping.
/\ WARNING: The capacitor in the SCR controller
/ I\ can hold an electrical charge after the battery is Installation
ChLbJ disconnected. To prevent electrical shock and The operator's compartment is installed similar to the way it
injury, discharge the capacitor before inspecting or repairing was removed. The mast on the lift truck must be secured in the
any component in the drive unit compartment. Wear safety raised position with chains high enough to allow the lift truck to
glasses. Make certain the battery has been disconnected. be maneuvered into position above the load rollers of the
Use a jumper wire between the two terminals to discharge operator's compartment. Follow the procedure below:
capacitor C1 . Block the drive wheels.
1. Align the operator's compartment and the lift truck into the
13. Discharge the capacitor. proper position for installation. The mast inner weldment
should be positioned above the load rollers of the operator's
/\ WARNING: Lift chains, hoses and cables can roll compartment.
gf\ over the sheaves, fall and cause an injury if the
ends are not fastened. Keep control of the ends of 2. Disconnect the battery and separate the connectors.
the lift chains, hoses and cables as they are removed. Usewire
to temporarily connect the ends of the lift chains, hoses or 3. Insert the wire take-up harness and strain relief through
cables. the opening in the center of the mast side of the operator's
compartment. Secure the strain relief with the two screws.
14. Close the drive unit compartment and connect the battery. Connect the wire harness in the operator's compartment by
plugging in the two connectors.
/\ WARNING: The operator's compartment may be
/|\ unstable when removed and can fall and cause an 4. Open the drive unit compartment.
injury. Support the operator's compartment from
above with an overhead hoist or be sure that the operator's /\ WARNING: The capacitor in the SCR controller
compartment is securely supported from below and cannot tip g I\ can hold an electrical charge after the battery is
over. disconnected. To prevent electrical shock and
15. Using caution to avoid pinching any hoses or cables, any component in the drive unit compartment. Wear safety
slowly raise the mast with the lift/lower control until the inner glasses. Make certain the battery has been disconnected.
mast section is clear of the load rollers of the operator's
compartment. Use a jumper wire between the two terminals to discharge
capacitor C1 . Block the drive wheels.
J\ WARNING: Mast parts are heavy and can move.
g 1\ Distances between parts are small. Serious injury 5. Discharge the capacitor.
of the mast or the operator's compartment. Never put any part 6. Slowly lower the mast inner weldment onto the load rollers
of the body into or under the mast or operator's compartment of the operator's compartment using the manual lowering valve
unless all parts are completely lowered or a safety chain is on the hydraulic pump. Gradually turn the valve clockwise and
installed. Also make sure that the power is OFF and the key is wait until the mast is completely lowered. Use caution to avoid
removed. Refer to SAFETY PROCEDURES WHEN pinching any hoses or cables. Close the manual lowering valve
WORKING NEAR THE MAST, Page 9-4. by rotating the valve counterclockwise to the stop.
9-12
Yale
/\ WARNING: Be careful when removing or through a tube welded to the top of the fork and holes in the
11\ installing snap rings. These snap rings are large operator's compartment assembly. It is necessary to raise the
LlJ and can come loose during removal or installation operator's compartment to access the forks pins.
A
snap ring pliers and wear eye and face protection during WARNING: Forks are heavy and can cause an
removal or installation. injury. Do not try to remove forks without using a
lifting device.
7. Check the adjustment of the tapered load rollers of the
operator's compartment. Check for zero clearance at the Removal
tightest point of travel within the mast channel. Adjustment to
the tapered load rollers is made using shims behind each load
roller as required. Use caution when removing the snap ring f \ Distances between parts are small. Serious injury
I
retaining the load roller to the bracket. The operator's
compartment must be centeredand parallel with the mast inner
weldment within 1.5 mm (0.060 in.).
installed. Also make sure that the power is off and the- key is
8. Remove the safety chains preventing the mast and

operator's compartment from moving.
9. Close the drive unit compartment and connect the battery.
10. Raise the operator's compartment using the lift/lower

control untilthe floor of the operator's compartment is even with
the top of the drive unit compartment. 1. FORK 5. SPACER
2. PIN 6. WASHER
/\ WARNING: Mast parts are heavy and can move. 3. SNAP RING 7. WASHER
II\ Distances between parts are small. Serious injury 4. SHIM
of the mast or the operator's compartment. Never put any part Figure 9-9 - Fork Assembly
unless all parts are completely lowered or a safety chain is 1. Raise the mast to gain access to the fork pins.
removed. Refer to SAFETY PROCEDURES WHEN 2. Support the fork using a hoist and sling and/or jack.
11. Install the clamp at the bottom of the mast-side of the / 1\ installing snap rings. These snap rings are large
operator's compartment that secures the wire take-up and can come loose during removal or installation
assembly to the floor of the operator's compartment. with enough force to cause an injury. Always use the correct
snap ring pliers and wear eye and face protection during
12. Install the spring that holds tension on the wire take-up removal or installation.
assembly.
3. Remove the snap ring from the end of the fork pin.
MAST OPERATION, page 9-5. 4. Remove the fork pin andwashers. Guide the fork out of the
fork retainer and carefully lower it to the floor.
FORKS
NOTE: If shims are used, mark them for installation during
Each fork is connected to the operator's compartment by a pin fork installation.
near the edge of the operator's compartment. The pin fits
9-13
Yale
Installation
A
WARNING: Forks are heavy and can cause an
injury. Do not try to install forks without using a
lifting device. PEDAL
1. Raise the mast to gain access to the fork pins.

II\ Distances between parts are small. Serious injury
removed. Refer to SAFETY PROCEDURES WHEN PALLET CLAMP NA00299
2. Support the fork using a hoist and sling and/or jack.

Figure 9-10 - Pallet Clamp
3. Raise the fork into the fork retainer and align the fork tube TRIPLEX MAST ASSEMBLY
with the fork pin support holes under the operator's
compartment. Removal
1. Remove the operator's compartment. Refer to
NOTE: If shims are used, install them in the original positions.
OPERATOR'S COMPARTMENT - REMOVAL.
4. Install the fork pins and washers. 2. Operate the lift/lower control handle to raise the inner
weldment high enough to access the four capscrews and
/\ WARNING: Be careful when removing or washers that fasten the bottom of the mast to the truck frame.
/ ?\ installing snap rings. These snap rings are large DO NOT remove the capscrews at this time.
and can come loose during removal or installation
with enough force to cause an injury. Always use the correct /V WARNING: Mast parts are heavy and can move.
If\ Distances between parts are small. Serious injury
5. Install the snap ring on the fork pins. of the body into or under the mast or operator's compartment
PALLET CLAMP installed. Also make sure that the power is off and the key is
/\ WARNING: Mast parts are heavy and can move. WORKING NEAR THE MAST, Page 9-4.
or death can result if part of the body is hit by parts 3. Install safety chains to keep the mast components from
of the mast or the operator's compartment. Never put any part moving.
unless all parts are completely lowered or a safety chain is 4. Remove the four capscrews and washers that fasten the
installed. Also make sure that the power is off and the key is bottom of the mast outer weldment to the truck frame. Do NOT
removed. Refer to SAFETY PROCEDURES WHEN disconnect any hydraulic fittings.
5. Disconnect the spring holding tension on the wire take-up
The pallet clamp is designed to automatically engage as the assembly and remove the spring from the truck.
center of a pallet slides into the clamp. To release the clamp,
depress the pallet clamp pedal. Refer to Figure 9-10. If the 6. Remove the safety chains installed in Step 3. Carefully
clamp is not working properly, adjust the actuating rods operate the lift/lower control handle to fully lower the operator's
beneath the operator's compartment. The clamp should be compartment and inner weldment. Make sure that all hydraulic
adjusted so the gap is 12.7 mm (1/2 in.) in the initial position and pressure is removed from the system.
76 mm (3in.) maximum opening. Refer to PALLET CLAMP,
Page 2-4 for instructions on checking the operation of the pallet 7. Remove the bolt from above the wire take-up assembly
clamp. sheave. Slip the wire take-up assembly off of the sheave and
9-14
Yale
support the wire from above at the stationary mast with a removed. Use chains to connect a crane or other lifting device
bungee cord. to the top of the mast assembly. Operate the crane until it gives
supportto the weight ofthe mast assembly. Move the crane to a
8. Disconnect the hydraulic hose to the mast at the fitting position so that the mast assembly will be lifted vertically. Make
attached to the outside of the drive unit compartment. Cap the sure the chains will not damage the sheaves or other parts of
hose and the fitting to avoid excessive hydraulic fluid loss. the mast assembly. Make sure the chains and crane have the
Secure the disconnected hose to the mast so the hose will be capacity to lift approximately 2000 kg (4500 lbs). Use safety
out of the way when the mast is removed. chains to fasten all the mast weldments together so that they
cannot move. Install a chain or sling to the operator's
9. Disconnect the battery and separate the connectors. compartment to keep the mast assembly from tipping during
removal. Remove the four capscrews that fasten the trunnion
10. Open the drive unit compartment. caps.
/\ WARNING: The capacitor in the SCR controller 15. Use the crane or overhead hoist to raise the mast
II\ can hold an electrical charge after the battery is assembly high enough to clear the trunnions.
Lm) disconnected. To prevent electrical shock and
injury, discharge the capacitor before inspecting or repairing 16. Move the mast assembly away from the truck. Place the
any component in the drive unit compartment. Wear safety mast securely on a level floor and support the mast to prevent
glasses. Make certain the battery has been disconnected. accidental movement.
Use a jumper wire between the two terminals to discharge
capacitor C1. Block the drive wheels. Cleaning and Inspection
11. Discharge the capacitor. /\ WARNING: Cleaning solvents can be flammable

