OPERATING INSTRUCTIONS
HOW TO PUTA LIFT TRUCK ON BLOCKS 1-
HOW TO TOW THE LIFT TRUCK 1-
HOW TO TOW THE LIFT TRUCK 1-
MOVING A DISABLED LIFT TRUCK 1-
MOVING A DISABLED LIFT TRUCK 1-
SAFE MAINTENANCE PROCEDURES 1-
SAFE MAINTENANCE PROCEDURES 1-
- Section 1 Section
- GENERAL HYDRAULIC TANK 2-
- SAFETY AND INFORMATIONAL LABELS 1-2 Inspection 2-
- OPERATOR PRECAUTIONS Repairs. Small Leaks 2-
- OPERATOR PRE-CHECKS AND INSPECTION 1-3 Repairs. Large Leaks 2-
- SHUT DOWN PROCEDURE 1-4 Steam Method of Cleaning 2- OPERATING PROCEDURE 1-3 Cleaning
- SAFETY AND OPERATIONAL CHECK LIST 1-5 Additional Preparations for Repair 2- FORK ADJUSTMENT 1-4 Chemical Solution Method of Cleaning
- MODEL AND CONTROL INFORMATION 1-
- TYRES AND WHEELS 2- WELDING REPAIRS
- instrument Panel A (STANDARD) '-lo HOW TO CHANGE THE WRES 2-
- Instrument Panel B (OPTIONAL) 1-10 General 2-
- instrument Panel (OPTIONAL) '-lo PNEUMATIC TYRES 2-
- Temperature Indicator Lamp 1-
- SAFE MAINTENANCE PROCEDURES 1-
- MOVING A DISABLED LIFT TRUCK 1-
- HOW TO TOW THE LIFT TRUCK 1-
- HOW TO PUT A LIFT TRUCK ON BLOCKS 1-1
- HOW TO RAISE THE STEERING TYRE 1-
- HOW TO RAISE THE DRIVE TYRES 1-
- PRECAUTIONS FOR TRUCKS IN STORAGE 1-
- IN STORAGE 1- PRECAUTIONS FOR BATTERIES
- Section
- GENERAL 2-
- FRAME 2-
- FLOOR PLATE 2-
- REAR COMPARTMENT COVER 2-
- FRONT COVER 2-
- STEERING COLUMN COVER 2-
- Remove the Wheel from the Lift Truck 2.
- Remove the Tyre from the Wheel 2-
- Install the Tyre on the Wheel 2-
- Add Air to the Tyres 2-
- Remove the Wheel from the Lift Truck 2-
- Remove the Tyre from the Wheel 2-
- 2-
- SOLID TYRES 2-
- PNEUMATIC SHAPED SOLID TYRES 2-
- Remove the One Piece Wheel and Tyre 2- Install the Tyre on the Wheel
- Install the Tyre on the One Piece Wheel 2-
- Install the Wheels on the Lift Truck 2-
- LABEL REPLACEMENT 2-
- YALE WARRANTY INFORMATION 2-
- OF MAINTENANCE 2- RECOMMENDED SCHEDULE
- LUBRICATION INSTRUCTIONS 2-
- EVERY 8 HOURS 2-
- EVERY 350 HOURS 2-
- EVERY 2000 HOURS 2-
- HYDRAULIC OILS 2-
- GEAR OILS 2-
- GREASE 2-
- FREEZER APPLICATIONS 2-
- HYDRAULIC CONTROL VALVE COVERS 2-
- BATTERY COVER 2-
- Open 2-
- Close 2-
- Removal 2-
- Installation 2-
- BATTERY REMOVAL AND INSTALLATION 2-
- BATTERY PLATFORM 2-
- Modifications 2-
- Complete Truck 2-
- Control ComDartment 2-
- OVERHEAD GUARD 2-4 Electrical System 2-
- Removal 2-4 Battery Compartment 2-
- Installation 2-4 Ignition Switch 2-
- Removal 2-5 Accelerator Pedal 2-
- Installation 2-5 Drive. Hydraulic and Steering Motors 2-
- COUNTERWEIGHT 2-4 Steering Linkage and Pivot Points 2-
- Section
- Brake Lines and Linkage 2-
- Tilt Cylinders 2-
- Upright and Carriage 2-
- MAINTENANCE 2-
- Complete Truck 2-
- Electrical System 2-
- Ignition Switch 2-
- Control Compartment 2-
- Battery Compartment 2-
- Steering Linkage and Pivot Points 2-
- Accelerator Pedal 2-
- Drive, Hydraulic and Steering Motors 2-
