Yale SM NR035 040 045AD - NDR030 ADB815 - NS040 050 AEB816
Yale SM NR035 040 045AD - NDR030 ADB815 - NS040 050 AEB816
Yale SM NR035 040 045AD - NDR030 ADB815 - NS040 050 AEB816
For Models
NR 035/040/045 AD
NDR 030 AD
(B815)
NS 040/050 AE
(B816)
Authorized Dealer
NARROW AISLE
REACH
-RATED CAPACITY
030 - 3,000 Lbs.
035 - 3,500 Lbs.
-
040 4,000 Lbs.
045 - 4,500 Lbs.
050 - 5,000 Lbs.
SPECIAL DESIGNATION
A, B - As Assigned
DESIGN SERIES
N R A, B, C, D etc.
MANUFACTURING SOURCE
N - North America
N D R 035 A D N S 24 T V 089
DOUBLE REACH
FULLY LOWERED
N S MAST HEIGHT
Measured in Inches
L_ STRADDLE
MAST TYPE
-
V Simplex
E -Triplex
-CONTROL
T -Transistor
- VOLTAGE
24, 36
-SBATTERY COMPARTMENT
- 12.5 Small - (Small Chassis)
M - 14.6 Medium - (Small Chassis)
. L - 16.6 Large - (Small Chassis)
ÿ cT M - 18.8 Medium- (Large Chassis)
1 L - 21.1 Large - (Large Chassis)
ÿ
'7
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.
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 backand thumbing the pages to the
corresponding tab.
SECTIONS
1 OPERATING INSTRUCTIONS
3 ELECTRICAL SYSTEM
4 DRIVE UNIT
5 BRAKE SYSTEM
6 STEERING SYSTEM
7 HYDRAULIC SYSTEM
10 USER SUPPORTINFORMATION
11 ALPHABETICAL INDEX
Yale
Industrial Trucks
SECTION 1
OPERATING INSTRUCTIONS
Yale
IndustrialTrucks
-
SECTION 1 CONTENTS
INTRODUCTION
......
HOW TO TOW A LIFT TRUCK 1-10
HOW TO PUT A LIFT TRUCK ON BLOCKS 1-10
HOW TO RAISE THE LOAD WHEELS 1-11
HOW TO RAISE THE DRIVE/STEER TIREAND CASTER WHEELS 1-11
PRECAUTIONS FOR TRUCKS IN STORAGE 1-11
PRECAUTIONS FOR BATTERIES IN STORAGE 1-12
Yale
Industrial Trucks OPERATING INSTRUCTIONS
10—MOO
©1
ÿ
NOTICE TO USER
Yale Model no. eV
ÿTruck Serial no.
Battery Type Volts Max AH. ÿ""S&Hour Rate)
The U.S.A. Occupational Safety and Health Act 3
Q. Battery Size In x inx In
of 1970 and other national safety codes require <1) Truck Weight Less Battery lb
stated on plate. Obtain the correct plate from E Allowable Bait. Wt Range to to
<13 Outrigger Width
your authorized dealer. Articulation: Drive Side
Inches Wheetoase
Inches
Inches
Inches/ Caster Side
Fortu M*annum
For* Load
Megn Cow | A WARNING
—
TRAINED OPERATORS
ANO MECHANICS ONLY
a«<—i
DO NOT OVERLOAD
s'1
» ;
cI—L.3
1
1-1
Yale
IndustrialTrucks OPERATING INSTRUCTIONS
/j\ CAUTION 6. Make sure chains are not damaged or kinked. Check for
excess slack or mistracking on the sheaves.
Directs attention to hazards or unsafe practices which may 7. Make sure all latches are adjusted (if necessary) and
result in minor personal injury, product or property damage if fastened.
the proper precautions are not taken.
8. Operate brake, hydraulic controls, lift, tilt and auxiliary and
/j\ WARNING steering. Make sure all controls operate correctly and return to
their proper positions. See section on Operating Controls for
detailed descriptions.
Directs attention to unsafe practices which could result in
personal injury or death if proper precautions are not taken. 9. Inspect condition of wheels and tires.
10. Inspect forks for damage. Make sure they are correctly
/j\ DANGER attached and locking clips are in their proper position.
11. Test horn, lights, gauges and meters. Make sure they work
Directs attention to unsafe practices and/or existing hazards correctly.
which WILL result in severe personal injury or death if proper
precautions are not taken.
1-2
Yale
IndustrialTrucks OPERATING INSTRUCTIONS
12. Make sure any unusual noises are investigated ÿ Operate a loaded truck with the load upgrade. Operate an
immediately. unloaded truck with the lifting mechanism downgrade.
ÿ Do not permit passengers to ride on the truck. ÿ Observe all traffic regulations, including authorized plant
speed limits. Under normal traffic conditions, keep to the right.
ÿ Observe and comply with instructions concerning floor Maintain a safe distance from the truck ahead (approximately
loadings. Know the weight of your truck and load combined. three truck lengths), and keep the truck under control at all
Truck weight information is located on the nameplate. times.
ÿ Travel with the load lowered and where possible, tilted
ÿ Yale lift trucks are not intended for use on public roads.
back. Do not elevate the load except during stacking.
ÿ When leaving truck unattended, lower the lifting
ÿ The operator can change the direction of travel while the lift mechanism, shut off power and remove key. Chock wheels if
truck is moving, by moving the direction control lever in the truck is parked on an incline.
opposite direction. The truck will come to a stop and then
accelerate in the opposite direction, unless the control lever is ÿ Report all accidents involving personnel, building
released. This is called plugging. structures and equipment to the proper authority.
ÿ Look in the direction of travel and keep a clear view of the
ÿ Check all gauges and indicator lights for correct operation.
path of travel. Frequent reading of the instrument panel should become a
habit.
ÿ If visibility is impaired by the load, operate truck with the
forks trailing and always look in the direction of travel. ÿ Avoid any abrupt moves. Be a professional. "HANDLE
WITH CARE."
ÿ Start, stop, travel, steer andbrake smoothly. Slow down for
turns and on uneven or slippery surfaces that could cause truck ÿ Follow the Recommended Schedules of Maintenance.
to overturn or slide. Maintain your lift truck for dependable and economical
operation.
ÿ Watch clearances around forks. The driver must be aware
that the forks can sometimes extend beyond the load.This may
cause the forks to hit an object or lift another load. SHUT DOWN PROCEDURE
When leaving truck unattended, fully lower forks, shut off
ÿ Watch out for any obstructions, especially those overhead. power, set brake, set coast control to off (when equipped),
Check clearances. neutralize controls and remove key. If you park the truck on an
incline, chock the wheels.
ÿ Do not run over objects on the roadway surface as truck
stability and steering may be adversely affected.
FORK ADJUSTMENT
ÿ When approaching cross aisles, slow down, sound horn Forks should'be spaced as far apart on the fork carriage as the
and keep to the right side of aisle. load being moved will allow. Both forks should always be the
same distance from the center of the fork carriage.
ÿ Operate truck under all conditions at a speed that will
permit it to be brought to a stop in a safe manner. Check for the presence and condition of studs at each end of
the carriage upper fork clip slide. If studs are damaged or
ÿ Narrow Aisle trucks are designed for use on smooth, hard
missing they should be repaired or replaced before the forks
floors with minimal grades. are adjusted.
1-3
Yale
Industrial Trucks OPERATING INSTRUCTIONS
To adjust the forks, raise them a few inches off the floor. Lift up can be obtained from your local Yale IndustrialTruck Dealer for
on the keeper pin and slide the forks along the carriage by a nominal fee.
pushing them away from you. Do not pull the forks toward you.
When the forks are set to the desired position, make sure the Both this manual and the Operating Manual contain the
keeper pin is down in a slot on the top of the fork carriage plate. Recommended Schedules of Maintenance which should be
used as a guide along with the Lubrication Instructions.
SAFETY AND OPERATIONAL CHECK LIST A professional operator should also be familiar with the
A "Daily Check List" similar to the one shownonihe next page information contained -in the American JVIational Safety
should be used every day before operating the truck. The check Standard for Powered Trucks - ANSI B56.1, Part II.
lists are available in tablet form with 50 sheets per tablet and
1-4
Yale
IndustrialTrucks 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.
1-5
Yale
IndustrialTrucks OPERATING INSTRUCTIONS
1-6
Yale
IndustrialTrucks OPERATING INSTRUCTIONS
1-7
Yale
IndustrialTrucks OPERATING INSTRUCTIONS
1. BRAKE PEDAL
2. OPERATOR SENSING SWITCH
1-8
Yale
Industrial Trucks OPERATING INSTRUCTIONS
7. The Operating Manual is sent with the truck and is located 5. Avoid fire hazards and have fire protection equipment
in the container on the mast screen. The Operating Manual is a present. Do not use an open flame to check level of electrolyte.
permanent reference and must be available for the operator's Do not use open pans of fuel or flammable cleaning fluids for
use at all times. Read and understand this manual before cleaning parts.
operating the lift truck.
6. Raise the lift truck only if it is on a solid level floor.
Disconnect the battery. Use.scrtid.tjne piece blocks or other
ÿD000H]
ÿÿÿÿODD positive truck positioning devices to support the truck. Chock
ÿÿÿÿÿno the wheels to prevent movement of the truck.
All standard trucks conform to the Underwriters' Laboratories 11. All parts of lift and tilt mechanisms and frame members
requirements for the type designation shown on the nameplate. should be carefully and regularly inspected and maintained in a
The truck is also equipped with certain safety devices as safe operating condition.
standard equipment. For example, all high lift trucks are
equipped with a load backrest extension and high lift rider 12. All hydraulic systems should be regularly inspected and
trucks with an operator's overhead guard. maintained in conformance with the maintenance schedules.
Lift cylinders, valves and other similar parts should be checked
No additions, omissions or modifications should be made that to assure that "drift" has not developed to the extent that it would
will affect compliance to the above requirements or in any way create a hazard.
reduce the effectiveness of the safety devices.
13. Special trucks or devices designed and approved for
The following instructions have been prepared for your safety hazardous area operation should receive special attention to
and the safety of your fellow workers during maintenance ensure that maintenance preserves the original approved safe
operations and should be strictly followed. Carefully read and operating features.
understand the maintenance procedures before attempting to
repair the truck. When in doubt of any maintenance procedure, 14. Modifications and additions which affect capacity and
contact your local Yale industrial truck dealer. safe truck operation should not be performed by the customer
or user without the manufacturer's prior written approval.
1. When necessary to work with mast in a raised position, Capacity, operation and maintenance instruction plates, tags or
install a safety chain to restrain moving parts. Connect moving labels should be changed accordingly.
parts to a part that does not move.
15 . -Capacity, operation and maintenance instruction plates,
2. The Recommended Schedules of Maintenance should be tags and labels should be maintained in legible condition.
used as a guide for inspection of the truck.
16. The truck should be kept in clean condition to minimize
3. Only qualified and authorized personnel should be fire hazards and facilitate detection of loose or damaged parts.
permitted to maintain, repair, adjust and inspect the truck.
17. Checking the performance of the truck or attachments
4. The work area should be properly ventilated. Keep shop should be conducted in an authorized safe clearance area.
clean and floor dry.
1-9
Yale
Industrial Trucks OPERATING INSTRUCTIONS
18. Always use Yale replacement parts to be sure they are truck or towing vehicle to slide. Steep grades will increase the
interchangeable with the original parts and are of a quality required brake effort.
equal to that provided in the original equipment.
HOW TO TOW A LIFT TRUCK
You should also be familiar with additional maintenance safety
instructions contained in the following publications: 1. • The towed lift truck must have an operator.
-
1. ANSI B56.1 Safety Standard for Powered Industrial 2. Depress the brake pedal during towing to release the
Trucks brake.
This booklet can be obtained from:
3. Tow the lift truck slowly.
Society of Mechanical Engineers
345 E. 47th Street 4. Raise the carriage and forks approximately 12 inches (30
New York, NY 10017 cm) from the surface. Install a chain to prevent the carriage and
mast from moving.
-
2. ANSI/NFPA 505 Type Designations, Area of Use,
Maintenance and Operation of 5. If another lift truck is used to tow the disabled lift truck, that
Powered Industrial Trucks lift truck must have an equal or larger capacity than the disabled
This booklet can be obtained from: lift truck. If a counterbalanced lift truck is being used for towing,
place a half capacity load on its forks. This half capacity load will
National Fire Protection Assoc. increase the traction of the lift truck. Keep the load as low as
Batterymarch Park possible.
Quincy, MA 02269
Never lift a disabled lift truck unless the lift truck must be moved
and cannot be towed. The lift truck used for lifting the disabled
3. Code of Federal Regulations Title 29, Chapter XVII, truck must have a rated capacity equal to or greater than the
Section 1910.178 (OSHA) Powered Industrial Trucks weight of the disabled lift truck. The capacity must be for a load
This booklet can be obtained from: center equal to half the width of the disabled lift truck. See the
nameplate of the disabled lift truck for the approximate total
Superintendent of Documents weight. The forks must extend the full width of the disabled lift
U.S. Government Printing Office truck. Center the weight of the disabled lift truck on the forks and
Washington, DC be careful not to damage the underside of the lift truck.
1-10
Yale
Industrial Trucks OPERATING INSTRUCTIONS
Ftrÿ
c£p!=
1-11
Yale
IndustrialTrucks OPERATING INSTRUCTIONS
Prior to operating the truck, make a visual inspection for leaks The following procedure should be followed when placing a
or signs of deterioration. Check the fluid level in the hydraulic battery in storage or when not in operation for more than 30
tank and brake master cylinder. Take corrective action if days.
necessary.
1. Give equalizing charge prior to placing new batteries in
When a truck is returned to service, itshouldbe given the 350
hour inspection shown in the Recommended Schedule of
Maintenance found in Section 2.
storage. Used batteriesaretobe<fully charged and allowed to
balance for approximately three more hours. - •- •
1-12
Yale
IndustrialTrucks
SECTION 2
SECTION 2 - CONTENTS
GENERAL TRUCK AND LUBRICATION
GENERAL 2-1
FRAME 2-1
LOAD BACKREST AND FORKS 2-1
MAST SCREEN 2-1
ACCESS DOOR AND COVERS 2-1
OVERHEAD GUARD 2-2
BATTERY COMPARTMENT 2-2
CHANGING THE BATTERY ..2-3
TIRES AND WHEELS 2-3
SOLID TIRES 2-4
REMOVE THE ONE PIECE WHEEL AND TIRE 2-4
INSTALL THE TIRE ON THE ONE PIECE WHEEL 2-4
INSTALL THE WHEELS ON THE LIFT TRUCK 2-4
TANDEM LOAD WHEELS 2-5
REMOVAL-TANDEM LOAD WHEELS 2-5
INSTALLATION-TANDEM LOAD WHEELS 2-5
SINGLE LOAD WHEELS 2-5
REMOVAL-SINGLE LOAD WHEELS 2-5
INSTALLATION-SINGLE LOAD WHEELS 2-5
CASTER AND CASTER WHEELS 2-6
DESCRIPTION 2-6
REMOVAL-CASTER 2-6
INSTALLATION-CASTER 2-6
REMOVAL-CASTER WHEELS 2-6
INSTALLATION-CASTER WHEELS 2-7
ARTICULATION STOP ADJUSTMENT 2-7
ADJUSTMENT PROCEDURE 2-7
YALE WARRANTY INFORMATION 2-8
RECOMMENDED SCHEDULES OF MAINTENANCE (ALL MODELS) 2-8
___________
________
_________
______
LUBRICATION INSTRUCTIONS 2-8
EVERY 350 HOURS 2-8
EVERY 2000 HOURS 2-9
HYDRAULIC OILS 2-15
GEAR OILS 2-16
BRAKE FLUID .2-16
GREASE 2-17
ANTI-SEIZE LUBRICATING COMPOUND
FASTENERS-INTRODUCTION
___ 2-17
2-18
THREADS, NOMENCLATURE 2-18
STRENGTH IDENTIFICATION 2-18
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
<=>
The contactor panel area cover is located in the operator's BATTERY COMPARTMENT
compartment on the right handside of the lift truck. It covers the
The battery compartment is furnished in five sizes, depending
contactor panel and the PMC controller. The bottom edge of
on lift truck model and capacity. Refer to Table 2-1.
this cover fits in a slot on the frame weldment. Two capscrews
and self retaining "U" nuts retain the top of the cover to the
Battery retainers are located en both sides of the fifttruck. They
frame. To remove the contactor panel area cover, remove the
can be removed by raising them up using the hand opening and
two screws from the top of the cover and lift the cover out of the
moving them away from the frame weldment. A battery may be
slot. To replace the cover, install the bottom tab into the slot
installed or removed by moving the battery on the rollers
located in the frame. Align and install the two screws to retain
provided in the bottom of the battery compartment.
the cover to the frame.
NOTE: Complete information relating to the care and
The floor plate located in the operator's compartment is not
maintenance of batteries can be found in the literature shipped
attached. To remove the floor plate, lift the plate up off the frame
with the battery.
and disconnect the connector for the operator sensing switch
connector, then remove the floor plate from the lift truck. To
NOTE: Your company, industry and government safety
install the floor plate, connect the connector to the main
regulations should be reviewed to help reduce accidents and
harness and position the floor plate in the frame of the
damage to equipment.
operator's compartment.
NOTE: It is recommended that the battery be removed from
OVERHEAD GUARD the right hand side of the lift truck to reduce the possibility of
damaging the battery cables and the connector.
The overhead guard consists of the overhead guard weldment
and two supporting posts. The overhead guard weldment is
WARNING: Never operate the lift truck without
attached to the mast with six capscrews and hardened
both battery retainers in place. Spacers must also
washers. The bottom left hand post is attached to the lift truck
be used, as required, to maintain a maximum of
frame with a capscrew and washer in the drive unit
12.7 mm (0.50 in) between the battery and the side plates or
compartment, while the top slides into the overhead guard
retainers.
weldment. The bottom right hand post slides into a slot
provided in the frame and the top is attached to the overhead
guard weldment with a capscrew and washer. MODEL CAPACITY BATT. COMPT. VOLTAGE
The overhead guard is furnished in three different sizes, NR-AD 3500 318x986x800 mm
depending upon the battery compartment size. The length of 24
4000 (12.5x39x31.5 in)
the posts will also vary depending upon the size of the mast
furnished with the lift truck. NR-AD 3500
371 x 986 x 800 mm
To remove the overhead guard from the truck, open the drive 4000 24 OR 36
(14.6x39x31.5 in)
unit compartment and remove the capscrew and lockwasher
4500
retaining the post to the frame. Holdthe post while removing the
hardware so that the post does not slide out of the slot in the NR-AD 3500
overhead guard weldment. Remove the capscrew and 422 x 986 x 787 mm 24 OR 36
4000
lockwasher retaining the right hand post to the overhead guard (16.6x39x31.5 in)
weldment. Slide the post out of the slot in the lift truck frame. 4500
Attach a sling and lifting device to the overhead guard NDR-AD 3000 371 x 986 x 800 mm
weldment. Remove the six capscrews and hardened washers (14.6x39x31.5 in)
retaining the overhead guard weldment to the mast and lower 24 OR 36
the overhead guard weldment to the floor. 3000 422 x 986 x 787 mm
(16.6x39x31.5 in)
To replace the overhead guard weldment, use a sling and lifting NS-AE 4000 318x986x800 mm
24
device to raise the overhead guard weldment. Align the (12.5x39x31.5 in)
weldment and the mast and install the six capscrews and 371 x 986x800 mm
4000
hardened washers. Tighten the capscrews to 149 N«m (110 Ibf (14.6x39x31.5 in)
ft). Slide the right hand post into the slot located in the frame. 24 OR 36
Align the top of the post with the weldment and install the 5000 422 x 986 x 787 mm
capscrew and lockwasher. Align the left hand post with the slot (16.6x39x31.5 in)
inthe overhead weldment and slide the post intothe opening. Table 2-1 - Battery Compartment
Align the lower portion of the post with the frame in the drive unit
compartment and install the capscrew and washer to retain the
left hand post.
2-2
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
CHANGING THE BATTERY /\ WARNING: Make sure the capacity of the crane
/\ WARNING: If a different size battery is installed in
I
f\ and the spreader bar is greater than the weight of
the battery. The weight of the battery is normally
11\ the lift truck the battery spacers must be changed.
shown on the battery case. The maximum battery weight is
See the parts manual for the correct battery spacer
shown on the lift truck nameplate. The spreader bar must not be
arrangement.
made of metal or it must have insulated straps.
/\ WARNING: To prevent personal injury and
/\ WARNING: If the lift truck has been operated with
11\ unexpected battery movement, the battery must
11\ a low battery, check the contactors for welded
be level when it is moving. Make sure the &attery
contacts before a charged battery is connected.
stand is on a level surface and is aligned and adjusted as
The circuit will not reset and lift truck operation cannot be
described in the following procedure.
controlled if the contacts are welded.
4. If the battery is lifted usea spreader bar and crane to lift the TIRES AND WHEELS
battery from the battery stand.
1. Check the tires for damage. Inspect the tread and remove
any objects that will cause damage.
1. BATTERY 2. Smooth any cuts or tears to prevent further damage. Check
2. BATTERY DISCONNECT for bent or damaged rims. Check for loose or missing parts.
3. ROLLERS Remove any wire, straps or other material that may have
4. BATTERY STAND wrapped around the axle.
5. RATCHET LOCK LEVER
6. BATTERY PULLER Standard tire sizes are listed in Table 2-2 for both drive/steer,
caster and load wheels. For lift trucks equipped with special
tires consult your nearest authorized Yale industrial truck
dealer.
2-3
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
2. Remove the wheel nuts and remove the wheel from the lift
truck.
2. Tire sizes listed in Table 2-2 are for both drive and steer 1. PRESS RING
tires. 2. OLD TIRE
3. NEW TIRE
3. Position the new tire in the press. See Figure 2-5. Align the 4. WHEEL HUB
wheel and tire assembly removed from the truck on top of the
new tire. Make certain the wheels are aligned. Make certain the Figure 2-5 - Position Tire on Wheel
tires are level. Position a press ring on top of the wheel hub.
2-4
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
SOLID
TIRE
WHEEL HUB
INNER
EDGE
PRESS TIRE
FLUSH TO
THIS SIDE
1. AXLE SHAFT
Figure 2-6 - 12 x 5.5 Solid Tire Pressed onto Wheel
2. WASHER
3. BRACKET
SOLID 4. AXLE SLEEVE
TIRE 5. BEARING
6. LOAD WHEEL
7. NUT
WHEEL HUB
Figure 2-8 - Tandem Load Wheels
OUTER NOTE: On lift trucks used in freezer applications, apply the
• EDGE recommended Anti-Seize Lubricant listed in the
LUBRICATION SCHEDULE, this section, to the load wheel
PRESS TIRE axle shaft.
FLUSH TO
THIS SIDE 2. Remove the blocks from under the lift truck.
2-5
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
CASTER AND CASTER WHEELS 2. Remove the four capscrews and lockwashers that retain
Description the caster to the articulating axle weldment. Remove the caster.
The caster is on the right hand end of the articulating axle Installation-Caster
weldment. The caster is one support for the rear of the lift truck.
The drive wheel on the master drive unit is the other support at 1. Align and install the replacement caster on the articulating
the left hand end of the articulating axle weldment. The axle of axle weldment using the capscrews and lockwashers. Tighten
the caster is an articulated axle. The articulation of the axle the capscrews to 68 N«m (50 Ibf ft) torque.
permits both wheels of the caster to always have equal weight
on each wheel. Caster operation and wheel wear are improved 2. Remove the blocks from under the lift truck.
with this design. The caster is attached to the articulating axle
weldment by four capscrews and lockwashers. The complete Removal-Caster Wheels
caster can be replaced as a unit or the wheels can be replaced.
NOTE: Always replace the wheels as a set. Replacing only
Always replace the wheels as a set for better caster operation one wheel causes more wear on the new wheel. The caster
and wheel wear. A single new wheel will wear rapidly. also will not operate correctly when a single wheel is replaced,
causing more wear or caster damage.
1. Put the rear of the lift truck onbiocks. See HOW TO RAISE
THE DRIVE/STEER TIRE AND CASTER WHEELS, Section 1.
2-6
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
DRIVE/STEER WHEEL
Figure 2-11 - Drive Unit Articulation Stops Nameplate
CASTER WHEELS -
Figure 2-12 - Articulation Stop Location
2-7
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
YALE WARRANTY INFORMATION and Maintenance Manuals are also available from your Yale
industrial truck dealer for a nominal charge.
A Yale Warranty Statement is provided with each new Yale
industrial truck. To maintain your Yale Warranty in good
For the optimum in professional repair and maintenance, we
standing you must follow the Recommended Schedules of
recommend your Yale industrial truck dealer's factory trained
Maintenance and perform the daily operational and safety
mechanics for Yale service and a Yale Maintenance
checks and maintenance functions described in this manual.
Agreement.
If you require a warranty repair you must contact your Yale
industrial truck dealer for warranty service during the periods RECOMMENDED SCHEDULES OF MAINTENANCE
outlined in the Warranty Statement. Your Yale industrial truck (ALL MODELS)
dealer has complete details on which components are covered
Although the following Recommended Schedules of
and the types of repairs that are warrantable. When in doubt
Maintenance are intended for use with all Electric Narrow Aisle
about your warranty coverage, be sure to contact your Yale
lift truck models, not all models are equipped with all the items
industrial truck dealer. If you have a warranty problem that
listed in this schedule.
cannot be resolved with your Yale industrial truck dealer, you
may request a review of your problem by contacting the Yale
Be certain this schedule is read thoroughly and all operations
Regional Service Representative.
are followed. If in doubt of any procedure or component to be
inspected, adjusted and lubricated, or if the truck is specially
All new Yale trucks will be shipped with an Operating Manual
equipped and used for special applications, consult your
and a Standard Parts Manual through your Yale industrial truck
nearest authorized Yale industrial truck dealer for assistance.
dealer. Additional Standard Manuals, Special Parts Manuals
2-8
Yale
IndustrialTmcks GENERAL TRUCK AND LUBRICATION
Apply lithium base, multi-purpose No. 2 grease with a high 20. Door Latch Capscrew and Hinge Pin
pressure gun to the following fittings. Clean lube fittings before
and after lubricating. 21. Control Handle Torsion Springs
Location of Lube Fittings No. of Fittings A WARNING: The articulation stops must be
/|\ adjusted every 350 hours or whenever a drive
1. Master Drive Unit Bearing 2 wheel tire or caster wheel tire is replaced. Failure
to adjust these stops properly can reduce stability as well as
2. Articulation Shaft . . 1 traction. Refer to the ARTICULATION ADJUSTMENT, Section
4, this manual for the adjustment procedure and proper
3. Caster Wheel Assembly 4 clearance dimensions.
4. Thrust Rollers - Reach Frame/Fork Carriage 2 22. Brake Master Cylinder - The brake fluid reservoir is
mounted to the inside of the drive unit compartment door.
5. Reach Cylinder Pivot Pins - Upper and Lower 4 Remove cap from reservoir and check fluid level. Correct level
is 6.35 mm (0.25 in) from top of reservoir. Add brake fluid if
6. Reach Arms - NR 6 necessary. Use SAE J1703 hydraulic brake fluid, Federal
Motor Vehicle Safety Standard - FMVSS 116 (DOT 3). The
7. Reach Arms - NDR 12 capacity of the reservoir is 0.45 litre (0.12 gal.).
8. Articulating Chain Anchors - NS (Triplex Mast) 2 23. Hydraulic Oil Level - Removeand wipe dipstick. With forks
fully lowered and oil at normal operating temperature, (above
Apply lithium base, multi-purpose No. 2 grease to the 100°F), measure oil level with dipstick. Add hydraulic oil, if
following surfaces: necessary, to the "full" mark on the dipstick. Remove and clean
breather/filler assembly and the breather with solvent. Blow dry
9. Mast Load Roller Wear Plugs Sliding Surfaces with compressed air, replace and tighten. Replace the
breather/filler assembly and breather if they cannot be cleaned
10. Reach Load Roller Radial and Thrust Wear Surfaces or they are damaged. DO NOT OVERFILL.
Apply silicone spray lubricant to all of the following 24. Drive Unit Oil Level - Park truck on a level floor. Remove oil
friction points: level/fill plug. Oil level should be at the bottom edge of the hole.
If low, fill with SAE 80W-90 weight gear oil untiloil runs out of the
11. Lift Chain Sheaves oil level/fill hole. Replace plug. DO NOT OVERFILL.
Apply engine oil (SAE 30) to all friction points of the NOTE: The manufacturer recommends draining and refilling
following: the drive unit oil after the first 500 hours of use on ail new trucks.
Park truck on a level floor. Remove drain plug. Drain gear oil
12. Master Drive Unit Chain Assembly into a suitable container and discard in accordance with local
regulations. Replace drain plug and fill with gear oil through
13. Upper Steering Chain and Sprockets level/fill hole. Drive truck slowly to circulate oil. Drive Unit
Capacity 2.6 litres (0.69 gallons) for AD/AE models.
14. Lift Chains -Wipe off all oldoil using a clean cloth, then use
compressed air to blow off chains. With a clean brush, apply
EVERY 2000 HOURS
SAE 30 weight oil to the full length of chain. Oil must penetrate
chain joints. 25. Brake Master Cylinder - Drain and flush system. Fill the
system 'With new hydraulic brake fluid. After filling, bleed the
Apply anti-seize lubricating compound to all friction brake system. Brake System Capacity 0.45 litres (0.12
points of the following: gallons).
15. Articulation Stop Hardware 26. Hydraulic Oil Strainer - Remove dipstick and
breather/filler assembly. Remove hydraulic oil strainer. Clean
16. Articulation Shaft Retaining Bolt and Ends of Shaft strainer with solvent and blow dry with compressed air. Replace
strainer if dirt cannot be removed. Replace the breather/filler
17. Drive Wheel Lug Nuts assembly.
18. Load Wheel Axle Bolts 27.-*Hydrau1ic Oil Filter - Lower mast. Replace-hydraulic oil
filter, located in drive unit compartment, at each oil change.
19. Brake Rods and Brake Drum Splines
2-9
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
9,11,14
21.23,26
1,12,13,15 5,6,7
16,19,20
22,24,25 n
27,28,29
3,17
2-10
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
LEGEND
A - Every 8 Hours X -Visually Inspect, Test and Adjust as Required
B - Every 350 Hours 0 -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 0
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 o
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:
Hour Meter - Operates Correctly X
Battery Indicator - Operates Correctly X
Instrument Monitors - Operates Correctly X
2-11
Y&fe
IndustrialTrucks general truck and lubrication
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
Drive Unit Oil Level (Initial drain and refill at 500 hours) X 0
2-12
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
- -
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
2-13
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
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 FuH Forward and Backward (See Note 4)
Attachment - Operate all Functions
NOTES: 4. With a rated load at 609.6 mm (24 in) load center, check tilt
cylinder, if equipped, for drift. Tilt drift must not exceed 25.4 mm
1. Tires - Condition affects Stability, Safety and Load (1.0in)in2minutes,oilat26°C(79°F).RefertoServiceBulletin
Capacity 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. Refer to Service News Bulletin SE-643for Procedure on does not necessarily indicate a lead.
Field Testing Load Forks. The Bulletin also defines minimum
acceptable fork tine thickness due to wear.
6. (> A) Recycle ail 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.
To obtain more information on the above reference Service Bulletin, contact your nearest authorized Yale industrial truck dealer.
2-14
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
HYDRAULIC OILS
2-15
Yalo
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
GEAR OILS
BRAKE FLUID
2-16
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
GREASE
NLGI Grade 2
Dropping Point Approximately +500° F (+262°C) +398° F (+205 °C)
237 @ +100°F (+38°C)
Base Oil Viscosity (SUS) 67/75 @ +210°F (+100°C)
51 @ +210°F (100°C)
-30 to +350°F ÿ10 to +250 °F
Nominal Operating Temperature Range (-35 to +178° C) (-40 to +122°C)
• Container must be plainly Container must be plainly
Identification marked with supplier's product marked with supplier's product
identification identification
APPROVED SOURCES
Exxon Corporation Ronex MP
Texaco Regal AFB 2
Mobil Oil Corporation Mobil Grease 532
Soiene Lubricants Incorporated Soiene S-1065
Union 76 Unocal UNOBA EP Grease 2
Field Personnel Note: The greases as listed herein 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 is unauthorized.
2-17
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
FASTENERS-INTRODUCTION The number of threads per inch for inch fasteners may either be
shown as UNC (Unified National Coarse) or UNF (Unified
Threaded fasteners like bolts, nuts, capscrews, and studs are
National Fine). Metric fasteners show the thread pitch.
made to specifications that describe the mechanical strength
and hardness of the fastener. A fastener used in a design
A capscrew will have the following description:
application is selected according to its specifications. Vale
Materials Handling Corporation buys parts from many
countries. Parts that are purchased must be to Yale standards. INCH METRIC
There are several standards used by these countries in the
manufacture of threaded fasteners. Many of these fasteners 1/2x13 UNCxrt-1/2 M12x1.75x 50
are similar, but cannot be used as a direct replacement. To A x B C x D A x B x C
make sure that you have the correct fastener, order fasteners
and parts through the Yale Parts Distribution Center, A = Shank Diameter A = Thread Size
Danville, IL.
B = Number of Threads B = Pitch
Sen/ice persons must use replacement fasteners that have the Per Unit of Length C = Length
same specifications. Fasteners made to each specification
have identification marks for that specification. This C = Type of Thread
specification is commonly called "Grade" for SAE standards
and "property class" for metric standards. This section D = Shank Length
describes the identification of some common fasteners. Table 2-5 - Capscrew Description
The metric system used by Yale Materials Handling Strength Identification
Corporation is described as SI (Le Systeme d'Unites or the
International System of Units, also called SI in all languages). The most common property classes for metric fasteners are 8.8
The SI system of measurement is described in ISO Standard and 10.9. The property class is marked with a number on the
1000, 1973. A conversion table of common measurements is head of the capscrew or on a nut. Property classes lessthan 8.8
shown in Table 2-13. are often not marked. Grades for inch bolts go from 2 to 8.
Grade 2 fasteners normally do not have any marks. The
Threads, Nomenclature following tables show the marks that identify the grades and
property classes for different fasteners.
The thread design is specified by a series of numbers and
letters for inch and metric fasteners. See Figure 2-14. The CAUTION: When fasteners must be replaced,
diameter of the shank of the fastener is shown first in the series the new fasteners must be of the same strength or
[M12 = 12 mm, M20 = 20 mm (1/2 = 1/2 inch, 3/4 = 3/4 inch)]. greater than the original fasteners. The new
fasteners must also be the correct size.
The length of the shank is often indicated as part of the
description of a fastener. This length is shown in inches for inch NOTE: Identification marks are according to bolt strength.
fasteners and in millimetres for metric fasteners. 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
U.S.
\ vwwwwww (DIA. x NO. OF THREADS PER INCH)
DIA.
METRIC
M12X1.75 mm -THREAD
(mm DIA. xTHREAD PITCH mm)
2-18
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
4.&/ .5.
G O0O
5.2
v/v
/JX
Viv
8
9.8 10.9
00.9/
12.9
J2.
HEX HEAD BOLTS AND MARKINGS FOR
CAPSCREWS SIZE M5 AND
LARGER
10.9 12.9
MARKINGS NOT REQUIRED
10.9 12.9
HEX SOCKET HEAD
CAPSCREWS
4.8* 9.8
5.1
SEMS
2-19
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
OR
cud mD cm
HEX NUTS OR
o o o
ED cm
5 8 9 10 12
CCD MARKINGS NOT REQUIRED
m ™ ct ra mzi
HEX SLOTTED NUTS
10 12
jrx MARKINGS NOT REQUIRED
2-20
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
iTTfl
OR
OR
JUL JUL
Table 2-8 - Torque Nuts
2-21
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
OR
2-22
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
SAE Grade
o 1960 Series 1936 & 60 Series
Size (in) Thread Dry Lub. Dry Lub. Dry Lub. Dry Lub. Dry Lub.