II\ and toxic, and can cause skin irritation. Wear
12. Disconnect the three connectors of the wire take-up
harness and proximity sensor harness in the drive unit
manufacturer.
compartment.
1. Clean the mast weldments with steam or solvent.
13. Locate the clamp at the bottom of the mast-side of the
2. Inspect the sliding and rolling surfaces ofthe channels for
assembly to the floor of the operator's compartment. Remove
damage (dents) and wear (grooves). Inspect all welds for
the bolt that secures the clamp to the operator's compartment
cracks.
and remove the clamp from the truck.
14. Mark the trunnion caps so they can be reassembled in the

same position and on the same trunnion from which they are
9-15
Yale
IndustrialTrucks mast
1. INNER WELDMENT
2. SECONDARY WELDMENT
3. OUTER WELDMENT
4. MAIN LIFT CYLINDER
A. LOCK PLATE
B. RETAINER
5. CHAIN ANCHOR
6. CHAIN SHEAVE ASSEMBLY (RH)
A. CHAIN SHEAVE
B. BALLBEARING
C. SNAP RING
7. MAIN LIFT CHAIN
8. LOAD ROLLER
9. FLOW REGULATOR HOUSING
10. FLOW REGULATOR
11. HYDRAULIC ACCUMULATOR
12. HYDRAULIC HOSE (MAIN LIFT)
REAR VIEW
HOSE ROUTING - LIFT
12 12
NA00296
Figure 9-11 - Triplex Mast Assembly

9-16
Yale
Installation 9. Connectthe hydraulic linetothe mast atthe fitting attached

to the outside of the drive unit compartment.
WARNING: Mast parts are heavy and can move.
Distances between parts are small. Serious injury
10. Remove the safety chains installed in Step 1.
11. Close the drive unit compartment and connect the battery.
12. Operate the lift/lower control handle to raisethe operator's
compartment and inner weldment high enough to expose the
mast mounting bolt holes at the bottom of the outer mast
weldment.
1. Use chains to connect a crane or other lifting device to the
WARNING: Mast parts are heavy and can move.
top of the mast assembly. Operate the crane until it gives
Distances between parts are small. Serious injury
support to the weight of the mast assembly. Movethe crane to a
position so thatthe mast assembly will be suspended vertically.
Make sure the chains will not damage the sheaves or other
parts of the mast assembly. Make sure the chains and crane
havethe capacity to lift approximately 2000 kg (4500 lbs). Use
safety chains to fasten allthe mast weldments together so that
they cannot move. Install a chain or sling to the operator's
compartment to keep the mast assembly from tipping during
installation.
13. Install the four capscrews and washers that secure the
bottom of the mast outer weldment to the truck frame. Tighten
2. Use the crane or overhead hoist to raise the mast
to a torque value of 203 N*m (150 Ibf ft).
assembly high enough to clear the trunnion support on the
truck. Carefully move the mast assembly in position above the
14. Install the clamp at the bottom of the mast-side of the
trunnion supports.
assembly to the floor of the operator's compartment.
3. Carefully lower the mast onto the trunnion supports. Be
sure the bottom of the mast outer weldment is against thetruck
15. Install the spring that holds tension on the wire take-up
frame at the bottom.
assembly.
4. Assemble the trunnion caps onto the trunnion supports
16. Remove the safety chains.
taking care to install them exactly the same way as they were
removed.Tighten thetrunnion cap bolts to a torque value of 203
N*m (150 Ibf ft).
MAST OPERATION, page 9-5.
5. Disconnect the battery and separate the connectors.
6. Open the drive unit compartment.
WARNING: The capacitor in the SCR controller

can hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
any component in the drive unit compartment. Wear safety
glasses. Make certain the battery has been disconnected.
Use a jumper wire between the two terminals to discharge
capacitor C1. Block the drive wheels.
7. Discharge the capacitor.
8. Carefully route the three connectors from the wire take-up

harness and proximity sensor harness through the opening in
the drive unit compartment and connect them to the proper
mating connectors.
9-17
Yale
Inner and Secondary Mast Assemblies-Removal and MAIN CYLINDERS

Installation
Removal
1. The load rollers and wear plugs must be removed to NOTE: It is necessary to remove the mast assembly from the
remove the inner or secondary weldments. Refer to LOAD truck to remove the main cylinders.
ROLLERS AND WEAR PLUGS, REMOVAL AND INSTALLA¬
TION. 1. Remove the mast assembly. Refer to TRIPLEX MAST
ASSEMBLY, REMOVAL.
2. The lift chains, hoses and electrical cable must also be 2. Secure the mast in a horizontal position.
removed to remove the inner or secondary weldments. To
remove the lift chains, hoses and sheaves, refer to TRIPLEX WARNING: The mast weldments can move and
LIFT CHAINS, REMOVAL AND INSTALLATION, and cause an injury even if the mast assembly has
TRIPLEX CHAIN SHEAVES, DISASSEMBLY AND AS¬ been removed from the lift truck. Make sure the
SEMBLY. mast assembly is level to prevent the components from moving
without being moved. Use safety chains to prevent movement
3. Use safety chains to fasten the secondary weldment to the after components are in the correct position.
outer weldment. Use a crane or lifting device to support the
inner weldment while sliding it out of the secondary weldment. 3. Remove the safety chains that fasten the mast weldments
together and use a prybar to carefully and slowly move the
4. Remove the safety chains that fasten the secondary secondary weldment approximately 75 mm (3 in) out of the
weldment to the outer weldment. Use acraneor lifting device to outer weldment.
support the secondary weldment while sliding it out of the outer
weldment. 4. Install a sling and crane to support the cylinder. Remove
the capscrews, washers and lock plate at the base of one main
5. Installthe load rollers and wear plugs during assembly of cylinder.
the mast weldments.
WARNING: Be careful when removing or
Replace Hoses installing snap rings. These snap rings are large
1. To replace any hydraulic hose, fully lower the operator's
compartment. Make sure that the system does not have with enough force to cause an injury. Always use the correct
hydraulic pressure by holding the lift/lower control for
approximately five seconds to release the pressure. Make sure removal or installation.
the hydraulic pump does NOT operate. Move the key to the
5. Remove the snap ring, back-up washer, rubber bushing
OFF position. Disconnect the battery and put a tag or lock on
the battery connector. and shims (if applicable) that fasten the cylinder rod to the
secondary weldment. If shims are used, make a note of the
shim arrangement. Normally, the shim arrangement for the
NOTE: Access can be difficult for some fittings. If necessary,
replacement cylinder will be similar.
operate the system to move mast weldments or the operator's
compartment. Make sure to follow the SAFETY
PROCEDURES WHEN WORKING NEAR THE MAST, Page 6. Remove the hose or tube between the main cylinder and
9-4, after moving components BEFORE starting work. Also
the manifold. If necessary, use a prybar to carefully move the
make sure the system does not have pressure as described in operator's compartment and mast weldments for access.
Step 1. Install a cap on the regulator fitting to prevent leakage.
7. Remove the main cylinder retainer, capscrews and

2. Disconnect hoses, drain any excess oil into a container
and install caps to prevent dirt from entering the hydraulic washers.
system.
8. Push the cylinder toward the top of the mast assembly to
3. Replace the hose. Operate the system to remove allthe air move the cylinder off the locating dowel pin. Continue to push
from the oil and to check for leaks. the cylinder so that the rod moves into the cylinder to allow
removal from the secondary weldment.
MAST OPERATION, page 9-5. 9. Repeat Steps 4 through 8 to remove the other main
cylinder.
Installation
1. Install the cylinder onto the locating dowel pin.
2. Install the cylinder retainer, capscrews, and washers.

9-18
Yale
3. Install the hydraulic hose to the cylinder. 3. Remove the retainer from the piston rod. Remove and
discard the O-rings, seals, and wear rings.
/ 1\ installing snap rings. These snap rings are large /\ WARNING: Be careful when removing or
and can come loose during removal or installation 11\ installing snap rings. These snap rings are large
with enough force to cause an injury. Always use the correct and can come loose during removal or installation
snap ring pliers and wear eye and face protection during with enough force to cause an injury. Always use the correct
removal or installation. snap ring pliers and wear eye and face protection during
4. Installthe snap ring, back-up washer, rubber bushing, and
shims (if applicable), that fasten the cylinder rod to the 4. Remove the snap ring, washer, and check valve from the
secondary weldment. If shims are used, be sure to installthem base of the piston.
in the same way as they were removed.
5. Clean allthe parts. Check the sliding surfaces for damage.
5. Installthe capscrews, washers and lock plate at the base Install new parts if the damaged parts cannot be repaired.
of one main cylinder.
ASSEMBLY OF A LIFT CYLINDER
DISASSEMBLY OF A LIFT CYLINDER
1. Lubricate all internal parts of the lift cylinder with clean
A CAUTION: Carefully disassemble the lift

cylinders so that the piston rods and sliding
surfaces are not damaged.
NOTE: The lift cylinders are disassembled from the rod end of
hydraulic oil or packing lubricant (Yale Part No. 504234269).
Use new O-rings, seals, and wear rings.
I
/\
|
\ installing snap rings. These snap rings can come
the cylinder shell. loose during removal or installation with enough
force to cause an injury. Always use the correct snap ring pliers
1. Loosen the retainer with a spanner. Remove the retainer and wear eye and face protection during removal and
from the shell. installation.
2. Pull the rod and piston assembly from the shell. Drain the
hydraulic oil into a container.
9-19
Yale
Q
MAIN LIFT CYLINDER
1. ROD WIPER 5. TUBEWELDMENT 9. WEAR RING 13. WASHER
2. SEAL 6. SPACER 10. FLOATING PISTON 14. CHECK VALVE
3. GLAND 7. VELOCITY FUSE 11. BACK-UP RING 15. "O" RING
4. "O" RING 8. SNAP RING (2) 12. SHIM 16. PISTON ROD
NA00295
Figure 9-12 - Lift Cylinder