- Brake Lines and Linkage 2-
- Section
- General 3-
- Check the Hand Set 3- Connect. Disconnect. and
- Check and Adjust Functions 3-
- FUNCTION DESCRIPTIONS 3-
- Traction Control Cards 3-
- PUMP CONTROL CARD (LABEL LETTER PX) 3-
- TABLES FOR FUNCTION VALUE SETTINGS 3-
- TROUBLESHOOTING 3-
- CONTACTORS 3-
- TESTING CONTACTORS 3-
- Removal 3-
- Installation 3-
- TMM1 CARD 3-
- Tilt Cylinders 2-
- Upright and Carriage 2-
- Removal 3-
- Installation 3-
- Hydraulic System 2-25 CIRCUIT PROTECTION 3-
- Current Limit 3-
- Upright and Carriage 2-
- Threads. Nomenclature 2-26 Thermal Protection 3-
- Strength Identification 2-26 Suppressors (Filter Blocks) 3-
- FAST EN E R S - I N T R 0 D U CT I 0 N 2 -
- Section 3 FUSES 3-
- ELECTRICAL SYSTEM -G EN ERAL 3-
- EV-1 OOLX MOTOR CONTROLLER 3-
- EV-100 DESCRIPTION AND OPERATION 3-
- The Silicon Controlled Rectifier 3-
- A Motor Circuit that Operates with Pulses 3-
- Traction Circuit 3-
- Hydraulic Pump Motor 3-
- The SCR 1 "OFF" Circuit 3-
- INDUCTION CURRENT FROM THE MOTOR 3-
- THE CONTROL CARD 3-
- Pulse Monitor Trip 3-
- SRO Circuit 3-
- Control Card Adjustments 3-
- Accelerator Control 3-1
- CONTROL CARD 3-1
- Status Codes 3-1
- SEQUENCE OF OPERATION 3-
- SCR CONTROL 3-1
- CONTROL CARD CONNECTIONS 3-
- HAND SET 3-
- CONTROL CARD 3-1 CHECKS AND ADJUSTMENTS,
- Function Codes 3-1
- Bench Tests 3-1
- Tests-Control Card Installed in a Lift Truck 3-1
- FU N CT I 0 N SETT I N G S 3-
- PRINTED CIRCUIT BOARDS 3-
- Steering Angle Control Board 3-
- Operation 3-
- Testing 3-
- Operation 3-
- Testing 3-
- Lift Pump Control Board 3-
- Bypassing the Lift Pump Control Board 3-
- Steering Angle Control Board 3-
- ACCELE RAT0 R 3-
- Removal 3-
- Installation 3-
- POWER STEERING 3-
- KEY SWITCH 3-
- INSTRUMENT PAN EL 3-
- Standard Instrument Panel 3-
- MOTOR MAINTENANCE - GENERAL 3-
- BRUSH AND COMMUTATOR INSPECTION 3-
- NORMAL COMMUTATOR SERVICE 3-
- COMMUTATOR PROBLEMS 3-
- HYDRAULIC PUMP MOTORS 3- BRUSH REPLACEMENT, DRIVE AND
- Traction Motor Removal 3-
- Hydraulic Pump Motor Installation 3-
- Power Steering Pump Motor 3-
- 3-
- Traction Motor 3-
- Traction Motor Installation 3-
- Section
- Lift Pump and Motor Removal 3-
- Lift Pump and Motor Installation 3-
- Power Steering Pump and Motor Removal 3-
- Power Steering Pump and Motor Installation 3-
- Disassembly 3-
- Assembly 3-
- PRINTED CIRCUIT BOARDS 3-
- TRACTION MOTOR REPAIR 3-
- COMMUTATOR REPAIRS 3-
- TESTS 3-
- Damaged Field and Armature 3-
- Short-Circuit in an Armature Winding 3-
- Short-Circuit in the Armature 3-
- Open Circuit in a Field Coil 3-
- Short-circuit in a Field Coil 3-
- Short-circuit Between Field and Motor Case 3-
- Brush Holder 3-
- Damaged Field and Armature 3-
- WIRING DIAGRAMS AND SCHEMATICS 3-
- Section
- TRANSAXLE-GENERAL 4-
- TRANSAXLE SPEC1 FlCATl ONS $4-
- REMOVAL 4-
- INSTALLATION 4-
- D I SASSE M B LY 4.