1/4 20 6 4 8 6 12 9 13 10 16 12
1/4 28 6 7 10 7 14 10 15
11J 18 14
5/16 18 11 8 17 13 25 18 28 20 33 25
5/16 24 12 9 19 14 25 20 30 22 36 27
3/8 16 20 15 30 23 45 35 48 36 58 44
3/8 24 23 17 35 25 50 35 55 41 65 49
7/16 14 30 24 50 35 70 55 77 58 93 70
7/16 20 35 25 55 40 80 60 86 65 104 78
1/2 13 50 35 75 55 110 80 118 89 142 106
1/2 20 55 40 90 65 120 90 132 99 160 120
9/16 12 70 55 110 80 150 110 170 127 205 153
9/16 18 80 60 120 90 170 130 189 141 228 171
5/8 11 100 75 150 110 220 170 235 176 283 212
5/8 18 110 85 170 130 240 180 267 200 320 240
3/4 10 175 130 260 200 380 280 417 313 501 376
3/4 16 195 145 300 220 420 320 467 350 559 420
7/8 9 165 125 430 320 600 460 672 504 707 530
7/8 14 185 140 470 350 660 500 741 562 778 584
1 8 250 190 640 480 900 680 1006 756 1060 795
1 12 270 200 700 530 1000 740 1125 833 — —
1 14 340 260 750 580 1030 785 1230 883 1190 892
1-1/8 7 350 270 800 600 1280 960 1283 966 1702 1276
1-1/8 12 400 300 880 660 1440 1080 1425 1066 1908 1431
1-1/4 7 500 380 1120 840 1820 1360 1600 1200 2162 1621
3
1-1/4 12 550 420 1240 920 2000 1500 1800 1350 2660 1995
1-3/8 6 660 490 1460 1100 2380 1780 2382 1782 — —
1-3/8 12 740 560 1680 1260 2720 2040 2708 2033 — —
1-1/2 6 870 650 1940 1460 3160 2360 2800 2100 4177 3133
1-1/2 12 980 730 2200 1640 3560 2660 3000 2260 4700 3525
NOTES:
1. The term lub. includes the application of high stress lubrication to the fastener, and 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. _
Table 2-10 - General Guide to Torque Values
2-23
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
Grade JIS F4T ISO 8.8 or JIS F8T ISO 10.9 or JIS F11T ISO 12.9
Size Pitch N-m Ibfft N«m Ibfft N»m Ibfft N«m Ibfft
M4 0.7 2.9 4.1 4.9 3.5
M5 0.8 8.5 10
M6 1.0 4.3 10 14 10 17 12
M8 1.25 10 25 18 35 25 41 30
M8 1.0 10 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 2.5 172 124 410 297 580 420 690 499
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.
2-24
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
2-25
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
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)
2-26
Yale
IndustrialTrucks
SECTION 3
ELECTRICAL SYSTEM ]
Yale
Industrial Trucks
SECTION 3 - CONTENTS
ELECTRICAL SYSTEM
INTRODUCTION 3-1
GENERAL 3-1
COMPONENT REPAIR AND TESTING 3-2
GENERAL 3-2
CONTACTOR PANEL ASSEMBLY 3-2
DESCRIPTION/FEATURES 3-2
REMOVAL 3-2
INSTALLATION 3-3
CONTACTORS 3-3
DESCRIPTION/FEATURES 3-3
AUXILIARY SWITCH .3-3
TESTING 3-4
REMOVAL 3-4
INSTALLATION 3-4
"EE" CONTACTORS 3-5
FUSES 3-5
RELAYS 3-6
DESCRIPTION/FEATURES 3-6
ENABLE 3-6
HOUR METER 3-6
COIL TESTING 3-7
CONTACT TESTING 3-7
REMOVAL AND INSTALLATION 3-7
HEIGHT LIMIT SWITCH 3-7
REMOVAL 3-7
TESTING 3-8
INSTALLATION 3-8
KEY SWITCH 3-8
REMOVAL 3-8
INSTALLATION 3-8
BATTERY DISCONNECT SWITCH 3-8
REMOVAL 3-8
INSTALLATION 3-9
PROPORTIONAL ELECTRO-HYDRAULIC VALVES 3-9
MANUAL LOWERING 3-9
OPERATION 3-10
SELECTOR VALVES 3-10
TESTING/REMOVAUINSTALLATION 3-10
MULTI-FUNCTION CONTROL HANDLE 3-11
DESCRIPTION/FEATURES 3-11
OPERATION 3-11
DISASSEMBLY 3-11
ASSEMBLY 3-12
TRACTION AND HYDRAULIC POTENTIOMETER 3-15
TESTING 3-15
INSTALLATION 3-15
ADJUSTMENT 3-15
(Continued on following page)
Yale
IndustrialTrucks
.....
STEP 2 ERASE THE MODEL CODE 3-19
STEP 3 SET THE MODEL CODE 3-19
STEP 4 CALIBRATE HYDRAULIC POTENTIOMETER RANGE ....3-19
STEP 5 CALIBRATE TRACTION POTENTIOMETER RANGE 3-19
STEP 6 EXIT THE SET-UP MODE AND SAVE NEW VALUES 3-20
CUSTOMIZING MIB FUNCTIONS 3-20
MIB FUNCTION DESCRIPTIONS 3-21
MIB PLUG PIN IDENTIFICATION 3-24
MIB STATUS, WARNING AND FAULT CODES 3-25
GENERAL 3-25
TROUBLESHOOTING CHARTS 3-25
MIB BLANK OR UNDEFINED CODES 3-26
MIB STATUS CODES 3-30
MIB WARNING CODES 3-37
MIB FAULT CODES 3-40
TRACTION MOTOR CONTROLLER 3-59
DESCRIPTION/FEATURES 3-59
REMOVAL 3-59
TESTING 3-59
INSTALLATION 3-59
PROGRAMMER HAND SET 3-61
DESCRIPTION/FEATURES 3-61
SCROLL DISPLAY KEYS 3-61
-
.. .........
...... CHANGE VALUE KEYS
MORE INFO KEY
OPERATION
CONNECTING THE HAND SET TO THE
TRACTION MOTOR CONTROLLER
DISCONNECTING THE HAND SET FROM THE
TRACTION MOTOR CONTROLLER
3-61
3-61
3-61
3-61
3-62
.....
-
PROGRAMMER SELF TEST
OPERATING MODES
PROGRAM MENU
"TEST MENU
DIAGNOSTICS MENU
DIAGNOSTIC HISTORY
• *™»»«**SPECIAL PROGRAM MENU
3-62
3-63
3-84
3-85
3-85
3-86
3-85
(Continued on following page)
Yale
IndustrialTrucks
INTRODUCTION
GENERAL
OPERATOR CONTROLS
FCRWARO/REVERSE. THROTTLE
HYORAUUC FUNCTIONS
SELECTOR BUTTONS STATUS. WARNINGS & ~AULTÿ
DA5H 01SPLAY
MODE SELECTS
FORWARD/REVERSE
MIB
MAIN INTERFACE BOARD
THROTTLE TRACTION
(SYSTEM SUPERVISOR) MOTOR
CONTROLLER
1
BRAKE
SWITCH
1 SETUP AND
DIAGNOSTICS
VIA HANDSE
HYDRAUL IC PUMP
TRACTION
VARIABLE CONTRtltTl CONTACTORS
OPERATOR MOTOR
ON/OFF SOLENOIDS ON/OFF SENSING
5WITCH
5W ITCH
AUX/STEER LIFT
PUMP PUMP
MOTOR MOTOR
3-1
Yale
Jndustrial Trucks ELECTRICAL SYSTEM
3-2
Yale
IndustrialTrucks ELECTRICAL SYSTEM
J\ WARNING: The capacitor in the traction motor coil moves the armature against spring pressure to close the
/f\ controller can hold an electrical charge after the
battery is disconnected. To prevent electrical
contact. When the coil is deenergized, the spring pressure
moves the armature and opens the contacts. When a spring
shock and injury, discharge the capacitor before inspecting or holds the contacts of a switch open, the switch is called
repairing any component. Wear safety glasses. Make certain normally open (NO). If a spring holds the contacts of a switch
the battery has - been disconnected. Discharge the closed, the switch is called normally closed (NC).
capacitors in the controller by connecting a load (such as a
contactor coil or a hom) across the controller's B + and B -
terminals (eentecÿ ierminals). DO NOT use a screwdriver to
discharge the traction motor controller.
J
5. To remove the panel assembly, tag and disconnect the
power wires to the contactors and the fuses.
6. Unplug the control wires from the main wire harness at the
X-5 connector.
3-3
Yale
IndustrialTrucks ELECTRICAL SYSTEM
5. Check the contactor for loose, broken or corroded 1. Disconnect the battery and separate the connectors.
connections at the contactor.
2. Refer to CONTACTOR PANEL ASSEMBLY, REMOVAL
6. Check the mechanical function of the contactor. Use an for access to the contactors.
insulated tool, such as an electricians screwdriver to manually
close the contactor tips. Check for looseness or binding of the 3. Tag and disconnect the wires and/or buss bars to the
moving parts of the contactor. The parts should move freely, but contactor.
the parts must not be so loose that the movement is sloppy.
4. Remove the capscrews, flat washers and lockwashers
7. Visually check the tips for pitting, burning or wear. retaining the contactor to the contactor panel assembly. For the
pump contactor, remove the capscrews, lockwashers, flat
8. If a external suppressor is attached to the coil, remove the washers and nuts.
suppressor. Check the resistance of the contactor coil.
Compare the reading against the values for the type of Installation
contactor being tested. See Table 3-3, Page 3-7 for coil
resistance values. Readings not within the listed limits indicate 1. Align the contactor to the contactor panel assembly. Install
the following: the contactor using the capscrews, flat washers and
lockwashers.
High Resistance . . . Corrosion or an open coil
Low Resistance ... Shorted or a burnt coil 2. Connect the wires and/or buss bars to the contactor. Refer
to WIRING SCHEMATICS AND DIAGRAMS at the end of this
section for wiring details.
3-4
YaleIndustrialTrucks ELECTRICAL SYSTEM
"EE" Contactors
When "EE" contactors are used, additional steps are required
to service the contactors as the contactors are covered by an
enclosure shroud.
2 1. Remove the capscrews retaining the enclosure shroud to
the contactor. Remove the shroud.
FUSES
The fuses for these lift trucks are located on the contactor panel
assembly. To access the contactor panel assembly, Refer to
CONTACTOR PANEL ASSEMBLY/REMOVAL and remove
the operator's compartment cover.
When the lift truck has the provision for "EE" the fuses FU1,
FU2 and FU3 are enclosed in a fuse box on the contactor panel
assembly. For access to the fuses, see Figure 3-5. Remove the
capscrews and lockwashers retaining the floor insulator, wall
insulator and the fuse box enclosure to the base plate to test or
remove the fuses.
3. Install the operator's compartment cover. Refer to FU5 Key Switch to Control Wiring Circuits 10 Amp
CONTACTOR PANEL ASSEMBLY INSTALLATION. FU6 Horn and Drive Unit Fan 10 Amp
4. Connect the battery and test the operation of the truck. FU7 Operator Compartment Lamp and Fan 10 Amp
1. INSULATOR-TERMINAL
2. ENCLOSURE-FUSE BOX
3. NUT
4. LOCKWASHER
5. SPACER
6. LOCKNUT
7. FUSE 100 AMPS
8. SCREW
9. WASHER
10. TERMINAL POST
11. CAPSCREW
12. INSULATOR-FLOOR
13. SPACER
14. WASHER
15. NUT
16. FUSE 400 AMPS
17. FUSE 325 AMPS
18. INSULATOR-WALL
19. LOCKWASHER
20. CAPSCREW
RELAYS
85 87A
Description/Features
The "ER" (enable relay) is found on all NR/NDR/NS model lift
30
trucks. The "HMR" (hourmeter relay) is present only on "EE" 87
rated trucks. Both relays are mounted on the contactor panel 0D
assembly.
Enable 86
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IndustrialTrucks ELECTRICAL SYSTEM
COIL RESISTANCE
COIL LOCATION MANUFACTURER @ 21 °C (70° F) TEST POINTS
"HMR" (hourmeter relay) coil Drive Unit Robert Bosch Corp. 305 ± 15 ohms
("EE" trucks only) Terminals 85 and 86
Compartment Potter & Brumfield Co. 360 ± 35 ohms
"SS" (sideshift) coils Extend Assembly HydraForce Inc. 39 ± 4 ohms Coil leads
"EX" (reach) coils Mast HydraForce Inc. 39 ± 4 ohms Coil leads
Drive Unit
"P" (lift pump) Albright 15 ± 2 ohms Coil leads
Compartment
"PS" (power steering) Contactor Panel Albright 52 ± 4 ohms Coil leads
Traction Contactor Panel Albright 17 ± 2 ohms Coil leads
Table 3-3 - Hydraulic Control 3elay Coil Resistance Values
Coil testing HEIGHT LIMIT SWITCH
The "ER" and "HMR" relay coils can be tested for resistance Removal
across terminals 85 and 86. See Figure 3-6 for test point
1. Move the lift truck to a safe level area. Raise the mast high
locations. Replace any relay which has a coil resistance value
enough to obtain access to the height limit switch. SAFETY
outside of specifications. See Table 3-3 for coil resistance
CHAIN THE MAST. See - Section 8. Turn the key switch off
values.
and remove the key. Put a "DO NOT OPERATE" tag on the
multi-function control handle. Put blocks under the drive wheels
NOTE: The "ER" (enable relay) and "HMR" (hourmeter relay)
to keep the lift truck from moving. See Section 1 - HOW TO
are both single pole, double throw (SPDT) type relays.They are
PUT A LIFT TRUCK ON BLOCKS.
manufactured by either The Bosch Company or Potter &
Brumfield. When testing these relays, it is important to identify
WARNING: Do not raise the frame of the truck
the manufacturer due to different coil resistance values. The
with the forks raised. The stability of the truck is
name of the manufacturer is stamped on the relay.
reduced. Raising the frame of the truck with the
forks raised could cause it to tip over. Tipping of the truck can
Contact testing
cause personal injury or property damage.
The normally open contacts of the "ER" and "HMR" relays are
checked at terminals 30 and 87. Check for a voltage drop WARNING: Disconnect the battery and separate
across the N.O. contacts with the relay energized. Replace any the connector before opening the compartment
relay which has a voltage drop exceeding 2 volts. See cover or inspecting/repairing the electrical system.
Figure 3-6 for test.point locations. If a tool causes a short-circuit, the high current flow from the
battery can cause an injury or parts damage.
Removal and Installation
2. Disconnect the battery and separate the connectors.
To remove the relays, tag and disconnect the wires. Remove
the capscrews and lockwashers retaining the relay to the
3. Disconnect the X-11 plug.
contactor panel assembly or the mounting bracket.
4. Remove the two capscrews retaining the cover to the
Replace the relays by aligning the relay with the mounting holes
switch body. Pry the cover from the switch.
in the contactor panel assembly or mounting bracket and
installing the capscrews and lockwashers.
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Industrial Trucks ELECTRICAL SYSTEM
5. If the switch must be replaced, tag and disconnect the WARNING: Disconnect the battery and separate
wires. the connector before opening the compartment
cover or inspecting/repairing the electrical system.
6. Remove the switch by removing the mounting capscrews, If a tool causes a short-circuit, the high current flow from the
lockwashers and nuts. battery can cause an injury or parts damage.
7. Verify that the switch is activated with the inner mast BATTERY DISCONNECT SWITCH
lowered and not activated with the inner mast elevated. Check
Removal
wire #74 at the X-11 plug. Battery volts should be present at
wire #74 with the inner mast elevated. Near 0 volts should be 1. Move the lift truck to a safe level area. Turn the key switch
present at wire #74 with the inner mast lowered. off and remove the key. Put a "DO NOT OPERATE" tag on the
multi-function control handle. Put blocks under the drive wheels
8. Check the truck for proper operation. Maximum travel to keep the lift truck from moving. See Section 1 - HOW TO
speed must be limited with the mast elevated above free lift. PUT A LIFT TRUCK ON BLOCKS.
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IndustrialTrucks ELECTRICAL SYSTEM
7. Rotate the red knob to align the hole in the housing with the
hole in the shaft.
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Industrial Trucks ELECTRICAL SYSTEM
Operation
The four electrically operated proportional valves located on
the main hydraulic control valve are controlled by solenoids.
These solenoids can be checked for resistance by removing
the leads to the solenoids and tested using a volt ohmmeter.
See Table 3-3, Page 3-7 for coil resistance values.
SELECTOR VALVES
(Used on REACH model trucks only.)
If the lift truck has provisions for tilt, sideshift and reach there
are solenoids used to operate these functions located on
selector valves. One selector valve assembly, containing two
selector valves and two solenoids is located on the mast
assembly and used to select between reach or tilt. See
Figure 3-9. A second selector valve assembly, also containing
two selector valves and two solenoids is located on the reach
assembly and used to select between tilt and sideshift. See
Figure 3-10. The second selector valve assembly is only fitted
on reach model trucks equipped with an optional sideshifter.
1. SOLENOID
2. VALVE BODY
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LOWER
1 HORN TILT DOWN
I BUTTON SIDESHIFT LEFT
RETRACT
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industrial Trucks ELECTRICAL SYSTEM
WARNING: The capacitor in the traction motor WARNING: Be careful when removing or
controller can hold an electrical charge after the installing snap rings. Snap rings can come loose
battery is disconnected. To prevent electrical during removal or installation with enough force to
shock and injury, discharge the capacitor before inspecting or cause an injury. Always use the correct snap ring pliers and
repairing any component. Wear safety glasses. Make certain wear eye and face protection during removal and installation.
the battery has been disconnected.
12. Remove the snap ring retaining the torsion spring on the
4. Discharge the capacitors in the controller by connecting a bottom of the mounting plate. Remove the back-up washer and
load (such as a contaetorcoil or a horn) across the controller's torsion spring. Remove the shoulder screw from the bottom of
B + and B - terminals (center 2 terminals). DO NOT use a the lever cam with gear section. Remove the snap ring retaining
screwdriver to discharge the traction motor controller. the lever cam with gear section to the mounting plate. Remove
the back-up washer and the lever cam with gear section with
5. Disconnect X-7, X-8 and X-9 plugs from the connectors. the bracket. Separate the bracket from the lever cam with gear
section by removing the two capscrews (one socket head and
6. Remove the multi-function control handle by one flat head) and single lockwasher. Inspect the bushings in
disconnecting the X-7 connector and then removing the roil pin the lever cam with gear section and remove the bearings if they
retaining the handle to the handle weldment. Remove the are damaged or worn.
handle, disk and springs.
13. Remove the mounting plate by removing the two
7. The top cover of the handle is retained with two screws. capscrews, lockwashers, flat washers and nuts retaining the
Remove the cover, membrane, buttons and switch retainer. mounting plate to the lift truck frame
Remove switches, as required, complete with the wires
attached. Assembly
1. Install the mounting plate on the lift truck frame using the
8. Use Amp Connector Extraction Tool P/N 5180968-81 to
two capscrews, lockwashers, flat washers and nuts.
remove the pin connectors on the ends of the switch wires from
the X-7 amp connector. Make note of the color and wire position
WARNING: Be careful when removing or
before removal. Fasten a piece of string to the wires before
installing snap rings. These snap rings can come
pulling them through the handle. Fasten the wires of the new
loose during removal or installation with enough
switch to the string and use the string to pull the wires through
force to cause an injury. Always use the correct snap ring pliers
the handle. Install the wires in the X-7 amp connector as earlier
and wear eye and face protection during removal and
noted. Refer to WIRING SCHEMATICS AND DIAGRAMS at
installation.
the end of this section for wiring details. Install the switch
retainer, buttons, membrane and top cover. Install the two
2. Install the bushings in the lever cam with gear section.
screws retaining the top cover.
Install the bracket on the lever cam using the two capscrews
(one socket head and one flat head). Position the lockwasher
CAUTION: Pulling the potentiometer gear from
under the head of the socket head capscrew. Install the lever
the potentiometer assembly can cause damage to
cam with gear section on the mounting plate. Install the back-up
the potentiometer.
washer and snap ring to retain the lever cam to the mounting
plate. Install the shoulder screw in the lever cam. Install the
9. To remove either one or both of the potentiometers, tag
torsion spring, back-up washer and snap ring on the bottom of
and disconnect the electrical wires. Loosen the setscrew
the mounting plate.
holding the gear to the potentiometer shaft and remove the
potentiometer gear. Use a screwdriver positioned in the slot of
3. Align the handle weldment with the lever cam and install
the potentiometer shaft to hold the potentiometer shaft while
the handle weldment. Position the cam with gear sector, torsion
pulling the gear. PQtfing" 'on" the potentiometer gear without
spring and back-up washer on the handle weldment and install
holding the potentiometer shaft can damage the potentiometer.
the roll pin.
Remove the nut and lockwasher retaining the potentiometer to
the mounting plate or-bracket. Remove the potentiometer.
4. Align the insulator, switch and nut plate in position on the
mounting plate or bracket and install the capscrews and
10. To remove a forward, reverse or neutral micro switch, tag
lockwashers to retain the switches.
and disconnect the electrical wires. Remove the capscrews,
lockwashers and nut plates retaining the switch. Remove the
5. Locate the conical spring on the handle weldment and the
switch and the insulator.
disk on the multi-function control handle. Insert the smaller
spring in the handle. Align the multi-function control handle and
11. To separate the handle weldment and the cam and gear
install on the handle weldment. Install the roll pin retaining the
sector from the lever cam with gear section, remove the roll pin,
multi-function control handle.
back-up washer and the cam with gear sector. Remove the
handle weldment from the lever cam with gear section.
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Industrial Trucks ELECTRICAL SYSTEM
1. CONTROL HANDLE
2. ROLL PIN
3. COMPRESSION SPRING
4. CONNECTOR
5. TY-WRAP
6. LEVER CAM WITH GEAR SECTION
7. MOUNTING PLATE WITH PINS
8. CONTROL HANDLE DISK
9. CONICAL SPRING
10. ROLL PIN
11. HANDLE WELDMENT
12. POTENTIOMETER ASSEMBLY
13. SPUR GEAR
14. BACK-UP WASHER
15. TORSION SPRING
16. CAM WITH GEAR SECTOR
17. RETAINING RING
18. BUTTON HEAD SCREW
19. LOCKWASHER
20. ROUND HEAD SCREW
21. LOCKWASHER
22. MICROSWITCH
23. INSULATOR
24. NUT PLATE ASSEMBLY
25. SOCKET HEAD SCREW
26. FLAT HEAD SCREW
27. MOUNTING BRACKET
28. RETAINING RING
29. BACK-UP WASHER
30. BUSHING
31. SOCKET HEAD SCREW
u>
17
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Industrial Trucks ELECTRICAL SYSTEM
TRACTION AND HYDRAULIC POTENTIOMETER 2. Connect the wires to the potentiometerterminals as shown
in Table 3-5.
Testing
Potentiometer's operation can be verified by disconnecting the
wiring and checking resistance. Use an analog volt ohmmeter.
Traction Pot Hydraulic Pot
Pot Terminal
Wire Number Wire Number
Watch the needle on the meter while slowly rotating the
potentiometer shaft. Look for a smooth sweep of the needle 1 21 31
from minimum to maximum values. Replace any potentiometer
with erratic reÿggsor operation. Potentiometer specifications 2 22 32
are listed in Table 3-4.
3 23 33
Adjustment
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During normal operation, the left two digits show the "STATUS"
code of the truck and the right two digits show "00". Whenever a
truck function is selected, the left two digits are updated to
display the selected function.
The two digits on the right side of the display are used to display
either a "WARNING" code or a "FAULT" code. If neither a
"WARNING" code nor a "FAULT" code is present, the right two
digits continue to display "00". If multiple faults are present, the
Figure 3-16 - Main Interface Board (MIB) highest priority "FAUL"T code is displayed. After the highest
priority fault is repaired, the next highest priority "FAULT' code
OPERATION will be displayed.
When the key switch is in the "ON" position and the operator is If a "WARNING" code and a "FAULT" code are received at the
not on the truck, the MIB should display "0200" and the dash same time, the left two digits will display the "WARNING" code,
display should read "POWER ON". If the operator is present on the right two digits will display the "FAULT" code, and the
the truck, and the brake pedal is pressed (operator sensing "STATUS" code will not be displayed. Always troubleshoot the
switch and brake switch closed), the MIB should display "0300" code shown on the right side of the display first.
and the dash display should read "READY".
Codes are displayed as follows:
NOTE: When the operator enters the operators
compartment, the operator sensing switch (under right foot) • "STATUS" codes -+ numbers 01 to 16.
and the brake switch (under left foot) must both be closed to • "WARNING" codes-*- numbers 34 to 38.
change the MIB display to "0300" and the dash display to • "FAULT" codes -+ numbers 40 to 85.
"READY". Afterwards, either of the two switches may be
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3. Remove the battery compartment cover for access to the 4. Align the new main interface board with the holes in the lift
main interface board (MIB). truck frame and install the capscrews and lockwashers.
WARNING: The capacitor in the traction motor 5. Before installing the battery compartment cover, the MIB
controller can hold an electrical charge after the must be programmed for the lift truck that it is being installed in.
battery is disconnected. To prevent electrical The MIB must also be calibrated to the traction and hydraulic
shock and injury, discharge the capacitor before inspecting or potentiometers. Refer to MAIN INTERFACE BOARD
repairing any component. Wear safety glasses. Make certain ADJUSTMENTS.
the battery has been disconnected. Discharge the
capacitors in the controller by connecting a load (such as a 6. Install the battery compartment cover and connect the
contactor coil or a horn) across the controller's B + and B - battery. Remove the blocks from under the drive wheels,
terminals (center 2 terminals). DO NOT use a screwdriver to remove the "DO NOT OPERATE" tag and install the key.
discharge the traction motor controller.
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6. Move the multifunction control handle to the full speed CAUTION: The brake pedai must remain pressed
lower position. Hold for 2 seconds. during the traction potentiometer calibration
procedure.
7. Repeat Step 5.
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IndustrialTrucks ELECTRICAL SYSTEM
7. Move the multi-function control handle to the full speed 4. Release both buttons. After several seconds the dash
forward position. Hold for 2 seconds. display will change from MIB SET-UP MODE to the current
truck status (POWER ON, READY, etc.). This indicates thatthe
8. Move the multi-function control handle to the full speed new values have been saved and that the set-up mode has
reverse position. Hold for 2 seconds. been exited.
9. Repeat Step 7. NOTE: To exit without saving new values, turn the key switch
to the "OFF position.
10. Repeat Step 8. • •
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3. Select the function number to be customized by pressing Function 02 Lift - Minimum Rate
and holding button "A", then pressing button "C" or "D" until the
This function adjusts the slowest speed the forks lift with the
left two digits of the LED show the desired function number.
multi-function control handle in the slow lift position (pump
Release button "A".
motor first starts).
4. Change the function value (the right two digits) to the
Increasing this value will increase the slowest speed the forks
desired value, taking care to ensure that the value is within the
lift. Decreasing this value will decrease the slowest speed the
acceptable range for the specific truck model. The function
forks lift. Decreasing this value below the default value can
value is changed impressing either button "C" or "D" until the
increase the distance the multi-function control handle has to
desired value is obtained.
be moved to start lift.
5. Repeat the steps above for each function to be adjusted.
Function 03 Lift - Maximum Rate
A
This function adjusts the fastest speed the forks lift with the
?\ CAUTION: Failure to exit the set-up mode multi-function control handle in the fast lift position.
properly wiil result in the loss of all new settings.
The factory default value allows maximum lift speed.
6. Exit the Set-up Mode and save the new values. Select Increasing this value from the default value will not increase lift
function number 30 by pressing and holding button "A", then speed, but will allow maximum lift speed to occur at a point
pressing button "C" or "D" until the left two digits of the LED closer to the neutral position of the multi-function control
show 30. Release button "A" when the desired function number handle. Decreasing this value will decrease maximum lift
is reached. The MIB display should show "3050". speed. After programming the minimum value allowed, an
additional reduction in lift speed can be realized by decreasing
7. Verify that the MIB display shows "3050". the value of Function 02, if desired.
8. Press and hold button "B", then press button "C". Function 04 Lower - Minimum Rate
This function adjusts the slowest speed the forks lower with the
9. Release both buttons. After several seconds the dash
multi-function control handle in the slow lower position
display will change from MIB SET-UP MODE to the current
(lowering valve is first activated).
truck status (POWER ON, READY, etc.). This indicates that the
new values have been saved and that the set-up mode has
Increasing this value will increase the slowest speed the forks
been exited.
lower. Decreasing this value will decrease the slowest speed
the forks lower. Decreasing this value below the default value
NOTE: To exit without saving new values, turn the key switch
can increase the distance the multi-function control handle has
to the "OFF" position.
to be moved to start lowering.
10. Verify the correct operation of all traction and hydraulic
Function 05 Lower - Maximum Rate
functions.
This function adjusts the fastest speed the forks lower with the
multi-function control handle in the fast lower position.
MIB FUNCTION DESCRIPTIONS
Function 01 Model Code Default Values The factory default value allows maximum lower speed.
Increasing this value from the default value will not increase
This function permits the programming of MIB factory default lower speed but will allow maximum lowering speed to occur at
values for each model truck. Setting this function to the value
a point closerto the neutral position of the multi-function control
corresponding to the specific truck model will program MIB handle. Decreasing this value will decrease maximum lower
function numbers" 2 Through 29 to the corresponding factory
speed. After programming the minimum value allowed, an
default values. See Table 3-6 for a list of settings for each model additional reduction in lower speed can be realized by
truck. Refer to MIB SET-UP PROCEDURE for detailed decreasing the value of Function 04, if desired.
instructions for programming the MIB.
Function 06 Extend - Minimum Rate
/\ CAUTION: Function 01 will not program values
11\ for the traction potentiometer (Function 34) or This function adjusts the slowest speed the forks extend with
hydraulic potentiometer (Function 32). These the multi-function control handle in the slow extend position
components must be manually calibrated to the MIB. Refer to (auxiliary valve is first activated).
MIB SET-UP PROCEDURE for detailed instructions.
Increasing this value will increase the slowest speed the forks
extend. Decreasing this value will decrease the slowest speed
the forks extend. Decreasing this value below the default value
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Increasing this value will provide faster speeds. Decreasing Increasing this value will increase the slowest speed the
this value will provide slower speeds. After programming the sideshifter moves left. Decreasing this value will decrease the
minimum value allowed, an additional reduction in tilt up speed slowest speed the sideshifter moves left. Decreasing this value
can be realized by decreasing the value of Function 10, if below the default value can increase the distance the
desired. multi-function control handle has to be moved before sideshift
left occurs.
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Industrial Trucks ELECTRICAL SYSTEM
Increasing the starting rate value increases the time it takes for Function 24 Power Steering Contactor - Maximum
a hydraulic function to accelerate to the selected speed Current
(accelerates more slowly). Decreasing the starting rate value
WARNING: Do not customize this function. This
decreases the time it takes for the hydraulic function to
function must remain at the default value. Values
accelerate (accelerates more quickly).
other than the default value can cause improper
operation of the lift truck. Improper lift truck operation can cause
Function 19 Hydraulic Function - Stopping Rate
personal injury or property damage.
This function adjusts the stopping rate, or rate of deceleration,
of ail hydraulic functions. Function 25 Lift Pump Contactor - Minimum Current
WARNING: Do not customize this function. This
Increasing the stopping rate value increases the time it takes
function must remain at the default value. Values
for a hydraulic function to stop (decelerates more slowly).
other than the default value can cause improper
Decreasing the stopping rate value decreases the time it takes
operation of the lift truck. Improper lift truck operation can cause
for the hydraulic function to stop (decelerates more quickly).
personal injury or property damage.
Function 20 Maximum Travel Speed - Mast Elevated
Function 26 Lift Pump Contactor - Maximum Current
This function adjusts the maximum travel speed (speed limit) of
WARNING: Do not customize this function. This
the truck with the mast elevated above free lift.
function must remain at the default value. Values
other than the default value can cause improper
WARNING: Never adjust Function 20 to a value
operation of the lift truck. Improper lift truck operation can cause
greater than the value specified for the truck
personal injury or property damage.
model. Refer to Table 3-19 through Table 3-28 for
specific maximum values. Lift trucks can tip over even at very
Function 27 Auxiliary Function Coils - Minimum
slow speeds. A lift truck is less stable with the forks elevated.
Current
Tip over can cause personal injury or property damage.
WARNING: Do not customize this function. This
Decreasing the maximum travel speed value lowers the speed function must remain at the default value. Values
of the truck with the mast elevated. other than the default value can cause improper
operation of the lift truck. Improper lift truck operation can cause
Function 21 Model Code - MTVFD personal injury or property damage.
/\ WARNING: Do not customize this function. This
Function 28 Auxiliary Function Coils - Maximum
/ I\ function must remain at the default value. Values
Current
CJLJ other than the default value can cause improper
operation of the lift truck. Improper lift truck operation can cause WARNING: Do not customize this function. This
personal injury or property damage. function must remain at the default value. Values
other than the default value can cause improper
operation of the lift truck. Improper lift truck operation can cause
personal injury or property damage.
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Function 31 Erase
This function is used as a utility for erasing model code
information during the MIB calibration. No customization for MIB PLUG PIN IDENTIFICATION
this function is applicable.
CAUTION: Never attempt to probe through the
Function 32 Hydraulic Potentiometer - Set-up
This function is used as a utility for setting the hydraulic
potentiometer range during MIB calibration. No customization
for this function is applicable.
6
the
he J1 or JS
back of the J1 or J2 MIB plugs. These plugs are
specially sealed plugs. Probingthrough the back of
J2 MIB plugs will destroy the seal and can cause a
short circuit. If a circuit must be tested for voltage, check for
voltage at an "amp" type plug, a switch or a component. If the
Function 33 NOT USED circuit to the MIB is suspect, check the circuit by removing the
MIB and disconnecting the J1 and J2 plugs. Refer to MIB
Function 34 Traction Potentiometer - Set-up REMOVAL. Test continuity from the front (pin end) of the plugs.
This function is used as a utility for setting the traction
potentiometer range during MIB calibration. No customization
for this function is applicable.
11 ÿ
-3C
56D
40- 42
-5C
45- -44
74-
-29
a 81-
60-
83-
-6
-85
-32
FRONT VIEW
1 1
-36
92
22
70
13
FRONT VIEW
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
TRUCK RESPONSE
LOGIC
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
"Blank
"Blank Display"
Display"
CONDITION
No display on MIB or dash display.
15 15
TRUCK RESPONSE
Travel and hydraulic functions are disabled. 1 -
POSSIBLE CAUSES AND TEST PROCEDURES
• B + and/or B - missing at the MIB and dash display. 01 OASH
C\i
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
"LIFT' function is disabled, traction and auxiliary functions are
normal.
trj
OASH
DISPLAY
J
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
"LIFT" function is disabled. Travel and "AUXILIARY HYDRAULIC"
functions may or may not be disabled.
LOGIC
Displayed when any of the following conditions are not
satisfied:
Continuity should exist from J1-7 (wire #81) to X6-8 (wire #81),
from J1-15 (wire #82) to X6-9 (wire #82), and from J1-8 (wire
#83) to X6-10 (wire #83).
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Industrial Trucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Traction controller too hot. Determine and correct cause.
TRUCK RESPONSE
Yellow "WARNING" indicator illuminates.
Traction controller goes into thermal cutback.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Traction controller fault.
TRUCK RESPONSE
Red "FAULT" indicator illuminates.
Traction is disabled until fault condition is corrected.
LOGIC
Displayed when the traction motor controller determines that
the throttle input is out of range.
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Industrial Tmcks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Traction controller fault.
TRUCK RESPONSE
Red "FAULT indicator illuminates.
Traction is disabled until fault condition is corrected.
LOGIC
Displayed when the traction motor controller determines that a
fault has occurred.
NOTE: Throttle input faults and traction motor controller high
temperature warnings are displayed by separate dash display
messages.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Yellow "WARNING' indicator illuminates.