2. Installthe check valve and O-ring in the base of the piston. 3. Installthe wear ring, piston seal and back-up ring onto the
Make sure the arrow on the check valve is towards the base of piston assembly. If a spacer is used, install it.
the piston. Installthe washer and snap ring for the check valve.
4. Carefully push the piston and rod assembly into the shell.
CAUTION: A difficult and important step in
assembling lift cylinders is the correct installation 5. Install the rod seal ring and wiper into the retainer. Install
of the seals. Most lift cylinder maintenance is the O-ring and back-up ring on the outside of the retainer.
caused by seal leaks. Do not damage any parts during
assembly. 6. Carefully install the gland on the piston rod. Engage the
threads and tighten the retainer in the shell until it is tight. Use a
NOTE: The main lift cylinder packing kits are furnished with correct spanner. Do not hit the gland with a hammer and driver.
sleeves to aid in assembly of the seal onto the piston and to
installthepistonassemblyintotheshell. Usethe sleeves, along 7. Installthevelocityfuse. Make sure the special washer and
with the furnished instruction sheet, to insure proper assembly. the spring are installed correctly. A wrong installation can cause
the load to lower too fast.
9-20
Yale
LOAD ROLLERS AND WEAR PLUGS-REMOVAL AND WARNING: The mast weldments can move and
INSTALLATION cause an injury even if the mast assembly has
1. Remove the operator's compartment and mast assembly.
been removed from the lift truck. Make sure the
mast assembly is level to prevent the components from moving
Refer to OPERATOR'S COMPARTMENT, REMOVAL and
without being moved. Use safety chains to prevent movement
TRIPLEX MAST ASSEMBLY, REMOVAL. Removethe main lift
cylinders. Refer to MAIN CYLINDERS-REMOVAL AND
after components are in the correct position.
INSTALLATION. The mast assembly must be horizontal.
2. Remove the safety chains that fasten the mast weldments
together and use a prybar to carefully and slowly move the
correct mast weldment for access to the load rollers. The inner
weldment load rollers are at the bottom. The load rollers for the
outer weldment are at the top. The load rollers for the
7 secondary weldment are at the top and the bottom of the
weldment. Use safety chains to fasten the inner weldment to
the outer weldment so that they do not separate completely.
NOTE: If the inner weldment and the secondary weldment

4 will be disassembled from the outer weldment, do not installthe
load rollers at this time.

installing snap rings. These snap rings are large
3. Always install safety chains to preventthe weldments from

moving BEFORE starting to replace any load roller. Remove
the snap rings that fasten the load rollers.
NOTE: Replace wear plugs at this time to save the cost of

removal and disassembly of the mast assembly for wear plug
replacement.
4. Use a prybar to remove the load roller from the mast

weldment. See Figure 9-14.
7 1
1. LOAD ROLLER WITH SNAP RING REMOVED

2. PRYBAR
1. OUTER WELDMENT 5. SNAP RING Figure 9-14 - Removing Load Roller

2. SECONDARY WELDMENT 6. WEAR PLUG
5. Use a cloth to clean each load roller. Inspect the load
3. INNER WELDMENT 7. SET SCREW rollers for cracks, flat spots or bearings that do not turn freely.
4. LOAD ROLLER 8. JAM NUT Replace any roller that shows wear or is damaged.
NA00298
Figure 9-13 - Triplex Load Rollers 6. Adjust the wear plugs after all load rollers and wear plugs
are replaced. See CHECKS AND ADJUSTMENTS. The wear
plugs are adjusted after the mast assembly is installed on the lift
truck.
9-21
Yale
TROUBLESHOOTING-MAST
MIB malfunction. See ELECTRICAL SECTION.
No operation of lift cylinders No oil or not enough oil to supply cylinders
Bad hydraulic leaks, bad pump or pump drive, relief valve set too low,
bad check valve
Not enough oil supply to cylinder(s)
Bad cylinder seal(s). Check for seal leaks insidethe cylinder by install¬
Slow operation of lift cylinders ing a gate valve in the hydraulic line. See Checks and Adjustments.
Relief valve pressure is wrong
The spring for the relief valve is weak or damaged
Air in the hydraulic system
Bent rods, cylinders with distortion or damage

Rough movement of the mast assembly
Mast assembly damaged or not in alignment
Wear plugs or wear strips adjusted too tight
9-22
NOTES
9-23
Yale
IndustrialTrucks
SECTION 10
10 BATTERY AND CHARGING SYSTEM

Yale
IndustrialTrucks
-
SECTION 10 CONTENTS
BATTERY AND CHARGING SYSTEM
DESCRIPTION
GENERAL
SAFETY TIPS FOR HANDLING INDUSTRIAL TRUCK BATTERIES
BATTERY TROUBLESHOOTING
LEAD-ACID BATTERIES
SPECIFIC GRAVITY
......
PAGE NUMBER
10-1
10-1
10-3
10-5
10-5
CHEMICAL REACTION 10-5
HOW TO SELECT THE BATTERY 10-6
VOLTAGE OF A BATTERY 10-6
BATTERY RATINGS 10-7
KILOWATT HOURS 10-7
THE BATTERY AS A COUNTERWEIGHT 10-7
THE NEW BATTERY 10-7
BATTERY MAINTENANCE 10-8
MAINTENANCE RECORDS 10-8
CLEANING THE BATTERY 10-9
ADDING WATER 10-9
SPECIFIC GRAVITY 10-10
TEMPERATURE 10-10
CHARGING THE BATTERY 10-11
TYPES OF BATTERY CHARGES 10-11
DAILY CHARGE 10-11
EQUALIZING CHARGE 10-11
METHODS OF CHARGING 10-11
GRADUAL CHARGE 10-11
MODIFIED CONSTANT VOLTAGE
TWO-RATE CHARGE
TROUBLESHOOTING THE CHARGER
HOW TO KNOW WHEN THE BATTERY IS FULLY CHARGED
BATTERY CHARGING AREA
EQUIPMENT NEEDED
PRECAUTIONS FOR BATTERIES IN STORAGE
.......
10-11
10-12
10-12
10-12
10-12
10-12
10-12
Yale
IndustrialTrucks BATTERY AND CHARGING SYSTEM
GENERAL
A
This section describes the selection and maintenance of large
industrial batteries used in electric lift trucks. This information \
| CAUTION: Disposal of batteries must meet local
pertains to the service personnel that maintain industrial truck LJ environmental regulations.
batteries.
245=o23a 22ÿ 21 20 19 :
13J 14 15 16
£17 so18 o
i ;
to o
12J 11 [8 :
10 9 i 7
mi
1 5 2 4 L 5 so o
1. LEAD BUSHING 5. POSITIVE PLATE

2. VENT AND FILLER CAP 6. NEGATIVE PLATE
3. TERMINAL POST 7. SEPARATOR
4. CELL COVER 8. CONTAINER
-
Figure 10-1 Lead-Acid Industrial Truck Battery
SAFETY TIPS FOR HANDLING INDUSTRIAL TRUCK BATTERIES

1 WARNING: Be sure water is readily available in
WARNING: Disconnect the battery from the lift case electrolyte accidentally splashes on yourskin
truck when doing maintenance and repair work. or clothing. Extreme care should be taken in
flushing electrolyte from the eye. Use plain water only and
-
Why The live current may cause arcing or a short circuit, obtain medical attention immediately.
causing injury or damage to equipment.
-
Why Volumes of water applied quickly and continuously will
A
WARNING: Wear rubber apron, gloves, boots prevent serious injury to the skin. Quick medical attention is
and goggles, when handling, checking, filling, necessary to assure proper care and treatment.
charging or repairing batteries.
A
WARNING: Apply strong neutralizer such as
Why -To protect yourself against burns resulting from baking soda when acid is spilled on the floor and
accidental spillage of electrolyte (a mixture of sulfuric acid and clean up promptly.
water).
-
Why Baking soda will neutralize the acid and make it safe to
A WARNING: Keep open flames away from

batteries - do not check electrolyte level with a
cigarette lighter or match. USE A FLASHLIGHT
OR PERMANENT LIGHT. Do not smoke or create sparks.
clean or flush from the floor.
A
WARNING: Take proper care in melting the
sealing compound when preparing to seal a
battery. Avoid puncturing the hard surface of
-
Why The space betweenthe underside of the cover and the partially melted compound with a screwdriver or other sharp
top of the electrolyte in the cell usually contains a hydrogen tool. Compound may ignite if it is heated too rapidly.
oxygen mixture which is explosive when ignited.
Why - The hot liquid may squirt up and burn your hand, face or
body. If it should catch fire it creates the hazard of an open
10-1
Yale
flame. Burning consumes oil in the compound and impairs its 13. Allow only authorized personnel (qualified by training and
useful characteristics. experience) in the battery room.
7. Remove vent caps from nearby cells when preparing to -

Why An untrained or inexperienced person may unknowingly
assemble a repaired cell into the battery. Cover the vent holes break normal rules for proper handling, causing injury to
with layers of damp cloth before using lead burning equipment themselves and damage to batteries and equipment.
on the intercell connectors in order to integrate the cell into the
battery circuit. Also, use dark glasses to protect the eyes. 14. Enclose all bare wires and bus bars in the battery room by
wire guards, guard rails or other means of isolation from
-
Why To prevent a possible hydrogen oxygen concentration general plant traffic.
from exploding when a flame is lit.
8. Be sure to shut off the power when changing or repairing