- ASSEMBLY 4.
- TROUBLESHOOTING 4.
- Section
- GENERAL 5.
- SPEC IF I CAT I ON S 5-
- PARKING BRAKE ADJUSTMENT 5-
- SERVl CE BRAKE ADJUSTMENT 5-
- REMOVAL- SERVICE BRAKE PADS 5-
- INSTALLATION-SERVICE BRAKE PADS 5-
- REMOVAL-SERVICE BRAKE CALIPER 5-
- INSTALLATION-SERVICE BRAKE CALIPER 5-
- DISASSEMBLY-SERVICE BRAKE CALIPER 5-
- ASSEMBLY-SERVICE BRAKE CALIPER 5-
- REMOVAL-PARKING BRAKE CALIPER 5-
- INSTALLATION-PARKING BRAKE CALIPER 5-
- DISASSEMBLY-PARKING BRAKE CALIPER 5-
- ASSEMBLY-PARKING BRAKE CALIPER 5-
- MASTER CYLl NDER- REMOVAL 5-
- MASTER CYLINDER-INSTALLATION 5-
- MASTER CYLINDER-DISASSEMBLY 5-
- MASTER CY LI N DE R - ASS EM BLY 5.
- REMOVAL 5- PARKING BRAKE LEVER ASSEMBLY-
- Section
- INSTALLATION 5- PARKING BRAKE LEVER ASSEMBLY-
- TROUBLESHOOTING 5-
- Section
- TRAIL AXLE 6-
- WHEEL ASSEMBLY 6-
- Removal 6-
- Installation 6-
- Removal 6-
- Installation 6-
- Removal 6-
- Installation 6-
- POWER STEERING SYSTEM 6-
- General 6-
- Description 6-
- WHEEL HUB 6-
- STEER AXLE ASSEMBLY : 6-
- ASSEMBLY 6- STEERING WHEEL AND COLUMN
- 6-
- Installation 6-
- Cleaning 6-
- Disassembly 6-
- Assembly 6-
- Installation 6-
- Removal 6-
- Installation 6-
- Disassembly 6-
- Assembly 6-
- Remove Air from the System 6-
- Check the Operation 6-
- Steering Pressure 6-
- POWER STEERING CYLINDER 6-
- CHECKS AND ADJUSTMENTS 6-
- TROUBLESHOOTING 6-
- Section
- GENERAL 7-
- HOIST SYSTEM 7-
- TILT SYSTEM 7-
- AUXl Ll ARY FUNCTIONS 7-
- Third Function Location 7-
- Fourth Function Location 7-
- HYDRAULIC OIL TANK 7-
- SPECIFICATIONS 7-
- Hydraulic Tank 7-
- Power Steering Pump 7-
- Hoist Pump 7-
- Third Function Location 7-
- Section
- Strainers 7-
- Hydraulic Oil Filter 7-
- TROUBLESHOOTING 4.
- HOIST PUMP 7-
- Removal 7-
- 7- Disassembly-Seal Replacement
- POWER STEERING PUMP AND MOTOR 7.