Travel and hydraulic functions are disabled.
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STATUS CODES
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
13-6
LOGIC
Displayed when MIB terminals J2-15, J2-23, and dash display
terminals X4-1, X4-2 are near battery voltage. MIB terminals
J2-7, J2-8, and dash display terminals X4-8, X4-10 are B-.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
56 56 11
l
1 s
LOGIC
CAUTION: If this status code occurs without both Displayed when MIB terminals J1-1 and J1-9 are near battery
/J\ pedals being ÿpressed, either the brake switch, the
operator sensing switch, or both are shorted. Check
voltage.
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IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
rr
56 56
Truck travels in the-forward direction.
FWD REV 6 21 22 23
TRACTiON POT
60 80
u
LOGIC
Displayed when MIB terminal J1-13 is near battery voltage and
MIB terminal J2-21 increases from the neutral value.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE 56 56
Truck travels in the reverse direction.
c c
pWDx 6 REV 22 23
TRACTiON POT
60 80
LOGIC
Displayed when MiB terminal J1-10 is near battery voltage and
MIB terminal J2-21 decreases from the neutral value.
3-31
Yale
IndustrialTmcks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Yellow "LIFT/LOWER" indicator illuminates.
Lift pump starts and forks lift. 10
NEUTRAL SWITCH
31 32 33
LOGIC
Displayed when MIB terminal J1-2 is near battery voltage and
MIB terminal J2-16 increases from the neutral value.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Yellow "LIFT/LOWER" indicator illuminates.
Forks lower.
LSI b
I fM I_ LOfi—
NEUTRAL SWITCH
31 32 33
; chi)
—VVVV — j clou)
HYDRAULIC POT
LOGIC
Displayed when MIB terminal J1-2 is near battery voltage and
MIB terminal J2-16 decreases from the neutral value.
3-32
Yale
Industrial Trucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Yellow "REACH" indicator illuminates.
10 10
REACH 31 32 33
NEUTRAL
SWITCH
3 (LOW)
HYDRAULIC POT
44 40
Id
LOGIC
Displayed when MIB terminal J1-18 is near battery voltage.
MIB terminal J1-2 is near 0 volts and MIB terminal J2-16 is at
the neutral value.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Forks extend. 10
REACH
NEUTRAL
SWITCH 31 33
40 AAA-'3 CLOW)
HYDRAULIC pot
I 0
LOGIC
Displayed when MIB terminals J1-18 and J1-2 are near battery
voltage.
MIB terminal J2-16 increases from the neutral value.
3-33
Yale
IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Forks retract. T
REACH
10
A
NEUTRAL
SWITCH 31 32 33
Lki a
LOGIC
Displayed when MIB terminals J1-18 and J1-2 are near battery
voltage.
MIB terminal J2-16 decreases from the neutral value.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Yellow TILT indicator illuminates.
10 10
tilt! 31 32 33
NEUTRAL
SWITCH
—WWN—
hydraulic pot
3 (LOW)
42 40
I ~i
LOGIC
Displayed when MIB terminal J1-17 is near battery voltage.
MIB terminal J1-2 is near 0 volts and MIB terminal J2-16 is at
the neutral value.
3-34
Yale
IndustrialTrucks electrical system
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Forks tilt up.
NEUTRAL
SWITCH
3 CLOW)
HYDRAULIC PO
LOGIC
Displayed when MIB terminals J1-17 and J1-2 are near battery
voltage.
MIB terminal J2-16 increases from the neutral value.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Forks tilt down. 10
TIL
NEUTRAL
SWITCH 31 32 33
42 uhiJ-WnX/—
HYDRAULIC POT
Lkl
LOGIC
Displayed when MIB terminals J1-17 and J1-2 are near battery
voltage.
MIB terminal J2-16 decreases from the neutral value.
3-35
Yale
IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Yellow "SIDESHIFT indicator illuminates. 10 10
Sideshift indicator on dash illuminates.
55 32 33
NEUTRAL
SWITCH
i HYDRAULIC POT
46 40
0 0
LOGIC
Displayed when MIB terminal J1-3 is near battery voltage.
MIB terminal J1-2 is near 0 volts and MIB terminal J2-16 is at
the neutral value.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Forks sideshift to the right. 10
I
SSI
NEUTRAL
SWITCH 32 33
id 0
LOGIC
Displayed when MIB terminals J1-3 and J1-2 are near battery
voltage.
MIB terminal J2-16 increases from the neutral value.
3-36
Yale
IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Forks sideshift to the left. IfN |_ |rvj
NEUTRAL
SWITCH
31 32 33
HYDRAULIC POT
LOGIC
Displayed when MIB terminals J1-3 and J1-2 are near battery
voltage.
MIB terminal J2-16 decreases from the neutral value.
WARNING CODES
NOTE: When WARNING codes and FAULT codes occur simultaneously, the left two digits display the WARNING code and the right
two digits display the FAULT code (e.g. XX34 becomes 3458, when 34 is the WARNING code and 58 is the concurrent FAULT code).
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
RESET TO NEUTRAL
35 BEFORE OPERATING
25 WARNING MIB
CONDITION
Traction or hydraulic control (multi-function control handle) is not — n -j— .< -f-
Vsvt-rcH
SHAKE !
in "NEUTRAL" position when the operator steps into the truck and i r i -5
H St SC
presses the brake pedal and the operator sensing switch. NEUTRAL
TRUCK RESPONSE SWITCH
s
Yellow "WARNING" indicator illuminates.
Travel and hydraulic functions are disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Multi-function control handle not in "NEUTRAL".
Reset multi-function control handle to "NEUTRAL".
H.
ills
„
*
TT1T
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
STEP ON PLATFORM
36 BEFORE OPERATING
24 WARNING MIB
CONDITION
Operator sensing switch not closed and operator tries to travel or
perform hydraulic function. (This only applies when the operator
initially steps onto the lift truck. After the operator sensing pedal
and the brake pedal have both been actuated, the operator NEUTRAL
SWITCH FWO |
sensing pedal can be released, as long as the brake pedal is not
released.) "J
TRUCK RESPONSE
Yellow "WARNING" indicator illuminates.
hi I r
Travel and hydraulic functions are disabled. ill m a a
POSSIBLE CAUSES AND TEST PROCEDURES B 1 a 11
• Operator sensing switch is not closed. 21 22 23 21 22 23 31 32 33 31 32 33
Stand in the operator compartment to close operator sensing
switch. Reset multi-function control handle to neutral — — ml 5ÿ1/ I111
TRACTION —
Tiom i .nl— — — !mij—VÿW—
ROT
imnl NICRAUL1C ROT
n»i
HTORAUCIC ROT
in
position.
• Operator sensing switch defective.
Replace operator sensing switch. LOGIC
• Open in operator sensing switch circuit. Displayed when greater than 14 volts is present at J 1-2, J1-10
Disconnect the battery and MIB J plugs. Check continuity or J1-13 with battery voltage present at J 1-9 and near 0 volts
between MIB plug terminal J1-1 and wire #11 at switch present at J1- 1.
connector X-13. Check continuity between wire #15 at X-13 Displayed when the voltage at J2-16 or J2-21 is above or below
and wire 15 atfuser&iRepair any open circuits in the operator approximately 2.5 volts (neutral voltage) with battery voltage
sensing switch circuit. present at J1-9 and near 0 volts present at J 1- 1.
3-38
Yale
Industrial Trucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
HlBWULi:
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
MUST BE ON TRUCK
38 BEFORE OPERATING
22 WARNING MIB
CONDITION
Brake switch and operator sensing switch are not closed and
operator tries to travel or perform hydraulic function.
TRUCK RESPONSE 10
c I
Yellow "WARNING" indicator illuminates.
NEUTRAL
Travel and hydraulic functions are disabled. SWITCH
NO !
POSSIBLE CAUSES AND TEST PROCEDURES 40
-
switch and brake switch. Reset traction and/or hydraulic
controls to neutral position.
• Operator sensing switch and brake switch out of adjustment or _B_9l_
defective. a a a
I i I I I I
Adjust or replace operator sensing switch and brake switch. 21 22 23
22 21 23
3-39
Yale
IndustrialTrucks ELECTRICAL SYSTEM
FAULT CODES
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
"REACH" button is pressed and the multi-function control handle
i0
is moved to the "EXTEND" or "RETRACT" position.
i1 -
TRUCK RESPONSE EX EX
Red "FAULT indicator illuminates. "REACH" is disabled. A B
ÿ
POSSIBLE CAUSES AND TEST PROCEDURES
• Shorted "EX" (reach) solenoid coil.
Disconnect the battery. Remove wires #1 0 and #92 from the
"EX" (reach) solenoids located on the mast. Measure the
resistance of each "EX" (reach) solenoid coil. If the coil
r
< i-
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
"REACH" button is pressed and the multi-function control handle
is moved to the "EXTEND" or "RETRACT" position. 1o
TRUCK RESPONSE
Red "FAULT indicator illuminates. "REACH" is disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
i
" ÿ EX
• Open "EX" (reach) solenoid coil. > B
<:-v y
Disconnect the battery. Remove wires #1 0 and #92 from the
"EX" (reach) solenoids located on the mast. Measure the
resistance of each, "EX" (reach) solenoid coil. If the coil
resistance measures outside of specifications, replace the
coil. Coil resistance @ 2TC (70°F) = 39 ±4 ohms.
• Open "EX" (reach) solenoid coil circuit. »
Disconnect the battery. Disconnect the J2 plug from the MIB.
Check the continuity from pin J2-5 to wire #92 at the "EX" 9 ro
(reach) solenoid and from wire #10 at the solenoid to wire #10
at the "ER" (enable relay) on the contactor panel. Both circuits
should test near 0 ohms. Greater than 0 ohms indicates an
Lÿj—
open. Locate and repair any open circuits.
LOGIC
• Failed MIB (open power FET in "EX" (reach) circuit).
Displayed when lower than normal current is sensed in the "EX"
A short in the "EX" (reach) solenoid coil circuit can cause a
(reach) solenoid circuit.
power FET to fail open. If the FET fails open the condition will
be reported as axiode XX41 . Troubleshoot as in MIB CODE
XX40. If the XX41 fault does not clear replace the MIB.
3-40
Yale
IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
"SIDESHIFT" button is pressed and the multi-function control
handle is moved t6 the "SIDESHIFT RIGHT or "SIDESHIFT 10
LEFT position.
TRUCK RESPONSE ss SS
Red "FAULT indicator illuminates. Sideshift is disabled. A 8
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
"SIDESHIFT button is pressed and the multi-function control
handle is moved to the "SIDESHIFT RIGHT or "SIDESHIFT 10
LEFT position.
TRUCK RESPONSE
Red "FAULT indicator illuminates. Sideshift is disabled.
POSSIBLE CAUSES AND TEST PROCEDURES ss SS
A 0
• Open "SIDESHIFT solenoid coil.
Disconnect the battery. Remove wires #10 and #91 from the
sideshift solenoids located on the mast. Measure the
resistance of .each sideshift solenoid coil. If the coil resistance
measures outside of specifications, replace the coil. Coil
resistance ® 2TC (70°F) = 39 ±4 ohms.
• Open "SIDESHIFT solenoid coil circuit.
Disconnect the battery. Disconnect the J2 plug from the MIB. 31
Check the continuity from pin J2-13 to wire #91 at the
sideshift solenoid and from wire #10 at the solenoid to wire
#1 0 at the "ER" (enable relay) on the contactor panel. Both I
circuits should test near 0 ohms. Greater than 0 ohms
indicates an open. Locate and repair any open circuits. LOGIC
• Failed MIB (open, power FET in "SIDESHIFT circuit). Displayed when lower than normal current is sensed in the
A short in the sideshift solenoid coil circuit can cause a power "SIDESHIFT solenoid circuit.
FET to fail open. If the FET fails open the condition will be
reported as a .code XX43. Troubleshoot as in MIB CODE
XX42. If the XX43 fault does not clear replace the MIB.
3-41
Yale
IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Any "AUXILIARY" function button is pressed and the
multi-function control handle is moved up.
TRUCK RESPONSE
Red "FAULT" indicator illuminates. "EXTEND", "TILT UP" and
"SIDESHIFT RIGHT functions are disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Shorted "AUX UP" (auxiliary up) solenoid coil. AUX
Disconnect the battery. Remove wires #10 and #72 from the UP
"AUX UP" solenoid. Measurethe resistance of the "AUX UP"
solenoid coil. If the coil resistance measures outside of
specifications, replace the coil. Coil resistance @ 21°C
(70°F) = 1.8 ±0.2 ohms.
• Shorted "AUX UP" solenoid coil circuit. 72
Disconnect the battery. Disconnect the J2 plug from MIB.
Disconnect wires #10 and #72 from the "AUX UP" solenoid.
Check the resistance between wires #10 and #72. There
should not be continuity. If continuity (low ohms) is measured,
wires #10 and #72 are shorted together somewhere in the LOGIC
harness. Locate and repair the short. Displayed when higher than normal current is sensed in the
"AUX UP" (auxiliary up) solenoid circuit.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Any "AUXILIARY" function button is pressed and the
multi-function control handle is moved up.
TRUCK RESPONSE
Red "FAULT indicator illuminates. "EXTEND", "TILT UP" and 10
"SIDESHIFT RIGHT functions are disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Open "AUX UP" (auxiliary up) solenoid coil.
Disconnect the battery. Remove wires #10 and #72 from the
d
L AUX
"AUX UP" solenoid. Measure the resistance of the solenoid O UP
coil. If the coil resistance measures outside of specifications,
replace the coil. Coil resistance @ 2TC (70°F) = 1.8 ±0.2
ohms.
• Open "AUX UP" solenoid coil circuit.
Disconnect the battery. Disconnect the J2 plug from the MIB. 72
Check continuity from pin J2-10 to wire #72 at the "AUX UP"
solenoid and from wire #10 at the solenoid to wire #10 at the
"ER" (enable relay) on the contactor panel. Both circuits
should test near 0 ohms. Greater than 0 ohms indicates an
I1
open. Locate and repair any open circuits.
• Failed MIB (opervpewer FET in "AUX UP" circuit).
A short in the "AUX UP" solenoid coil circuit can cause a LOGIC
power FET to fail open. If the FET fails open the condition will Displayed when lower than normal current is sensed in the
be reported as a code XX45. Troubleshoot as in MIB CODE "AUX UP" (auxiliary up) solenoid circuit.
XX44. If the XX45 fault does not clear replace the MIB.
3-42
Yale
IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Any "AUXILIARY" function button is pressed and the
multi-function control handle is moved down.
TRUCK RESPONSE
Red "FAULT indicator illuminates. "RETRACT, TILT DOWN", 10
and "SIDESHIFT LEFT functions are disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Open "AUX DOWN" (auxiliary down) solenoid coil.
Disconnect the battery. Remove wires #10 and #73 from the
d
AUX
"AUX DOWN" solenoid. Measure the resistance of the DOWN
yj
solenoid coil. If the coil resistance measures outside of
specifications, replace the coil. Coil resistance @ 21°C
(70°F) = 1.8±0.2 ohms.
• Open "AUX DOWN" solenoid coil circuit.
Disconnectthe battery. Disconnect the J2 plug from the MIB. 73
Check continuity from pin J2-3 to wire #73 at the "AUX
DOWN" solenoid and from wire #10 at the solenoid to wire
#10 at the "ER" (enable relay) on the contactor panel. Both
circuits should test near 0 ohms. Greater than 0 ohms
3
indicates an open. Locate and repair any open circuits.
• Failed MIB (open power FET in "AUX DOWN" circuit).
A short in the "AUX DOWN" solenoid coil circuit can cause a LOGIC
power FET to fail open. If the FET fails open the condition will Displayed when lower than normal current is sensed in the
be reportedÿs acode XX47. Troubleshoot as in MIB CODE "AUX DOWN" (auxiliary down) solenoid circuit.
XX46. If the XX47 fault does not clear replace the MIB.
3-43
Yale
IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Multi-function control handle positioned for "LIFTING".
TRUCK RESPONSE 10
Red "FAULT indicator illuminates. "LIFT function is disabled.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Multi-function control handle positioned for "LIFTING".
TRUCK RESPONSE
Red "FAULT indicator illuminates. "LIFT function is disabled. 10
POSSIBLE CAUSES AND TEST PROCEDURES
• Open "LIFT solenoid coil.
Disconnect the battery. Remove wires #10 and #71 from the
"LIFT solenoid. Measure the resistance of the solenoid coil.
If the coil resistance measures outside of specifications,
replace the coil. Coil resistance @ 21°C (70°F) = 6.5 ±0.5
ohms.
d>) LIFT
3-44
Yale
IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Multi-function control handle positioned for "LOWERING".
TRUCK RESPONSE 10
Red "FAULT" indicator illuminates. "LIFT" and "LOWER" functions
are disabled.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Muiti-function control handle positioned for "LOWERING".
TRUCK RESPONSE
Red"FAULT" indicator illuminates. "LIFT" and "LOWER" functions 10
are disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Open "LOWER" solenoid coil.
Disconnect the battery. Remove wires #10 and #70 from the
d 1ÿ
"LOWER" solenoid. Measure solenoid coil resistance. If the LOWER
coil resistance measures outside of specifications, replace
the coil. Coil resistance @ 21 °C (70°F) = 6.5 ± 0.5 ohms.
• Open "LOWER" solenoid coil circuit.
Disconnect the battery. Disconnect the J2 plug from the MIB.
Check continuity from pin J2-14 to wire #70 at the "LOWER" 70
solenoid and from wire #10 at the solenoid to wire #10 at the
"ER" (enable relay) on the contactor panel. Both circuits
should test near 0 ohms. Greater than 0 ohms indicates an
open. Locate and repair any open circuits. L±!
• Failed MIB (open power FET in "LOWER" circuit).
A short in the "LOWER" solenoid coil circuit can cause a LOGIC
power FET to fail open. If the FET fails open the condition will Displayed when lower than normal current is sensed in the
be reported as a code XX51.Troubleshoot as in MIB CODE "LOWER" solenoid circuit.
XX50. If the-XX5t fault does not clear replace the MIB.
3-45
Yale
IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Multi-function control handle positioned for "LIFTING".
TRUCK RESPONSE
Red "FAULT indicator illuminates. "LIFT function is disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Shorted "LIFT PUMP" contactor coil. LIFT
Disconnect the battery. Remove wires #1 0 and #28 from the PUMP
"LIFT PUMP" contactor coil. Measure the resistance of the -EE- J?s
"LIFT PUMP" contactor coil. If the coil resistance measures only (HMR)
outside of specifications, replace the coil. Coil resistance @ .85
21°C (70°F) = 15 ±1 ohms.
• Shorted "HMR" (hourmeter) relay coil (EE trucks only).
Disconnect the battery. Remove wires #10 and #28 from the
"HMR" relay coii. Measure the resistance of the "HMR" relay
28
coil. Coil resistance @ 21°C (70°F) = 305 ±15 ohms. If the
resistance is outside of specifications, replace the relay.
• Shorted "LIFT PUMP" contactor coil/"HMR" relay coil circuit.
Disconnect the battery. Disconnect the J2 plug from MIB.
Disconnect wires #10 and #28 from the "LIFT PUMP" LOGIC
contactor coil and the "HMR" relay coil. Check resistance Displayed when higher than normal current is sensed in the
between wires #10 and #28. There should not be continuity. "LIFT PUMP" / "HMR" (hourmeter relay) coil circuit.
If continuity (low ohms) is measured, wires #10 and #28 are
shorted together in the harness. Locate and repair the short.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Multi-function control handle positioned for "LIFTING".
TRUCK RESPONSE 10
Red "FAULT indicator illuminates. "LIFT function is disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Open "LIFT PUMP" coil or "HMR" (EE only) coil. LIFT
Disconnect the battery. Remove wires #1 0 and #28 from the PUMP
solenoid and relay. Measure the resistance of each coil. If the js
coil resistance measures outside of specifications, replace "EE- (HMR)
the coil. Lift Pump coil resistance @ 2TC (70°F) = 15±1 only as
ohms. HMR coil resistance @ 2TC (70°F) = 305 ± 15 ohms.
• Open "LIFT PUMP" / "HMR" solenoid coil circuit.
Disconnectthe battery. Disconnect the J2 plug from the MIB.
Check continuity from pin J2-4 to wire #28 at the "HMR" relay
coil and from wire #10 at the "HMR" relay coil to wire #10 at 28
the "ER" (enable relay) on the contactor panel. Both circuits
should test near 0 ohms. Greater than 0 ohms indicates an
open. Locate and repair any open circuits.
¥
• Failed MIB (open power FET in "LIFT PUMP" / "HMR" circuit).
A short in the "LIFT PUMP" / "HMR" coil circuit can cause a LOGIC
power FET to fail open. If the FET fails open the condition will Displayed when lower than normal current is sensed in the
be reported as a code XX53. Troubleshoot as in MIB CODE "LIFT PUMP" /"HMR" (hourmeter relay) coil circuit.
XX52. If the XX53 fault does not clear replace the MIB.
3-46
Yale
IndustrialTmcks electrical system
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
......... CONDITION
Multi-function handle is positioned for any hydraulic function.
TRUCK RESPONSE
Red "FAULT indicator illuminates. All hydraulic functions are
disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• "NEUTRAL" switch shorted or out of adjustment.
Check the operation and adjustment of the "NEUTRAL"
a a i
NEUTRAL 5WITCH
switch, adjust or replace as necessary. 31 32 33
IF THE "NEUTRAL" SWITCH TESTS GOOD, CONTINUE:
Disconnect the battery and J1 plug at the MIB. Check
continuity between wire #40 at the switch and wire #1 0 at the I (HI) -'WW-3 (LOW)
switch. If continuity exists wire #40 and wire #10 are shorted HYDRAULIC D0T
together. Locate and repair the short.
• Hydraulic potentiometer defective. 0
Disconnect the wires from the potentiometer and remove it
from the truck. Use an ohmmeter to check the potentiometer.
Resistance should be 10K ohms ±10% between pot
terminals 1 and 3, and 0-10K ohms±10%, depending on LOGIC
wiper position, between pot terminals 1 and 2 or 2 and 3. Displayed when battery voltage is present at MIB terminal J1-2
• Hydraulic potentiometer out of adjustment. (wire #40) with J2-16 at approximately 2.5 volts (neutral
Check hydraulic potentiometer adjustment. voltage).
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Multi-function control handle is positioned for any hydraulic
function. i_jua
TRUCK RESPONSE
Red "FAULT indicator illuminates. All hydraulic functions are 31 32 33
disabled. 10 /
POSSIBLE CAUSES AND TEST PROCEDURES HHI><-'WW'"—1 3 (LOW)
HYDRAULIC POT
• "NEUTRAL" switch failed open. NEUTRAL SWITCH
Replace any switch that does not read continuity between C
and NO with the switch activated. OR
• "NEUTRAL" switch/out of adjustment.
Adjust "NEUTRAL" switch. 40
• Open in the "NEUTRAL" switch circuit.
BBS
Disconnect the battery. Disconnect the J1 plug at the MIB.
Check continuity between J 1-2 and wire #40 at the switch, iil 32 33
and wire #10 at the switch and wire #10 at the "ER" (enable
relay) located on the contactor panel. Both circuits should
1
'-
(H!)
VVW-3 CLOW)
HYDRAULIC POT
test near 0 ohms. Greater than 0 ohms indicates an open.
• Hydraulic potentiometer defective or out of adjustment.
Check, replace and/or adjust pot. Disconnect the wires from
LOGIC
the potentiometer and remove it from the truck. Use an
Displayed when battery voltage is not present at MIB terminal
ohmmeter to check the potentiometer. Resistance should be
J 1-2 (wire #40) with the hydraulic potentiometer wiper above or
10K ohms ± 10% between pot terminals 1 and 3, and 0-1OK
below approximately 2.5 volts (neutral voltage).
ohms ± 10%,sdepending on wiper position, between pot
terminals 1 and 2 or 2 and 3.
3-47
Yale
IndustrialTrucks ELECTRICAL SYSTEM
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Operator is on the truck.
Key switch is on and battery disconnect switch is closed. PI IS 1
TRUCK RESPONSE
Red "FAULT indicator illuminates. All hydraulic functions are 32 33
disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Hydraulic pot circuit shorted between wiper and low side. 1CHI)1 -VVW-3 ' CLOW]
Disconnect the J2 plug from the MIB. Disconnect wires #31 , hydraul:c pot
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Operator is on the truck.
Key switch is on and battery disconnect switch is closed.
TRUCK RESPONSE
Ei m i
Red "FAULT indicator illuminates. All hydraulic functions are
disabled.
HVDRAULiC POT
high side.
Disconnect the J2 plug from the MIB. Disconnect wires #31 ,
#32 and #33 from the hydraulic pot. Measure the resistance With Multi-Function Control Handle in neutral:
from pin J2-2 to J2-16. 0 ohms indicates a short. Locate and Low side: J2-17 (wire # 33) should be approximately 0.5 volts
repair any shorts. Wiper: J2-16 (wire # 32) should be approximately 2.5 volts
High side: J2-2 (wire #31) should be approximately 4.5 volts
• Hydraulic potentiometer defective or out of adjustment.
Check, replace and/or adjust pot. Disconnect the wires from
the potentiometer and remove it from the truck. Use an
ohmmeterto check the potentiometer. Resistance should be LOGIC
10K ohms ± 10% between pot terminals 1 and 3, and 0-1OK Displayed when the MIB detects that the voltage at MIB
ohms ±10%, depending on wiper position, between pot terminals J2-16 and J2-2 is equal and greater than 4.0 volts.
terminals 1 and 2 or 2 and 3. MIB reference voltage at pin J2-16 (wiper) is too high.
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Operator is on the truck.
Key switch is.onandbattery disconnect switch is closed.
TRUCK RESPONSE
a i a
Red "FAULT indicator illuminates. All hydraulic functions are
disabled. 31 32
#31).
Disconnect the battery. Disconnect the J2 plug from the MIB.
Disconnect wires #31, #32 and #33 from the hydraulic With Multi-Function Control Handle in neutral:
potentiometer. Check continuity from pin J2-2 to wire #31 at Low side: J2-17 (wire # 33) should be approximately 0.5 volts
Wiper: J2-16 (wire # 32) should be approximately 2.5 volts
the hydraulic potentiometer. Greater than 0 ohms indicates
High side: J2-2 (wire #31) should be approximately 4.5 volts
an open. Locate and repair any open circuits.
• Hydraulic potentiometer defective or out of adjustment.
Check, replace and/or adjust pot. Disconnect the wires from
the potentiometer and remove it from the truck. Use an LOGIC
ohmmeter to check the potentiometer. Resistance should be Displayed when the MIB determines that the voltage at MIB
10K ohms ± 10% between pot terminals 1 and 3, and 0-1OK terminal J2-16 is near 0 volts.
ohms ±10%, depending on wiper position, between pot MIB reference voltage at pin J2-16 (wiper) is too low.
terminals 1 and 2 or 2 and 3.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Operator is on the truck.
Key switch is on and battery disconnect switch is closed.
TRUCK RESPONSE
Red "FAULT indicator illuminates. All hydraulic functions are
a in i
disabled.
POSSIBLE CAUSES AND TEST PROCEDURES
• Hydraulic potentiometer circuit open on the low side (wire #33)
or on the wiper side (wire #32).
Disconnect the battery. Disconnect the J2 plug from the MIB.
1 CHI) -WW1-- CLOW)
HYDRAULIC PCT
Disconnect wires #31, #32 and #33 from the hydraulic
potentiometer. Check continuity from pin J2- 17 to wire #33 at With Multi-Function Control Handle in neutral:
the hydraulic potentiometer. Check continuity from pin J2-16 Low side: J2-17 (wire # 33) should be approximately 0.5 volts
to wire #32 at the hydraulic potentiometer. Greater than 0 Wiper: J2-16 (wire # 32) should be approximately 2.5 volts
ohms on either circuit indicates an open. Locate and repair High side: J2-2 (wire #31) should be approximately 4.5 volts
any open circuits.
• Hydraulic potentiometer defective or out of adjustment.
Check, replace and/or adjust pot. Disconnect the wires from
the potentiometer and remove it from the truck. Use an LOGIC
ohmmeter to check the potentiometer. Resistance should be Displayed when the MIB determines that the voltage at MIB
10K ohms ± 10% between pot terminals 1 and 3, and 0-1OK terminal J2-16 is near 5.0 volts.
ohms ±10%, depending on wiper position, between pot MIB reference voltage at pin J2-16 (wiper) is too high.
terminals 1and 2 or 2 and 3.
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Red "FAULT" indicator illuminates. Travel, auxiliary and power
steering functions are disabled.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Operator is on the truck.
Key switch is on and battery disconnect switch is closed.
HUH
TRUCK RESPONSE 21 22 23
Red "FAULT indicator illuminates. Travel functions are disabled.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Operator is on the truck.
Key switch is on and battery disconnect switch is closed.
TRUCK RESPONSE
Iÿl (1 3
Red "FAULT indicator illuminates. Travel functions are disabled.
21 22 23
POSSIBLE CAUSES AND TEST PROCEDURES
• Traction potentiometer circuit shorted between wiper and low 1 CHI) -VAV- '3CLCH)
side. TRACTION POT
Disconnect the J2 plug from the MIB. Disconnect wires #21 ,
#22 and #23 from the traction pot. Measure the resistance With Multi-Function Control Handle in neutral:
from pin J2-9 to J2-21 . 0 ohms indicates a short. Locate and Low side: J2-1 (wire # 23) should be approximately 0.5 volts
repair any shorts. Wiper: J2-21 (wire # 22) should be approximately 2.5 volts
• Traction potentiometer defective or out of adjustment. High side: J2-9 (wire #21) should be approximately 4.5 volts
Check, replace and/or adjust pot. Disconnect the wires from
the potentiometer and remove it from the truck. Use an
ohmmeter to check the potentiometer. Resistance should be
10K ohms ± 10% between pot terminals 1 and 3, and 0-1OK LOGIC
ohms ±10%, depending on wiper position, between pot Displayed when the MIB detects that the voltage at MIB
terminals 1 and 2 or 2 and 3. terminals J2-9 and J2-21 is equal and greater than 4.0 volts.
MIB reference voltage at pin J2-21 (wiper) is too high.
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Operator is on the truck.
Key switch is on and battery disconnect switch is closed.
TRUCK RESPONSE
S~ i 3
Red "FAULT indicator illuminates. Travel functions are disabled.
21 22 23
POSSIBLE CAUSES AND TEST PROCEDURES
• Traction potentiometer circuit open on the high side (wire #21).
Disconnect the battery. Disconnect the J2 plug from the MIB. TRACTION POT
Disconnect wires #21, #22 and #23 from the traction
potentiometer. Check continuity from pin J2-9 to wire #21 at
With Multi-Function Control Handle in neutral:
the traction potentiometer. Greater than 0 ohms indicates an Low side: J2-1 (wire # 23) should be approximately 0.5 volts
open. Locate and repair any open circuits. Wiper: J2-21 (wire # 22) should be approximately 2.5 volts
• Traction potentiometer defective or out of adjustment. High side: J2-9 (wire #21) should be approximately 4.5 volts
Check, replace and/or adjust pot. Disconnect the wires from
the potentiometer and remove it from the truck. Use an
ohmmeter to check the potentiometer. Resistance should be
10K ohms ± 10% between pot terminals 1 and 3, and 0-1OK LOGIC
ohms ±10%, depending on wiper position, between pot Displayed when the MIB determines that the voltage at MIB
terminals 1 and 2 or 2 and 3. terminal J2-21 is near 0 volts.
MIB reference voltage at pin J2-21 (wiper) is too low.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Operator is on the truck.
Key switch is on and battery disconnect switch is closed.
r
TRUCK RESPONSE
Red "FAULT indicator illuminates. Travel functions are disabled.
jl Ij1 Is]
22 23
POSSIBLE CAUSES AND TEST PROCEDURES
• Traction potentiometer circuit open on the low side (wire #23)
or on the wiper side (wire #22).
-RACTI0N POT
Disconnect the battery, Disconnect the J2 plug from the MIB.
Disconnect wires #21, #22 and #23 from the traction
With Multi-Function Control Handle in neutral:
potentiometer. Check continuity from pin J2-1 to wire #23 at
Low side: J2-1 (wire # 23) should be approximately 0.5 volts
the traction potentiometer. Check continuity from pin J2-21 to Wiper: J2-21 (wire # 22) should be approximately 2.5 volts
wire #22 at the traction potentiometer. Greater than 0 ohms High side: J2-9 (wire #21) should be approximately 4.5 volts
on either circuit indicates an open. Locate and repair any
open circuits.
• Traction potentiometer defective or out of adjustment.
Check, replace and/or adjust pot. Disconnect the wires from
the potentiometer and remove it from the truck. Use an LOGIC
ohmmeter to check th'e potentiometer. Resistance should be Displayed when the MIB determines that the voltage at MIB
10K ohms ± 10% between pot terminals 1 and 3, and 0-1OK terminal J2-21 is near 5.0 volts.
ohms ±10%, depending on wiper position, between pot MIB reference voltage at pin J2-21 (wiper) is too high.
terminals 1 and 2 or 2 and 3.
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Multi-function control handle is in the "NEUTRAL" position.
vwB-. TRUCK RESPONSE
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Multi-function control handle is in the "FORWARD" travel position.
TRUCK RESPONSE
Red "FAULT indicator illuminates. Travel functions are disabled.
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE 55
Red "FAULT indicator illuminates. Travel functions are disabled.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Multi-function control handle is in the "REVERSE" travel position.
TRUCK RESPONSE
Red "FAULT indicator illuminates. Travel functions are disabled.
56
POSSIBLE CAUSES AND TEST PROCEDURES 0 I E
• "REVERSE" switch failed open. REV c
Replace any switch that does not read continuity between C 21 22 23
and NO with the switch activated. NO
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Red "FAULT indicator illuminates. Travel and hydraulic functions ER
! 86
are disabled.
•
2TC (70° F) = 305 ± 15 ohms.
Shorted "ER" (enable relay) coil circuit.
li±1
Disconnect the battery. Disconnect the J2 plug from MIB.
Check resistance between wires #15 and #16. There should LOGIC
not be continuity. If continuity (low ohms) is measured, wires Displayed when higher than normal current is sensed in the
#1 5 and #16 are shorted together somewhere in the harness. "ER" (enable relay) solenoid circuit.
Locate and repair the short.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
k
86
Disconnect the battery. Remove wires #15 and #16 from the j
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
MIB FAILURE
XX72 TRUCK DISABLED
2 FAULT MIB
CONDITION
Operator is on the truck.
Key switch is on and battery disconnect switch is closed.
TRUCK RESPONSE i
Red"FAULT" indicator illuminates. Travel and hydraulic functions
are disabled.
LOGIC
Displayed when the internal logic of the MIB detects a shorted
power FET.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
NONE (traction and hydraulic functions are disabled).
LOGIC
Displayed when the internal logic of the MIB detects a shorted
suppression zener diode.
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
TRUCK RESPONSE
Red "FAULT" indicator illuminates.
Travel and hydraulic functions are disabled.
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
CONDITION
Operator is on the truck.
Key switch is on and battery disconnect switch is closed.
TRUCK RESPONSE
Red "FAULT" indicator illuminates.
Travel functions are disabled.
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MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
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lockwashers to retain the controller between the mounting section. Plug the X-3 connector into the J1 receptacle of the
brackets.. traction motor controller.
2. Connect the wires to the terminals. See WIRING 3. See PROGRAMMING THE TRACTION MOTOR
SCHEMATICS AND DIAGRAMS located at the end of this CONTROLLER to set-up the controller.