-
Why Any open high current transmission equipment is a
possible hazard to you, other workers and equipment.
plugs or receptacles that are connected to the charging
equipment. This will prevent a short circuit and arcing. 15. Never lay metal tools such as wrenches or other material
on top of an open battery.
Why -
A short-circuit may injure you. Arcing may cause
explosion and fire. -
Why Sparking and short circuiting will occur and the battery
will quickly be discharged or may explode.
9. Disconnect the battery before removing the terminal lugs
from the receptacle when repairing a damaged or dirty plug or 16. Check batteries for cracks or leaks. Repair at once.
receptacle connected to a battery.
Why - Electrolyte will spill on floor or equipment, causing
-
Why The leads which terminate in the receptacle are live or corrosion of the steel tray and related equipment. Continuous
"hot" with the total voltage of the battery existing across the flow of leaking electrolyte can cause a ground path that reduces
terminals. Iftheterminal lugs are accidentally touched together battery life and capacity.
a short-circuit or arcing will occur with its attendant danger.
17. When batteries are disposed of as scrap at the end of
10 ÿ WARNING: When mixing acid to prepare useful life, they should be sent to a authorized recycling center
/ *\ electrolyte, ALWAYS POUR ACID SLOWLY INTO
WATER and never water into acid. Always store
or salvage dealer.
acid in plastic or glass container. -

Why Old batteries may have enough residual voltage left to
cause a spark if filled with electrolyte.
-
Why If water should be added to acid it will not readily mix and
will splash the acid due to the great difference in the specific 18. Familiarize yourself as completely as possible with
gravity of the two liquids. The effect of splashed acid is batteries and the proper rules for their charging, handling and
dangerous. maintenance.
11 /\ÿ
WARNING: Always lift batteries with mechanical -
Why Full knowledge of batteries andthe dangers of improper
/ I\ equipmentsuchasahoist.craneorlifttruck. Move handling will pay dividends in the elimination of injuries and
batteries horizontally with powertracks, conveyors damage.
or rollers. Make sure that hoist hooks, spreader bars and other
tools are of ample strength and properly installed. Cover top of CAUTION: Keep vent plugs in the cells at all
battery with rubber mat or other insulating material to prevent times, except when taking hydrometer readings,
external short circuits from chains or cables falling on top of adjusting specific gravity and electrolyte levels,
battery. troubleshooting or assembling a repaired cell.
-
Why Batteries are a heavy concentrated load and might NOTE: Your company, industry and government safety
easily cause painful strains or injury to your feet or hands. regulations should be reviewed to help reduce accidents and
Batteries may be seriously damaged or electrolyte spilled ifthe damage to equipment.
battery is dropped.
NOTE: If batteries are not in use, keep them charged. Check
12. Make sure that charging plugs and receptacle are properly specific gravities monthly and give a freshening charge (3 to 4
locked and all other connections tight, secure and free from hours at the finish rate) if the gravities have fallen 30 points
friction. (.030) or more, otherwise, give freshening charge every three
months.
-
Why A loose connection may mean sparking or even arcing
with attendant danger of gas explosion.
10-2
Yale
IndustrialTrucks battery and charging system
PROBLEM POSSIBLE CAUSE CORRECTION

Battery overheats on discharge Over discharge Limit discharge to 1.110 specific gravity.
Put more batteries into service. Set up
more frequent charging schedule.
Excessive load Determine cause of overload and correct.
Put more batteries into service if
equipment requirements exceed battery
capacity.
Not fully charged prior to work Needs more frequent and complete
assignment, resulting in over discharge charging.
Electrolyte levels low Add water as required. Do not assign
battery to work if levels are below top of
plates.
When overheating is confined to few Install heat insulating material between
cells, nearby operating equipment may equipment cells with air circulating space
be source between.
Operating in high ambient temperatures Provide cool location for charging and
good ventilation.
Low electrolyte level Broken or cracked jar Replace jar.
Water additions neglected or cell missed Better maintenance supervision. Add
in previous water addition. water as required to all cells.
Overcharging Adjust charging equipment.
a. Voltage relay set for many cells a. Connect relay for proper number of
cells.
b. Timer set for too many hours b. Reduce time.
c. Voltage change rate relay operating c. Reduce voltage value at which voltage
relay operates.
Specific gravity between cells not uniform Overfilled with water Do not fill above high level - give
equalizing charge and adjust acid.
Operating cell with cracked jar Replace jar and adjust acid.
Acid not adjusted properly after jar Adjust acid specific gravity.
change
Vent caps removed during operation Keep vent caps securely in place. Give
equalizing charge and adjust acid.
Electrolyte leaking through sealing Reseal and adjust acid.
compound
Operating battery with broken coil cover Replace cover and adjust acid.
Neutralizing agent in cell Keep vent caps in place at all times
except when adding water. Keep battery
clean.
Unequal cell voltages Refer to Unequal Cell Voltages
Unequal cell voltages Over discharge. Also more than 0.020 Give an equalizing charge and do not
points spread in specific gravity from discharge below 1.110.
average
Lack of equalizing charges Give an equalizing charge periodically.
Internal shunt Make internal inspection of low voltage
cell and correct cause. Check for split
separator and moss short.
10-3
Yale
PROBLEM POSSIBLE CAUSE CORRECTION

Unequal cell voltages (continued) Dirty battery top Neutralize and clean top of battery.
Cells operated with low electrolyte level Add water as required. Give equalizing
charge.
Low specific gravity of fully charged cell Adjust acid after equalizing charge.
Sediment space filled Replace battery.
Half tap on cells for lower voltage circuit Remove tap and connect load to battery
terminals through resistance.
External source heating certain cells Install heat insulating material between
heat source and battery.
Impurities in cell Add only distilled or approved water to
electrolyte.
Variation in charge rate Take readings when charge rate is
constant.
Battery will not work full shift Uneven cell voltages Give an equalizing charge.
Low electrolyte levels Refer to Low Electrolyte Level.
Battery not charged before work cycle Check charging schedules. Do not assign
discharged battery to work.
One or more jars leaking electrolyte Replace broken jars.
Incorrect battery (number of cells) Install battery with correct voltage and
assigned to equipment capacity to equipment.
Fully charged specific gravity below Adjust specific gravity to normal.
normal
Impurities in electrolyte Add only distilled or approved water to
electrolyte.
Operator "riding the brake" Discourage practice.
Using reverse in place of braking Discourage practice.
Inexperienced operator Instruct him on power conservation.

Load excessive Use larger battery or reduce load.
Wheels, axles and bearings need grease Plan lubrication schedule.
Tires under inflated or wrong type Plan periodic check of air pressure.
Brakes dragging Adjust brakes properly.
Series field in motor shorted or grounded Replace field and remove ground.
Armature needs repair Replace or repair armature.
Ground on equipment Find ground and insulate.
Excessive grades Use larger battery or revise battery
charge schedule.
Capacity or equipment assigned to job Reassign equipment.
is inadequate
10-4
Yale
Industrial Trucks BATTERY AND CHARGING SYSTEM
LEAD-ACID BATTERIES
A lead-acid battery converts chemical energy into electrical CHEMICAL REACTION
energy. The battery is discharged when the chemical reaction
The cell generates a voltage (potential difference) when two
has occurred and the battery will not supply its rated voltage
different types of metal are in the electrolyte. The two metals in
and current. A reverse chemical action must occur so that the
a lead-acid cell are lead peroxide (Pb03) for positive plates, and
battery can be used again. The batteries can be charged by an
sponge lead (Pb) for negative plates. A potential difference of
electric voltage and current from an outside source to provide
approximately two volts per cell is generated. The potential
the reverse chemical action. The lead-acid chemicals store the
difference does not vary according to the size of the cell.
electrical energy until needed.
During the discharging of the cell, lead peroxide and sponge
A lead-acid battery is made from several lead-acid batteries
lead mix with sulfuric acid to make lead sulfate (PbS04) on both
called cells. Each cell has positive and negative plates with
plates. This action decreases the voltage in the cell. When the
dielectric spacers between each plate. All of the plates are in a
sulfuric acid is removed from the electrolyte, the specific gravity
solution of electrolyte.
of the electrolyte decreases. The potential difference of a
discharged cell is approximately 1.73 volts.
SPECIFIC GRAVITY
The strength of the electrolyte is measured in points of specific
gravity. For example: a solution of sulfuric acid has a specific
gravity of 1.835. Water has a specific gravity of 1.000. LESS THAN
Electrolyte is 27% acid and 73% water and has a specific 2.06 VOLTS
gravity of 1.275.
/\ CAUTION: NEVER pour water into acid. The

11\ quick production of heat can cause the acid to boil DECREASED
and splash out of the container. ALWAYS pour acid SULFURIC
into water when making a dilute solution of acid. ACID
INCREASED
WATER .
2.06 3m
VOLTS DECREASED DECREASED
LEAD LEAD
SPONGE PEROXIDE
INCREASED LEAD SULFATE

ELECTROLYTE
Figure 10-3 - Cell Discharging

When a direct current is applied to a discharged cell, the lead
sulfate is changed into lead and sulfuric acid. The lead goes to
the positive plate and stays as lead and to the negative plate
and stays as lead peroxide. The concentration of sulfuric acid in
NEGATIVE POSITIVE
PLATE PLATE the electrolyte increases. The specific gravity of the electrolyte
increases as the concentration of sulfuric acid increases. In a
fully charged cell, the positive plate again contains the lead
SPONGE LEAD
peroxide and the negative plate contains the sponge lead. The
LEAD PEROXIDE
potential difference of a charged cell is approximately 2.2 volts.
In a fully charged cell, the electrolyte has a specific gravity of