- Removal 7-
- Installation 7-
- Disassembly 7-
- Assembly 7-
- Removal 7-
- CONTROL VALVE 7-
- Setti n g s 7-
- Removal 7-
- Installation 7-
- Disassembly 7-1
- Assembly 7-1
- MAST TILT ADJUSTMENT 7-
- CONTROL VALVE-EMERGENCY REPAIR 7-
- TROUBLESHOOTING 7-
- Section
- MAST 8-
- DESCRIPTION AND OPERATION 8-
- Carriage 8-
- Mast Mounts 8-
- Description and Operation 8-
- TWO STAGE MAST WITH FULL FREE LIFT 8-
- Description 8-
- Operation 8-
- Description 8-
- Operation 8-
- TWO STAGE MAST WITH LIMITED FREE LIFT 8-
- THREE STAGE MAST WITH FULL FREE LIFT 8-
- NEAR THE MAST 8- SAFETY PROCEDURES WHEN WORKING
- MAST REPLACEMENT 8-
- MAST REPAIRS 8-
- FORKS 8-
- Removal 8-1
- Installation 8-
- Removal, Standard Carriage 8-1
- Removal, Sideshift Carriage 8-1
- Repairs 8-1
- Installation, Standard Carriage 8-1
- CARRIAGES 8-
- Section
- Installation. Sideshift Carriage 8-
- MASTS 8-
- Removal 8-
- Mast with Limited or Full Free Lift 8- Disassembly Procedures for the Two Stage
- the Three Stage Mast 8- Disassembly Procedures for
- Cleaning and Inspection 8-
- with Limited and Full Free Lift 8- Assembly of the Two Stage Mast
- with Full Free Lift 8- Assembly of the Three Stage Mast
- Mast Installation 8-
- Removal of the Main Lift Cylinders 8-
- Removal of the Free Lift Cylinder 8-
- Disassembly of a Lift Cylinder 8-
- 8-
- Installation of the Main Lift Cylinders 8-
- Two Stage Mast with Limited Free Lift 8- Installation of Header Hoses for
- Two Stage Mast with Full Free Lift 8- Installation of Header Hoses for
- Three Stage Mast with Full Free Lift 8- Installation of Header Hoses for
- Removal 8-
- Disassembly 8-
- Cleaning 8-
- Assembly 8-
- Installation 8-
- Check the Lift Cylinders for Leaks 8-
- Check the Tilt Cylinders for Leaks 8-
- Adjust the Tilt Cylinders 8-
- Adjust the Lift Chains 8-
- Adjust the Mast 8-
- Adjust the Carriage 8-
- LIFT CYLINDERS 8-
- HEADER HOSE ARRANGEMENTS 8- Assembly of a Lift Cylinder
- TILT CYLINDERS 8-
- CHECKS AND ADJUSTMENTS 8-
- TROUBLESHOOTING 8-
- Section
- GENERAL 9- BATTERY AND CHARGING SYSTEM-
- INDUSTRIAL TRUCK BATTERIES 9- SAFETY TIPS FOR HANDLING
- LEAD ACID BATTERIES 9-
- Specific Gravity 9-
- Chemical Reaction 9-
- Section
- HOW TO SELECT THE BATTERY 9-
- Voltage of a Battery 9-
- Battery Ratings 9-
- Kilowatt Hours 9-
- THE BATTERY AS A COUNTERWEIGHT 9.
- THE NEW BATTERY 9-
- BAlTERY MAINTENANCE 9-
- Maintenance Records 9-
- Cleaning the Battery 9-
- Adding Water 9-
- Hydrometer 9-
- Battery Temperature 9-
- Types of Battery Charges 9-
- Methods of Charging 9-
- CHARGING THE BATTERY 9-
- Troubleshooting the Charger 9-
- Section
- is Fully Charged 9- How to Know when the Battery
- Battery Charging Area 9.
- Equipment Needed 9-
- TROUBLESHOOTING 9-
- Section
- ORDERING INSTRUCTIONS 10- SERVICE PARTS
- HOW TO ORDER SERVICE PARTS 10-
- WHEN ORDERING PARTS 10-
- TECHNICAL PUBLICATIONS 10-
- PARTS MANUAL 10-
- OPERATING MANUAL 10-
- OPERATOR TRAINING 10-
- SERVICE TRAINING COURSES 10-
- SERVICE TRAINING MATERIALS 10-
- Troubleshooting the Charger 9-
- FORKADJUSTMENT 1- CONTENTS
- GENERAL 1-
- HOW TO PUTA LIFT TRUCK ON BLOCKS 1-
- HOW TO RAISE THE DRIVE TYRES 1-
- HOW TO RAISE THE STEERING TYRE 1-
- HOW TO TOW THE LIFT TRUCK 1-
- MODEL AND CONTROL INFORMATION 1-
- Instrument Panel A (STANDARD) 1-
- Instrument Panel B (OPTIONAL) 1-
Instrument Panel C (OPTIONAL) 1-
- MOVING A DISABLED LIFT TRUCK 1-
- OPERATOR PRECAUTIONS 1-
- OPERATING PROCEDURE 1-
- OPERATOR PRE-CHECKS AND INSPECTION 1-
- PRECAUTIONS FOR BATTERIES IN STORAGE 1-
- PRECAUTIONS FOR TRUCKS IN STORAGE 1-
- SAFENAND INFORMATIONAL LABELS 1-
- SAFETYAND OPERATIONAL CHECK LIST 1-
- SAFE MAINTENANCE PROCEDURES 1-
- SHUT DOWN PROCEDURE 1-