PROGRAMMER
HAND SET
CONNECTION
15A- L±J
ÿÿ
a
56C- -30 UD ÿÿ
CC
DM1
DM2- -29 O
O O
cc A 1- 1
-A :
FM1 ÿ
-14 o
FM2- '46 18 z
o cc
— LlJ
a A2
I— _J
O _J J-
<c o
o
o
X-3
CJ F1 o ÿ
r i
(CONNECT TO J1)
X-3 PIN 1 KEY SWITCH INPUT X-3 PIN 13: NOT USED
X-3 PIN 2 BRAKE SWITCH X-3 PIN 14: THROTTLE REFERENCE VOLTAGE
X-3 PIN 3 DRIVE MODE SELECT #2 INPUT X-3 PIN 15: 0-5 VOLT THROTTLE SIGNAL INPUT
X-3 PIN 4 DRIVE MODE SELECT #1 INPUT X-3 PIN 16: NOT USED
X-3 PIN 5 FAULT 1 OUTPUT X-3 PIN 17: TRACTION COIL DRIVER
X-3 PIN 6 FAULT 2 OUTPUT X-3 PIN 18: NOT USED
X-3 PIN 7 NOT USED X-3 PIN 19: NOT USED
X-3 PIN 8 NOT USED X-3 PIN 20: NOT USED
X-3 PIN 9 KEY SWITCH INPUT (COIL RETURN) X-3 PIN 21: NOT USED
X-3 PIN 10: FORWARD SWITCH INPUT X-3 PIN 22: NOT USED
X-3 PIN 11: REVERSE SWITCH INPUT X-3 PIN 23: NOT USED
X-3 PIN 12: NOT USED X-3 PIN 24: NOT USED
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m
SELECTED values available for the selected item. |f the minimum or
ITEM maximum value has been programmed, a message replaces
down the bar graph and any dependencies are listed.
OPERATION
SELECTS MORE INFO, SPECIAL Connecting the Hand Set to the Traction Motor
PROGRAM AND DIAGNOSTIC MENUS Controller
-
Figure 3-22 Curtis Model 1307 Programmer Hand Set NOTE: Each time the programmer hand set is connected to
the controller, it acquires all of the controller function value
The display window contains a four line LCD display. This settings and stores them in its temporary memory. This allows
display is visible in most lighting conditions. When the the user to revert back to the original settings at any time. The
programmer is in the PROGRAM, TEST or DIAGNOSTICS SPECIAL PROGRAM menu selection RESET ALL SETTINGS
mode, four lines-ofaimenu are displayed. The item at the top of is used to revertto the original settings. Any inadvertent change
the display window is the selected item (in the PROGRAM made to any of the function values can be "undone" in this
menu, the selected item will be highlighted with a flashing manner, as long as the programmer has not been unplugged
arrow). •: : or the key switch turned off (power disconnected).
SCROLL DISPLAY Keys 1. Turn the key switch to the "OFF position.
To scroll up and down within a menu, use the two SCROLL 2. Disconnect and separate the battery connector.
DISPLAY arrow keys. The SCROLL DISPLAY arrow keys can
be pressed repeatedly or held down. When a key is held down, 3. Remove the two screws retaining the metal cover located
the scrolling speed increases the longer the key is held. on the right side of the operator compartment. Remove the
cover.
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WARNING: The capacitor in the traction motor A WARNING: The capacitor in the traction motor
/|\ controller can hold an electrical charge after the /|\ controller can hold an electrical charge after the
CJm) battery is disconnected. To prevent electrical CJLj battery is disconnected. To prevent electrical
shock and injury, discharge the capacitor before inspecting or shock and injury, discharge the capacitor before inspecting or
repairing any component. Wear safety glasses. Make certain repairing any component. Wear safety glasses. Make certain
the battery has been disconnected. Discharge the the battery has been disconnected. Discharge the
capacitors in the controller by connecting a load (such as a capacitors in the controller by connecting a load (such as a
contactor coil or a hom) across the controller's B + and B - contactor coil or a horn) across the controller's B + and B -
terminals. DO NOT use a Screwdriver to discharge the traction terminals (center 2 terminals). DO NOT use a screwdriver to
motor controller. discharge the traction motor controller.
4. Discharge the capacitors in the traction motor controller by 4. Disconnect the Programmer Hand Set from the 4 pin
connecting a load (such as a contactor coil or a hom) across the Molex connector on the traction motor controller.
controller's B + and B - terminals.
NOTE: The Programmer Hand Set should only be connected
NOTE: The Programmer Hand Set should only be connected and disconnected with the key switch in the off position.
and disconnected with the key switch in the off position.
5. Install the cover in the operator's compartment. Install the
5. Connect the Programmer Hand Set to the 4 pin Molex two screws.
connector on the traction motor controller. See Figure 3-21.
6. Reconnect the battery.
6. Reconnect the battery.
Programmer Self Test
NOTE: The brake pedal must be released (up position).
You can test the programmer by displaying two special test
screens. Press and hold the MORE INFO key while the
7. Turn the key switch to the "ON" position. Ensurethe battery
programmer is powering up. During the SELF TEST, you can
disconnect switch is closed.
toggle between the two test screens by pressing the SCROLL
DISPLAY keys. The first screen turns on every LCD element,
Disconnecting the Hand Set from the Traction Motor
and the second screen displays all the characters used in the
Controller
various menus. As part of the SELF TEST, you can also test the
1. Turn the key switch to the "OFF position. keys by pressing each one and observing whether its corner
LED lights up. To exit the SELF TEST, unplug the programmer
2. Disconnect and separate the battery connector. or turn off the controller.
SCROLL
DISPLAY
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Mode 3 neutral braking, as % of brake MAIN CONT Traction contactor open or closed.
M3 Neut Brk %
C/L Fault 1 driver status: on (low)/off
FAULT 1
Mode 2 neutral braking, as % of brake OUTPUT (high).
M2 Neut Brk %
C/L
FAULT 2 Fault 2 driver status: on (low)/off
Mode 1 neutral braking, as % of brake OUTPUT (high).
M1 Neut Brk %
C/L
MODSEL 1 Mode select inputs 1 and 2 together
M3 Accel Rate Mode 3 acceleration rate, in seconds define the operating mode from the
dash display to the controller. Refer to
M2 Accel Rate Mode 2 acceleration rate, in seconds MODSEL 2 Table 3-9.
M1 Accel Rate Mode 1 acceleration rate, in seconds Table 3-8 - Test Menu
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PROGRAMMING THE TRACTION MOTOR CONTROLLER 10. Press the MORE INFO button to display additional
information, if desired, on the selected function. The green LED
WARNING: NEVER adjust function settings
in the comer of the MORE INFO button lights to indicate that the
outside the range recommended for the specific
MORE INFO option has been selected.
truck model.
NOTE: Some function values are limited by values set for
WARNING: Program changes affect lift truck
other fucntions. For example, the value for M2
performance and operation. If function settings are
ACCELERATION RATE (Mid Mode) must be equal to or less
changed, make sure all operators of the lift truck
than the value for Ml ACCELERATION RATE (Turtle Mode)
know that the truck has been changed and may operate
and equal to or greater than the value for M3 ACCELERATION
differently.
RATE (Rabbit Mode). Press the MORE INFO key to display the
1. Turn the key switch to the "OFF position. limiting function, shown on the bottom line in place of the
minimum and maximum values normally displayed..
2. Disconnect and separate the battery connector.
WARNING: NEVER adjust function settings
3. Remove the two screws retaining the metal cover located outside the range recommended for the specific
on the right side of the operator compartment. Remove the truck model.
cover.
11. Press the CHANGE VALUE buttons to change the function
WARNING: The capacitor in the traction motor value higher or lower, as required. A green LED on each
controller can hold an electrical charge after the CHANGE VALUE button lights to indicate that the function
battery is disconnected. To prevent electrical value can be changed in the corresponding direction. If the
shock and injury, discharge the capacitor before inspecting or green LED on one of the CHANGE VALUE buttons is not
repairing any component. Wear safety glasses. Make certain illuminated, the value has reached the limit for the
the battery has been disconnected. DO NOT use a corresponding direction.
screwdriver to discharge the traction motor controller.
WARNING: Program changes affect lift truck
4. Discharge the capacitors in the traction motor controller by performance and operation. If function settings are
connecting a load (such as a contactor coil or a horn) across the changed, make sure all operators of the lift truck
controller's B + and B - terminals. know that the truck has been changed and may operate
differently.
5. Connect the PROGRAMMER HAND SET to the traction
motor controller. The cord of the hand set plugs into the 4 pin 12. Press the MORE INFO button to return to the PROGRAM
Molex, Mini-Fit Jr. receptacle on the front of the controller. menu, if the MORE INFO screen had been selected.
NOTE: Each time the programmer hand set is connected to 13. Repeat Steps 9 thru 12, as required, until all of the
the controller, it acquires all of the controller function value functions are set to the desired values.
settings and stores them in its temporary memory. This allows
the user to revert back to the original settings at any time. The NOTE: Any inadvertent change made to any of the function
SPECIAL PROGRAM menu selection RESET ALL SETTINGS values can be "undone" using the SPECIAL PROGRAM menu
is used to revert to the original settings. Any inadvertent change selection RESET ALL SETTINGS, as long as the programmer
made to any of the function values can be "undone" in this has not been unplugged or the key switch turned off (power
manner, as long as the programmer has not been unplugged disconnected).
or the key switch turned off (power disconnected).
14. Turn the key switch to the "OFF" position.
6. Reconnect the battery.
15. Disconnect and separate the battery connector.
NOTE: The brake pedal must be released (up position)
during Step 7.
WARNING: The capacitor in the traction motor
7. Turn the key switch to the "ON" position. Ensure battery controller can hold an electrical charge after the
disconnect switch is closed. battery is disconnected. To prevent electrical
shock and injury, discharge the capacitor before inspecting or
8. Press the PROGRAM button on the PROGRAMMER repairing any component. Wear safety glasses. Make certain
HAND SET. The green LED in the corner of the PROGRAM the battery has been disconnected. DO NOT use a
button lights to indicate that the HAND SET has been placed in screwdriver to discharge the traction motor controller.
the PROGRAM mode.
16. Discharge the capacitors in the controller by connecting a
9. Press the SCROLL DISPLAY buttons, as required, until load (such as a contactor coil or a horn) across the controller's
the desired function is shown on the top line of the display. B + and B - terminals.
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IndustrialTrucks ELECTRICAL SYSTEM
17. Disconnect the programmer hand set cord from the 18. Installthe cover in the operator's compartment. Install the
traction motor controller. two screws to retain the cover. Reconnect the battery.
NOTE: Changes made to the BRAKE C/L settings may necessitate changes to the TAPER RATE setting below to ensure smooth
operation when transitioning from regen braking to plug.
M3 NEUT BRK %
% of Regen
M2 NEUT BRK % Neutral Braking Level 16 Oto 50
C/L
M1 NEUT BRK %
24 volt trucks only 0.5 0.1 to 5.0
M3 ACCEL RATE M3 Acceleration Seconds
Ramp Rate 36 volt trucks only 0.7 0.1 to 5.0
NOTE: Changes made to the TAPER RATE setting may necessitate changes to the BRAKE C/L settings above to ensure smooth
operation when transitioning from regen braking to plug.
Standard 65 0 to 65
24 volt trucks only
"EE" 65 0 to 65
M1 MAX SPEED M1 Speed Limit % of Throttle
Standard 65 0 to 65
36 volt trucks only
"EE" 65 0 to 65
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0,1 Controller operational, no faults The charts on the following pages should be used in
conjunction with the wiring diagrams at the end of this section
1,2 Hardware failsafe fault for best results. The DIAGNOSTIC (and DIAGNOSTIC
1,3 M-, current sensor, or motor fault
HISTORY) menu items are shown, followed by the TEST menu
items.
2,1 Throttle fault
2,2 Static return to off (SRO) fault
2,3 High pedai disable (HPD) fault
3,1 Contactor driver overcurrent
3,2 Welded contactor
Diagnostics Menu
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position.
TRUCK RESPONSE
Traction may or may not function normally.
LOGIC
Initial communication between the traction motor controller and
the programmer hand set is not valid.
LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
NOKNOWNfAUlTS:
NO KNOWN FAULTS HAVE
OCCURREDv " V
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
TRUCK RESPONSE
Traction functions normally.
LOGIC
Displayed when no known faults are present.
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LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
RAMME
"Any LED Code"
CONDITION
Hand set is plugged nto the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
TRUCK RESPONSE
Traction may or may not function normally.
LOGIC
Displayed when the internal check logic of the traction motor
controller does not get the correct communication from the
programmer hand set.
LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
RMAL CUTBACK
ERMAL CUTBACK DUE
OVER/UNDER TEMP
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
TRUCK RESPONSE
Traction speed is reduced.
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LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
wmm
VATED
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
BRAKE BRAKE
SW ITCH SWITCH
TRUCK RESPONSE
Traction is disabled until fault condition is corrected. r
SG
OPER OPER
FWO REV SEN FWO REV SEN
POSSIBLE CAUSES AND TEST PROCEDURES SW SW SW SW 5W SW
c c
• Forward or reverse direction is selected before the brake is o
released (operator is on the truck, initial start-up only).
Check brake switch for proper operation, an open brake
switch can cause this fault.
I
SO
r
"*x. ÿ
i *0
LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
r .r, •
-"iV J
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
15
TRUCK RESPONSE
Traction is disabled until fault condition is corrected. (The HPD
3RAKE
function has a three second delay during normal operation.) SWITCH
POSSIBLE CAUSES AND TEST PROCEDURES
• Throttle greater than 25% before the brake pedal is pressed. n
Check multi-function control handle to ensure it is in the 30 29 29 30
neutral position. ÿ
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LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
MM aSBHWRI
mmm
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position; Diagnostic menu is selected.
56 56
TRUCK RESPONSE
Traction is disabled until fault condition is corrected.
POSSIBLE CAUSES AND TEST PROCEDURES
• M - output shorted or internal short in the traction motor. TRACTION
Verify voltage between battery- and M- to be 10% less MOTOR c c
than battery volts with the multi-function control handle in FWO ft REV O
neutral.
• Traction motor shorted.
Check traction motor for shorted condition.
• Forward or reverse switch circuitry shorted. 50 80
Pin 13 and pin 10 should measure near zero volts with
multi-function control handle in neutral. Pin 13 (forward) or
pin 10 (reverse) should measure near battery voltage with IS
corresponding direction selected.
LOGIC
M - bus bar should measure approximately 10% less than
battery volts. Pin 13 and pin 10 should measure near zero volts
with multi-function control handle in neutral. Pin 13 (forward) or
pin 10 (reverse) should measure near battery voltage with
corresponding direction selected.
LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
-mm
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
BATTERY
(-) o
U
I
TRUCK RESPONSE
Traction is disabled until fault condition is corrected.
LOGIC
Traction controller is designed to operate with 24 and 36 volt
batteries only.
3-71
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IndustrialTrucks ELECTRICAL SYSTEM
LEO CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
QVEBCQRREN&
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
ih*v.i iun
TRUCK RESPONSE
Traction is disabled until fault condition is corrected.
15 -c@>-
POSSIBLE CAUSES AND TEST PROCEDURES
Traction contactor coil shorted. 15
Check traction contactor coil for a shorted condition.
Contactor coil should measure approximately 17 T 1 ohms.
Shorted wire between the traction motor controller and the
contactor coil.
¥
LOGIC
Displayed when higher than normal current is sensed in the
traction contactor coil.
LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
TRUCK RESPONSE
Traction is disabled until fault condition is corrected.
LOGIC
Displayed when the internal check logic of the traction motor
controller determines an internal failure of the traction motor
controller.
3-72
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Industrial Tmcks ELECTRICAL SYSTEM
LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
BATTERY
TRUCK RESPONSE
Traction is disabled until fault condition is corrected.
LOGIC
B + bus bar on traction motor controller should measure near
truck battery voltage. Connections should be tight and
corrosion free.
LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
"Any or No LED
FAULT
Code" K3
'*</' TTi* "'V? < * ' * '
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
o
TRUCK RESPONSE rtDQ
l<2E J3g"
Traction is disabled until fault condition is corrected. !oS E cc
POSSIBLE CAUSES AND TEST PROCEDURES — ÿom
FM ! 15 1Q -' F
1
ffi .' o
SR.
• Traction motor controller isnot wired properly or is missing
required inputs. 150— 3- C-
HSa@: ES
Check controller connections. See WIRING SCHEMATICS
AND DIAGRAMS.
LOGIC
Displayed when internal logic of the traction motor controller
detects improper inputs.
3-73
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IndustrialTrucks electrical system
LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
,«i> ste « - : ., v.--. - .
3,4
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
TRUCK RESPONSE 15
Traction is disabled until fault condition is corrected.
contactor coil.
Check for continuity between pin 17 at the traction motor
controller and wire #14 at the contactor coil.
Check for continuity between pin 9 at the traction motor
controller and wire #15 at the contactor coil. LOGIC
These checks should read near zero ohms, if they do not, Displayed when lower than normal current is sensed in the
locate the open and repair it. traction contactor coil.
LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
FAI
-
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
TRUCK RESPONSE 29
Traction is disabled until fault condition is corrected.
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Industrial Trucks ELECTRICAL SYSTEM
LED CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
CONDITION
Hand set is plugged into the traction motor controller. Key switch
is in the "ON" position. Diagnostic menu is selected.
TRUCK RESPONSE
Traction is disabled until fault condition is corrected.
POSSIBLE CAUSES AND TEST PROCEDURES 30 30
• Throttle reference voltage (pin 14, wire #30) open or shorted.
Check wire #30 (pin 14 at the traction motor controller) for a
short to B - or B + .
CO
|
Check continuity between pin 14 (wire #30) at the traction IB
motor controller and J 1-16 (wire #30) at the MIB. You should
read near zero ohms. If the wire is open, find the open and
repair it. Wire #30 (pin 14 at the traction motor controller)
should measure approximately 0.2 volts.
• MIB failed.
Check the MIB for proper operation. The MIB provides the
throttle reference signal to the traction motor controller via
wire #30 (J1-16). With the key switch on pin 14 should LOGIC
measure approximately 0.2 volts. As the handle is moved in Pin 14 at the traction motor controller is above or below
a "FORWARD" or "REVERSE" direction the voltage should (approximately) 0.2 volts (reference voltage).
remain at approximately 0.2 volts.
Test Menu
Throttle signal is generated by the MIB and dependant on the throttle pot position.
Displays throttle reading in percent of full as seen by the traction motor controller.
Menu
TEST MENU OPERATING RANGE
Item
Scroll display until BATT For Additional Information: Approximately 20.76 to 26.4 24 volt truck
VOLTAGE is shown on the Press
top line MORE INFO Approximately 31.14 to 39.6 36 volt truck
4 BATT VOLTAGE 24 BATTERY VOLTAGE, (average 1.73 volts per cell discharged)
, VOLTS . 2ÿ (average 2.2 volts per cell charged)
Scroll display until For Additional Information: Between -25°C (-13°F) and 85 °C(185 °F)
HEATSINK °C is shown on Press
the top line MORE INFO
5 HEATSINK C 22 HEATSINK TEMPERATURE
*° 22
Indicates traction motor controller heatsink temperature.
Scroll display Until For Additional Information: Forward switch "OPEN" OFF
FORWARD INPUTis shown Press
on the top line MORE INFO Forward switch "CLOSED" ON
3-76
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IndustrialTrucks
Menu
Item
Item
Item
Item
10
on the top line
REVERSE 1nru
Menu
MAIN CONT
l(plw®lw
ISSIIi
33X8?$ * --
line
..
;:::;;5r >1;
M
>
Menu
upi i-r
Press
MORE INFO
i
,
1
ijyrg.-*- •*—'*
*Lÿ -
TEST MENU
(Multi-function control handle positioned for reverse travel.)
ni.[
ON
ÿ»— t
TEST MENU
OPEN
TEST MENU
.
||
-
'.
Shows status of reverse switch input at traction motor controller. Output of MIB.
Menu
TEST MENU
ÿ
'
Press
MORE INFO
REVERSE INPUT
MAIN CONTACTOR
DB.VEH.S
FAULT 1 OUTPUT
Press
MORE INFO
Qÿ|
ON
Reverse switch "CLOSED"
.
ELECTRICAL SYSTEM
OPERATING RANGE
OPERATING RANGE
OPERATING RANGE
OPERATING RANGE
OFF
. ON
ON
ON
OFF
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Industrial Trucks ELECTRICAL SYSTEM
Menu
TEST MENU OPERATING RANGE
Item
.......
-- ÿ ÿÿ
- . ÿ
*. '
'
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IndustrialTrucks ELECTRICAL SYSTEM
......
controller and is located on the panel adjacent to the steering
The Message Center is a 16 character, alpha-numeric, liquid
tiller.
crystal display (LCD), with green back-lighting. Hourmeter
Two versions of the dash display are available: readings, truck performance status messages, warning
Standard -25* to70'C (-13' to 158' F) messages and fault messages are shown on the Message
Freezer ......
. -W to 70'C (-40° to 158' F) Center.
The dash display contains the following features: The Hourmeter Switch isused to display hourmeter information
in the Message Center . The switch is marked with an hour
• Three "button-selectable" drive modes glass symbol. Press once to display truck hours to 1/10 of an
• Sixteen character English LCD Message Center display hour. Press twice to display drive motor hours. Press three
for status, warning, and fault messages
times to display the lift motor hours. Press four times to return to
• Three "button-selectable" hourmeters (Traction, Lift and the current operational status display. After 30 seconds, the
Total Hours)
display defaults to the current operational status of the truck.
• Four hydraulic function selection lights
• Ten bar LED battery state of charge indication The Warning/Fault Indicatorblinks to alert the operator to check
• Low battery lift interrupt indication and permissive output the Message Center. When a warning message is displayed,
the Warning/Fault Indicator blinks yellow. When a fault
Drive Mode Hourmeter
Switch Message Center Switch message is displayed, the Warning/Fault Indicator blinks red.
Warning/Fault
Indicator
/ POWER ON
'/////'///////
\/k —
smi \
The Function Selection Lights are for the display of Lift, Reach,
Tilt and Sideshift operations.
The Battery Indicator has a 10 bar green, yellow and red light
emitting diode (LED) to indicate battery state of charge. As
\
Function battery power is used, the LEDs will turn off in sequence,
enter
fl Selection starting with green. The red LED second from the bottom
(juu /
Lights
flashes to indicate when the battery is nearly discharged. The
ax /] red LED on the bottom of the display will alternately flash with
the low-battery indicator LED (a crossed battery symbol) to
indicate that the battery is discharged and the hoist function is
disabled.
Battery Indicator
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IndustrialTrucks ELECTRICAL SYSTEM
FRONT VIEW
FM1
ÿBARE
1 SB 3-5
JT -3
X-1 5 CONNECTOR
TO DASH DISPLAY
l® -J 1-2
FRONT VIEW FRONT VIEW
5. Disconnect the two plugs from the rear of the dash display
assembly. DASH DISPLAY ADJUSTMENT
The dash display assembly has two potentiometers located
6. Remove the two thumbscrews and the retainers securing between the connectors on the back of the assembly. The
the dash display assembly to the instrument panel. Removethe potentiometers are set at the factory and should not require
dash display assembly. adjustment.
INSTALLATION The RESET potentiometer sets the level to which the battery
must be charged before the battery indicator resets. The
1. Adjust the pots on the rear of the dash display assembly. RESET potentiometer is set at the factory to B. At the factory
See DASH DISPLAY ASSEMBLY, ADJUSTMENT. setting, the battery must have open circuit voltage greater than
2.09 volts per cell to cause the battery indicator to reset. The
2. Connect the two plugs to the rear of the dash display. battery must be disconnected for a minimum of 15 seconds
(before a charged battery is connected) for the RESET function
3. Position the dash display assembly in the instrument to operate.
panel. Install the retainers and the thumbscrews to retain the
dash display assembly to the instrument panel. The DISCHARGE potentiometer sets the level at which LIFT
interrupt occurs. The DISCHARGE potentiometer is set at the
4. Install the drive unit cover and the battery cover. Close and factory to L. At the factory setting, the battery must have open
secure the drive unit compartment door. circuit voltage of approximately 1.63 volts per cell to cause the
lift interrupt function to occur. Adjustment of the DISCHARGE
5. Install the hydraulic tank dipstick. potentiometer from L toward K allows the battery to discharge
more before lift interrupt occurs. Adjustment of the
6. Connect the battery. DISCHARGE potentiometer from L toward P allows the battery
to discharge less before lift interrupt occurs.
7. Remove the blocks from under the drive wheels, remove
the "DO NOT OPERATE" tag and install the key. Adjust the settings, if necessary, by inserting a small
screwdriver through the access hole in the rear of the dash
Voltage Selection display and into the long slot in each adjustment screw. Rotate
Voltage selection (24 or 36 volt battery) is achieved by means of the screwdriver fully clockwise, then counterclockwise until the
an "X-15A" jumper assembly. The "X-15A" jumper assembly is dotted end of the slot is aligned to the desired setting. See
plugged into the "X-15" connector for 24 volt battery operation Figure 3-26.
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IndustrialTrucks ELECTRICAL SYSTEM
DOT screwdriver
SLOT
r. A
16 9
0.QD.QLO,OQ0
oooonona
RESET DISCHARGE
EXPLODED VIEW
V Y)
Figure 3-26 - Battery Indicator Adjustment
- 2.00 K 1.56
A 2.06 L 1.63
(factory setting)
B 2.09
(factory setting) M 1.68
C 2.12 N 1.73
D 2.15 0 1.78
E 2.18 P 1.82
TROUBLESHOOTING
Inoperative Dash Display Assembly Inoperative Drive Mode Selection
If the dash display is blank (no display, no LEDs) with the key If pressing the mode selection button causes the green LED
switch on and the battery disconnect switch closed, check the mode indicators to change, but truck performance appears
following: Verify that the battery disconnect switch is closed by unchanged, check the communication from the dash display to
measuring for battery voltage on both sides of the switch. the traction motor controller as follows:
Check fuses 4, 5, and 6. Check for battery voltage at the MIBat
J2-15 and J2-23 (wire #15). Check J2-7 and J2-8 (wire #13) for Troubleshooting the Dash Display with a Programmer
B-. Check for battery voltage at the dash display at X4-2 (wire Hand Set
#15). Wires X4-8 and X4-10 at the dash display should be B-. If
all of these conditions are correct, the dash display or the MIB Using the Programmer Hand Set, enter the TEST MENU.
could be defective. Check the MODE SELECT INPUT 1 and the MODE SELECT
INPUT 2. See Table 3-16 for the correct inputs.
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IndustrialTrucks ELECTRICAL SYSTEM
2. Program M1 (turtle mode) MAX SPEED to 40%. If the voltages at DM1 and DM2 are correct and correspond to
the appropriate drive modes, but lift truck operation is still
3. Program M2 (mid mode) MAX SPEED to 70%. incorrect, a programmer hand set will be required for further
troubleshooting.
4. Program M3 (rabbit mode) MAX SPEED to 100%.
No Warnings or Faults Displayed
5. Operate the truck in each drive mode and check for
differences in top speed in each mode. Communication from the traction motor controller to the dash
display occurs through two wires, FM1 and FM2. Wires FM1
If the speeds are different for each drive mode and correspond and FM2 are located in the X-3 connector of the traction motor
to the selected mode, the mode selection feature is working. If controller and in the X-6 connector at the dash display. These
speeds do not differ for each drive mode, the traction motor two wires transmit digital codes corresponding to warnings or
controller may be faulty. faults affecting the traction controller.
6. Reprogram the traction motor controller to the correct During normal operation (no faults or warnings present), the
values. See PROGRAMMING THE TRACTION MOTOR voltage between FM1 and battery negative, and the voltage
CONTROLLER. between FM2 and battery negative, should be less than + 5.0
volts, respectively. In a fault or warning condition, the voltage
Troubleshooting Without a Programmer Hand Set between FM1 and battery negative and/or FM2 and battery
If a Programmer Hand Set is not available, communication from negative will change.
the dash display to the traction motor controller can be checked
using a digital volt ohmmeter. Check the voltage levels on wires STATUS / WARNING / FAULT
DM1 and DM2 by testing connector pins 3 and 4 at the traction
motor controller with respect to the B- terminal of the traction TEST Drive Ctrl Drive Ctrl Drive Ctrl
motor controller. POINT Limit Error Fault
Normal
Speed Check Check
.
NOTE: Do not disconnect the wire harness at the dash
display or the traction motor controller. Voltage checks must be
Reduced Error Code Fault Code
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MOTOR MAINTENANCE-GENERAL
This portion of the electrical section describes disassembly and 1. Raise the drive wheel off the floor. Block the lift truck. See
assembly, brush replacement, inspection and checks for Section 1 - HOW TO PUT A LIFT TRUCK ON BLOCKS.
malfunction of DC motors. Inspect the commutator and Disconnect the battery.
brushes every 350 hours of operation. The commutator is the
rotating electric connection between the armature and the /\ WARNING: Disconnect the battery and separate
electric power supplied by the battery. Brushesmade of carbon /|\ the connector before opening the compartment
compounds slide on the rotating commutator and are the path CbJLJj cover or inspecting/repairing the electrical system.
for electricity from th#lSt4§ry to the commutator and the If a tool causes a short-circuit, the high current flow from the
armature. The maintenance of the commutator and the battery can cause an injury or parts damage.
brushes is important to the good operation of a DC motor.
2. Disconnect the battery and separate the connectors.
Traction motors and hydraulic pump motors are similar in
design. The hydraulic pump motors are smaller than the 3. Open the drive unit compartment cover.
traction motors, but the disassembly and maintenance of these
motors are similar. WARNING: The capacitor in the traction motor
controller can hold an electrical charge after the
battery is disconnected. To prevent electrical
shock and injury, discharge the capacitor before inspecting or
repairing any component. Wear safety glasses. Make certain
the battery has been disconnected. Discharge the
V\ capacitors in the controller by connecting a load (such as a
contactor coil or a horn) across the controller's B + and B -
terminals (center 2 terminals). DO NOT use a screwdriver to
Jul discharge the traction motor controller.
-
Figure 3-27 Traction Motor 8. Installthe brush covers, when used and close the drive unit
compartment cover.
Brush and Commutator Inspection
WARNING: Put blocks under each side of the 9 Connect the battery. Remove the blocks under the drive
truck under the drive unit frame. Position blocks on wheel. Test operate the lift truck before returning the truck to
both sides of the load wheels. The blocks must service.
prevent the lift truck from falling and causing injury or damage.
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A DARK COLOR ON THE SURFACE OF THE VARIATIONS BETWEEN LIGHT BROWN AND
COMMUTATOR WHERE IT ROTATES ON DARK BROWN COLORS ARE ALSO NORMAL.
THE BRUSHES IS A NORMAL CONDITION. THE SURFACE OF THE COMMUTATOR MUST
BE SMOOTH.
Commutator Problems
Commutator problems and motor problems are shown in Figure 3-29 through Figure 3-36. See COMMUTATOR REPAIRS, this section.
mujhHhHÿfil
LOAD
• BRUSH PRESSURE IS TOO LOW
• WORN BRUSHES
6939
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Industrial Trucks ELECTRICAL SYSTEM
I h H|P|
M i
ÿ
iiiT I GROOVES THAT ARE THE WIDTH OF THE BRUSHES.
-----
POSSIBLE CAUSES:
——— —
• OPERATION OF THE MOTOR IN DIRTY AND ABRASIVE
"H- o- < CONDITIONS
• WRONG TYPE OF BRUSHES FOR THIS MOTOR AND
OPERATION
• BRUSH PRESSURE IS TOO HIGH
6940
. . --v
6939
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IndustrialTrucks ELECTRICAL SYSTEM
693!
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IndustrialTrucks ELECTRICAL SYSTEM
Brush Replacement - Traction and Hydraulic Motors discolored (heat) brush springs. Check that the brush springs
for approximately equal pressure. Brush springs normally have
Worn motor brushes must be replaced before they damage the
a spring pressure of approximately 1.0 to 2.0 Newtons per each
surface of the commutator. Move the brush spring and remove
a brush from the brush holder. Measure the length of the brush
cm2 (1.5 to 3.0 Ibf per each in2) when measured with a spring
scale.
as shown in Figure 3-37. Replace all of the brushes if the length
of one brush is less than the minimum length. Brushes are
NOTE: Measure the surface area on the brush which
made to different specifications for motors used in different
contacts the commutator (thickness x width). See (6)
applications. Use only replacement brushes approved by YALE
MATERIALS HANDLING CORPORATION.
Figure 3-37. Multiply the surface area times 1.5 to 3.0 to
determine the brush spring force.
1. Move the lift truck to a safe level area. Turn the key switch
off and remove the key. Put a "DO NOT OPERATE" tag on the
multi-function control handle. Put blocks under the drive wheels
to keep the lift truck from moving. See Section 1 - HOW TO
PUT A LIFT TRUCK ON BLOCKS.
6. Loosen the screw that fastens the brush wire to its BRUSH HOLDER (4)
terminal. Remove the brush springs and brushes. BRUSH YOKE
BRUSH SPRING (4)
7. Inspect the brush holders for burns and damage. Make BRUSH SET
sure the brush holder is fastened tightly to the mounts at the end SPRING SURFACE OF BRUSH
of the motor. Make sure the new brushes will move freely and COMMUTATOR SURFACE OF BRUSH
smoothly in the brush holders.
Figure 3-37 - Traction Motor Brushes
8. Connect the new brush wire to its terminal mount.
A brush for a traction motor has an area of approximately
NOTE: When the brushes must be replaced, it is 4.27 x 0.96 cm = 4.3 cm2 (1.75 x 0.378 in = 0.665 in2). Brush
recommended that the brush springs also be replaced. springs for the traction motor normally have a spring force of
approximately 8.5 ± 1.1 Newtons (2 Ibf ± 4 ozf) when measured
9. Check the brush springs for damage from heat and with a spring scale as shown in Figure 3-39. (Look for a reading
corrosion. Replace damaged brush springs. Replace of approximately 2 ± .25 pounds on the spring scale.) These
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IndustrialTrucks ELECTRICAL SYSTEM
brushes will have a minimum length of 14 mm (0.55 in). 11. Close the drive unit compartment cover.
Replace all brushes if any one of the brushes are less than the
minimum brush length. 12. Connect the battery.
13. Remove the blocks from under the drive wheels, remove
the "DO NOT OPERATE" tag and install the key.
1. SPRING SCALE
(0-5 LB FISH SCALE)
2. BRUSH IN BRUSH HOLDER
3. COMMUTATOR
4. BRUSH SPRING
h
1. BRUSH
2. BRUSH SPRING
o
-
Figure 3-38 Brush Removal and Inspection
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IndustrialTrucks ELECTRICAL SYSTEM
STEERING PUMP AND MOTOR - INSTALLATION drive unit compartment cover must be removed for access to
the motor. Raise the drive wheel. See Section 1 - HOW TO
The procedure for assembly of the pump and motor and
PUT A LIFT TRUCK ON BLOCKS.
installation of the steering pump and motor is outlined in
Section 6.
CAUTION: Do not permit the brush seater stone
to stay in contact with the commutator too long and
Commutator Repairs
cause more wear than necessary.
WARNING: Wear eye protection. Raise the drive
wheel. Operate the motor at low speed. Protect 2. Operate the motor so that the commutator rotates in the
your fingers, Do not use a brush seater stone less same direction as the long tips of the brushes. Apply the brush
than 2.5 in. (60 mm) in. length. seater stone to the moving commutator with light pressure.
Move the brush seater stone backward and forward across the
1. If the commutator has grooves or other damage, the surface of the commutator until the marks on the commutator
armature must be removed so that the commutator can be are removed. Apply the brush seater stone to the commutator
repaired. Motors are normally repaired by service personnel before each set of brushes so that the brush seater particles
that have the special equipment required for the repair. have an even distribution.
Connect the battery so that the motor can be operated. The
NOTE: A brush seater stone can also be fastened to a wood stick with glue as shown in the
illustration. This arrangement makes it easier to apply a brush seater stone in small places.
4. When the brushes have the correct contact surface with The armature windings in large electric motors normally have
the commutator, use compressed air to remove the abrasive less than one ohm of resistance. The two commutator bars for a
dust from the commutator area and the motor. winding are found 180° apart on the commutator. If a volt
ohmmeter (Rx1 scale) is used to check the resistance
5. When the installation and checks are complete, install the between the two commutator bars of the winding, a resistance
brush cover. Make sure that the wires to the brushes do not of more than one ohm indicates a problem in that winding. A
touch any part of the motor case and cause a short-circuit. resistance of infinity (°°) indicates an open (damaged) winding.