1.270. NEVER discharge a battery below a specific gravity of
1.130. The battery can have permanent damage if discharged
Figure 10-2 - Fully Charged Cell below 1.130.
10-5
Yale
IndustrialTrucks
MINIMUM
SPONGE
LEAD
1.75
VOLTS
MINIMUM OF
SULFURIC
ACID
MAXIMUM
WATER
MAXIMUM LEAD SULFATE

S
Sk
MINIMUM
LEAD
PEROXIDE
Figure 10-4 - Discharged Cell
HOW TO SELECT THE BATTERY

ÿ
The battery needed to operate a period of eight hours depends

on many conditions. Operations that require the lift truck to go
up ramps or require the use of additional attachments
increases the use of power from the battery. Some work
conditions require that more than one battery must be used
during a work period. The number of eight-hour work periods
per day is normally equal to the number of batteries needed.
The capacity of the battery you need is found as follows:
• The size of the lift truck and the attachments.
• The type of work. Heavy duty operation or normal operation
for one eight-hour work period.
The battery voltage you need is found as follows:
• Will your lift truck operate on more than one voltage?
• If you have more than one lift truck in operation, do the
battery voltages need to be the same?
Lift trucks are available in various voltage ranges. The small
"Motorized Hand" trucks are normally 12 to 24 volts. Larger
"Sit-down Rider" lift trucks are normally 24 to 48 volts.
VOLTAGE OF A BATTERY
To reach the necessary battery voltage, the cells are connected
in series. For example:
• 24 volts 12 cell battery
10-6
izi
INCREASED
SPONGE
LEAD
CHARGER
ACID
DECREASED LEAD SULFATE
Figure 10-5
iii
•V • >
* ÿ*—
-• r.rl
2.33
VOLTS
INCREASED
SULFURIC
DECREASED
. WATER
.
BATTERY AND CHARGING SYSTEM
BATTERY
INCREASED
LEAD
PEROXIDE
- Cell Charging
%:;r- V..?
Figure 10-6 Cell Voltage -

.\
>
FSS1
L2±T
r": S%-
."
__
.•
s
Yale
BATTERY RATINGS (0.5 in) from side to side and 12.7 mm (0.5 in) fore and aft.
(Reference ANSI B-56.1.)
The ratings of batteries are measured in ampere-hours (AH)
and kilowatt-hours (KWH) at a constant rate of discharge. The
number and size of plates increases the amp-hour rating. A THE NEW BATTERY
rating of six hours is the standard. Ampere-hours is the
Inspect every new battery for damage. Make sure the
measurement of battery capacity. To calculate ampere-hours,
electrolyte in each of the cells is at the correct level. Charge the
multiply amperes by hours. For example: 5 amperes times 5
battery for six hours or untilthe specific gravity is correct. Some
hours is 25 ampere-hours. You cannot change the potential
new batteries may require cycling 7 to 10 times before the
difference of a cell. You can increasethe ampere-hour rating by
battery accepts a full charge. (Cycling is charging and then
increasing the number of plates in a cell, or by installation of
discharging the battery at a prescribed rate. Refer to the
larger plates. The constant rate of discharging can be
instructions shipped with the battery.) Make sure the battery is
compared to a measurement of the battery capacity and
correctly installed in the lift truck. Use a correct spreader bar
ampere-hours. For example: a battery with a rating of 600
with slings to lift and move the battery.
ampere-hours during a work period of six hours will generate
100 amperes per hour for six hours. (The same battery cannot
CAUTION: Always use a spreader bar and slings
generate 300 amperes for two hours. The heat generated with
that lift vertically on the lifting eyes of the battery.
the battery will damage the battery.)
DO NOT use a chain or sling without a spreader
bar or you will damage the battery.
Kilowatt Hours
__
A kilowatt is 1000 watts. A watt is a measure of electric power. Use the correct blocks or spacers to hold the battery in
The capacity in kilowatt-hours is the total power generated by position in the lift truck. Make sure that the battery
the battery. Watt-hours are measured by multiplyingthe voltage compartment is clean and dry. All of the vent caps must be in
by ampere-hours. To measure the kilowatt-hours, divide the position when the battery is in service. If the vent caps are
watt-hours by 1000. not installed, the electrolyte will leak, causing corrosion of the
battery case and in the battery compartment.
[
V ———————
/ volts x ampere x hours \
1.000 J
) = kilowatt hours of KWH
To calculate the kilowatt-hours for a battery that has a rating of NON METALLIC
600 ampere-hours and a 48 volt system, use this formula. STRAPS
48 x 600 ( Power available from a fullv \

1,000 V charged battery.
J
All the electrical operations figure a specific watt-hours in
electric energy. These operations include distances, loads,
ramps, lifting heights, attachments, etc. The watt-hours can be
converted to kilowatt-hours to indicate the battery needed for
the operation. Always select the correct type of battery.
Remember, a battery that has a rating of 300 ampere-hours will
not do the same job as a battery that has a rating of 600
ampere-hours. Do not permit the specific gravity to go below
the limits shown in the manual.
THE BATTERY AS A COUNTERWEIGHT

On electric lift trucks that use the battery as part of the
counterweight, the battery is part of the capacity of the lift truck
to lift loads. The minimum weight of the battery is shown on the
nameplate. If the battery is not the minimum weight, the
capacity of the lift truck is reduced. If the battery used in the lift
truck is less than the size of the battery compartment, blocks
and spacers must be installed to hold the battery in position. -
Figure 10-7 Lifting the Battery
The maximum allowable movement of a battery is 12.7 mm
10-7
Yale
BATTERY MAINTENANCE
Battery maintenance must include a good battery charger, a 7. Keep batteries in a charged state.
clean battery, keeping the electrolyte at the correct level, and
keeping a record of the battery. 8. Do not charge a battery with a charger that has an
ampere-hour rating higher than that of the battery. This will give
1. Keep batteries clean and free of acid spills. too high a charging current and excessive heating. Charging
with a lower ampere-hour charger will cause no harm, but may
2. Do not over discharge. Excessive discharge shortens require longer than 8 hours to fully charge.
battery life.
3. Do not overcharge. Overcharging produces corrosion of MAINTENANCE RECORDS

positive grids and excessive gassing, which loosens the active Always complete the Battery Inspection Report and the Daily
material of the plates. Battery Report.
4. Charge batteries in a well-ventilated area to remove the NOTE: Follow the same sequence when you record the cell
explosive gases and acid fumes. number. Always begin the record with a positive cell. Follow a
sequence so that the last cell is always the cell for the
5. Maintain electrolyte at the proper level. If low, add water. negative cable.
Before charging, make sure tops of plates are covered; after
charge, fill to recommended level. Do not add acid. Recordthe beginning ampere reading of the charger eachtime
the battery is charged. Any difference in the daily ampere
6. Keep batteries from freezing. reading can indicate a problem with the battery or the charger.
Battery Inspection Report it-
*—
cm pomTivt cm cm tNORC
<2St VOLTS CADMIUM
IMCt»»e
GRAVITY
TCMP.
MO. VOLTS
KMMTIVC
CADMIUM OKAVtTY
TCMT.
i 21
2 22
3 23
4 24
9 2S
e 26
7 27
•
9
28
29
10 30
11 31
12 32
-
Figure 10-8 - Battery Inspection Report
10-8
Yale
IndustrialTrucks battery and charging system
knm »•
turn, IW
l«tf C
OATC
fm HI
TRUCK
NO.
___ Daily Battery Record
VKCIFIC OKAVITV
IN OUT
_
TlMF. flMC
-
-
»•
TIMI
HLOTCtU. ON CHANGE OF* CMAMOK
-
*<"
INITIAL
——
MATIN
ADMO OMNATON
-
Figure 10-9 Daily Battery Record
CLEANING THE BATTERY each week. If the level of the electrolyte goes belowthe level of
the top of the separators for the plates, the cell can be
Keep the battery compartment clean and dry. Use a clean cloth
damaged.
to wash the battery with water. Dry with compressed air.
A WARNING: To prevent personal injury and
A CAUTION: Do not cleanthe battery with steam or

hot water. Do not use a high pressure hose.
Remove any electrolyte from the battery compartment to

/ 1\ unexpected battery movement, the battery must
uJ) be level when it is moving. Before removing the
battery to check the electrolyte levels, make sure the battery
stand is on a level surface and is aligned and adjusted.
prevent corrosion. If there is electrolyte on the top of the battery,
NOTE: Keeping the electrolyte level within the correct limits
apply a solution of bicarbonate of soda. Mix a solution
is the most important item of battery maintenance. Always use
containing 1.11b (0.5 kg) of soda for every 4.22 qts (4 litres) of
distilled water. If you add distilled water, wait five minutes
water. Apply the solution, then flush the solution from the
before measuring the specific gravity with a hydrometer. Do not
battery with clean water. Wash the battery and battery
add distilled water to a cell during the charging cycle. The
compartment as needed. Six months between cleaning is the
electrolyte can flow out of the cell through the fill hole. Figure
maximum recommended interval.
9-10 shows a general ruleforthe incorrect electrolyte level. See
the instructions from the manufacturer of your battery for the
NOTE: If the top of the battery is wet from electrolyte, check
operating level of the electrolyte.
to see if the electrolyte level is too high or the battery charger
is not operating correctly.
-
Table 10-1 Electrolyte Level
CELL HEIGHT DIMENSION "A"
ADDING WATER
Some water is lost from the electrolyte of each cell during the Less than 38 cm (15 in) 3 mm (1/8 in)
charge and discharge cycle when the battery is in service. 38 to 61 cm (15 to 24 in) 6 mm (1/4 in)
Check the electrolyte level daily. Some service persons check
some of the cells each day so that all of the cells are checked Greater than 61 cm (24 in) 12 mm (1/2 in)
10-9
Yale
TEMPERATURE
BOTTOM OF FILL TUBE
The temperature ofthe electrolyte will change the reading ofthe
COVER \ FILL HOLE specific gravity. When the temperature increases
HIGH LEVEL approximately 6° C (10° F), the specific gravity will decrease by
SSSSSSSSÿ
4\ 0.003 points. Refer to Table 10-2 for making specific gravity
corrections.
LOW LEVEL f
p ÿ
IE""1
Never charge or discharge a battery at a rate that will raise the
temperature of the electrolyte above 50° C (120° F). A
temperature above this amount will damage the battery. The
cells in the center of the battery are normally at the highest
temperature. If the battery temperature is too hot, make sure
ELECTROLYTE
the ventilation ofthe battery is increased and make sure that the
charge or discharge rate is not too high. A recommendation for
PLATE PROTECTOR TOP OF SEPARATORS a battery in service is 8 hours of use (discharge), followed by 8
hours of cooling, followed by 8 hours of charging.
Figure 10-10 - Electrolyte Level
-
Table 10-2 Specific Gravity Temperature Corrections
SPECIFIC GRAVITY SPECIFIC
GRAVITY ELECTROLYTE CORRECTION CORRECT
Use a hydrometer to measure the specific gravity of the battery. READING TEMPERATURE POINTS VALUE
Make sure there is enough electrolyte in the battery cells. A
high level or low level of the electrolyte can change the specific 1.210 31° C (87° F) + 0.003 1.213
gravity measurement. When the electrolyte level is low, the
percent of sulfuric acid in the electrolyte increases. When the 1.210 27° C (80° F) + 0.001 1.211
electrolyte level decreases by 3 mm (0.12 in) the specific 1.210 25° C (77° F) + 0.000 1.210
gravity measurement can increase by 3 to 5 points.
1.210 18° C (64° F) -0.004 1.206
When using the hydrometer, make sure there is enough liquid
in the barrel to letthe float move freely. The float must not touch + 0.001 for each 1.7° C (3° F) from the 25° C (77° F)
the side, top, or bottom of the barrel for the correct method of Base Value Degrees C + 17.8 x 1.8 = Degrees F.
reading the hydrometer.
The normal electrolyte temperature is 25° C (77° F). At this
temperature the electrolyte has a specific gravity of
1.285-1.295 with no correction for temperature. If the
hydrometer you are using does not have a temperature
correction, you will have to use a thermometer. Special battery
thermometers are available that will indicate the correction
factor directly and add or subtract the correct number of points.
LIQUID
SPECIFIC
LEVEL
GRAVITY-
SCALE
FLOAT
Figure 10-11 - Hydrometer
10-10
Yale
If lift truck operation results in only partial discharges (50% or

less) and specific gravities are 1.210 to 1.220 or more at the end
rN of the shift, recharging may be deferred and the battery used for
another shift providing the work load is not expected to
increase. Hydrometer readings and experience will disclose
the frequency of charge intervals under these circumstances.
iai
m -ii /\ CAUTION: A battery should always be recharged
IN
• • !
/ I\ immediately following a complete discharge.
Never allow it to remain in a discharged condition,
ii - •
N
since permanent damage may result.
«
u •- 1
- •>i
• TYPES OF BATTERY CHARGES
* it
* i«
* Daily Charge
This charge is normally eight hours and will keep the battery
fully charged if the battery is not discharged below the limit.
\
Equalizing Charge
This charge is at a low rate and balances the charge in all of the
cells. The equalizing charge is normally given approximately
once per week and is three hours at a low rate in addition to the
regular charging cycle. The most accurate specific gravity
measurements for a charged battery will be after an equalizing
charge.
NOTE: Sometimes the capacity of a battery is not enough to

complete a work period. Check for the following conditions:
• The battery is too small for the job.
• The battery is not fully charged.
• The battery charger is not operating correctly.
Figure 10-12 - Battery Thermometer • The battery is near the end of its service life.
METHODS OF CHARGING
CHARGING THE BATTERY
There are three methods of charging a battery.
/\ WARNING: Batteries produce explosive
/ t\ hydrogen gas when charging. Always open the
battery cover or hood and provide good ventilation
Gradual Charge
This method uses a solid state automatic battery charger. The
when charging. charging rate begins at 20-25 amps/100 amp-hours and
decreases to less than 5 amps/100 amp-hours when the
To charge the battery, a direct current must pass through the battery is 80% charged. The charging current decreases when
cells in the opposite direction to the discharging current. The the voltage across the cell increases during the charging cycle.
ampere-hours must be equal to the discharging ampere-hours The increase in the voltage from the charger is approximately
plus the energy lost as heat. This additional amount of charge
the same as the increase in the specific gravity in the cells.
will vary according to the battery and the temperature, but the
average additional charge is 12%. When the battery is nearly Modified Constant Voltage
charged, the final charging must be at a low rate. A charging
rate that is too high will cause heating in the battery and a high This method uses a generator to generate a constant voltage
loss of water from the electrolyte. The charging of the battery that is controlled by a resistor. When the charging current
must be done correctly or the service life of the battery will be decreases, the voltage across the resistor causes an
decreased. increasing voltage at the battery terminals. The charging is
similar to the gradual charge. The resistor must be correctly set
NEVER discharge a battery below 1.130 to 1. 110. Discharging or the charging rate will be wrong.
a battery beyond the design limits will decrease the service life
of the battery.
10-11
Yale
Two-rate Charge 4. Constant meter indications on the charger will indicate the
end of the charging cycle.
This method also uses a high charging rate at the beginning
followed by a lower rate. Two resistors control the charging
rate. One resistor controls the charging rate at the beginning of BATTERY CHARGING AREA
the cycle and a second resistor reducesthe charging rate when
the voltage in the cells reach 2.37 volts. A relay automatically To increase the service life and reduce maintenance, a special
area is needed for charging the batteries. The following
controls the second resistor.
information should be considered when setting up an area.
TROUBLESHOOTING THE CHARGER 1. Location of power supply.

Battery chargers normally operate automatically without
2. Ventilation. Hydrogen gas comes from the batteries during
constant attention. It is necessary to make a periodic check to
charging.
determine if the charger is operating correctly. Check for the
following conditions:
3. Drains for cleaning the batteries.
1. Battery temperature is too high - The temperature in a
battery will not normally rise more than 14° C (25° F) during an
4. Type and size of the batteries.
eight hour charging period. Higher temperatures indicate that
the charging rate needs adjustment. 5. Type of lift truck.
6. Distances that the lift trucks must travel for service.

2. Continuous operation of the charger - Check the
automatic controls on the charger. Check the charging rate. A
low charging rate can be the problem.
7. Safety regulations and instructions.
Equipment Needed
3. Continuous operation of a charger at a high rate -
Normally, the charging rate begins at a high rate and decreases • A lifting device to remove the battery from the lift truck.
as the battery becomes charged. If the rate does not decrease,
• Racks to hold the batteries during charging and storage.
the control need repair or adjustment. These racks must be made of wood and must not be metal
unless the metal racks are covered with an insulating
/\ WARNING: Always connectthe positive cable to material.
/ I\ the positive terminal and connect the negative
CmLbJ terminal. Any other connection will cause injury A battery charger that will charge your batteries.
and damage. Tools for maintenance.
An area with a drain for cleaning batteries and battery
A
WARNING: Always charge the battery atthe end compartments.
of the work period (shift). Never let the specific
Distilled water.
gravity reach a level less than the limits shown in
the manual. Air and water supplies for cleaning.
Maintenance records.
A
WARNING: Always deenergize the charger A work bench.
before you connect or disconnect the charger from
Spare parts and repair equipment.
the battery.
Protective clothing and safety equipment for handling
batteries.
HOW TO KNOW WHEN THE BATTERY IS FULLY
CHARGED Water sources for washing eyes and preventing acid burns.
Install a NO SMOKING sign in the service area.
1. During charging, the voltage increases slowly. When the
battery is fully charged, the voltage level is constant. Keep the charger in a clean, dry area with good ventilation.
2. Remove a vent cap and look in the opening. If you see PRECAUTIONS FOR BATTERIES IN STORAGE
bubbles in the electrolyte, the battery is either fully charged Batteries should be placed on a wooden pallet and stored in a
or in the final stage of charging. dry, moderately cool area. Lead acid batteries will slowly "self
discharge" over a period of time due to their chemical make-up.
3. The specific gravity reading is constant and within the If the self discharge is left uncontrolled, excessive sulfating can
limits of a charged battery. If the temperature increases after occur which is difficult to reduce and may damage the plates.
the battery is charged, the specific gravity will decrease a small
amount. A discharged battery with a specific gravity of 1.100 will freeze
at + 18° F. Afully charged battery with a specific gravity of 1.280
10-12
Yale
will freeze at - 87° F. This "self discharge" is due to a chemical

reaction, therefore, that chemical reaction can be accelerated
by heat resulting in a more rapid "self discharge". The rate of
discharge can amount to an average of about 0.001 point drop
in specific gravity per day.
The following procedure should be followed when placing a

battery in storage or when not in operation for more than 30
days.
1. Give equalizing charge prior to placing new batteries in

storage.
Used batteries are to be fully charged and allowed to balance

for approximately three more hours.
2. Neutralize and clean the battery. Clean with a solution of