Tests If the armature has an open circuit, there will normally be two
burned commutator bars on opposite sides of the commutator.
Damaged Field and Armature
These burned areas will cause the brushes to wear rapidly.
The tests described in the following paragraphs are to help a When the motor operates, large electric sparks and arcs occur
service person check a motor for damage and determine if it as the damaged commutator bars rotate under each brush.
must be sent to. .a~repair service for rebuilt motors. The See Figure 3-33.
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. . . . . . . . . . . . . . . . . . . .
27 Auxiliary Function Coils-Minimum Current 03 0.10 - j 03/03 Do Not Adjust
- 60/60 Do Not Adjust
.......................
28 Auxiliary Function Coils-Maximum Current 60 2.04
29 Steer Pump Time Delay 30 - 3.0 seconds ; 30/30 Do Not Adjust
30 EXIT and SAVE NEW VALUES Depress buttons "B" and "C" together to EXIT.
31 ERASE Enter number "75", then depress buttons "B" and "D" together to ERASE AL_ VALUES.
32 Hydraulic Potentiometer Set-up Calibrates the MIB to the hydraulic potentiometer.
34 Traction Potentiometer Set-up Calibrates the MIB to the traction potentiometer.
57 Hydraulic' Auxiliary Function Damping Sets delay for fine-tuning auxiliary hydraulic functions;do not adjust.
Table 3-19 - MIB Function Code Values - 24 Volt NR035AD Model Trucks
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IndustrialTrucks ELECTRICAL SYSTEM
. . . . . . . . . . . . . . . . . . . .
27 Auxiliary Function Coils-Minimum Current 03 0.10 - 03/03 Do Not Adjust
- Do Not Adjust
.......................
28 Auxiliary Function Coils-Maximum Current 60 2.04 60/60
29 Steer Pump TimeDeJay 30 - 3.0 seconds 30/30 Do Not Adjust
30 EXIT and SAVE NEW VALUES Depress buttons "B" and "C" together to EXIT
31 ERASE Enter number "75", then depress buttons "B" and "D" together to ERASE ALL VALUES.
32 Hydraulic Potentiometer Set-up Calibrates the MIB to the hydraulic potentiometer.
34 Traction Potentiometer Set-up Calibrates the MIB to the traction potentiometer.
57 Hydraulic Auxiliary Function Damping Sets delay for fine-tuning auxiliary hydraulic functions; do not adjust.
Table 3-20 - MIB Function Code Values - 24 Volt NR040AD Model Trucks
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. . . . . . . . . . . . . . . . . . . .
27 Auxiliary Function Coils-Minimum Current 03 0.10 - 03/03 Do Not Adjust
.......................
28 Auxiliary Function Coils-Maximum Current 60 2.04 - 60/60 Do Not Adjust
29 Steer Pump Time Delay 30 - 3.0 seconds . 30/30 Do Not Adjust
30 EXIT and SAVE NEW VALUES Depress buttons "B" and "C" together to EXIT.
31 ERASE Enter number "75", then depress buttons "B" and "D" together to ERASE ALL VALUES.
32 Hydraulic Potentiometer Set-up Calibrates the MIB to the hydraulic potentiometer.
34 Traction Potentiometer Set-up Calibrates the MIB to the traction potentiometer.
57 Hydraulic Auxiliary Function Damping Sets delay for fine-tuning auxiliary hydraulic functions; do not adjust.
Table 3-21 - MIB Function Code Values - 36 Volt NR035AD Model Trucks
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IndustrialTrucks ELECTRICAL SYSTEM
....................
27 Auxiliary Function Coils-Minimum Current 03 0.10 - 03/03 Do Not Adjust
28 Auxiliary Function Coils-Maximum Current 60 2.04 - 60/60 Do Not Adjust
29
30
31
32
34
ERASE .......................
Steer Pump Time Delay
EXIT and SAVE NEW VALUES
. . . . . . . . . . . . . . . . . . . .
27 Auxiliary Function Coils-Minimum Current 03 0.10 - 03/03 Do Not Adjust
28 Auxiliary Function Coiis-Maximum Current 60 2.04 - 60/60 Do Not Adjust
29
30
31
32
34
......
................
Steer Pump Time Delay
EXIT and SAVE NEW VALUES
ERASE
Hydraulic Potentiometer Set-up
Traction Potentiometer Set-up
30 - 3.0 seconds 30/30 Do Not Adjust
Depress buttons "B" and "C" together to EXIT.
Enter number "75", then depress buttons "B" and "D" together to ERASE ALL VALUES.
Calibrates the MIB to the hydraulic potentiometer.
Calibrates the MIB to the traction potentiometer.
57 Hydraulic Auxiliary Function Damping Sets delay for fine-tuning auxiliary hydraulic functions; do not adjust.
Table 3-23 - MIB Function Code Values - 36 Volt NR045AD Model Trucks
3-97
Yale
IndustrialTrucks ELECTRICAL SYSTEM
. . . . . . . . . . . . . . . . . . . .
27 Auxiliary Function Coils-Minimum Current 03 0.10 - 03/03 Do Not Adjust
-
.......................
28. Auxiliary Function Coils-Maximum Current 60 2.04 60/60 Do Not Adjust
29 Steer Pump Time Delay 30 - 3.0 seconds 30/30 Do Not Adjust
30 EXIT and SAVE NEW VALUES Depress buttons "B" and "C" together to EXIT.
31 ERASE Enter number "75", then depress buttons "B" and "D" together to ERASE ALL VALUES.
32 Hydraulic Potentiometer Set-up Calibrates the MIB to the hydraulic potentiometer.
34 Traction Potentiofheter Set-up Calibrates the MIB to the traction potentiometer.
57 Hydraulic Auxiliary Function Damping Sets delay for fine-tuning auxiliary hydraulic functions; do not adjust.
3.24 - MIB Function Code Values - 24 Volt NDR030AD Model Trucks
3-98
Yale
IndustrialTrucks electrical system
. . . . . . . . . . . . . . . . . . . .
27 Auxiliary Function Coils-Minimum Current 03 0.10 - 03/03 Do Not Adjust
.......................
28 Auxiliary Function Coils-Maximum Current 60 2.04 - 60/60 Do Not Adjust
29 Steer Pump Time Delay 30 - 3.0 seconds 30/30 Do Not Adjust
30 EXIT and SAVE NEW VALUES Depress buttons "B" and "C" together to EXIT.
31 ERASE Enter number "75", then depress buttons "B" and "D" together to ERASE ALL VALUES.
32 Hydraulic Potentiometer Set-up Calibrates the MIB to the hydraulic potentiometer.
34 Traction Potentiometer Set-up Calibrates the MIB to the traction potentiometer.
57 Hydraulic Auxiliary Function Damping Sets delay for fine-tuning auxiliary hydraulic functions; do not adjust.
Table 3-25 - MIB Function Code Values - 36 Volt NDR030AD Model Trucks
3-99
Yale
Industrial Trucks ELECTRICAL SYSTEM
. . . . . . . . . . . . . . . . . . . .
27 Auxiliary Furlctfdtt Coils-Minimum Current 00 - - I 00/00 Do Not Adjust
28 Auxiliary Function Coils-Maximum Current 60 2.04 - 60/60 Do Not Adjust
29
30
31
32
34
ERASE .......................
Steer Pump Time Delay
EXIT and SAVE NEW VALUES
3-100
Yale
Industrial Trucks ELECTRICAL SYSTEM
....................
27 Auxiliary Function Coils-Minimum Current 00 - - 00/00 Do Not Adjust
28 Auxiliary Function Coils-Maximum Current 60 2.04 - 60/60 Do Not Adjust
29
30
31
32
34
ERASE .......................
Steer Pump Time Delay
EXIT and SAVE NEW VALUES
. . . . . . . . . . . . . . . . . . . .
27 Auxiliary Function Coils-Minimum Current 00 - - 00/00 Do Not Adjust
- 60/60 Do Not Adjust
.......................
28 Auxiliary Function Coils-Maximum Current 60 2.04
29 "Steer Pump Time' Delay 30 - 3.0 seconds 30/30 Do Not Adjust
30 EXIT and SAVE NEW VALUES Depress buttons "B" and "C" together to EXIT.
31 ERASE Enter number "75", then depress buttons "B" and "D" together to ERASE ALL VALUES.
32 Hydraulic Potentiometer Set-up Calibrates the MIB to the hydraulic potentiometer.
34 Traction Potentiometer Set-up Calibrates the MIB to the traction potentiometer.
57 Hydraulic Auxiliary Function Damping Sets delay for fine-tuning auxiliary hydraulic functions; do not adjust.
Table 3-28 - MIB Function Code Values - 36 Volt NS050AE Model Trucks
3-102
Yale
IndustrialTrucks ELECTRICAL SYSTEM
NOTES
3-103
Yale
IndustrialTrucks ELECTRICAL SYSTEM
8RAKE SW
5I0ACT0R
PS LIFT
PUMP
S-XJ MOTOR
ARM PUMP
MOTOR
SHIELD
5241353-87
Sheet 1 of 7
Figure 3-43 - Wiring Schematic 5241353-87 - NR/NDR/NS Revision 2
3-104
ELECTRICAL SYSTEM
TTT
56 S6 56 56 IS IS IS 10 10 10 10 10 10 10 10 10 10 10 10 10 2S
o
56 56 56 56 IS IS IS
1 a 10 10 10 10 10 10 <0
i
'
ENABLE tilt ss REACH
HN
RLY LIFT PS 1
ss'ss REACH REACH AUX
— 1 6 HORN
| PUSH
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ws -C Ho h: 'EE'
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SO 30 74 56 11 IS IS 16 42 46 23 36 91 70 77 73
E(|-
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ijlJ p uj
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CONTROL LOGIC
DATA LI*
A |ijl M IB BOARD
Sl
21 22 23 31 32 33
»«•»» L\yPÿJ
TRACTION POT
la
HYORAULIC POT
-— 1 3-6
5241353-87
Sheet 2 of 7
Revision 2
Figure 3-43 - Wiring Schematic 5241353-87 - NR/NDR/NS (Continued)
3-105
Yale
IndustrialTrucks ELECTRICAL SYSTEM
WHITE
NOTES:
TEMP Swl
<h A' t. ALL SWITCHES ARE SHOWN IN THE STATIC TRUCK POSITtON.
2. FOR ALL SPLICE DETAILS SEE SHEET 3 OF 7.
3. ALL CONNECTORS ARE SHOWN FROM THE FRONT VIEW
ANO ARE ENLARGED FOR CLARITY.
a :©:
BLK 3LK
i i
T I
5241353-87
Sheet 3 of 7
Revision 2
— —
Pfgure 3-44 Options Schematic 5241353-87 NR/NDR/NS
3-106
Yale
IndustrialTrucks electrical system
NOTES
3-107
Yale
IndustrialTrucks ELECTRICAL SYSTEM
0A5H30AR0
<2
IS I I I-1SA
DISPLAY
U COQW BA«
d® —13
-3—010
Hi
sa—KUO
PUMP
MOTOR
BRAKE
3N I
SW 1 TCH
ILrl |
D ©— — 'ÿ
a _ ]_ >2
€lH-"
ÿ"ÿ4
TRACTION TRACTION
1
MOTOR MOTOR
36 VOLTS 24 VOLTS
iC D( LOCZSC.
L_
A1 A2 PM2
SHEET S OF 7
E
FOR ALL OTHER NOTES SEE SHEET 3 OF 7
5241353-87
Sheet 4 of 7
Figure 3-45 - Wiring Diagram 5241353-87 — NR/NDR/NS Revision 2
3-108
ELECTRICAL SYSTEM
XT
J2
nnr r€lGHT LIMIT SWITCH
=_d
L10 JU
10192
92 MO I
I 92 I10
Iill
fefl
HAiN
INTERFACE BOARO
CM IB)
@s a-j'Cg
K—10
"
TIJj ![JgT,''r3iT]l
SHEET 6 OF 7
CONNECTOR X-16 FOR
ACCESSORY
WHEN USED
SEE SHEET 7 0F 7
-ATTACHMENT HANDLE -
S-
pJOLr, (NPt-AO AMI MJR-AO OHLY)
EXT SW TILT SW SS SW
"I 3ATTERY
OISCONNECT
SWITCH
IGNITION
SWITCH
«|z
nrg iggig I
f
?????? °
m
biktiJ
L9LU•n-i,
HO TtL SDN GMN dLU OHN oai.
a (br I I [J I )
mar
mr -ÿi
—'
;ÿ z
i
~
|0- "hi te
lo- SWAT
- e io— "Mire
i
lO -GHAT
—
-
'
- Iff _
CONTROL VALVE J J
POT HYORAULIC
POT
I 32 ! NEUTRAL
AUX JUWN 31 | 33 CNEU)
, 1 IJ > SWITCH
tedlMl
L-U1— 1
jlllASigJ
LOWER 31 I 33
ill
POWER STEER
PUMP MOTOR
PS1 PS2
- NEG POS
I T II "c
SHEET S OF 7
I - -
_ ! ——————— > POS »ÿ
FROM
SHEET
«
A OF 7
MAIN TRUCK +
NEG STUD /
-- \
A
»S2 ÿ
5241353-87
Sheet 5 of 7
"Figure 3-45 - Wiring Diagram 5241353-87 - NR/NDR/NS (Continued) Revision 2
3-109
Yale
IndustrialTrucks ELECTRICAL SYSTEM
a'j-rfia&a
PROM
SHEET S OF 7
BATTERY
ONTACTOR PANEL
SAT POS
5HEET 5 OF 7
24 I rs | 37
- CONTACTOR PANEL
"E" STYLE SHOWN FOR
EE SEE SHEET 7 OF 7
SO
eo
30
<sa
-*913
00
OPERATOR SENSING
SW ITCH
5241353-87
Sheet 6 of 7
Revision 2
Figure 3-45 - Wiring Diagram 5241353-87 - NR/NDR/NS (Continued)
3-110
Yale
Industrial Trucks ELECTRICAL SYSTEM
TO HA IN
TRUCK HIRE HARNESS
SEE SHEET <CF 7
X-'2
SLACK
HA IN TRUCK HARNESS
FAN SWITCH
f1
LIGHT SWITCH
T—T f!
CONTACTOR
~EE* CONTACTOR PANEL POWER STEER
— —
9SA- T 5I0ACT0R
r— 98-
— 98-
=J HOUR METER
RELAY
(HN)
SHEET S OF 7
NOTES
3-112
Yale
IndustrialTrucks
SECTION 4
DRIVE UNIT
Yale
IndustrialTrucks
SECTION 4 - CONTENTS
DRIVE UNIT
GENERAL 4-1
DESCRIPTION 4-1
ARTICULATION STOP ADJUSTMENT 4-1
ARTICULATION ADJUSTMENT PROCEDURE 4-2
AXLE ASSEMBLY 4-2
TRACTION MOTOR 4-2
REMOVAL 4-2
INSTALLATION 4-3
HYDRAULIC STEERING MOTOR 4-3
DESCRIPTION 4-3
REMOVAL 4-3
INSTALLATION 4-4
REPAIR 4-4
REMOVAL-ARTICULATING AXLE WELDMENT 4-4
INSTALLATION-ARTICULATING AXLE WELDMENT 4-4
MASTER DRIVE UNIT 4-5
DESCRIPTION 4-5
REMOVAL 4-5
INSTALLATION 4-6
DISASSEMBLY 4-7
ASSEMBLY 4-9
TROUBLESHOOTING 4-16
Yale
IndustrialTrucks DRIVE UNIT
GENERAL
This section has a description and the repair and adjustment
procedures for the parts of the Master Drive Unit (MDU). The
final drive ratio of the MDU is 14.5:1. The traction motor,
steering and brake repair procedures are in separate sections.
The main parts of the MDU are the case, pinion (motor) and
large gear set, the pinion and spiral bevel gear set, bearings,
and the axle and wheel. The large ball bearing for steering is
part of the upper housing of the MDU.
DESCRIPTION
(See Figure 4-1 and Figure 4-3)
11390
Six capscrews fasten the large ball bearing and MDU to the
articulating axle. The bearing lets the MDU turn for steering.
There is a small helical pinion on the motor armature shaft. This Figure 4-1 - Master Drive Unit with Wheel and Traction
pinion turns a large helical gear attached to the bevel pinion Motor
shaft in 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 the top end of the motor shaft to stop rotation of the DRIVE UNIT ARTICULATION STOPS
shaft. The brake action works through the gears to stop the unit.
DRIVE SIDE ADJUSTMENT
ARTICULATION STOP ADJUSTMENT
CASTER SIDE ADJUSTMENT
The stability and traction will also be affected if the drive unit
articulation stops are not adjusted properly.
2. When a drive and/or caster wheel is changed. Figure 4-2 - Drive Unit Articulation Stops Nameplate
4-1
Yale
IndustrialTrucks DRIVE UNIT
6147 mm
a
BELOW (242 in)
STOP 6147 mm AND
SETTING (242 in) ABOVE
5. Tighten the locknuts and torque to 108 N»m (80 Ibf ft).
11408
6. Close and lock the compartment door.
1. TRACTION MOTOR
AXLE ASSEMBLY 2. ARTICULATING AXLE
3. CAPSCREW TO FASTEN BEARING AND MDU
The axle assembly consists of an axle weldment which is the 4. ADAPTER PLATE
mount for the master drive unit (MDU), the hydraulic steering 5. CAPSCREW TO FASTEN MOTOR
motor andthe caster. Thetraction motor fastens to the top of the 6. LARGE BALL BEARING
MDU near the left end of the axle weldment. The MDU is 7. BEARING SHIELD
attached to the bottom of the axle weldment and rotates on a 8. TOP CASE
large bearing. The traction motor supplies the power to turn the 9. HELICAL PINION (MOTOR)
drive wheel. The hydraulic steering motor rotates the MDU for 10. HELICAL GEAR
steering. The caster supports the right end of the axle 11. HOUSING
weldment. The axle weldment assembly is fastened to the lift 12. BEVEL PINION SHAFT AND GEAR SET
truck by an articulating shaft. The articulating axle assembly 13. COVER
pivots on the shaft. 14. AXLE SHAFT
4-2
Yale
IndustrialTrucks DRIVE UNIT
CAUTION: Brake fluid damages paint. Immedi¬ to the brake reservoir. Bleed the air from the brake system. See
ately remove any brake fluid that is on a painted Section 5.
surface.
6. Install the wires to the brake switch.
4. Position a container under the slave cylinder to catch the
brake fluid and remove the hose assembly. Cap the hose 7. Close the drive unit compartment door. Connect the
assembly. Allow the brake fluid to drain from the slave cylinder. battery.
Installation
1. Install a new O-ring on the traction motor housing. Use 2
O-ring lubricant on the O-ring.
4-3
Yale
IndustrialTrucks DRIVE UNIT
5. Put the flange of the motor in a soft jawed vise. Hold the 2. Open the drive unit compartment. Remove the traction
sprocket and remove the nut and washer. Do not damage the motor, master drive unit (MDU) and hydraulic motor. See
sprocket teeth. REMOVAL-TRACTION MOTOR, REMOVAL-MASTER
DRIVE UNIT and REMOVAL-HYDRAULIC MOTOR.
6. Carefully remove the sprocket and woodruff key. Do not let
the woodruff key fall. The woodruff key is located between the 3. Position a floor jack under the lower part of the axle
sprocket and shaft. weldment.
NOTE: Most service personnel do not repair the hydraulic 4. Remove the capscrew, washer and nut retaining the pivot
motor. The cost of repairs can be greater than the cost of a pin.
replacement motor.
5. Raise the jack so that it is the support for the axle
Installation weldment, but does not support the lift truck. Install a 1/2-13
UNC capscrew in the threaded hole in the pivot pin and pull the
1. If the hydraulic motor is a new replacement, remove the
pivot pin out through the hole provided in the lift truck. The
nut, washer and tape used to retain the woodruff key in the
shims between the lift truck frame and the articulating axle
shaft. Do not use the washer, use the washer removed from the
weldment will fall free. Straighten and wire the shims together
original motor.
for reuse at installation.
2. Installthe woodruff key in the shaft of the hydraulic steering
WARNING: The truck frame and axle weldment
motor. Align the slot of the sprocket with the woodruff key and
are heavy. Be sure that all lifting devices (hoists,
carefully install the sprocket in the shaft. Install the washer
cables, chains, slings, etc.) are suitable and of
removed during the removal procedure. Install and tighten the
adequate capacity to lift the truck frame and axle weldment.
nut. Do not damage the sprocket teeth when tightening the nut.
The axle weldment can weigh approximately 60 kg (125 lb).
3. Refer to the labels made during removal and connect the
6. Use an overhead crane and sling to raise the truck frame
two hydraulic hoses to their correct ports on the hydraulic
off the axle weldment. Move the frame away from the axle
motor. If necessary, install the fittings from the old motor on the
weldment and lower the frame to the floor.
new motor. Use new O-rings. Make sure that the hoses will not
be twisted when the motor is in the correct position on the
7. Remove the bushings in the axle weldment. Use a long
articulating axle weldment.
brass drift to remove the bushings. The brass drift must be
approximately 250 mm (10 in) long. Use a block of hard wood
NOTE: If the chain anchor came off the MDU upper housing,
against the bushing and a large hammer to remove the
install the chain anchor at the mark made during removal.
bushings. Do NOT use a hammer on the bushings.
4. Install the shims and motor on the articulating axle
Installation - Articulating Axle Weldment
weldment. Use the steering chain to check that the sprocket is
aligned with the chain flange on the master drive unit. If 1. Install new bushings in the axle weldment. Use the brass
necessary, add or remove shims between the motor and axle drift and the block of hard wood to install the bushings in the lift
weldment for correct alignment. Install the capscrews and truck frame. Do NOT use a hammer on the bushings.
lockwashers. Tighten the capscrews to 68 N*m (50 Ibf ft)
torque. 2. Apply multi-purpose grease in the ID of the bushings and
on the OD of the pivot pin.
5. Install the steering chain on the chain anchor. Install the
offset link and link pin on the chain anchor. Use a new cotter pin WARNING: The axle weldment is heavy. Be sure
to complete the assembly. that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capacity
6. Operate the steering system to check that the system is to lift the axle weldment. The axle weldment can weigh
operating correctly. Check for hydraulic leaks. approximately 60 kg (125 lb).
4-4
Yale
IndustrialTrucks DRIVE UNIT
1. SHIMS
2. BUSHINGS
3. PIVOT PIN
4. CAPSCREW
5. NUT
6. ARTICULATING AXLE WELDMENT
3. Use the overhead crane and sling and position the axle MASTER DRIVE UNIT
weldment in the lift truck frame.
Description
4. Align the bores of the axle weldment and the lift truck frame The master drive unit (MDU) isturned by the steering chain and
using the floor jack. Make certain to install the shims between the hydraulic motor. The housing for the steering bearing is
the frame of the lift truck and the axle weldment. Install the fastened to the bottom of the articulating axle weldment. The
tapered end of the articulating shaft into the bore. Use a brass traction motor is also fastened to this bearing housing.
hammer or a hammer with a soft face to install the articulating
shaft. Do not install the shaft too far into the bore. Install the Removal
shaft so that the groove near the end of the shaft is aligned with
CAUTION: The capscrews used to fasten the
the hole for the capscrew. The total end movement must not
Master Drive Unit (MDU) and traction motor are all
exceed 0.76 mm (0.03 in). If the end movement exceeds the
metric. Do not damage them using the wrong tools.
recommended limit, install additional shims as required. Bend
the ends of the shims protruding below the lift truck frame over
WARNING: There are close clearances between
so the shims do not rotate and fall out.
the MDU, drive chassis and base arm assembly
that can cause serious injury. NEVER put hands,
5. Install the capscrew, washer and nut to retain the
arms, head or legs between these parts unless the parts have
articulating axle. Tighten the nut to 31 N«m (23 Ibf ft) torque.
blocks to prevent movement.
Lubricate the articulating shaft and bushings using the grease
fitting with the recommended grease as listed in the
1. Move the steering wheel so that the drive wheel is in a
LUBRICATION SCHEDULE, Section 2.
position for straight travel. Make certain the key switch is in the
OFF position.
6. Install the hydraulic motor, master drive unit and traction
motor. Refer to INSTALLATION - HYDRAULIC MOTOR,
2. Disconnect and remove the battery. Use the CHANGING
INSTALLATION - MASTER DRIVE UNIT and INSTALLATION THE BATTERY procedure in the OPERATING MANUAL or
-TRACTION MOTOR.
Section 2 of this manual.
7. If removed, replace the caster wheel assembly. 3. Open the drive unit compartment door. Fasten the doors
so that they are fully open. Put a pan under the MDU drain plug
8. Remove the blocks and lower the drive/steering wheel to
and remove the drain plug. After the oil has completely drained,
the floor. Connect the battery.
4-5
Yale
IndustrialTrucks DRIVE UNIT
installthe drain plug. Tighten the drain plug to 22 N*m (16 Ibf ft) 2. Move the MDU into approximate alignment under the
torque. frame or axle plate.
WARNING: The traction motor is heavy. Be sure 3. Hold the MDU in the vertical position through the hole in the
that all lifting devices (hoists, cables, chains, plate. Do NOT put any part of your body between the MDU and
slings, etc.) are suitable and of adequate capacity the frame or axle plate. Carefully raise the frame and remove
to lift the traction motor. The traction motor can weigh the blocks. Carefully lower the frame and align the capscrew
approximately 40 kg (85 lbs). holes in the large ball bearing, adapter plate and the axle
weldment.
4. Removethe three capscrews and lockwashers that fasten
the traction motor to the adapter ring on the MDU. Carefully lift 4. Install the six capscrews and lockwashers that fasten the
the motor and set the motor out of the way. Do not damage the adapter plate and MDU to the axle weldment. Use a cross
pinion gear on the motor shaft. Use rope to fasten the motor to pattern to slowly tighten the capscrews to approximately 25
prevent the motor from falling. N*m (34 Ibf ft) torque. Make sure the large ball bearing and
adapter plate are in the correct position around the complete
5. Loosen the locknut at the chain anchor for the steering circumference. Use the cross pattern to tighten the capscrews
chain. Removethe capscrew at the chain anchor. Put a mark on to 68 N*m (50 Ibf ft) torque.
theMDUforthe location of the pin that fastens the chain anchor
to the sprocket. Remove the pin. Carefully remove the chain NOTE: If the chain anchor came off the MDU upper housing,
anchor and chain from the sprocket. install the chain anchor at the mark made during removal.
WARNING: The lift truck is heavy. Be sure that all 5. If the helical pinion on the motor shaft was removed, install
lifting devices (hoists, cables, chains, slings, etc.) the key, pinion, lockwasher and nut. Tighten the nut to 54 N«m
are suitable and of adequate capacity to lift the lift (40 Ibf ft) torque. If an impact wrench is used, make sure it does
truck. The lift truck can weigh up to approximately 3541 kg not tighten the nut to more than the correct torque.
(7800 lbs) empty.
6. Install a new O-ring on the motor using O-ring lubricant.
6. Carefully put a sling under the lift truck frame on the mast Carefully install and align the motor on the adapter plate and
side of the MDU. MDU. Do NOT damage the helical pinion on the motor shaft or
the helical gear of the MDU. Install the three capscrews and
7. Remove the six capscrews and lockwashers that fasten lockwashers. Tighten the capscrews to 20 N»m (15 Ibf ft)
the adapter ring and MDU to the frame or axle plate. torque.
8. Holdthe MDU and raisethe lift truck frame so that the MDU 7. Make sure the MDU is in the position for straight travel with
is free. The axle weldment will pivot on the pivot pin. Carefully the tire to the left of the case (facing MDU). Carefully install the
lowerthe MDU to the floor and move the MDU from underthe lift steering chain. Use the pin to install the chain anchor on the
truck. Lower the lift truck frame on blocks. adapter plate. Use the capscrew to fasten the two chain
anchors together. Adjust the steering chain.
Installation
8. Lubricate the large ball bearing using the recommended
WARNING: There are close clearances between grease listed in Section 2. Add the grease through both fittings.
the MDU, drive chassis and base arm assembly Slowly rotate the MDU while filling the fittings with grease. A dry
that can cause serious injury. NEVER put hands, bearing will take approximately 55 g (0.12 lb) of grease to fill the
arms, head or legs between these parts unless the parts have bearing completely.
blocks to prevent movement.
9. Lower the lift truck to the floor. Fill the MDU to the level/fill
1. Use a crane and chain or sling with a capacity rating of 450 plug using the recommended oil listed in Section 2. Add the oil
kg (1000 lbs) to lift the frame. Lift the frame for clearance to slide slowly. The oil must go through the bearings to the lower part of
the MDU underthe frame. Temporarily install blocks underthe the MDU. Fill until the oil just starts to run out. Install the plug
frame to prevent lowering. Lay the MDU on the floor. Slide the and tighten to 22 N*m (17 Ibf ft).
MDU under the drive chassis.
10. Close the drive unit compartment door. Installand connect
the battery.
4-6
Yale
IndustrialTrucks DRIVE UNIT
A
CAUTION: The capscrews and nuts used on the
and axle shaft have been removed from the drive
MDU are all metric. Do not damage them using the
unit lower housing.
wrong tool.
4. Remove the capscrews retaining the drive unit cover.
1. Remove the wheel nuts and the drive/steer wheel.
Remove the drive unit cover.
2. Removethe nine capscrews that fasten the lower housing
5. Install two wheel nuts on to the wheel bolts. Position a
to the upper housing. Remove the four capscrews inside the
piece of wood or bar between the nuts to retain the drive axle
upper housing. See Figure 4-6. There are also two capscrews
while removing the special capscrew retaining the bevel gear to
inside the case that are secured with washers and nuts on the
the axle shaft. Remove the special capscrew (24 mm) and the
opposite side of the upper housing. Make certain to remove the
special washer.
capscrews, lockwashers and nuts before attempting to
separate the upper housing from the lower housing.
A
falling.
WARNING: If the MDU falls, it can cause an
injury. Hold the MDU vertical to prevent it from
NOTE: If the bevel pinion and gear set will NOT be replaced,
andthe shim set is not damged, the same shim set can be used
during assembly. Adjustment will not be necessary.
4-7
Yale
IndustrialTrucks drive unit
TRACTION MOTOR
CAPSCREW
CENTERING RING
O-RING
HELICAL PINION
LOCKWASHER AND KEY
NUT
UPPER HOUSING
LEVEL AND FILL PLUG
CAPSCREW
NUT
HELICAL GEAR
BEARING CUP AND CONE
SHIMS
SPACER
BEVEL PINION SHAFT AND GEAR SET
SPECIAL WASHER
CAPSCREW
COVER
DRAIN PLUG
CAPSCREW
INNER SEAL
BEARING SHIELD
BEARING SEAL
AXLE SHAFT 25
WHEEL /
TIRE
WHEEL BOLT /ÿr\
/ 2'
LUG NUT / /ÿf)
/ /
CAPSCREW
HOUSING
CtrM
M| (Mfÿ
/
11410
4-8
Yale
IndustrialTrucks DRIVE UNIT
4-9
Yale
IndustrialTrucks DRIVE UNIT
NOTE: The helical pinion and gear andthe bevel pinion shaft c. Add the value d/2 which is 44.45 mm (1.75 in). The
and bevel gear are matched sets and MUST be replaced as result is dimension E.
sets. When replacing the gear sets, always replace the tapered E = L - F + d/2
roller bearings. The bearing cup and bearing cone MUST be L = bushing length
from the same manufacturer. Lubricate the bearings with clean F = the difference between the bearing bore for the
transmission oil prior to assembly. axle and the end of the bushing
d/2 = 44.45 mm (1.75 in)
NOTE: Assembly of the drive unit requires the use of a
d. Measure dimension T (the width of the lower bearing).
standard micrometer, torque wrench and a dial indicator. The
procedure below specifies the use of a special measuring tool e. Subtract assembly dimension B (stamped on the
(Yale P/N 518096888) and a special clamping tool (Yale P/N bevel pinion shaft) from dimension E (found in Step c.,
518096890). The measuring tool can be fabricated, if desired, above). Then subtract dimension T. The result is
as follows: Make a bushing to fit the bore of the lower pinion dimension X (the correct thickness of the lower bearing
shaft bearing. The bushing must have an outside diameter of shim set).
51.5 mm (2.03 in) and a length of 67.5 mm (2.66 in) long. The X = E -B - T
special clamping tool fascilitates easy assembly but can be E = the value found in Step c.
substituted for as well. B = the number stamped on the bevel pinion shaft
T = the total thickness of the bearing
3. Insert the special measuring tool in the pinion shaft lower
bearing bore. Determine the correct thickness for the lower 4. Assemble the proper combination of shims to equal the
bearing shim set (dimension X) as follows (see Figure 4-10): correct thickness for the lower bearing shim set, as determined
above ( ± 0.05 mm [0.002 in]). Installthe lower bearing shim set
a. Measure dimension F (the difference between the intothe lower bearing bore. Press the lower bearing cup intothe
bearing bore for the axle and the end of the bushing). bore.
b. Subtract the value Ffrom the length (L) of the bushing.
4-10
Yale
IndustrialTrucks DRIVE UNIT
WHEEL SHAFT
INNER BEARING
BORE SHIM SET
WHEEL SHAFT
OUTER BEARING
BORE SHIM SET
_ SHOWN WITH BEARING
AND SHIMS INSTALLED_
-
Figure 4-11 Wheel Shaft Shim Sets Figure 4-12 - Shim Measurement
13. Place the helical gear onto the pinion shaft and install the
CAUTION: Do not use damaged or distorted nut. Hold the helical gear with a strap wrench and tighten the
shims in the following steps. nut to a torque value of 100 N»m (74 Ibf ft). Do not stake the nut.
The bearing clearance must be checked and adjusted before
5. Install the shim set removed during disassembly from the staking the nut.
inner bearing bore of the wheel shaft into the inner bearing
bore. This shim set will be used for the preliminary adjustment 14. Removethe special clamping tool or piece of wood holding
of the wheel shaft. Drive the inner bearing cup into the inner the pinion shaft in place.
bearing bore (see Figure 4-11).
15. Pressthe pinion shaft downward by handwhile turning the
6. Install the shim set removed during disassembly from the shaft several times. This will align the taper rollers within the
outer bearing bore of the wheel shaft into the outer bearing bearing.
bore. This shim set will be used for the preliminary adjustment
of the wheel shaft. Press the outer bearing cup into the outer 16. Place the dial indicator on the housing as shown in
bearing bore (see Figure 4-11). Figure 4-13. Adjust the dial to indicate zero. Mark the point of
measurement on the helical spur gear with a colored pencil. Lift
NOTE: Do not install the wheel shaft seal until after the
the pinion shaft upward by carefully prying up beneath the
adjustment procedure has been completed.
helical spur gear with two levers. Read any deflection on the
7. Press the taper roller bearing cone up to the stop on the dial indicator. This value is the bearing clearance. Repeat the
pinion shaft. procedure to be sure to obtain the correct value.
10. Measure the distance "A" between the top of the spacer
bushing and the bottom of the bore for the upper bearing (see
Figure 4-12).
12. Press the upper bearing cup into the bearing bore. Press Figure 4-13 - Checking Pinion Shaft Bearing Clearance
the upper bearing cone onto the pinion shaft up to the stop.
4-11
Yale
IndustrialTrucks DRIVE UNIT
17. Remove the pinion shaft and bearing. Remove the upper 1. SPIRAL BEVEL GEAR
bearing cup. Additional shims must be added to the upper 2. DIAL INDICATOR
bearing bore to preload the bearing. To determine the correct 3. WOOD WEDGE ÿ
18. Install the pinion shaft. Press the upper bearing cup into
the bearing bore. Pressthe upper bearing cone onto the pinion
shaft up to the stop.
11411
19. Cover the splines of the helical gear with a thin coat of
Loctite 270. Wipe off any excess Loctite with a clean rag.