16 ounces of baking soda in one (1) gallon of water.
3. Store in a cool, dry location.
4. Check each cell in the battery at least once every 30 days

and boost charge when specific gravity falls below 1.240.
5. Protect batteries from ambient contamination. If a greasy

film forms on the top of a battery, it is acid and must be
neutralized with a solution of 16 ounces of baking soda in one
(1) gallon of water.
10-13
NOTES
10-14
Yale
Industrial Trucks
SECTION 11
11 USER SUPPORT INFORMATION

Yale
Industrial Trucks
USER SUPPORT INFORMATION
SERVICE PARTS ORDERING INSTRUCTIONS 11-1

TECHNICAL PUBLICATIONS 11-1
PARTS MANUAL 11-1
OPERATING MANUAL 11-1
OPERATOR TRAINING 11-1
SERVICE TRAINING COURSES 11-1
SERVICE TRAINING MATERIALS 11-1
Yale
IndustrialTrucks user support information
Your investment in a Yale® industrial truck is important to you and to your Yale industrial truck dealer. You measure the return on your
investment through the drivers who operate the trucks and the mechanics who service them safely and efficiently.
A"Guideto LiftTruck Use and Maintenance", which addresses lifttruck safety inthe workplace, good maintenance practices andtraining
programs, is available from your Yale industrial truck dealer. Order manual 524139078.
The following information and programs are intended to help you to achieve your investment objectives.
SERVICE PARTS ORDERING INSTRUCTIONS OPERATOR TRAINING

In order to avoid delay, unnecessary correspondence and to Yale "Basic Operator Training" program helps industrial truck
have your orders filled correctly, promptly and at the least users increase materials handling productivity and safety
possible expense, the following is the recommended through proper lifttruck operation training and motivation. The
procedure to use when ordering replacement parts. Yale program is based upon real life experience - not
theoretical concepts. We developed a "complete" programthat
Contact your authorized Yale industrial truck dealer and give is totally self-contained - incorporating the most modern
him the following information: instructional techniques, including elements of self-study,
1.
audio-visual support (both video and slides) and
Your purchase order number.
classroom study.
2. Complete invoicing and shipping address.
3. Specify the method of shipment, otherwise, the least SERVICE TRAINING COURSES
expensive method will be used.
User and Yale industrial truck dealer service technicians can
4. Correct part number(s) and description(s). Use your improvetheirtechnical ability for maintaining and repairingYale
parts manual as a reference. industrial trucks and reduce down-time and cost by
participating in Yale sponsored Service Training courses. A
5. Model and serial number of the truck.
variety of mechanical, electrical and electronic subjects are
offered at published tuition rates. Courses are available at user
TECHNICAL PUBLICATIONS and dealer facilities in addition to regularly scheduled courses
which are conducted at Yale Corporate Headquarters.
Technical literature, with detailed information, is available at a
nominal fee to assist users to effectively maintain Yale
industrial trucks in a safe, useful condition. Parts Manuals with SERVICE TRAINING MATERIALS
complete replacement parts identification, Service
Your own service training efforts are supported through a
Maintenance Manuals which provide service and overhaul
complete line of Yale Service Training materials. An index is
procedures andadditional copies of this Operating Manual, can
available from your Yale industrial truck dealer which lists
be obtained from your Yale industrial truck dealer.
textbooks, audio-visual programs, films and their cost which
will provide your trainer with everything necessary to conduct
-
PARTS MANUAL 520679604 service training for your organization.
OPERATING MANUAL 520679601- For additional information or assistance in obtaining these user
support publications and programs, contact your Yale industrial
To provide instructions for safely operating and servicing Yale
truck dealer or: Yale Materials Handling Corporation
industrial trucks, each truck is equipped with an Operating
1400 Sullivan Drive
Manual.
Caller No. 12011
Greenville, NC 27834-2011 USA.
The Operating Manualdescribesvarious operating techniques
and safety warnings for the operator. The Operating Manual
also contains a guide to safe maintenance practices and
recommended schedules for maintenance.
If the Operating Manual is missing from any Yale industrial

truck, it should be replaced. Replacement copies are available
for a nominal fee from your Yale industrial truck dealer.
11-1
NOTES
11-2
Yale
IndustrialTrucks
SECTION 12
12 ALPHABETICAL INDEX
Yale
IndustrialTrucks
ANSI Information
Accelerator Potentiometer
Removal and Installation
Accelerator Switch
Troubleshooting
Battery and Charging System

Battery Maintenance
Adding Water
Cleaning the Battery
Maintenance Records
Specific Gravity
Temperature
Charging the Battery
Battery Charging Area
Equipment Needed
Chemical Reaction
A
Anti-Seize Lubrication Compound
How to Know When a Battery is Fully Charged

Methods of Charging
Troubleshooting the Charger
Types of Battery Charges
General
How to Select the Battery
Battery Ratings
Kilowatt Hours
Voltage of a Battery
Lead Acid Batteries
Safety Tips for Handling Batteries

The Battery as a Counterweight
The New Battery
Troubleshooting
Battery Discharge Indicator/Hourmeter
Reset and Discharge Adjustments
Battery Indicator/Hourmeter
Battery Installation
Battery Operation
Battery Storage
Battery Storage
Bolts and Screws
Brake Pedal
Brake System
Brake Switch
Brake Switch-Remove and Replace
Description and Operation
Electric Brake Adjustment
Electric Brake-Assembly and Installation
Electric Brake-removal and Disassembly
General
Troubleshooting
Capacity Rating
Cleaning
Changing the Battery
C
2-1
2-14
3-12
3-28
3-29
10-8
10-9
10-9
10-8
10-10
10-10
10-11
10-12
10-12
. 10-12
10-11
10-11
10-11
10-1
10-6
10-7
10-7
10-6
10-5
10-5
10-1
10-7
10-8
10-3
3-32
3-32
3-32
1-1
2-2
2-2
2-17
10-12
2-19
1-2
5-1
5-1
5-3
5-1
5-2
5-2
5-2
5-1
5-4
1-4
10-11
2-3
2-3
Checking
Inspection
Repair
Assembly .

Assembly and Disassembly
Teating
Contactor Coil
Contoller Replacement
Conversion Table - Metric/English
Diode Block
Testing
Replacing
Drive Motor

Disassembly and Assembly
Drive Motor Brush and Holder
Drive Unit
Checks and Adjustments
D
Axle Shaft Bearing Clearance
Bevel Gear Installation

ALPHABETICAL INDEX
Backlash and Tooth Contact Pattern

Trunnion Bearing
Description
Gear Tooth Contact
General
Installation
Bevel Pinion Shaft Installation

Disassembly
Removal
Troubleshooting
Electric Power Steering

EPS
Adjustments
E
Feedback Potentiometer Adjustment

Sensitivity Adjustment
Slow Travel Adjustment
Steering Chain Adjustment
Tachometer Adjustment
Checks
Checking High Lift Traction Shut-Off
Checking Slow Travel Speed
Checking the Steering System
for Correct Operation
Dipswitches
General
LED Indicators
Description
General
2-3
Contactor and Electrical Panels Checks/Adjustments . . 3-19
Contactors 3-19
3-21
3-22
3-20
3-9
3-13
2-26
3-26
3-26
3-34
3-37
3-38
3-38
3-38
4-8
4-8
4-8
4-9
4-1
4-11
4-1
4-9
4-1
4-4
4-6
4-4
4-2
4-1
4-12
6-3
6-5
6-4
6-7
6-7
6-4
6-1
6-3
6-3
6-3
6-1
6-2
6-1
6-2
6-1
6-1
12-1
Yale
Industrial Trucks ALPHABETICAL INDEX
E Removal 8-6
Repair 6-7 Lift Pump and Motor 8-4
Electronic Control Module Replacement 6-9 Installation 8-6
Feedback Potentiometer Replacement 6-9 Removal 8-4
Steer Motor Assembly and Steering Chain Seal Replacement 8-6
Replacement 6-9 Specifications 8-3
Tachometer Replacement 6-7 Troubleshooting 8-7
Troubleshooting 6-10 Hydrometer Use 10-10
EVERY 2000 HOURS 2-7
I
EVERY 350 HOURS 2-6
Inner and Secondary Mast Assemblies
EVERY 8 HOURS 2-6
Removal and Installation 9-17
F Instrument Display 1-1
Fasteners 2-18 Removal and Installation 3-31
Bolts and Screws 2-19 K
Strength Identification 2-18 Key Switch 1-2
Studs and Nuts 2-20 Removal and Installation 3-31
Thread Nomenclature 2-18
Torque Nuts 2-21 L
Torque Nuts with Nylon Inserts 2-22 Lift and Lower Switches
Torque Value Guide 2-23 Removal and Installation 3-29
Flashing Light 1-3 Limit Switch
Foot Switch-Removal and Installation 3-32 Removal and Installation 3-33
Forks 9-12 Load Rollers 9-5
Installation 9-12 Load Rollers and Wear Plugs
Forward and Reverse Switches Removal and Installation 9-20
Removal and Installation 3-29 Loose Chain Switch
Fuses 3-19 Removal and Installation 3-33
Lubrication Instructions 2-6
G
Gear Oils 2-13 M
Grease 2-14 Main Cylinders
Assembly 9-18
H Disassembly 9-18
Hoist Motor Installation 9-17
Brush Replacement 3-41 Removal 9-17
Disassembly and Assembly 3-41 Maintenance 2-1
Removal and Installation 3-41 Safe Maintenance Procedures 2-1
Horn 1-2 Maintenance Schedules 2-7
How to Put a Lift Truck on Blocks 2-5 Drive Unit Check 2-9
How to Raise the Drive/Steer Tire 2-5 Electrical System Check 2-10
How to Raise the Load wheels 2-5 General Check 2-10
Hydraulic Oils 2-12 Hydraulic System Check 2-9
Hydraulic Schematic 8-3 Lubrication Check 2-9
Hydraulic System Mast/Carriage/Attachment Check 2-10
Description 8-1 Road and Load Test 2-11
Accumulator 8-1 Safety and Operational Checks 2-8
Filter 8-3 Mast
Flow Regulator 8-2 Adjustments 9-6
Lift Pump and Motor 8-1 Check for Leaks in Hydraulic System 9-5
Main Lift Cylinder 8-3 Check Lift Chains 9-5
Manual Lowering 8-1 Check Operation 9-5
Tank 8-3 Checks 9-5
Velocity Fuses 8-3 Description 9-1
Introduction 8-1 Simplex Mast 9-1
Repairs 8-4 Triplex Mast 9-1
Hydraulic Tank 8-6 Operator's Compartment 9-3
Disassembly 8-6
Installation 8-6
12-2
Yale
IndustrialTrucks
Introduction
Operation-Simplex Mast
Operation-Triple Mast
Load Rollers
Lubricate Chains
Maintenance
Adjust Spring Washers