Figure 4-14 - Checking Backlash
20. Place the helical gear onto the pinion shaft and install the
nut. Hold the helical gear with a strap wrench and tighten the 28. Adjust the dial indicator to zero. Turn the wheel shaft in
nut to a torque value of 100 N*m (74 Ibf ft). Stake the nut to the both directions to measure any deflection. The admissable
pinion shaft. range for backlash is between 0.03 and 0.11 mm (0.0012 to
0.0043 in). Backlash is adjusted by adding or removing shims
21. Press the wheel bolts into the wheel shaft until the bolt beneath the inner wheel bearing cup. The ideal backlash is
contacts the stop. Be sure the flattened side of the bolt faces the 0.07 mm (0.028 in).
wheel shaft center.
29. Check the tooth contact pattern by coating 3-4 tooth flanks
22. Pushthe sealing ring onto the wheel shaft. Press the outer of the bevel gear with ink. Meshthe coated teeth with the pinion
wheel bearing cone onto the wheel shaft until the bearing gear several times and then inspect the wear pattern of the ink
contacts the stop. Wait to grease the bearing until after the on the coated teeth. Slight deviations from the ideal tooth
preload adjustments are performed. contact pattern are admissable. Significant tooth contact
pattern misalignment is an indication that a mistake was made
NOTE: After the proper backlash has been obtained, grease at an earlier step in the procedure and will necessitate
the seal ring and fill the outer bearing cone using Shell Alvania repeating the assembly procedure. See Figure 4-16.
R3 grease prior to assembly.
30. Check the wheel bearing clearance. Press down on the
23. Press the inner wheel bearing cone onto the bevel gear wheel shaft by handand rotate it several times. Arrange the dial
until the bearing cone contacts the stop. indicator on the housing as shown in Figure 4-15. Adjust the
dial to indicate zero. Lift the wheel shaft upward by carefully
24. Insert the bevel gear into the MDU housing. prying up beneath the bevel gear with two levers. Read any
deflection on the dial indicator. This value is the bearing
NOTE: Do not install the inner seal ring until the bearing clearance. Repeat the procedure to be sure to obtain the
preload has been adjusted. correct value.
25. Insert the wheel shaft into the housing and engage the
splines of the shaft intothe bevel gear. Secure the bevel gear on
the wheel shaft using the M16 capscrew and special washer.
26. Prevent the axle from turning. Tighten the M16 capscrew
to 245 N«m (332 Ibf ft) torque.
4-12
Yale
IndustrialTrucks DRIVE UNIT
/V v\ |'
' Some movement in the direction of the arrows can be
necessary. Adjust the thickness of the shim sets as
described in the assembly procedure.
As. The spiral bevel pinion is too close to the center of the
y<7\ BASE CONTACT f bevel gear.
ÿ ÿ spiral
Some movement in the direction of the arrows can be
necessary. Adjust the thickness of the shim sets as
described in the assembly procedureÿ
—.
The spiral bevel pinion is too far from the center of the
INNER CONTACT ÿ spiral bevel pinion.
/(/ v\ f , y—
D Some movement of the spiral gear away from the spiral
bevel pinion can be necessary. Adjust the shim sets at
the spiral bevel gear as described in the assembly
procedure.
The spiral bevel pinion is too far from the center of the
OUTER CONTACT T —j spiral bevel pinion.
—®
/f7" '
Some movement of the spiral gear toward the spiral
bevel pinion can be necessary. Adjust the shim sets at
the spiral bevel gear as described in the assembly
procedure.
4-13
Yale
IndustrialTrucks DRIVE UNIT
THREAD
PROTECTIVE
SHIELD
2
11411
31. Remove the wheel shaft and outer bearing. Remove the 36. Thoroughly clean the seat of the thread protective shield
outer bearing cup. Add or remove shims as required to obtain a on the housing with Loctite Fast Cleaner 706 or equivalent.
bearing clearance of 0.02 mm (0.00078 in). Install the outer
bearing cup, bearing, and wheel shaft. Repeat Step 30. After 37. Coat the seat of the thread protective shield with Loctite
the bearing clearance is confirmed to be 0.02 mm (0.00078 in), No. 270. Press the thread protective shield on the lower
remove the wheel shaft, outer bearing and outer bearing cup housing as far as possible. See Figure 4-18.
again. Add 0.10 mm (0.004 in) additional shims to the outer
bearing bore to preload the bearing. 38. Remove the outer bearing cup and shims. Thinly coat the
radial shaft seal with Loctite No. 574. Install the inner seal into
32. Install the outer bearing cup, outer bearing, and wheel the lower housing. The inner seal, when properly installed,
shaft. Verify that the wheel shaft can be turned by hand. If not, should be 1.8 mm (0.071 in) below the bottom edge of the outer
reducethe preload set in the previous step in 0.01 mm (0.00039 bearing bore. See Figure 4-18. Install the shims and outer
in) increments until the wheel shaft can be turned by hand. bearing cup.
33. After the bearing preload has been properly set, check the 39. Coat the entire surface of the inner splines of the bevel
backlash again. Use a dial indicator to check the backlash gear with Loctite No. 270. Insert the bevel gear in the housing.
between the bevel gear and the pinion. The backlash is the See Figure 4-19.
clearance between the teeth of the bevel gear and the teeth of
the pinion gear. See Figure 4-17. Position the dial indicator on 40. Fill the inner seal ring andthe cone on the wheel shaft with
the housing so that the dial indicator foot is as close as possible Shell Alvania R3 grease. See Figure 4-19.
to being perpendicular to the tooth flank of the bevel gear.
Install a wood wedge underthe large gear at the top of the MDU
M16 CAPSCREW
to keep the gear and pinion from moving. LOCTITE NO 270
SPECIAL WASHER
34. Adjust the dial indicator to zero. Turn the wheel shaft in
both directions to measure any deflection. The admissable BEVEL GEAR
range for backlash is between 0.03 and 0.11 mm (0.0012 to
0.0043 in). If the backlash needs to be adjusted at this point, the
total thickness of the outer plus the inner shims must remain
constant (i.e.: If you remove a shim from beneath the inner
bearing cup, you must add it to the shims beneath outer bearing
cup). The ideal backlash is 0.07 mm (0.028 in). GREASE
HOUSING
WHEEL SHAFT
35. After the proper backlash and preload has been obtained,
remove the bevel gear and wheel shaft in order to mount the
thread protective shield and the radial shaft seal. -
Figure 4-19 Wheel Shaft Assembly
4-14
Yale
IndustrialTrucks DRIVE UNIT
41 . Insert the wheel shaft into the housing and engage the
splines of the shaft into the bevel gear. Remove excess Loctite
DRIVE
with a clean cloth. 9— VENTING
! FILTER
42. Secure the bevel gear on the wheel shaft using the M16
capscrew and special washer. Prevent the axle from turning.
Tighten the M16 capscrew to 245 N*m (332 Ibf ft) torque.
43. Coat the flat housing surface with Loctite No. 574 before Or
mounting the housing cover. Apply one drop of Loctite No. 243
to the threads of each of the housing cover mounting bolts and
install the bolts.
GREASE
NOTE: If the tapped holes in the bottom of the lower housing FITTING
extend through the housing, completely seal the capscrews
with Loctite to prevent oil from leaking from aroundthe threads.
44. Tighten the housing cover capscrews to 9.5 N»m (7 Ibf ft) Figure 4-21 - Install Drive Venting Filter and Grease
torque. Fitting
45. Inspect the upper part of the MDU. The upper part of the 48. Raisethe upper housing using a lifting device and a spring
MDU must be replaced if: balance to obtain approximately 50 kg (110 lb) of force. Rotate
the trunnion bearing several times and position at the mark
a. The caulked cover plate on the trunnion bearing has again. The maximum bearing clearance is 0.03 mm (0.0012 in).
separated. Check visually. If the bearing clearance is more than the recommended
b. The trunnion bearing is difficult to turn or binds. Check clearance, the trunnion bearing and upper housing must be
manually. replaced.
c. The maximum trunnion bearing clearance is
exceeded. Check as described below. NOTE: The large ball bearing is part of the upper housing.
The upper housing and the ball bearing are replaced as a unit.
46. Clamp the upper part of the MDU to an assembly table.
Installthree eyebolts into the outer race of the trunnion bearing 49. Install the drive venting filter as far as possible into the
and rotate the bearing several times. See Figure 4-20. upper part of the MDU. See Figure 4-21 .
47. Install a cable in each eye bolt. Position three dial 50. Install grease fitting. See Figure 4-21 .
indicators on the trunnion bearing and set the indicators to zero.
Mark the position of one dial indicator on the trunnion bearing 51. Use Loctite 574 to install the upper housing on the lower
with a marking pen. housing. Make sure the upper housing is aligned correctly and
use a punch to install the two dowels, if removed. Install the
capscrews. Tighten the 8 mm capscrews to 23 N«m (17 Ibf ft)
torque. Tighten the 10 mm capscrews to 46 N*m (34 Ibf ft)
torque. Install the Allen head capscrews and the washers and
nuts. Tighten the nuts to 23 N«m (17 Ibf ft) torque.
52. Install the wheel and the lug nuts. Tighten the nuts in a
cross pattern to one-half the torque value specified in Section 2.
Tighten the lug nuts again using the cross pattern to obtain the
proper torque.
54. Fill the MDU to the level/fill plug using the recommended oil
listed in Section 2. Add the oil slowly. The oil must go through
Figure 4-20 - Check Trunnion Bearing the bearings to the lower part of the MDU. Fill until the oil just
starts to run out. Install the plug and tighten to 22 N»m (17 Ibf ft).
4-15
Yale
IndustrialTrucks drive unit
TROUBLESHOOTING
Oil leaks at the housing cover. Housing cover is not sealed or properly seated.
Oil leaks at the filler plug or drain plug. Dirt between sealing ring and housing.
Oil leakage between lower and upper housings. Sealing surface not sealed off.
Breather defective.
Banging noise at helical gears. Teeth on the helical gear or helical pinion damaged.
Trunnion bearing difficult to turn, binds or exceeds maximum The centering ring has separated and dirt has penetrated into
clearance. the bearing.
4-16
Yale
IndustrialTrucks
SECTION 5 - CONTENTS
BRAKE SYSTEM
GENERAL 5-1
BRAKE ASSEMBLY 5-1
REMOVAL AND DISASSEMBLY 5-1
ASSEMBLY AND INSTALLATION) 5-2
MASTER CYLINDER AND PEDAL ASSEMBLY 5-4
REMOVAL AND DISASSEMBLY 5-4
ASSEMBLY AND INSTALLATION 5-4
FLOOR PLATE ASSEMBLY 5-5
REMOVAL AND DISASSEMBLY 5-5
ASSEMBLY AND INSTALLATION 5-5
MASTER CYLINDER 5-6
DISASSEMBLY 5-6
ASSEMBLY 5-7
SLAVE CYLINDER 5-7
DISASSEMBLY . 5-7
ASSEMBLY 5-7
BRAKE SWITCH-REPLACE 5-7
CHECKS AND ADJUSTMENTS 5-7
BRAKE ADJUSTMENT 5-7
REMOVE AIR FROM THE BRAKE SYSTEM 5-8
TROUBLESHOOTING 5-9
Yale
IndustrialTrucks BRAKE SYSTEM
5-1
Yale
IndustrialTrucks BRAKE SYSTEM
WARNING: Put a "DO NOT OPERATE" tag in the 5. Loosenthe jam nut retaining the set screw and push rod to
operator's compartment and remove the key as a the slave cylinder. Remove the capscrew, lockwasher and
warning to prevent operation. To help prevent hose clamp retaining the hose assembly. Back off on the set
injury or damage, do not operate the lift truck without a brake. screw far enough to remove the push rod. Position a container
under the slave cylinder to catch any excess brake fluid.
2. Remove the nut that attaches the brake drum to the Removethe hose assembly. Cap the hose assembly. Remove
armature shaft of the traction motor. Remove the hardened the capscrew and lockwashers retaining the slave cylinder to
washer. Depress and holdthe brake pedal to release the brake the brake mounting bracket. Refer to SLAVE CYLINDER
shoes. Remove the tifaKe'drum from the armature shaft. -DISASSEMBLY AND ASSEMBLY if the slave cylinder
requires repairs.
3. Check for damaged or broken parts. Replace any
damaged or broken parts. Replace both brake shoes if the 6. Tag and remove the wires to the brake switch. Remove the
minimum thickness of either brake lining is 2.4 mm (0.09 in) or two screws, lockwashers, nut plate and insulator retaining the
less. Disconnect the shoe return springs to remove the brake brake switch to the brake mounting bracket.
shoes. See Figure 5-2. The maximum allowable inside
diameter of the brake drum is 153.2 mm (6.032 in). Replace the
brake drum if the maximum inside diameter exceeds the WARNING: The spring has tension and can
maximum allowable inside diameter. release with enough force to cause an injury.
7. Use a drift pin to drive the groove pin retaining the spring
guide to the control bar. Remove the control bar. bushings and
brake spring.
2. Install the bushings for the spring guide in the control bar.
/ 1\ WARNING: Do not allow brake fluid, grease or oil
Position the brake spring on the spring guide, align the spring
ChJ to get on the brake linings or shoes.
guide and spring with the control bar and install the groove pin.
4. Loosen the locknut dn the actuation rod. Remove the jam
3. Install the bushings for the shoulder screw in the control
nut and lockwasher retaining the actuation rod to the cam lever
bar. Align the control bar with the brake mounting bracket. The
on the brake assembly. Remove the two socket head
spring guide must be located so the guide will fit through the
capscrews and lockwashers retaining the brake assembly to
opening in the brake mounting bracket. Position the flat washer
the brake mounting bracket. Be certain to note the position that
between the control bar and the brake mounting bracket and
the capscrews are assembled in. Remove the brake assembly.
install the shoulder screw and jam nut. The control bar must be
free to move.
CAUTION: Brake fluid damages paint. Immedi¬
ately remove any brake fluid that is on a painted
surface.
5-2
Yale
IndustrialTrucks BRAKE SYSTEM
42. RESERVOIR
43. CLAMP
44. FEED HOSE
45. TY-WRAP
1. LOCKNUT
2. WASHER
3. BRAKE DRUM
4. SOCKET HEAD CAPSCREW
5. LOCKWASHER
6. SOCKET HEAD CAPSCREW
7. LOCKWASHER
8. BRAKE ASSEMBLY
9. JAM NUT
10. LOCKWASHER
11. CAPSCREW
12. LOCKWASHER
13. SLAVE CYLINDER
14. HOSE ASSEMBLY
15. BRAKE MOUNTING
BRACKET
16. CLAMP
17. LOCKWASHER
18. CAPSCREW
19. PUSH ROD
20. ACTUATION ROD
21. BRAKE SPRING
22. SPRING GUIDE
23. BUSHING
24. CAPSCREW
25. FLAT WASHER
26. CONTROL BAR
27. GROOVE PIN
28. BEARING
29. TUBE
30. LOCKNUT
31. SCREW
32. LOCKWASHER
33. MICRO SWITCH
34. INSULATOR
35. SPACER-BRAKE-ASSEMBLY
36. SPACER-BRAKE-DRUM
37. NUT PLATE
38. JAM NUT
39. JAM NUT
40. SETSCREW
41. BUSHING
5. Align the slave cylinder with the brake mounting bracket 2. Position a drain pan under the master cylinder. Remove
and install the capscrews and lockwashers. Install the hose both the hose assembly and brake fluid feed hose from the
clamp, capscrew and lockwasher. Connect the hose to the master cylinder. Install caps on the brake hoses and master
slave cylinder. Loosen the jam nut and loosen the set screw and cylinder port or fitting.
install the push rod between the set screw and the slave
cylinder. Adjust the set screw so the push rod remains in place 3. Hold the master cylinder assembly. Remove the two
between the slave cylinder and the set screw, then tighten the capscrews, washers and nuts that fasten the master cylinder to
jam nut. the lift truck frame.
6. Depress the brake pedal. Install the brake drum spacer, NOTE: It is not necessary to remove the pedal from the
brake drum, hardened washer and locknut. Tighten the locknut master cylinder to replace the pedal pad.
to 136 N«m (100 Ibf ft).
4. Straighten and remove the cotter pin and flat washer. Use
7. Install the brake switch on the brake mounting bracket a punch to remove both the groove pin and rod end pin that
using the insulator, lock plate, capscrew and lockwasher. fastens the brake pedal weldment to the master cylinder.
Connect the wires to the brake switch. Adjust the switch so that Remove the brake pedal weldment from the master cylinder.
the switch will open when the pedal is depressed. Remove the bushings from the master cylinder.
8. Adjust the brakes as described in CHECKS AND 5. Check for damaged or broken parts. Replace any
ADJUSTMENTS. damaged or broken parts. If the master cylinder requires
repairs, see MASTER CYLINDER-DISASSEMBLY AND
9. Remove the air from the brake system as described in ASSEMBLY.
CHECKS AND ADJUSTMENTS.
Assembly and Installation
10. Remove the blocks from under the drive wheel. Close the 1. Install the bushings in the master cylinder. Align the pedal
compartment door. Connect the battery. and the master cylinder. Install the groove pin.
23 N«m 136 N»m (100 Ibf ft) 2. Install the rod end pin through the brake pedal weldment
(17 Ibf ft) dry and the master cylinder. Install the flat washer and a new cotter
pin.
4. Align the master cylinder to the lift truck frame and install
the two capscrews, lockwashers and nuts.
-\
A
CAUTION: Brake fluid damages paint. Immedi-
I ately remove any brake fluid that is on a painted
surface.
5. Remove the caps and install the hose assembly and brake
fluid feed hose. Fill the reservoir using clean brake fluid as listed
in the Maintenance Schedule.
5-4
Yale
IndustrialTrucks BRAKE SYSTEM
4 5 ,6
1. SPRING
2. SPRING RETAINER 10. VALVE STEM
3. PISTON * 11. VALVE SEAL
4. CUP 12. CONNECTION BOLT
5. RETAINING RING * 13. GASKET
6. RUBBER BOOT * 14. FITTING
7. CUP 15. GASKET
8. VALVE RETAINER 16. CYLINDER BODY
9. VALVE SPRING 17. HOSE CONNECTION
5-6
Yale
Industrial Trucks BRAKE SYSTEM
Assembly
5
1. Keep ail parts clean. If the bore and parts are in good
condition, lubricate the bore and all parts with clean brake fluid.
2. Install the valve seal on the valve stem. Align the parts as
shown in Figure 5-6 and install the parts in the cylinder body.
5. Assemble the master cylinderto the brake pedal weldment 1. RUBBER BOOT
and install the pedal and master cylinderto the lift truck frame. 2. CUP
See MASTER CYLINDER AND PEDAL ASSEMBLY-AS¬ 3. PISTON
SEMBLY AND INSTALLATION. 4. CYLINDER BODY
5. BLEED SCREW
SLAVE CYLINDER
Disassembly
-
Figure 5-7 Slave Cylinder
2. Remove the cup and piston from the slave cylinder body. 2. Tag and disconnect the brake switch wires from the brake
switch.
WARNING: Do NOT use mineral oil solvent to
clean the slave cylinder or brake system parts. 3. Remove the brake switch. See BRAKE
Mineral oil will damage rubber seals. Damage to ASSEMBLY-REMOVAL AND DISASSEMBLY.
the seal can cause brake failure. Clean the slave cylinder using
isopropyl alcohol, or a solvent approved for cleaning brake 4. Install the replacement brake switch. See BRAKE
parts. ASSEMBLY-ASSEMBLY AND INSTALLATION.
WARNING: Be careful when removing or 5. Close the compartment door and turn the screw one
installing snap rings. These snap rings can come quarter turn to lock the door. Remove the blocks from under the
loose during removal or installation with enough drive wheels. Connect the battery.
force to cause an injury. Always use the correct snap ring pliers
and wear eye and face protection during removal and CHECKS AND ADJUSTMENTS
installation.
Brake Adjustment
Assembly (See Figure 5-8)
1. Keep all parts clean. If the bore and parts are in good NOTE: If the brake shoes need replacing, replace them
condition, lubricate the bore and all parts with clean brake fluid. before adjusting the brake. Check and replace the brake shoes.
2. Install the piston into the cylinder body. Install the cup and 1. Disconnect the battery. Put blocks on each side of the drive
rubber boot. Make sure to install a cap at the brake line port until wheel to prevent movement of the lift truck. Open the door for
the slave cylinder is installed in the lift truck. access to the brake assembly.
3. Install the slave cylinder in the lift truck. See BRAKE 2. Tighten the actuation locknut until the brake spring length
ASSEMBLY-ASSEMBLY AND INSTALLATION. is 63.5 ± 0.8 mm (2.50 ± 0.03 in).
5-7
Yale
IndustrialTrucks BRAKE SYSTEM
3. Loosen the jam nut and set screw retaining the push rod
between the set screw and slave cylinder so that the push rod is BRAKE ASSEMBLY
loose, but cannot be removed. MOUNTING
SCREWS y
4. Tighten the set screw until the push rod causes the slave
cylinder to bottom. Back off on the set screw one full turn and
lock in place by tightening the jam nut.
BRAKE SWITCH
5-8
Yale
IndustrialTmcks BRAKE SYSTEM
TROUBLESHOOTING
5-9
Yale
IndustrialTrucks brake system
NOTES
5-10
Yale
IndustrialTrucks
SECTION 6
STEERING SYSTEM
Yale
Industrial Trucks
SECTION 6 - CONTENTS
STEERING SYSTEM
STEERING SYSTEM-INTRODUCTION has a fixed rotor with seven vanes and a stator. There is
hydraulic pressure between the vanes and stator. The pressure
A hydrostatic steering system is used in the narrow aisle lift
makes the stator rotate in the rotor.
truck series. This system utilizes a Steering Control Unit (SCU)
and a Hydraulic Steering Motor. The components are mounted
A drive link, in the motor housing, has two purposes:
inside the drive unit compartment. The SCU is connected to the
steering tiller through a sprocket and chain. The steering tiller is a. To rotate the output shaft, and
positioned for easy operation and requires only five turns to
b. To rotate the commutator
obtain full steering of 180°.
The commutator is a valve that controls the flow of oil to and
When the SCU is activated by the chain, hydraulic oil is directed
to the steering motor assembly. The steering motor assembly,
from the motor assembly. This control of oil flow permits the
valve to control the amount of hydraulic energy. The need for
mounted on the articulating axle weldment, is connected to the
hydraulic energy changes as the need for mechanical energy
drive unit with a second chain. The hydraulic oil from the SCU
changes. The mechanical energy needed at the output shaft
drives the steering motor assembly to turn the drive unit in the
changes with the steering conditions.
desired direction.
6-7
Yale
IndustrialTrucks STEERING SYSTEM
1. CAPSCREW
2. LOCKWASHER
3. NUT
4. SNAP RING
5. BACK-UP WASHER
6. THRUST WASHER
7. KNOB
8. TILLER
9. BUSHING
10. ROLLER CHAIN
11. CAPSCREW
12. HARDENED WASHER
13. NUT PLATE
14. SNAP RING
15. SPROCKET
16. WOODRUFF KEY
17. BACK-UP WASHER
18. BEARING
19. TILLER SHAFT
20. MOUNTING BRACKET
21. CAPSCREW
22. LOCKWASHER
23. PIN
24. SPROCKET
25. STEERING COLUMN 36. HOSE ASSEMBLY
26. CAPSCREW 37. HOSE ASSEMBLY
27. LOCKWASHER 38. CAPSCREW
28. CHECK VALVE
™ " "
39. LOCKWASHER
29. FITTING 40. LOCKNUT
30. FITTING 41. HARDENED WASHER
31. FITTING 42. SPROCKET
32. ORBITROL UNIT 43. FITTING
33. MOUNTING BRACKET 44. STEERING MOTOR
34. CAPSCREW 45. O-RING
35. HARDENED WASHER
6-2
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IndustrialTnicks STEERING SYSTEM
Removal 3. Refer to the labels made during removal and connect the
two hydraulic hoses to their correct ports on the hydraulic
WARNING: Make sure the brake pedal is
motor. If necessary, install the fittings from the old motor on the
released and the brake is applied. Put blocks on
new motor. Use new O-rings. Make sure that the hoses will not
both sides (front and back) of the drive/steer tire
be twisted when the motor is in the correct position on the
andthe caster wheels to prevent movement of the lift truck. Put
articulating axle weldment.
a block on each side (front and back) of the load wheels to
prevent movement of the lift truck.
1. Use the steering system to move the master drive unit for
access to the chain anchor of the steering chain. Disconnect
the battery. Open the drive unit compartment cover. Block the
drive/steer tires, caster wheels and load wheels on both sides
to prevent movement of the lift truck.
6-3
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IndustrialTrucks STEERING SYSTEM
STEERING CONTROL UNIT 5. Remove the caps from the hydraulic lines and the plugs
from the steering control unit. Install the hydraulic lines on the
Removal
steering control unit.
WARNING: Make sure the brake pedal is
released and the brake is applied. Put blocks on WARNING: If the hoses are incorrectly
both sides (front and back) of the drive/steer tire connected the tiller will move with high force when
and the caster wheels to prevent movement of the lift truck. Put the truck is started. Do not place the hands near
a block on each side (front and back) of the load wheels to the tiller when testing.
prevent movement of the lift truck.
6. Install the drive unit cover and the battery compartment
1. Disconnect the battery. Block the drive/steer tires, caster cover. Remove the blocks from the tires and wheels. Connect
wheels and load wheels on both sides to prevent movement of the battery and test the steering control unit. Check for leaks.
the lift truck. Open the drive unit compartment cover. Remove Close the drive unit compartment cover.
the battery compartment cover and the drive unit cover.
Installation
1. Align the steering column and the steering control unit and
install the two capscrews and lockwashers.
2. Align the steering column and steering control unit with the
mounting bracket and install the two capscrews and
lockwashers. 1. STEERING CHAIN
2. MOUNTING BRACKET
3. Align the chain and sprocket with the steering column and 3. SPRING PIN
install the spring pin to retain the sprocket on the steering 4. SPROCKET
column.
6-4
IndustrialTrucks steering system
1. CAPSCREW
11876 2. COVER
3. O-RING
1. STATOR
2. ROTOR
3. PORT PLATE
4. O-RING
5. CENTER SHAFT
11877
-
Figure 6-7 Stator and Rotor Removal
6-5
Yale
IndustrialTrucks STEERING SYSTEM
11875
1. SCREW
2. CHECK VALVE ASSEMBLY
3. CHECK BALL
11876
1. SNAP RING
2. SEAL
3. BUSHING
4. O-RING
5. OIL SEAL
12650
1. HOUSING
2. DUST SEAL
6-7
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IndustrialTrucks STEERING SYSTEM
6-8
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IndustrialTrucks STEERING SYSTEM
5. Installthe thrust washers and thrust bearing on the spool. seal (8) and the O-ring (3) in the housing. Use the snap ring (7)
Carefully install the spool and sleeve assembly in the housing. to hold the bushing in position. Make sure the sleeve rotates
Installthe dust seal (9) in the bushing (6). Installthe bushing (6), freely in the housing.
1. HOUSING 6. BUSHING
2. SPOOL AND SLEEVE ASSEMBLY 7. SNAP RING
3. O-RING 8. SEAL
4. THRUST WASHER 9. DUST SEAL
5. THRUST BEARING
1
11879
-
Figure 6-15 Spool Housing Assembly
6. Install the check ball and sleeve. Make sure the sleeve is O-ring (3) and install the O-ring and port plate (4). Align the
even with or below the surface of the housing (2). Lubricate the holes in the port plate with the holes in the housing.
i(i>\
11885
6-9
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IndustrialTrucks STEERING SYSTEM
7. Installthe center shaft (1) so that it engages with the center the slot (center pin) in the center shaft. Installthe O-ring (5) and
pin (2) in spool and sleeve assembly. Make sure the center pin stator (4). Make sure to align the marks made during
isstill parallel to the surface with the ports. Installthe rotor (3) on disassembly.
the center shaft. Make sure that a valley in the rotor aligns with
CENTER SHAFT © o
CENTER PIN
ROTOR
STATOR
O-RING
11885
1. SPACER PLATE
2. O-RING
3. END CAP
4. CAPSCREW
5. CHECK BALL
(D ©
1
11886
6-10
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IndustrialTrucks STEERING SYSTEM
9. Install the steering column on the steering control unit. 5. Installthe mounting bracket on the lift truck frame using the
Make sure the spines are aligned. two capscrews, hardened washers and nut plate.
/\ WARNING: Be careful when removing or 1. Disconnect and remove the battery. Refer to CHANGING
/f\ installing snap rings. These snap rings can come THE BATTERY, Section 2, this manual.
loose..during removal or installation with enough
force to cause an injury. Always use the correct snap ring pliers 2. Remove the battery compartment cover by removing the
and wear eye and face protection during removal and five capscrews that retain the cover to the frame.
installation.
3. Identify and tag the power cables on the terminals of the
3. Use a pair of snap ring pliers and install the snap ring to motor for correct connection during installation. Disconnect the
retain the tiller shaft in the mounting bracket. Installthe back-up cables from the motor.
washer.
3. Align the pump shaft with the opening in the motor. Align
the marks made during disassembly.
6. Install the pump and motor assembly in the truck using the
four capscrews, lockwashers, brackets and rubber channel
mounts.
Figure 6-19 - Battery Compartment Cover Removal 8. Connect the power cables to the proper motor terminals.
4. Install labels on the hydraulic lines for proper installation at 9. Install the battery compartment cover using the five
assembly. Disconnect the hydraulic lines and install caps on capscrews that retain the cover to the frame.
the lines and fittings.
10. Install and connect the battery. Refer to CHANGING THE
WARNING: The motor and pump assembly has a BATTERY, Section 2, this manual.
weight of approximately 27 kg (60 lb). The steering
pump motor has ceramic magnets. Do not let the 11. Check the oil level in the hydraulic tank. Remove blocks
motor fall. The magnets can be damaged. from wheels. Test operate the steering system and check for
leaks.
5. Remove the four capscrews, lockwashers, brackets and
rubber channel mounts. Remove the pump and motor
assembly from the lift truck frame.
8. Mark the pump mounting flange and the motor housing for
alignment during assembly. Mark the parts of the motor housing
for proper orientation during assembly.
1. CAPSCREW 5. ELBOW
2. O-RING 6. ELBOW
3. FITTING 7. PUMP
4. ELBOW 8. MOTOR
Disassembly-Steering Pump 4. Remove the four capscrews from the pump body.
Separate the mounting flange and the end cover from the pump
1. Disassemble the fittings, elbows and O-rings from the
body. Remove the back-up rings, seals,bushings and O-rings.
pump body. Disassemble the pressure relief valve from the
pump body.
5. Remove the idler gear and drive gear.
WARNING: Be careful when removing or
6. Inspect the drive gear, idler gear and the pump body for
installing snap rings. These snap rings can come
damage. If any of these parts are damaged, the pump must be
loose during removal or installation with enough
replaced with a new pump. All seals, O-rings, back-up rings,
force to cause an injury. Always use the correct snap ring pliers
and snap ring must be replaced if the present pump is to be
and wear eye and face protection during removal and
used.
installation.
NOTE: The manufacturer does not recommend servicing the
2. Use a pair of snap ring pliers and remove the snap ring
individual components within the load sensing valve assembly.
retaining the shaft seal to the drive gear shaft. Removethe shaft
seal.
6-13
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Industrial Trucks steering system
1. CAPSCREW
2. SNAP RING
3. SHAFT SEAL
4. FLANGE
5. BACK-UP RING
6. SEAL
7. BUSHING
8. O-RING
9. DOWEL
10. PUMP BODY
11. IDLER GEAR
12. DRIVE GEAR SHAFT
13. LOAD SENSING VALVE ASSEMBLY
14. PRESSURE RELIEF VALVE
6-14
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IndustrialTrucks STEERING SYSTEM
Steering Pressure Adjustment 5. Connect the battery and operate the steering system to
remove air. Refer to REMOVE AIR FROM STEERING
The steering pump does not normally require any adjustment.
SYSTEM. Operate the steering system for a full turn. Do not
After servicing the pump for any reason, the pump should be
hold the steering tiller in a full turn for more than three seconds
checked to make certain that the pump operating pressure is
without letting the motor cool. Check that the maximum
correct.
pressure is 8.4 ±0.35 MPa (1200 ±50 psi).
1. Disconnect the battery.
6. To adjust the pressure relief valve, remove the plug
covering the adjusting screw on top of the pump. Use a
2. Remove the Battery compartment cover by removing the
screwdriver to make the adjustment as required. When the
five capscrews that retain the cover to the frame.
proper pressure has been obtained, install the plug covering
the adjusting screw.
3. Place a cloth under the pump to keep hydraulic oil off the
other components. Remove the plug on the rear of the pump.
7. After the pressure check is completed, remove the gauge
and hydraulic line. Install the plug in the rear of the pump.
4. Install a hydraulic line and a 20 MPa (3000 psi) pressure
gauge to check and adjust the steering pressure.
8. Operate the steering system again to remove any air that
may have entered the system. Refer to REMOVE AIR FROM
CAUTION: Do not hold the steering tiller so that
the steering pump and motor is operating for more
STEERING SYSTEM.
than three seconds. The steering pump motor may
9. Install the battery compartment cover using the five
overheat and be damaged.
capscrews that retain the cover to the frame.
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE
No steering action when the steering wheel is turned. Low oil level or no oil in hydraulic tank.
Hydraulic hoses or connections are open.
The sleeve and spool in the control unit will not move.
The lift truck steers slowly. The steering tiller is difficult to turn. Low oil level or no oil in hydraulic tank.
The hydraulic lines to the control unit are damaged or have a
restriction.
The sleeve and spool in the control unit are worn.
The parts of the metering section are worn.
The check valve in the control unit does not open.
The relief valve in the manifold block is damaged or not adjusted
correctly.
The steering tiller turns the steering tires in the wrong The hydraulic hoses at the control unit are not connected
direction. correctly.
The metering rotor is not aligned correctly
The steering continues to turn after the steering wheel stops. The neutral position springs are broken.
The spool or sleeve is damaged.
6-15
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IndustrialTrucks steering system
NOTES
6-16
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IndustrialTrucks
SECTION 7
HYDRAULIC SYSTEM
Yale
IndustrialTrucks
-
SECTION 7 CONTENTS
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM-INTRODUCTION
The hydraulic system for these lift trucks is comprised of three JUUUUUUUUUUU
"innrannnrF'—
separate sub-systems. These sub-systems are:
NOTE: The hydraulic system on the NS series of lift trucks Handle Adjustment'
differs because there is no reach mechanism used.
The hydraulic system includes two pumps. The hoist pump will
only operate when the control handle is moved to start the hoist -
Figure 7-1 Control Handle
function. The hoist pump and motor is located in the drive unit
compartment. The steering pump operates when the key Truck Model
switch is turned on and the operator is in the proper position in
the operator's compartment. The steering pump provides Switch NS NR/NDR
hydraulic oil for the auxiliary functions and the power steering A Horn Horn
function. The steering pump has a built in priority valve to insure Sideshift
priority flow to the power steering. When both the power B (If so equipped) Extend
steering and auxiliary functions are used at the same time, the
Sideshift
priority valve will insure that full flow is provided to the power C Not Available (If so equipped)
steering. The steering pump is located in the compartment
above the battery. See Section 6 for information on the steering D Not Available Tilt
pump. Table 7-1 - Control Handle Switch Locations
The main and auxiliary hydraulic functions are controlled by an If the operator wants to perform an auxiliary function in one
electro-hydraulic control vaive. This valve is custom designed direction, immediately followed by the reverse direction
to provide full proportional control of the Hoist, Reach, Tilt and (example: extend then retract), the reach auxiliary function
Sideshift functions. To provide maximum control, each function switch should be pressed and held until the handle is moved
is operated electronically using an electro proportional EPV from the extend (up) position, through the neutral position into
Seri- ; Vaivistor® valve. The valve also provides proportional the retract (down) position. If the switch is not held while moving
control for the auxiliary functions. Separate hoist and auxiliary through the neutral position the control will select the lowering
relief valves are provided to allow operation at different function and mast lowering will occur.
pressures and minimize energy consumption.