Adjust Wear Plugs
Adjust Wear Strips
MIB Function Descriptions
Model Code
Model Description
Motor Failure Causes
Motor Tests
Moving a Disabled Lift Truck
Multifunctional Control
Nameplate
Operating Controls
Operating Manual
Operating Manual
Operating Precautions
Operating Procedures
O
N
M

Replace Hoses
Troubleshooting
Mast Adjustments
Adjust Chains
Adjust Main Lift Chain
Adjust Platform Lift Chains
Operator Prechecks and Inspection

Operator Training
Operator's Compartment
Installation
Removal
Operator's Daily Checklist
Pallet Clamp
Pallet Clamp
Parts Manual
Power Disconnect Switch
Parts Ordering Instructions
Power Steering Solenoid
Testing
Replacing
Power Steering Motor
Brush Replacement
Disassembly and Assembly
Relays
General
Remove and Installation
P
R
9-1
9-2
9-1
9-6
9-8
9-10
9-5
9-17
9-21
9-8
9-8
9-8
9-9
9-7
9-8
3-8
1-4
1-1
3-35
3-36
2-16
1-2
1-4
1-1
1-3
11-1
1-9
1-7
1-7
11-1
9-10
9-11
9-10
1-8
2-4
9-13
11-1
3-31
11-1
3-27
3-27
3-43
3-43
3-43
3-26
3-26
3-26
Serial Number
Specific Gravity
Technical Publications
Tether Line and Belt
Tires and Wheels
Checking
S
Safety and Informational Labels
Safety Labels
Specific Gravity Temperature Corrections
How to Change the Drive/Steer Tire

How to Change the Load Wheels
Torque Nuts
Torque Nuts with Nylon Inserts
Torque Value Guide
Torque Values-Hydraulic Fittings
Towing the Lift Truck
Training
Materials
Operator Training
Service Courses
Transistor Motor Controller
TRAM Steer Adjustment Verification

Triplex Mast Assembly
Installation
Removal
Troubleshooting
Accelerator Switch
Battery
Drive Unit
Mast
Truck Weight
Voltmeter
Warranty Information
Water Additions
Wheels & Tires
Wire Guidance
Adjustments
W
V
Adjusting RT1 to the Operational Midpoint

Adjusting RT2 for Straight Travel
Adjusting Sensors to Lift Truck Centerline
Adjusting the Steering Chain Clearance
Adjusting the Travel Speeds
Medium Speed
Slow Speed
Adjusting TRAM
.
ALPHABETICAL INDEX
Slack Chain Indicator Light-Removal and Installation

Specific Gravity Temperature Corrections
Steering Indicator Gauge
Testing
Steering Wheel
T
1-4
1-4
1-4
10-5
2-2
. . 3-32
10-10
1-1
3-31
3-32
1-2
11-1
2-4
2-15
2-15
2-15
2-21
2-22
2-23
2-25
2-16
11-1
11-1
11-1
3-2
3-9
7-17
9-13
9-14
9-16
9-13
3-29
10-3
4-12
9-21
1-4
3-32
2-7
2-3
2-15
1-2
7-14
7-14
7-17
7-20
7-15
7-18
7-18
7-19
7-17
12-3
Yale
IndustrialTrucks
12-4
General
Checks
Automatic Checks
Checks to the Lift Truck
General
W
Centering the MDU Potentiometer
Centering the Steer Tire
Checking the Steering at Mast Heights

Checking the Steering Contactor
Checks 06 Through 09 - Sensor Levels
General
How to Operate the Wire Guidance System
Introduction
Description
General
Operation Modes
Manual Steering
Wire Guidance
Repair
General
MDU Gearmotor
Replacing the Gearmotor Assembly
and Steering Chain
Replace the ECM

Replace the Complete Module
Replace the ECM Power Transistors
Replace the Logic Board Set
Replace the MDU Potentiometer
Replace the Sensors
Replace the Steering Contactor
Steer Wheel Assembly
Assembly and Installation
Removal and Disassembly
Troubleshooting
.
Checking for Short Circuits to the Frame
Manual Checks
Check 02 - Steering Input Voltage
Check 01 - Operator Controls
Check 03 - MDU Potentiometer
Coarse Amplifier
Check 04 - MDU Centering
Check 05 - Direction Inputs
Check 10 - Steered End Sensor Balance
Check 11 - Load End Sensor Balance
Check 13 - Medium Travel Speed
Check 14 - Slow Travel Speed
Checking the ECM Power Transistors
----
.....
7-16
7-16
7-14
7-8
7-8
7-8
7-8
7-8
7-10
7-10
7-10
7-10
7-10
7-11
7-11
7-12
7-12
7-12
7-13
Checking the Operation of the Shut-off Circuit 7-12
7-12
7-14
7-11
7-4
7-4
7-3
7-1
7-1
7-1
7-2
7-3
7-2
7-21
7-21
7-21
7-22
Replace Guidance Switch, Indicator and Alarm . . 7-27
7-27
7-27
7-28
7-27
7-27
7-31
7-30
7-25
7-26
7-25
7-33
Wiring
EPS
Diagram
Options Diagram
Schematic
Wire Guidance
Diagram
Options Diagram
Schematic
ALPHABETICAL INDEX
3-48
3-51
3-45
3-55
3-58
3-52

Yale OS 030 EBB801

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Yale OS 030 EBB801

Загружено:

Авторское право:

Доступные форматы

SERVICE MAINTENANCE

EXPLANATION OF MODEL CODE

DESCRIPTION PAGE NUMBER

MODEL DESCRIPTION 1-1

The control handle allows the use of one hand to control

Before attempting to operate this lift truck, carefully read and

No additions, omissions, changes, or modifications should be NA00734

4. Brake Pedal - The brake is applied when the pedal is re¬

2. The Control Handle is a multifunctional grip for lifting and

7. The Pallet Clamp will automatically engage the pallet. The i

Part No. 520679601

FOR DRIVER S USE

SAFETY AND INFORMATIONAL LABELS

Truck Weight Dim C

This is the approximate weight of the lift truck without a load on

/j\ WARNING /j\ CAUTION

A CAUTION: Directs attention to hazards or unsafe

1. LABEL, OPERATOR WARNING *

* TEXT OF OPERATOR WARNING

Truck Model No.

THIS TRUCK 18 TO BE EQUIPPED WITH

TRAINED OPERATORS ANC

lb In In in A WARNING DO NOTOPERATE THIS TRUCK UNTIL YOU HAVE

Figure 1-10 - Serial Number, Nameplate and Label Locations

OPERATOR PRE-CHECKS AND INSPECTION

OPERATOR'S DAILY CHECK LIST

Record of Fluid Added

SAFETY AND OPERATIONAL CHECKS (Prior to each shift)

Leaks - Hydraulic Oil, Battery

Form 944-6418-A (5/93)

GENERAL TRUCK AND LUBRICATION SCHEDULE

DESCRIPTION PAGE NUMBER

3. Code of Federal Regulations Title 29, Chapter XVII,

This booklet can be obtained from:

1.210 18° C (64° F) -0.004 1.206

A CAUTION: Disposal of batteries must meet local

When recharging afully discharged battery, the starting charge

CHARGING THE BATTERY

4. If the battery is lifted, use a spreader bar and crane to lift

NOTE: Complete information relating to the care and 1. Checkthattheforktipsarealignedwithin13mm(0.5in)of

2. Inspect forks for cracks and wear. Never repair damaged

Figure 2-4 - Checking the Forks

2. Use a special low clearance hydraulic jack under the front

Figure 2-5 - How to Put the Lift Truck on Blocks

Refer to both the Recommended Schedules of Maintenance EVERY 350 HOURS

4. Hose and Wire Sheaves - Mast Take-up

5. Drive Unit Compartment Door Hinges

6. Pallet Clamp and Linkage - Elevate Platform

7. Side Rails - (pivoting option)

8. Steering Spinner Knob

11. Drive Unit Steer Chains - Refer to Step 10.

12. Drive Wheel Lug Nuts

13. Load Wheel Axle Bolts

14. Hydraulic Oil Level - The sight gauge is visible through a

EVERY 2000 HOURS

16. Hydraulic System - There is no drain plug in the hydraulic

Figure 2-6 - Lubrication Locations

YALE WARRANTY INFORMATION

RECOMMENDED SCHEDULES OF MAINTENANCE

THE OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA)

HYDRAULIC SYSTEM CHECK: A B C

DRIVE UNIT CHECK: A B C

ELECTRICAL SYSTEM CHECK: A B C