The electro-hydraulic control valve is actuated by the control WARNING: Unintentional mast lowering can
handle. The multi-function control handle is a two axis control, cause damage or injury.
used for both hydraulic and traction operation. Each auxiliary
function, Reach, Tilt and Sideshift (optional) has a separate The power steering system is controlled by the movement of
switch located on the control handle. There is also a switch for the steering tiller. Turning the steering tiller will direct the flow of
the hom. Not ail functions are used on each lift truck and the hydraulic oil to the steering control unit and the steering motor.
location of the functions may vary between lift truck models. The steering tiller will turn from lock to lock in five revolutions
See Figure 7-1 and Table 7-1. and provide 180° of steering angle at the drive/steer wheel.
The control handle is moved horizontally for forward and The hoist system features a single pump and motor. The
reverse travel. Up and down movement while pressing an motors that drive the hoist or steering pumps can be 24 or 36
.
auxiliary function ÿwitch, controls the auxiliary hydraulic volts. The 24 volt hoist pump motor is rated at 7.9 hp while the
functions. Up and down movement without pressing an 36 volt motor is rated at 14.5 hp. The 24 volt power
auxiliary function switch operates the lift function, up for lift, steering/auxiliary function pump motor is rated at 2.5 hp and the
down for lower. Once the handle is moved from the neutral 36 volt motor is rated at 2.4 hp. See Section 3 for additional
position the switch can be released. The function will be locked information concerning the motors.
until the handle is returned to the neutral position.
The hydraulic system also includes a molded plastic tank. The
NOTE: Diagonal movement of the handle will control both tank is common for all hydraulic functions. The size of the tank
travel and a hydraulic function simultaneously. is determined by the size of the battery compartment. See
Table 7-2.
7-1
Yale
IndustrialTrucks HYDRAULIC SYSTEM
BATTERY OIL TANK CAPACITY The hydraulic level dipstick is externally mounted and may be
COMPARTMENT SIZE TO FULL MARK accessed without opening any covers. The compartment cover
must be removed to sen/ice the hydraulic tank. There is a
317.5 mm (12.5 in) 17.6 litres (4.64 gal) breather/filler screwed onto the top of the tank to cover the fill
370.8 mm (14.6 in) 19.5 litres (5.16 gal) spout and strainer. The strainer and breather/filler assembly
421.6 mm (16.6 in) 21.5 litres (5.67 gal) are mounted in the fill spout. A second breather is also screwed
into the top of the hydraulic tank. There is a 10 micron spin on
Hydraulic System = Tank Capacity + 4.01 litres filter located in the return line to the hydraulic tank. The
(t;0&gallons) in lines breather/filler assembly, strainer, breather and filter should be
-
Table 7-2 Hydraulic Oil Tank Capacities serviced in accordance with the recommended lubrication
charts found is Section 2.
REACH TRUCK
EXTEND
REACH CYL. HOIST CYUNOER HOIST CYLINDER
TILT UP
RV5
HYDROSTAT
SHIFT LEFT SHIFT RIGHT
PROPORTIONAL T1 (PLUGGED)
SIDESHIFT CYLINDER (OPTIONAL) UFT/LOWER/AUX.
VALVE
LS PF EF
1200
/_!*
GAUGE PORT
AUX.
INLET
STEER¬ AUX. PUMP
ING W/PRIORITY
CONTROL VALVE
UNIT FILTER
STEERING MOTOR
HYDRAULIC TANK
7-2
Yale
IndustrialTnicks hydraulic system
1. HOSE CLAMP
2. HOSE
3. HOSE
4. HOSE
5. CAPSCREW
6. LOCKWASHER
7. SPACER BLOCK
18. HOSE \\
19. TUBE \\
20. HOSE \\
21. ISOLATOR-MOUNT ®
22. CAPSCREW k ÿ-*27
23. LOCKWASHER .
24. FLAT WASHER
25. HOIST PUMP AND MOTOR
26. FITTING W/O-RING
27. 45° FITTING W/O-RING
28. HOSE ASSEMBLY
29. HOSE ASSEMBLY
30. HOSE ASSEMBLY
31. CAPSCREW
32. LOCKWASHER
33. FLAT WASHER
34. NUT
35. BRACKET 42. FITTING W/O-RING 49. 90°FITTING W/O-RING
36. RUBBER CHANNEL MOUNT 43. BULKHEAD FITTING 50. FITTING W/O-RING
37. MOUNTING PLATE 44. TUBE AND NUT ASSY. 51. FITTING W/O-RING
38. STEERING PUMP AND MOTOR 45. TUBE AND NUT ASSY. 52. 90°FITTING W/O-RING
39. 45° FITTING W/O-RING 46. CAPSCREW 53. HOSE FITTING
40. FITTING W/O-RING 47. FLAT WASHER 54. BULKHEAD FITTING
41. FITTING W/O-RING 48. CONTROL VALVE 55. HYDRAULIC TANK ASSY.
7-4
Yale
IndustrialTrucks HYDRAULIC SYSTEM
1. SNAP RING
2. SHAFT SEAL
3. MOUNTING FLANGE
4. BACK-UP RING
5. SEAL
6. BUSHING
7. O-RING
8. PUMP BODY
9. IDLER GEAR
10. DRIVE GEAR 12
11. END COVER
12. CAPSCREW
7-5
Yale
IndustrialTmcks HYDRAULIC SYSTEM
6. Inspect the drive gear, idler gear and the pump body for 3. Remove the battery compartment cover.
damage. If any of these parts are damaged the pump must be
replaced with a new pump. All seals, O-rings, back-up rings, 4. Identify and tag all electrical and hydraulic connections to
and snap ring must be replaced if the present pump is to be the hydraulic control valve. Remove the electrical connections.
used. Disassemble and cap the hydraulic hoses and plug the
openings in the hydraulic control valve to prevent dirt from
Assembly entering the system and from the hydraulic oil leaking.
1. Apply clean hydraulic oil to all the pump components
WARNING: The hydraulic control valve is heavy.
before assembly.
Be sure that all lifting devices (lifts, cables, chains,
or slings) are suitable and of adequate capacity to
2. Align and install the idler gear and drive gear in the pump
lift the hydraulic control valve. The hydraulic control valve can
body. Install the O-rings in the pump body.
weigh approximately 110.3 kg (50 lb).
3. Align the end cover, pump body and mounting flange.
5. Remove the two capscrews and flat washers retaining the
Install the four capscrews.
hydraulic control valve to the top of the battery compartment.
Remove the hydraulic control valve from the lift truck.
4. Install a new shaft seal on the drive gear shaft.
Installation
5. Install both bushings on the shafts. Install the seals and
back-up rings in the body of each of the bushings. WARNING: The hydraulic control valve is heavy.
Be sure that all lifting devices (lifts, cables, chains,
WARNING: Be careful when removing or or slings) are suitable and of adequate capacity to
installing snap rings. These snap rings can come lift the hydraulic control valve. The hydraulic control valve can
loose during removal or installation with enough weigh approximately 110.3 kg (50 lb).
force to cause an injury. Always use the correct snap ring pliers
and wear eye and face protection during removal and 1. Align the hydraulic control valve with the mounting holes in
installation. the battery compartment. Install the capscrews and flat
washers.
6. Install a new snap ring.
2. Remove the plugs from the hydraulic control valve and the
7. Install new O-rings on the elbows and install the elbows in plugs from the hydraulic lines. Install the hydraulic lines on the
the pump. hydraulic control valve. Install the electrical connections to the
hydraulic control valve.
8. Align the splined shaft of the pump with the motor and
insert the shaft in the motor. Install the two lockwashers and two 3. Install the battery. Refer to Section 2 for battery installation
capscrews. procedures.
4. Check the level of the hydraulic oil in the tank using the
HYDRAULIC CONTROL VALVE
dipstick. Install the battery compartment cover.
Removal
5. Remove the blocks from under the drive/steer wheei,
WARNING: Make sure the brake pedal is
caster wheels and load wheels. Connect the battery.
released (in the up position) and the brake is
applied. Put blocks on both sides (front and back)
Disassembly
of the drive/steer tire and the caster wheels to prevent
movement of the lift truck.*Puta block on each side (front and The disassembly of the hydraulic control valve is limited to
back) of the load wheels to prevent movement of the lift truck. replacing the Coils, Valvistor (Lift or Lower), Proportional Valve
Relief Valves (Main and Auxiliary) and Check Valve. The
1. Turn the key switch to. OFF. Disconnect the battery. O-rings and back-up rings must be replaced when removing
any of the items listed above. See Figure 7-7.
2. Remove the battery. Refer to Section 2 for instructions on
How to Remove the Battery.
7-6
Yale
IndustrialTrucks hydraulic system
1. PLUG
2. O-RING 21. O-RING
3. AUX. RELIEF VALVE 22. BACK-UP RING
4. BACK-UP RING 23. LOWER VALVISTOR
5. O-RING 24. BACK-UP RING
6. O-RING 25. O-RING
7. PLUG 26. PROPORTIONAL VALVE
8. O-RING 27. COIL
9. PLUG 28. CAPSCREW
10. ORIFICE 29. O-RING
11. PLUG, SPRING 30. O-RING
12. O-RING 31. O-RING
13. SPRING 32. O-RING
14. RELIEF VALVE 33. PLUG
15. PLUG, STOP 34. O-RING
16. O-RING 35. CHECK VALVE
17. PLUG 36. O-RING
18. MUFFLER 37. O-RING
19. LIFT VALVISTOR 38. BACK-UP RING
20. O-RING 39. MANIFOLD BLOCK
NOTE: Make certain that the work area is clean. The Tighten the Main Relief Valve plug to 129 to 142 N«m (95 to 105
hydraulic control valve and its components are manufactured Ibf ft) torque.
to close tolerances. Any dirt in the system could cause the
components to stick and the valve will not operate properly. 5. Install the O-rings and back-up rings on the Lower
Valvistor. Install the Lower Valvistor. Tighten the Lower
1. Remove all the fittings from the hydraulic control valve. Valvistor to 108 to 122 N«m (80 to 90 Ibf ft) torque.
2. Remove the Proportional Valve by removing the four 6. Install the O-rings and back-up rings on the Lift Valvistor.
socket head capscrewsretaining the valve to the main body of Install the Lift Valvistor. Tighten the Lift Valvistor to 108 to 122
the hydraulic control valve. N«m (80 to 90 Ibf ft) torque.
3. Remove the Lower Valvistor. Use a 1-1/2 inch open end 7. Install the O-rings in the Proportional Valve A light coat of
wrench to remove the Valvistor. grease will hold the O-rings in place. Locate the Proportional
Valve on the hydraulic control valve body using the locating pin.
4. Remove the Lift Valvistor. Use a 1-1/2 inch open end Install the four socket head capscrews and tighten the
wrench to remove the Valvistor. capscrews to 4.5 to 6.0 N«m (40 to 50 Ibf in) torque.
WARNING: The springs used for the main relief 8. Install the fittings in the main body of the hydraulic control
valve, the auxiliary relief valve and the check valve.
valves have tension and can release with enough
force to cause injury.
HYDRAULIC TANK
5. Remove the Main Relief Valve. Use a 1-1/2 inch open end Removal
wrench to remove the valve plug. Remove the vaive plug slowly
WARNING: Make sure the brake pedal is
so the valve plug will not be released with excessive force.
released and the brake is applied. Put blocks on
Remove the spring and the Main Relief Valve subassembly.
both sides (front and back) of the drive/steer tire
The subassembly cannot be disassembled any further.
and the caster wheels to prevent movement of the lift truck. Put
a block on each side (front and back) of the load wheels to
6. Remove the Auxiliary Relief Valve. Use a 1 inch open end
prevent movement of the lift truck.
wrench to remove the Auxiliary Relief Valve. Remove the valve
slowly so the valve will not be released with excessive force.
1. Turn the key switch to OFF. Disconnect the battery.
Position block on both sides (front and back) of the drive/steer
7. Remove the Check Valve. Use a 1-1/2 inch open end
tire and the caster wheels. Put a block on each side (front and
wrench to remove the Check Valve. Remove the valve slowly
back) of the load wheels.
so the valve will not be released with excessive force.
2. Open the drive unit compartment and remove the battery
8. Inspect the valves or Valvistor for damage, erosion or worn
compartment cover. Remove the dipstick.
parts. Replace any of the items that may be suspect.. Replace
all O-rings and back-up rings.
3. Position a drain pan in the drive unit compartment. Tag all
the hydraulic lines to the hydraulic tank. Disconnect the suction
Assembly
tube to the hoist pump and allow the hydraulic oil to drain out of
1. Lubricate the O-rings and back-up rings using clean the tank. Clean up any spilled oil. Disconnect the rest of the
hydraulic oil before installing them. Lubricate all the internal hydraulic lines to the tank. Plug the hydraulic lines to prevent
parts of the valves and Valvistor before installing them in the dirt from entering the system.
body of the hydraulic control valve.
4. The hydraulic tank is not physically attached to the lift
2. Install the O-rings and back-up ring on the Check Valve. truck. It can be removed by lifting the tank straight up. Remove
Install the Check Valve. Tighten the Check Valve to 109 to 122 the breather/filler assembly and the breather from the top of the
N»m (80 to 90 Ibf ft) torque. tank. Remove the strainer from the fill tube.
3. Install the O-rings and back-up ring on the Auxiliary Relief 5. Remove the three capscrews, lockwashers nuts, flat
Valve. Install the Auxiliary Relief Valve in the body of the washers and O-rings retaining the tank cover to the hydraulic
hydraulic control valve. Tighten the Auxiliary Relief Valve to 47 tank. Remove the tank cover and gasket.
to 54 N«m (35 to 40 Ibf ft) torque.
6. Remove the baffle plate from the tank.
4. Install the O-rings and back-up ring on the Main Relief
Valve. Install the Main Relief Valve subassembly in the body of 7. Remove the hydraulic tank from the lift truck.
the hydraulic controLvaivev .Install the spring and valve plug.
7-8
Yale
IndustrialTnicks HYDRAULIC SYSTEM
1. DIPSTICK
2. BREATHER
3. BREATHER/FILLER ASSEMBLY
4. STRAINER
5. TANK COVER
6. NUT
7. LOCKWASHER
8. FLAT WASHER
9. GASKET
10. O-RING
11. CAPSCREW
12. BAFFLE ASSEMBLY
13. HYDRAULIC TANK
7-9
Yale
IndustrialTrucks HYDRAULIC SYSTEM
7. Install the breather on the hydraulic tank. Fill the hydraulic 9. Operate the lift truck through all functions. Check for oil
tank with the recommended hydraulic oil. Refer to Section 2. leaks. Check the hydraulic tank for the correct oil level.
Install the dipstick and the breather/filler assembly.
10. Install the battery compartment cover on the lift truck.
8. Remove the drain pan, close the drive unit compartment Remove the blocks from both sides of the wheels.
cover. Connect the battery.
7-10
Yale
IndustrialTrucks
SECTION 8
SECTION 8 - CONTENTS
MASTS AND REACH ASSEMBLY
MASTS 8-1
CARRIAGEASSEMBLY 8-1
REACHASSEMBLIES 8-1
LOAD BACKREST EXTENSION-
REMOVAL AND INSTALLATION 8-5
FORK REPLACEMENT 8-5
HOOKFORKS-NS 8-5
PIN FORKS-NR OR NDR 8-5
CARRIAGE ASSEMBLY-REMOVAL AND INSTALLATION 8-6
REACH ASSEMBLY-REMOVAL AND INSTALLATION 8-7
CARRIAGE LOAD ROLLERS-
REMOVAL AND INSTALLATION 8-8
SIDE ROLLERS-DISASSEMBLY AND ASSEMBLY 8-9
REPAIR-REACH ASSEMBLY 8-10
REACH ASSEMBLY OUTER FRAME 8-10
REMOVAL WITH SIDESHIFTER 8-10
DISASSEMBLY . 8-11
CLEANING AND INSPECTION 8-11
ASSEMBLY 8-11
INSTALLATION 8-11
REMOVAL WITHOUT SIDESHIFTER 8-11
DISASSEMBLY WITHOUT SIDESHIFTER 8-12
CLEANING AND INSPECTION 8-15
ASSEMBLY WITHOUT SIDESHIFTER 8-15
INSTALLATION WITHOUT SIDESHIFTER 8-15
SINGLE REACH SCISSOR ARMS 8-16
REMOVAL AND DISASSEMBLY 8-16
CLEANING AND INSPECTION 8-16
ASSEMBLY AND INSTALLATION 8-18
DOUBLE REACH SCISSOR ARMS 8-18
REMOVAL AND DISASSEMBLY 8-18
CLEANING AND INSPECTION 8-21
ASSEMBLY AND INSTALLATION 8-21
INNER FRAME ASSEMBLY 8-22
REMOVAL 8-22
DISASSEMBLY 8-23
ASSEMBLY 8-24
INSTALLATION 8-24
SIMPLEX MASTASSEMBLY 8-25
REMOVAL 8-25
CLEANING AND INSPECTION 8-26
LIFT CYLINDERS-REMOVAL AND INSTALLATION 8-26
INNER MAST ASSEMBLY-REMOVAL AND INSTALLATION 8-28
HOSES-REPLACE 8-28
HOSE AND CABLE SHEAVES-REPLACE 8-29
SIMPLEX LIFT CHAINS-REMOVAL AND INSTALLATION 8-29
CLEANING AND INSPECTION 8-29
SIMPLEX CHAIN SHEAVE-REMOVAL AND INSTALLATION 8-29
LOAD ROLLERS AND WEAR PLUGS-
REMOVAL AND INSTALLATION 8-31
INSTALLATION 8-32
TRIPLEX MASTASSEMBLY 8-33
REMOVAL 8-33
CLEANING AND INSPECTION 8-33
FREE LIFT CYLINDER-REMOVAL AND INSTALLATION 8-35
MAIN CYLINDERS-REMOVAL AND INSTALLATION 8-35
INNER AND INTERMEDIATE MASTASSEMBLIES-
REMOVAL AND INSTALLATION 8-36
HOSES-REPLACE 8-36
HOSE AND CABLE SHEAVE REPLACE 8-37
FREE LIFT HOSE SHEAVE 8-37
CARRIAGE OR REACH SHEAVES-
REMOVAL AND REPLACEMENT 8-37
TRIPLEX LIFT CHAIN REMOVAL AND INSTALLATION 8-40
FREE LIFT CHAINS 8-40
MAIN LIFT CHAINS 8-40
TRIPLEX CHAIN SHEAVES-DISASSEMBLY AND ASSEMBLY 8-40
FREE LIFT CHAIN SHEAVES 8-40
MAIN LIFT CHAIN SHEAVES 8-40
LOAD ROLLERS AND WEAR PLUGS-
REMOVAL AND INSTALLATION 8-41
TRIPLEX MAST ASSEMBLY-INSTALLATION 8-42
REACH CYLINDERS 8-42
REMOVAL 8-42
CLEANING AND INSPECTION 8-42
DISASSEMBLY 8-43
CLEANING AND INSPECTION 8-43
ASSEMBLY 8-43
INSTALLATION 8-44
TILT CYLINDER AND TILT PIVOT MECHANISM 8-44
REMOVAL-WTTH SIDESHIFTER 8-44
REMOVAL-WITHOUT SIDESHIFTER 8-45
DISASSEMBLY 8-47
CLEANING AND INSPECTION
ASSEMBLY
INSTALLATION-WITH SIDESHIFTER
INSTALLATION-WITHOUT SIDESHIFTER
SIDESHIFT CYLINDER
..8-48
8-48
8-48
8-49
8-49
REMOVAL 8-49
DISASSEMBLY 8-50
CLEANING AND INSPECTION 8-50
ASSEMBLY 8-50
INSTALLATION 8-50
REACH/TILT SELECTOR VALVE 8-51
REMOVAL 8-51
DISASSEMBLY 8-52
CLEANING AND INSPECTION 8-52
ASSEMBLY . . : 8-52
INSTALLATION 8-52
TILT/SIDESHIFT SELECTOR VALVE 8-52
REMOVAL 8-52
DISASSEMBLY 8-53
CLEANING AND INSPECTION 8-53
ASSEMBLY 8-53
INSTALLATION 8-54
CHECKS AND ADJUSTMENTS 8-54
CHECK MAST OPERATION 8-54
REMOVEAIR FROM HYDRAULIC SYSTEM 8-54
CHECK FOR LEAKS IN HYDRAULIC SYSTEM 8-54
CHECK LIFT CHAINS 8-55
CLEANING AND INSPECTION 8-55
LUBRICATION 8-56
MAST ADJUSTMENTS 8-56
ADJUST WEAR PLUGS 8-56
ADJUST WEAR STRIPS 8-57
ADJUST FREELIFT CHAIN (TRIPLEX ONLY) 8-57
ADJUST MAIN LIFT CHAINS 8-58
SIMPLEX: 8-58
TRIPLEX: 8-58
CARRIAGE OR REACH ASSEMBLY ADJUSTMENTS 8-58
ADJUST WEAR PLUG 8-58
ADJUST SIDEROLLERS .. 8-60
ADJUST THRUST ROLLERS 8-60
ADJUSTMENT FOR THE REACH CYLINDERS 8-61
ADJUSTMENT FOR THE TILT- CYLINDER ... 8-61
ADJUSTMENT FOR THE SIDESHIFT CYLINDER 8-62
TROUBLESHOOTING-MAST 8-63
TROUBLESHOOTING-REACH AND CARRIAGE 8-63
SPECIFICATIONS 8-64
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
MASTS fits on the standard carriage. The sideshift cylinder moves the
This section contains the removal, installation and adjustment
sideshift carriage on the standard carriage.
procedures for the simplex (limited free lift) and triplex (full free
lift) masts and for the reach and carriage assemblies. A
troubleshooting chart is provided at the end of this section.
8-1
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
The bottom arms at the outer frame or apron and the inner the elecro-hydraulic control valve control the rate and direction
frame have load bearings that fit into channels in the frame of oil flow. The switches located in the control handle, when
assemblies. The load bearings permit the ends of the arms to actuated, directs the Valvistors to open and close to control the
move vertically in the frame channels. The sideshift reach rate and direction of oil flow. A selector valve (Item 1, Figure 8-4
assemblies have another frame that can move sideways on the or Figure 8-3) directs the oil flow from the reach cylinders to the
apron. Two bearing blocks at the top of the apron and two at the tilt /cylinder. Another/selector valve with solenoids (Item 5,
bottom reduce the friction for side-to-side movement of the Figure 8-4 or Item 3, Figure 8-3) directs the flow of oil from the
outer frame. tilt cylinder to the sideshift cylinder for sideshift operation.
1. INNER FRAME
2. SCISSOR ARM
3. OUTER FRAME
4. FORKS
5. TILT CYLINDER
6. SCISSOR ARM WELDMENT
7. LOAD BEARING
8-2
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
V2
|C2
KlC3
|C3
V2
|C4 V11
ii 12661
8
1. SELECTOR (SOLENOID) VALVE, REACH/TILT 5. TILT CYLINDER
2. RELIEF VALVE 6. SIDESHIFT CYLINDER
3. SELECTOR (SOLENOID) VALVE, TILT/SIDESHIFT 7. PORT PLUGS WITHOUT SIDESHIFT
4. REACH CYLINDERS 8. TO MAIN CONTROL VALVE (TRUCK)
•REACH ASSEMBLY TUBE ASSEMBLIES FOR SIMPLEX AND TRIPLEX ARE DIFFERENT.
WITHOUT
SIDESHIFT
SAFETY PRECAUTIONS
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 carriage.
•• Never put any part of the body into otiunder thethe raast or carriageuntess alLpartsafeoampteiely lowered or
power is off and the key is removed.
a safety chain is installed. Also make sure that
• Put abattery
"DO NOT OPERATE" tag in the operator's compartment. Disconnect the battery and put a tag or lock on
the 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 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 carriage.
8-4
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
LOAD BACKREST EXTENSION- lifting device to move the fork away from the carriage. Follow
REMOVAL AND INSTALLATION the same procedure to remove the other fork.
1. Loosen the two upper capscrews that fasten the load
To install the forks, move the fork or carriage so that the top
backrest extension to the carriage assembly.
hook on the fork engages the top crossmember of the carriage.
Raise the carriage ot lower the fork to move the lower hook
2. Remove these two capscrews and lay the load backrest
through the removal notch. Slide the fork on the carriage so that
extension on the forks.
both upper and lower hooks are engaged and the latch pin
engages a notch.
3. Remove the two lower capscrews that fasten the load
backrest extension to the carriage assembly.
Pin Forks-NR or NDR
4. Lift the load backrest extension off the forks. 1. Operate the tilt function so that the forks are fully tilted
back. Operate the reach function to fully extend the forks. Raise
5. Reverse the procedure to install the load backrest the forks off the floor and position a block of wood under each
extension. Tighten the capscrews to 203 N-m (150 Ibf ft) fork. Lower the forks to rest on the block of wood. Remove the
torque. load backrest extension as described in LOAD BACKREST
EXTENSION-REMOVAL AND INSTALLATION.
FORK REPLACEMENT
2. Remove the capscrew and nut at the center of the fork
WARNING: Forks are heavy and can cause an shaft. If the lift truck has sideshift option, remove the hair pin
injury. Do not try to remove forks without using a and pin from both fork brackets. See Figure 8-6. Use a brass
lifting device. drift to move the fork shaft toward the center of the lift truck until
the fork bracket and fork comes off the fork shaft. Use a crane
Hook Forks-NS and sling to move the fork. Repeat the procedure for the other
fork.
These forks are connected to the carriage by hooks. Latch pins
fit through the top fork hooks and into slots on the top
3. On models with the sideshift option, remove the capscrew
crossmember of the carriage to keep the forks in position.
and flat washer retaining the bearing block and spacer to the
outer frame.
To remove the forks, lift the latch lever and slide the fork to the
fork removal notch on the carriage. The removal notch is in the
4. To assemble the forks back in the outer frame, install the
bottom crossmember of the carriage as shown in Figure 8-7.
spacer and bearing block to the outer frame using the
Lower the carriage with blocks under the fork or raise the fork
capscrews and flat washers on models with sideshift option.
tip. The bottom hook of the fork will move through the fork
removal notch. Lower the carriage further or raise the fork so
5. Use a crane and sling to lift a fork for installation. Move the
that the top hook of the fork is disengaged from the top
fork and fork bracket into a position of alignment with the fork
crossmember. Move the carriage away from the fork, or use the
shaft.
PIN FORK
HOOK FORK
8-5
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
6. Install the fork shaft in the outer hole in the frame. Use a NOTE: Most repairs of the carriage assembly can be
hammer with a brass or copper head to drive the shaft in the completed without removing the carriage assembly from the
frame. mast.
7. Slide the fork and fork bracket on the shaft. Drive the shaft 1. Operate the LIFT/LOWER control handle to raise the
into position to install the other fork and fork bracket. Use the carriage assembly until the thrust rollers of the carriage are
crane and sling to align the other fork and install this fork in the above the top of the outer weldment.
same way. Install the shaft so that the end of the shaft is at the
outer edge of the frame. 2. Move the key to the OFF position and disconnect the
9. Align the fork and fork bracket on the shaft and install the /\ WARNING: Be careful when removing or
pin through each fork bracket and fork shaft. Install the hair pins / I\ installing snap rings. These snap rings are large
to retain the pins. 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
removal or installation.
CAPSCREW
1.
NUT
2. 4. Remove the snap rings, washers, thrust rollers and
HAIR PIN
3. spacers.
4.
PIN
FORK BRACKET
5. /\ WARNING: Lift chains, hoses and cables can roll
FLAT WASHER
6.
BEARING BLOCK
7.
/ I\ over the sheaves to fall and cause an injury if the
ends are not fastened. Keep control of the ends of
SPACER
8. the lift chains, hoses and cables as they are removed. Use wire
SPREADER BAR
9. to temporarily connect the ends of the lift chains, hoses or cable
10. FORK SHAFT to the masts.
8-6
Yale
IndustrialTrucks mast and reach assembly
8-7
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
chain does not touch the mount for the hose sheave, lift chains, 10. Adjust the reach assembly. See ADJUSTMENTS in
chain or hose sheaves, hoses, tubes or fittings. CHECKS AND ADJUSTMENTS. Test the reach assembly for
correct operation.
3. Move the key to the OFF position and disconnect the
battery. Remove the mast guard from the mast assembly.
7. Use a prybar to remove the load roller from the stub shaft
for the load roller. See Figure 8-10.
Figure 8-10 - Removing Load Roller NOTE: Observe the position of the shims.
8-9
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
4. Reverse the procedure to installthe side rollers. Adjust the NOTE: If the outer frame will NOT be disassembled, it can be
carriage side rollers during assembly. See CARRIAGE removed as one unit. If disassembly is a requirement, the outer
ADJUSTMENTS in CHECKS AND ADJUSTMENTS. frame must be removed from the scissor arms.
NOTE: To remove and replace load rollers, wear plugs, 1. If necessary, remove the forks as described in FORK
weldments or lift cylinders, it is necessary to remove the REPLACEMENT.
simplex mast assembly from the truck.
2. Remove the sideshift cylinder as described in SIDESHIFT
CYLINDER-REMOVAL.
REPAIR-REACH ASSEMBLY
NOTE: Most repairs of the reach assembly can be done 3. Install labels for correct connections during installation and
without removing the reach assembly from the mast. These disconnect the hydraulic lines at the top of theTILT/SIDESHIFT
repair procedures require that the reach assembly is installed selector valve. Install caps on the hydraulic lines and valve
in the mast and the scissor arms are fully extended. ports to prevent dirt from entering the system. Make a note of
the location of all cable ties for correct installation of new cable
WARNING: The reach assembly can fall or tip ties during installation.
easily and cause an injury when not installed in the
mast. If the reach assembly cannot be installed in a 4. Install labels for correct connections during installation and
mast during repair, make sure the inner frame is fastened to a disconnect the wires to the solenoids of the TILT/SIDESHIFT
support that cannot move. The inner frame must be in the same selector valve. Remove the hose and wire guide.
position as it is in the mast. The inner frame must also be
fastened so that it cannot move on the support. The support
must be strong enough to allow full extension of the reach
assembly without tipping.
frame channels. Move the outer frame away from the lift truck Installation
and put it flat on the floor (See Figure 8-12)
WARNING: The point between the scissor arms
Disassembly
and the outer frame is a pinchpoint and can cause
(See Figure 8-12)
an injury. Do NOT put any part of your body
1. Remove the tilt cylinder and tilt pivot assemblies as between these assemblies. Use a screwdriver or other tool to
described inTILT CYLINDER AND TILT PIVOT ASSEMBLIES. move the bearing blocks or assemblies into the correct
:
positions.
2. If necessary, install labels for correct connection during
assembly and remove any other hydraulic hoses on the 1. Use multi-purpose grease to lubricate the bushings on the
selector valve. Install caps on the hydraulic lines and valve inner and outer scissor arms. Use multi-purpose grease to hold
ports to prevent dirt from entering the system. the bottom bearings in the correct positions at the bottom of the
outer frame.
3. If necessary, remove the hose and wire guide and the
selector valve. 2. Use a crane to lift the outer frame. Align the outer frame
with the outer scissor arms. Install the pivot pins that retain the
4. If necessary, disassemble the selector valve as described inner scissor arms to the outer frame.
in DISASSEMBLY OF TILT/SIDESHIFT SELECTOR VALVE.
3. Install the roll pins to retain the pivot pins.
Cleaning and Inspection
4. If necessary, install the sideshift cylinder as described in
WARNING: Cleaning solvents can be flammable
INSTALLATION OF SIDESHIFT CYLINDER. Always use new
and toxic, and can cause skin irritation. Wear
O-rings on the O-ring fittings, if necessary to connect the
protection for eyes and skin. When using cleaning
hydraulic lines. Make sure any other hydraulic lines are
solvents, always follow the recommendations of the
correctly connected. Installthe electrical cable andwires on the
manufacturer.
tilt/sideshift selector valve. Install new cable ties at the original
locations for clearance of hoses and electrical cables during
CAUTION: Do NOT use steam to clean the load
operation.
bearings. Do not use compressed air on the
bearings. The bearings are sealed and
NOTE: The reach assembly must be installed on the mast
permanently lubricated. The air can force the lubricant out of
before doing Step 5.
the bearings.
5. After all hydraulic lines are connected, operate the
Clean all of the parts of the outer frame with solvent. Dry the
functions to check for leaks and correct operation. Remove the
parts with compressed air. Inspect the parts of the outer frame
air from the system and adjust the stroke of the tilt cylinder as
for damage and wear. Replace all bushings.
described in CHECKS AND ADJUSTMENTS.
Assembly
6. If necessary, install the forks and load backrest extension
(See Figure 8-12)
as described in FORK REPLACEMENT and LOAD
1. If necessary, assemble the selector valve as described in BACKREST EXTENSION REMOVAL AND INSTALLATION.
ASSEMBLY OF TILT/SIDESHIFT SELECTOR VALVE.
Removal without Sideshifter
2. If removed, install the selector valve, and the hose and (See Figure 8-13)
cable guide.
NOTE: Use safety chains on the 'inner frame and mast
weldments to keep the reach assembly and mast weldments
3. If removed, install the hydraulic hoses for the reach
from moving. Install the safety chains as described in SAFETY
cylinder. Always use new O-rings on the O-ring fittings.
PROCEDURES.
4. Install the tilt cylinder and tilt pivot assemblies as described
NOTE: Make sure that the reach assembly is fully extended.
in INSTALLATION OF TILT CYLINDER.
The outer frame can be removed with the forks installed or
removed.
8-11
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
/\ WARNING: There are pinch points on the reach /\ WARNING: The outer frame is heavy and can tip
JI\ assembly that can cause an injury. Use clamps II\ forward and cause an injury when removed from
and blocks to prevent the scissor arms from the scissor arms. Tipping is even more possible if
moving. Install the clamps and blocks at the channels of the the forks or outer frame are installed. Make sure to install the
inner frame to make sure that the load bearings cannot move in chains or slings between the crane and outer frame to prevent
the channel. See Figure 8-11 . tipping.
CAUTION: Do NOT operate the tilt or sideshift 5. Use a crane as a support for the outer frame. Use a brass
rl functions if the outer frame has been removed.
Hydraulic oil can come out of the hoses.
•drift toremovethe prvotpin-thatfastenslhe outerframeto the
top ends of the scissor arms.
1. Operate the tilt function for full back tilt. Operate the reach
function to fully extend the reach assembly. If necessary,
remove the load backrest extension as described in LOAD
BACKREST EXTENSION-REMOVAL AND INSTALLATION.
A CAUTION: Do not let the load bearings or shims
fall off the scissor arms.
6. Carefully move the top of the outer frame away from the
2. If necessary, remove the forks as described in FORK scissor arms. Slowly lower the outer frame until the load
REPLACEMENT. bearings at the bottom of the scissor arms are out of the frame
channels. Move the outer frame away from the scissor arms.
NOTE: If necessary, remove the outer frame as described in Put the outer frame on the ground so that the scissor side is
OUTER FRAME- REMOVAL . If necessary, remove the down.
sideshift cylinder from the outer frame as described in
SIDESHIFT CYLINDER-REMOVAL. NOTE: Install labels for each set of shims and the load
bearing for correct installation during installation of the outer
3. Install labels for correct connection during installation and frame or apron. When new load bearings are installed, the shim
remove the hoses at the top of the outer frame. For units without arrangement will normally be the same or similar.
sideshift, see Figure 8-13. For units with sideshift, see
Figure 8-12. Make a note of the location of all cable ties for Disassembly without Sideshifter
correct installation of new cable ties during installation. Install (See Figure 8-13)
caps on the hydraulic lines of the selector valve to prevent dirt
NOTE: The bearings for the outer frame are normally
from entering the system.
removed and installed with the outer frame. The selector valve
for the tilt/sideshift functions is also installed on the outer frame.
/\ WARNING: The points between the scissor arms
Plugs are installed at the ports for the sideshift cylinder and the
11\ and the outer frame are pinch points and can
solenoids. The tilt pivot assembly is also installed on the outer
cause an injury. Do NOT put your finger in the hole
frame.
when you remove the pins. Use the brass drift to remove the
pins.
1. Remove the tilt cylinder and tilt pivot assemblies as
described in TILT CYLINDER AND TILT PIVOT ASSEMBLIES.
4. Use a punch to remove the roll pin (Item 9, Figure 8-12)
(Item 7, Figure 8-13)
2. Remove the solenoid valve body and hose guide.
Disassemble the selector valve as described in
TILT/SIDESHIFT SELECTOR VALVE-DISASSEMBLY.
8-12
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
1. HOSE ASSEMBLY
2. HOSE ASSEMBLY
3. ELBOW
4. CONNECTOR
5. HOSE ASSEMBLY
6. HOSE ASSEMBLY
7. HOSE ASSEMBLY
8. HOSE ASSEMBLY
9. ROLL PIN
10. PIVOT PIN
11. CAPSCREW
12. LOCKWASHER
13. HOSE AND WIRE GUIDE
14. CAPSCREW
15. LOCKWASHER
16. SELECTOR VALVE
17. SOLENOID VALVE
18. CAPSCREW
19. LOCKNUT
20. FORK SHAFT
21. ROLL PIN
22. CYLINDER END PIN
23. LOCKNUT
24. COTTER PIN
25. WASHER (AS REQD)
26. FLAT WASHER
27. ROD END PIN
28. ROD END
29. SIDESHIFT CYLINDER
30. CAPSCREW
31. FLAT WASHER
32. BEARING BLOCK
33. SPACER
34. HAIRPIN
35. PIN
36. FORK BRACKET
37. SPREADER BAR
38. TILT CYLINDER PIN
39. ROD END
40. CAPSCREW
41. LOCKWASHER
42. TILT ROLLER SHAFT
43. TILT ROLLER SHAFT
44. TILT PIVOT-RIGHT HAND
45. BUSHING 54. ROD END
46. TILT SLIDER ASSEMBLY 55. BUSHING
47. BUSHING 56. LOCKNUT
48. CAPSCREW 57. LOCKWASHER
49. END CAP 58. TILT CYLINDER ASSEMBLY
50. BEARING BLOCK-POLY 59. TILT PIVOT-LEFT HAND
51. COTTER PIN 60. BUSHING
52. LOCKNUT 61. OUTER FRAME
53. PIN-SPACER 62. O-RING
-
Figure 8-12 Outer Frame with Sideshifter
8-13
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
1. HOSE ASSEMBLY
2. HOSE ASSEMBLY
3. ELBOW
4. CONNECTOR
5. HOSE ASSEMBLY
6. HOSE ASSEMBLY
7. ROLL PIN
8. PIVOT PIN
9. CAPSCREW
10. LOCKWASHER
11. HOSE AND WIRE GUIDE
12. CAPSCREW
13. LOCKWASHER
14. SELECTOR VALVE
15. FORK RETAINING PIN
16. CAPSCREW
17. LOCKWASHER
18. CAPSCREW
19. LOCKWASHER
20. FORK SHAFT
21. PIN
22. ROD END
23. CAPSCREW
24. LOCKWASHER
25. TILT ROLLER SHAFT
26. TILT ROLLER SHAFT
27. TILT PIVOT-RIGHT HAND
28. BUSHING
29. TILT ROLLER ASSEMBLY
30. BUSHING
31. COTTER PIN
32. LOCKNUT
33. PIN
34. ROD END
35. BUSHING
36. LOCKNUT
37. LOCKWASHER
38. TILT CYLINDER ASSEMBLY
39. TILT PIVOT-LEFT HAND
40. BUSHING
41. OUTER FRAME
42. O-RING
8-14
Yale
IndustrialTrucks IWIAST AND REACH ASSEMBLY
8-15
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
ADJUSTMENTS. Install new cable ties at the original locations 4. Carefully remove the clamps and blocks at the load
for clearance of hoses and electrical cables during operation. bearings on the channels of the inner frame. Slowly move the
scissor arms to align the load bearings with the removal notch
in the inner frame. Raise the scissor arm weldment and the
SINGLE REACH SCISSOR ARMS
scissor arms to move the load bearings out of the inner frame.
Removal and Disassembly
(See Figure 8-14) NOTE: Install labels for each set of shims and the load
bearing on the scissor arms for correct assembly during
NOTE: Make sure that the reach assembly is in the fully
installation of the scissor arms. When new load-hearings are
extended position.
installed, the shim arrangement will normally be the same or
similar. Remove the load bearings and shims.
WARNING: There are pinch points on the reach
assembly that can cause an injury. Use clamps
WARNING: The scissor arms are heavy and can
and blocks to prevent the scissor arms from
cause an injury if allowed to fall. Have another
moving. Install the clamps and blocks at the channels of the
person help you support the scissor arm during
inner frame to make sure that the load bearings cannot move in
removal and installation.
the channel. See Figure 8-11.
5. Install labels for correct installation of the right hand or left
NOTE: Use safety chains on the inner frame and mast
hand scissor arms. Carefully remove the three capscrews, the
weldments to keep the inner frame and mast weldments from
lockwashers, the end cap and the two thrust washers at the
moving. Install the safety chains as described in SAFETY
center pivot for the scissor arm andscissor arm weldment. Hold
PROCEDURES.
the scissor arm and carefully slide it off the bushing and stub
shaft of the scissor arm weldment. Removethe bushing and the
WARNING: Be careful when removing or
other two thrust washers. Remove the other scissor arm
installing snap rings. These snap rings are large
following this same procedure.
and can come loose during removal or installation
with enough force to cause an injury. Always use the correct
6. Remove the roll pins and anchor pins that fasten the
snap ring pliers and wear eye and face protection during
scissor arm weldment to the inner frame. Move the scissor arm
removal or installation.
weldment and put it on the floor without damaging the hose
sheave mount. Remove the bushings.
1. Remove the outer frame or the apron as described in
OUTER FRAME OR SIDESHIFT APRON-REMOVAL.
7. if necessary, install the forks and load backrest extension
Remove the snap rings and hose sheaves at the scissor arm
as described in FORK REPLACEMENT and LOAD
weldment. Fasten the cable (sideshift only) and hoses at the
BACKREST EXTENSION-REMOVAL AND INSTALLATION.
inner frame so that they are not damaged.
Cleaning and Inspection
2. Use a crane and chains or slings as a support for the
scissor arm weldment. Do not damage the hose sheave mount. WARNING: Cleaning solvents can be flammable
and toxic, and can cause skin irritation. Wear
WARNING: The points between the scissor arms protection for eyes and skin. When using cleaning
and the inner frame are pinch points and can cause solvents, always follow the recommendations of the
an injury. Do NOT put your finger in the hole when manufacturer.
you remove the pins at the reach cylinders or scissor arm
weldment. Use a brass drift to remove the pins. /\ CAUTION: Do NOT use steam to clean the load
/ 1\ bearings. Do not use compressed air on the
3. Use a punch to remove the roll pins in the rod ends of the ULJ bearings. The bearings are sealed and
reach cylinders (Item 2, Figure 8-30). Use a drift to remove the permanently lubricated. The air can force the lubricant out of
pins that fasten the rod ends of the reach cylinders to the the bearings.
scissor arm weldment. Use wire to hold each reach cylinder
and their hoses in a position for clearance as the load bearings Clean all of the parts of the scissor arm assembly with solvent.
move. Remove the bushings from the mounts. Dry the parts with compressed air. Inspect the parts of the
scissor arm assembly for damage and wear. Replace all
WARNING: The load bearings and scissor arms bushings and load bearings.
can move and cause an injury when the clamps
and blocks at the load bearings are removed.
Make sure the crane is in a position to pieventmovement of the
scissor arms as the clamps and blocks are removed.
8-16
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
1. SCISSOR ARM
2. REACH CYLINDER
3. SCISSOR ARM WELDMENT
4. LOAD BEARING
5. PIN
6. ROLL PIN
7. -BUSHING
8. SHIM
9. HOSE SHEAVE
10. MOUNT
11. SNAP RING
12. TWO THRUST WASHERS
13. END CAP
14. LOCKWASHER
15. CAPSCREW
16. ROD END
17. INNER FRAME
18. REMOVAL NOTCH
19. INSTALL CLAMPS AND BLOCKS HERE
8-17
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
Assembly and Installation arm assembly so that the load bearings move into the
channels.
NOTE: Use safety chains on the inner frame and mast
weldments to keep the inner frame and mast weldments from
5. Slowly raise the scissor arm assembly to align the mounts
moving. Install the safety chains as described in SAFETY
with the rod ends of the reach cylinders. Install the bushings,
PROCEDURES.
' pinsand roll pins to fasten the reach'cylinders to the scissor arm
weldment.
NOTE: Always use new bushings and load bearings. Install
a thin coat of multi-purpose grease on all new bushings, all
thrust washers, all shims, all stub shafts and all pins of the
CAUTION: Do not let the load bearings or shims
scissor arm assembly.
fall off the scissor arms.
WARNING: The points between the scissor arms
WARNING: Be careful when removing or
andthe inner frame are pinch points and cancause
installing snap rings. These snap rings are large
an injury. Do NOT put your finger in the hole when
and can come loose during removal or installation
you install the pins at the reach cylinders or scissor arm
with enough force to cause an injury. Always use the correct
weldment.
snap ring pliers and wear eye and face protection during
removal or installation.
1. Use a crane and chains or slings as a support for the
scissor arm weldment. Do not damage the hose sheave mount.
6. Install the shims and load bearings on the scissor arm
Move the weldment into a position of alignment to install the
weldment as marked during removal and disassembly. If
pins thatfasten the weldment to the inner frame. Align the holes
necessary, use tape to keep the load bearings on the scissor
for the roll pin. Installthe bushings, pins and roll pins. See Items
arms. Install the hoses on the hose sheaves and install the
5, 6 and 7 of Figure 8-30.
hose sheaves and snap rings at the mount of the scissor arm
weldment.
WARNING: The scissor arms are heavy and can
cause an injury if allowed to fall. Have another
person help you support the scissor arm during DOUBLE REACH SCISSOR ARMS
removal and installation.
Removal and Disassembly
(See Figure 8-15)
2. Install two thrust washers and the bushing on each stub
shaft of the scissor arm weldment. Installthe right hand and left NOTE: Make sure that the reach assembly is in the fully
hand scissor arms as shown in Figure 8- 14. Use the other two extended position.
thrust washers, the end cap, lockwashers and capscrews on
each stub shaft and bushing. Tighten the three capscrews at NOTE: Another installation method for the outer frame or
each end cap to 41 N»m (30 Ibf ft) torque. apron, is to raise the scissor arms and inner frame as a unit.
Operate the lift system of the lift truck to raise the scissor arms
WARNING: The scissor assembly is heavy and and inner frame above the outer frame or apron. Use the crane
can cause an injury during installation. NEVER put and a bar to align the channels of the outer frame or apron
any part of your body between the inner frame and under the load bearings of the scissor arms. Tilt the outer frame
the scissor arm assembly. NEVER put any part of your body or apron forward for clearance. Have another person slowly
between the parts of the scissor arm assembly. lower the scissor assembly so that the load bearings are in the
channels. Tilt the outer frame or apron back to align the scissor
arms to install the pins.
CAUTION: Do not let the load bearings or shims
fall off the scissor arms. WARNING: There are pinch points on the reach
assembly that can cause an injury. Use ciamps
3. Slowly raise the weldment so you can install the shim sets and blocks to prevent the scissor arms from
and load bearings on each scissor arm as marked during moving. Install the clamps and blocks at the channels of the
removal and disassembly. If necessary, use tape to keep the inner frame to make sure that the load bearings cannot move in
load bearings on the scissor arms. the channel. See Figure 8-11.
4. Use the crane to slowly raise the scissor arm weldment NOTE: Use safety chains on the inner frame and mast
and the scissor arms to align the load bearings with the removal weldments to keep the inner frame and mast weldments from
notches in the inner frame. Use the crane to move the scissor moving. Install the safety chains as described in SAFETY
PROCEDURES. - —
8-18
Yale
industrial Trucks MAST AND BEACH ASSEMBLY
HOSE SHEAVE
DETAIL 10
END PIVOT
HOSE SHEAVE DETAIL
DETAIL
WARNING: Be careful when removing or WARNING: The load bearings and scissor arms
installing snap rings. These snap rings are large "1 B" and "2B" can move and cause an injury when
and can come loose during removal or installation the clamps and blocks at the load bearings are
with enough force to cause an injury. Always use the correct removed. Make sure the crane (Step 5) is in a position to
snap ring pliers and wear eye and face protection during prevent movement of the scissor arms as the clamps and
removal or installation. blocks are-removed.
1. Remove the outer frame or the apron as described in 7. Carefully remove the clamps and blocks at the load
OUTER FRAME OR SIDESHIFT APRONr-REMOVAL. bearings oa ihe. channels of the inner frame. Slowly move
Remove the snap rings and hose sheaves at the scissor arm scissor arm weldment "A" to align the load bearings of scissor
weldments. Fasten the cable (sideshift only) and hoses at the arms "1 B" and "2B" with the removal notch in the inner frame.
inner frame so that they are not damaged. SeeFigure 8-15. Use the crane to move the scissor arm
assembly so that the load bearings are out of the inner frame.
2. Use a crane and chains or slings as a support for the
scissor arm weldment "A". Make sure to install the chains or NOTE: Install labels for each set of shims and the load
slings so that the weldment cannot slip inside the chains or bearing on the scissor arms "1 B" and "2B". Installthe labels for
slings. Do not damage the hose sheave mount. correct assembly during installation of the scissor arms. When
new load bearings are installed, the shim arrangement will
3. Bend the corners of the special lockwashers flat. Remove normally be the same or similar. Removethe load bearings and
the two capscrews, special lockwasher, end cap and two thrust shims.
washers (Items 12 through 15, Figure 8-15) from the bottom
pivot points of scissor arms "1A" and "2A". 8. Carefully lower the crane so the scissor arm assembly
"retracts" as the ends of the scissor arms move down the
WARNING: The scissor arms are heavy and can outside of the channel. Do not damage the stub shafts for the
cause an injury if allowed to fall. Have another load bearings.
person help you support the scissor arm during
removal and installation. 9. Install a safety chain between the inner frame and scissor
arm weldment "B" so that the weldment cannot move. Move the
4. Install labels for correct installation of the right hand or left crane and chains or slings so that they are a support for the
hand scissor arms. Carefully remove the three capscrews, the scissor arm weldment "A".
lockwashers, the end cap and the two thrust washers at the
center pivot for scissor arm "1A" and scissor arm weldment "A". 10. Remove the two capscrews, special lockwasher, end cap
Hold the scissor arm "1A" and slide it off the bushing and stub and two thrust washers from the top pivot point of scissor arms
shaft of the scissor arm weldment. Remove the bushing and the "1 B" and "2B".
other two thrust washers at the center pivot. Remove the
bushing and the other two thrust washers from the stub shaft at WARNING: The scissor arms are heavy and can
the end of the scissor arm. Remove scissor arm "2A" following cause an injury if allowed to fall. Have another
this same procedure. person help you support the scissor arm during
removal and installation.
5. Slowly lower scissor arm weldment "A" so that it hangs
from the ends of scissor arms "1B" and "2B". Move the crane 11. Install labels for correct installation of the right hand or left
and chains or slings so that they are a support for the scissor hand scissor arms. Carefully remove the three capscrews, the
arm weldment "B". lockwashers, the end cap and the two thrust washers at the
center pivot for scissor arm "1 B" and scissor arm weldment "B".
WARNING: The points between the scissor arms Make sure the crane is the support for scissor arm weldment
and the inner frame are pinch points and can cause "A" so that it cannot fall. Hold thescissor arm "1B" and slide it off
an injury. Do NOT put your finger in the hole when the bushing and stub shaft of the scissor arm weldment "B".
you remove the pins at the reach cylinders. Use a brass drift to Remove the bushing and the other two thrust washers at the
remove the pins. center pivot, Remove the bushing and the other two thrust
washers from the stub shaft at the end of the scissor arm.
6. Use a punch to remove the roll pins in the rod ends of the Remove scissor arm "2B" following this same procedure. Move
reach cylinders (Item 2, Figure 8-30 ). Use a drift to remove the scissor arm weldment "A" and put it on the floor without
pins that fasten the rod ends of the reach cylinders to the damaging the hose sheave mount.
scissor arm weldment "B". Use wire to holdeach reach cylinder
and hoses in a position for clearance as the load bearings 12. Use the crane and chains or slings as a support for the
move. scissor arm weldment "B" so that it cannot fail. Do not damage
the hose sheave mount. Carefully remove the safety chain.
8-20
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
/\ WARNING: The points between the scissor arms /\ WARNING: The scissor arms are heavy and can
/ 1\ and the innerframe are pinchpoints and can cause If \ cause an injury if allowed to fall. Have another
an injury. Do NOT put your finger in the hole when CJJi person help you support the scissor arm during
you remove the pins at the scissor arm weldment. Use a brass removal and installation.
drift to remove the pins.
2. Install two thrust washers and the bushing on each stub
13. Remove the roil pins, and anchor pins that fasten the shaft of scissor arm weldment "B". Install scissor arm "2B" on
scissor arm weldment "B" to the inner frame. Movescissor arm scissor arm weldment "B" as shown in Figure 8-15. Make sure
weldment "B" and put it on the floor withoutdamaging the hose there aretwo thrust washers on each side of-ttoe-6cissor arm.
sheave mount. Remove the bushings. Tighten the three capscrews at the end cap to 41 N*m (30 Ibf ft)
torque.
Cleaning and Inspection
3. Install two of the thrust washers and the bushing on the
/\ WARNING: Cleaning solvents can be flammable stub shaft at the end pivot of scissor arm "2B".
/j \ and toxic, and can cause skin irritation. Wear
LmJ protection for eyes and skin. When usingcleaning 4. Install the crane and chains or slings as a support for
solvents, always follow the recommendations of the
scissor arm weldment "A". Movethe weldment into a position of
manufacturer.
alignment to install the weldment on scissor arm "2B". Install
the weldment, the other two thrust washers, the end cap, a new
CAUTION: Do NOT use steam to clean the load
special lockwasher and the two capscrews. Tighten the two
/f\ bearings. Do not use compressed air on the
capscrews to 39 N«m (29 Ibf ft) torque. Bendthe comers of the
bearings. The bearings are sealed and
special lockwasher against the flat of each capscrew.
permanently lubricated. The air can force the lubricant out of
the bearings.
/\
11\
WARNING: The scissor arms are heavy and can
cause an injury if allowed to fall. Have another
Clean all of the parts of the scissor arm assembly with solvent.
person help you support the scissor arm during
Dry the parts with compressed air. Inspect the parts of the
removal and installation.
scissor arm assembly for damage and wear. Replace all
bushings and load bearings.
5. Installscissor arm "1B" on scissor arm weldments "B" and
"A" as shown in Figure 8-15. Make sure there are two thrust
Assembly and Installation
washers on each side of the scissor arm at the center pivot.
(See Figure 8-15)
Also make sure there are two thrust washers on each side of
NOTE: Use safety chains on the inner frame and mast the arm of scissor arm weldment "A". Use new special
weldments to keep the inner frame and mast weldments from lockwashers at the end pivots. Tighten the three capscrews at
moving. Install the safety chains as described in SAFETY the center pivot to 41 N«m (30 Ibf ft) torque. Tighten the two
PROCEDURES. capscrews at the end pivots to 39 N«m (29 Ibf ft) torque. Bend
the corners of the special lockwashers against the flat of each
NOTE: Always use new bushings and load bearings. Install capscrew.
a thin coat of multi-purpose grease on all new bushings, all
thrust washers, all shims, all stub shafts and all pins of the
scissor arm assembly.
/\
/ I\
WARNING: The points between the scissor arms
and the inner frame are pinchpoints and cancause
A CAUTION: Do not let the load bearings or shims
fall off the scissor arms.
10. Install the shims and load bearings on scissor arm 5. Remove the snap rings, washers, thrust rollers and
weldment "A" as marked during removal and disassembly. If spacers. Install labels on the thrust rollers for correct
necessary, use tape to keep the load bearings on the scissor installation during installation.
arms. Install the hoses on the hose sheaves and install the
hose sheaves and snap rings at the mounts of the scissor arm 6. Remove the safety chains installed in Step 4. Lower the
weldments. reach assembly or inner frame assembly for access to the
chain anchors of the inner frame. Install safety chains so that
they support the reach assembly or inner frame and the lift
INNER FRAME ASSEMBLY
chains become loose. Move the key to the OFF position and
NOTE: If the scissor arm assembly will be removed, it is disconnect the battery.
easier to remove while the inner frame is still installed in the
mast. See SINGLE REACH SCISSOR ARMS-REMOVAL NOTE: Removing the pins, at the chain anchors, will
AND DISASSEMBLY- or DOUBLE REACH SCISSOR disconnect the lift chains without changing the chain
ARMS-REMOVAL AND DISASSEMBLY- to remove the adjustment. Always adjust the chains if new lift chains or other
scissor arm assembly. components are installed.
Disassembly
(See Figure 8-16)
NOTE: It is usually not necessary to remove all the parts of
the inner frame assembly. Remove only the necessary parts to
do the repair. The thrust rollers are removed during removal of
the inner frame assembly.
2. Remove the jam nuts and set screws for the load rollers.
8-23
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
3
1. LOAD ROLLER WITH SNAP RING
1. LOAD ROLLER REMOVED
2. WEAR PLUG 5. JAM NUT 2. PRYBAR
3. SNAP RING 6. STUB SHAFT 3. MAST OR CARRIAGE COMPONENT
4. SET SCREW 7. INNER FRAME (CARRIAGE SHOWN)
Figure 8-17 - Load Roller and Wear Plug Assembly Figure 8-18 - Removing Load Roller
CAUTION: Do NOT use steam to clean the load Install all parts that were removed. If necessary, install the
bearings. Do not use compressed air on the selector valve as described in REACH/TILT SELECTOR
bearings. The bearings are sealed and VALVE-INSTALLATION. Install all shim sets in the original
permanently lubricated. The air can force the lubricant out of positions as marked during removal. Use new snap rings.
the bearings. Install the load rollers on the inner frame. Install the shims at
each location as marked during disassembly.
Clean all of the parts of the inner frame with solvent. Dry the
parts with compressed air. Inspect the parts of the inner frame Adjust the carriage side rollers during assembly. See
for damage and wear. Inspect all rollers for cracks, flat spots or ADJUSTMENTS in CHECKS AND ADJUSTMENTS.
bearings that do not turn freely. Replace any roller that shows
wear or is damaged. If the rod ends of the reach cylinders were removed, the reach
cylinders must be adjusted after the reach assembly is
Assembly completely assembled and installed in the mast. See
(See Figure 8-16) ADJUSTMENTS in CHECKS AND ADJUSTMENTS.
WARNING: Be careful when removing or NOTE: The side rollers must be adjusted while the reach
installing snap rings. These snap rings are large assembly is out of the mast channels. Adjust the side rollers as
and can come loose during removal or installation described in CHECKS AND ADJUSTMENTS.
with enough force to cause an injury. Always use the correct
snap ring pliers and wear eye and face protection during 1. InstaH lifting eyes in the reach assembly or inner frame
removal or installation. assembly for chains or slings. Fasten chains or slings to the
lifting eyes. Use a crane to raise the reach assembly or inner
frame assembly to align the load rollers with the channels of the
8-24
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
inner weldment of the mast. Carefully lower the inner frame mast assembly, operate the REACH/RETRACT control handle
assembly into the mast channels. Continue to lower the to fully retract the forks. Install safety chains so that the forks
assembly to a position to connect the hydraulic lines at the cannot extend. Install the safety chains around the center
manifold block. plates of the scissor arm weldment and the inner frame of the
reach assembly. Make sure a safety chain does not touch the
NOTE: Use safety chains on 1he inner frame and mast mountforthe hose sheave, lift chains, chain or hose shelves,
weldments to keep the inner frame and mast weldments from hoses, tubes or fittings. If installed, operate the SIDESHIFT
moving. Install the safety chains as described in SAFETY control handle to move the outer frame to the center position.
PROCEDURES.
1. Remove the capscrews and nuts that fasten the mast
2. Use safety chains to fasten the carriage or inner frame guard and remove the guard. See Figure 8-19.
assembly and inner weldment of the mast so that they cannot
move. 2. Remove the capscrews that fasten the rear legs to the
overhead guard. See Figure 8-19. The overhead guard will be
WARNING: Lift chains, hoses and cables can roll removed with the mast assembly.
over the sheaves to fall and cause an injury if the
ends are not fastened. Keep control of the ends of CAUTION: Do NOT move the control handle for
the lift chains, hoses and cables as they are installed. the reach, retract, tilt or sideshift functions. Oil will
flow from the hoses for these functions.
3. Connect the hydraulic hoses from the mast to the manifold
block as marked during removal. Connect the electrical wires of 3. Operate the LIFT/LOWER control handle to raisethe inner
the electrical cable to the selector valve as marked during weldment for access to the four capscrews, the shims and the
removal. nut plates that fasten the bottom of the outer weldment to the
truck frame. See Figure 8-20. Install safety chains to keep the
4. Use new cotter pins and install the lift chains on the chain mast components from moving.
anchors of the inner frame.
NOTE: The lift chains must be adjusted if the nuts of the chain
anchors at the mast were removed. Adjust the lift chains as
described in CHECKS AND ADJUSTMENTS.
6. Remove the safety chains and the lifting eyes from the
carriage or inner frame.
removedfrom the truck, first remove the NS carriage assembly 4. Remove the capscrews, shims and nut plates.
or on the NR or NDR models remove the outer frame as a
complete assembly. See CARRIAGE ASSEMBLY-REMOVAL 5. Remove the safety chains installed in Step 2. Do not
AND INSTALLATION OUTER FRAME-REMOVAL AND damage hydraulic hoses as the mast lowers. Carefully operate
INSTALLATION. If the outer frame will be removed with the the LIFT/LOWER control handle to fully lower the inner
8-25
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
weldment. Make sure that all hydraulic pressure is removed 1. Clean the mast weldments with steam or solvent.
from the system by holding the lever in the LOWER position for
approximately five seconds. /\ WARNING: Some parts can be damaged by
8-26
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
BACK VIEW
8-27
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
3. Use a crane or lifting device to support the inner weldment 1. INNER WELDMENT
while sliding the inner weldment far enough out to clear the 2. LIFT CYLINDER
outer weldment. 3. OUTER WELDMENT
4. SNAP RING
4. Reverse the removal procedure to install the inner mast 5. WASHER
assembly into the outer weldment. 6. RUBBER BUSHING
7. SHIMS (IF REQUIRED)
Hoses-Replace 8. RETAINER W/CUSHION
(See Figure 8-22) 9. LOCK PLATE
1. To replace any hydraulic hoses, fully lower the reach or
carriage assembly. Make sure that the system does not have Figure 8-21 - Lift Cylinder Removal
hydraulic pressure. Hold the control lever (for each function) in
the forward position for approximately five seconds to release 3. Replace the hose. Operate the system to remove all the air
the pressure. Make sure the hydraulic pump does NOT from the oil and to check for leaks.
operate. Move the key to the OFF position. Disconnect the
battery and put a tag or lock on the battery connector. NOTE: The following procedure describes how to replace the
hose and cable sheaves without removing the reach assembly,
2. Disconnect hose and install caps to prevent dirt from carriage assembly or mast assembly from the lift truck. If the
entering the hydraulic system. mast assembly has been removed, carefully move the carriage
assembly or inner weldment using a prybar.
8-28
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
Hose and Cable Sheaves-Replace 3. Remove the cotter pins that fasten the chain anchor pins.
(See Figure 8-22) Remove the chain anchor pins. Remove the lift chains.
/\ WARNING: The mast weldments can move and
I\ cause an injury even if the mast assembly has
J
CmJ been removed from the lift truck. Make sure the
mast assembly is level to prevent the components from moving
without being moved. Use safety chains to prevent movement
A
chains.
WARNING: Never replace just the worn section
of a lift chain. Replace the complete chain. Never
2. Fasten the hoses to the top of the inner mast at the Cleaning and Inspection
sheaves. Disconnect or remove the hoses at the reach or Clean and inspect the lift chains as described in CHECKS AND
carriage assembly. Install caps to prevent dirt from entering the ADJUSTMENTS.
hydraulic system.
Simplex Chain Sheave-Removal and Installation
3. Disconnect the spring of the tension device for the (See Figure 8-23)
electrical cable. Fasten the cable to the top of the inner mast at
the sheave. Install tags on the wires of the electrical cable at the 1. Operate the LIFT/LOWER control lever to raise the
reach assembly for correct connection later. Disconnect the carriage or reach assembly so that the forks are approximately
electrical cable. 150 mm (6 in) off the floor. Use safety chains to fasten the
carriage or reach assembly to the outer weldment so that it
4. Remove the capscrew, washers and cotter pin in the shaft cannot move.
at the sheave assembly. Use a drift to carefully remove the shaft
at the sheaves. Do not let the sheaves or shims fall. /\ WARNING: Keep control of the lift chains when
/ 1\ disconnecting them from the chain anchor. This
5. Follow the reverse procedure to install the hose and cable procedure will prevent the lift chains from falling
sheaves. Make sure to operate the reach or carriage hydraulic and causing injury or damage.
function(s) and check for leaks after the hoses are connected.
2. Removethe cotter pin from the pin that fastens the lift chain
Simplex Lift Chains-Removal and Installation to the chain anchor near the top of the outer weldment. Remove
(See Figure 8-23) the anchor pins.
1. Operate the LIFT/LOWER control lever to raise the reach 3. Put the lift chains over the carriage or reach assembly.
or carriage assembly so that the forks are approximately 150
mm (6 in) off the floor. Use safety chains to fasten the carriage /\ WARNING: Be careful when removing or
or reach assembly to the outer weldment so that it cannot / I\ installing snap rings. These snap rings are large
move. and can come loose during removal or installation
with enough force to cause an injury. Always use the correct
2. Lower the carriage or reach assembly so~that the safety snap ring pliers and wear eye and face protection during
chains are the support for the carriage or reach assembly and removal or installation.
the lift chains do not have tension.
4. Remove the snap ring from the sheave: mounting stud.
/\ WARNING: Keep control of the lift chains when
I
I\ disconnecting them from the chain anchor. This 5. Use a prybar to remove the sheave from the stud.
UmJ procedure will prevent the lift chains from falling
and causing injury or damage.
8-29
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
8-30
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
10. Operate the truck and test for correct operation of the chain
sheave. Check and adjust lift chains. Refer to CHECKS AND
ADJUSTMENTS.
A
weldments.
WARNING: The mast weldments can move and
cause an injury. Make sure the mast assembly is
level to prevent unexpected movement of the mast
9 r
inner weldment out of the bottom of the outer weldment for
access to the load rollers. The inner mast load rollers are at the
bottom. The outer mast load rollers are at the top. Use safety
chains to fasten the inner weldment to the outer weldment so
that they do not separate completely.
Figure 8-23 - Removing the Chain Sheave NOTE: Replace wear plugs at this time to save the cost of
removal and disassembly of the mast assembly for wear plug
6. Remove the internal snap ring from the chain sheave. replacement.
7. Inspect all parts for wear or damage. Replace any worn or 4. Use a prybar to remove the load roller from the mast
damaged parts. weldment. See Figure 8-10.
8. If necessary, use a press to remove and install new ball 5. Use a cloth to clean each load roller. Inspect the load
bearings in the sheaves for the lift chains. rollers for cracks, flat spots or bearings that do not turn freely.
Replace any roller that shows wear or is damaged.
9. Reverse the procedure to install the chain sheaves.
6. Reverse the procedure to install the load rollers.
8-31
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
7. Adjust the wear plugs. See MAST ADJUSTMENTS under NOTE: The inner mast assembly must be in a position to
CHECKS AND ADJUSTMENTS. The wear plugs are adjusted allow access to the mount capscrews at the bottom of the outer
after the mast assembly is installed on the lift truck. weldment. Use safety chains to fasten the mast weldments
together so that they cannot move.
3 1.. Use thexrane or lifting device to lift the mast assembly and
move it close enough to the truck to make the necessary
connections. Make sure the truck and mast assembly cannot
move.
NOTE: Make sure all hoses and the electrical cable are not
between a mast crossmember and the truck.
Installation 9. Tighten the four mount capscrews to 203 N»m (150 Ibf ft)
(See Figure 8-20 and Figure 8-22) torque.
NOTE: If the carriage or reach assembly is installed on the 10. Install the hose clamps and hose bracket. Operate the
mast, it must have a safety chain installed as described in LIFT/LOWERxontrol handle to raise the inner weldment high
SAFETY PROCEDURES. enough to carefully remove the safety chains. Remove the
safety chains.
WARNING: Do not install the simplex mast
assembly unless it is completely assembled. Mast 11. Tighten the four trunnion cap capscrews to 203 N»m (150
parts can move and cause an injury if not fastened Ibf ft) torque. Usethe crane to lower the inner weldment untiithe
together during assembly. chain and crane are no longer the support. Remove the chain
and crane.
8-32
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
12. Install the mast guard and capscrews that fasten the rear the top of the mast assembly. Operate the crane until it gives
legs to the overhead guard. support to the weight of the mast assembly. Movethe crane to a
position so that the mast assembly will be lifted vertically. Make
13. Make all adjustments and test the operation of the mast sure the chains will not damage the sheaves or other parts of
assembly before returning the truck to service. See CHECKS the mast assembly. Make sure the chains and crane have the
AMD ADJUSTMENTS. capacity to lift approximately 2000 kg (4500 lbs). Use -safety
chains to fasten all the mast weldments together so that they
cannot move. If installed, install a chain or sling to the reach or
TRIPLEX MAST ASSEMBLY
.carriage assembly to keep the mast assembly from tipping
tSEE FIGURE 8-25 AND FIGURE 8-27) during removal. Remove the four capscrews that fasten the
Removal trunnion caps.
NOTE: If the mast assembly will be disassembled after it is
7. Raise the mast assembly high enough to clear the
removed from the truck, first remove the NS carriage assembly
trunnions. Move the mast assembly approximately 30 cm (1 ft)
or the NR or NDR reach assembly as a complete unit. See
away from the truck for access to the hoses.
CARRIAGE ASSEMBLY or REACH ASSEMBLY-REMOVAL
AND INSTALLATION. If the reach assembly will be removed
8. Installlabels on the bulkhead hoses for correct connection
with the mast assembly, operate the REACH/RETRACT
during installation. Disconnect the mast and carriage or reach
control handle to fully retract the forks. Install safety chains so
hoses from their fittings as required. Install caps on the fittings
that the forks cannot extend. Install the safety chains around and hoses to prevent leakage.
the center plates of the scissor arm weldment and a
crossmember of the mast. Make sure a safety chain does not
9. Install labels on all plugs and wires for the electrical cable
touch the mount for the hose sheave, lift chains, chain or hose
for correct connection during installation. Disconnect the plugs
sheaves, hoses, tubes or fittings. If installed, operate the
and wires so that the cable is completely disconnected from the
SIDESHIFT control handle to move the outer frame to the truck. The plugs are near the cable tension device inside the
center position.
electrical compartment above the battery.
1. Removethe capscrew and nuts that fasten the mast guard
10. Move the mast assembly away from the truck.
and remove the guard. See Figure 8-19.
11. Lower the carriage or reach assembly so that the safety
2. Remove the capscrews that fasten the rear legs to the
chains are the support for the carriage or reach assembly and
overhead guard. See Figure 8-19. The overhead guard will be
the lift chains do not have tension.
removed with the mast assembly.
12. If the mast will be disassembled, put the mast on a level
CAUTION: Do NOT move the control handle for
floor with the overhead guard on the bottom as a support. Install
the reach, retract, tilt or sideshift functions. Oil will
a support under the other end. Make sure the mast is level.
flow from the hoses for these functions. Keep the safety chains on the mast assembly that were
installed in Step 6.
3. Operate the LIFT/LOWER control handle to raise the inner
weldment high enough to remove the four capscrews, the
13. If the mast will NOT be disassembled, put the mast on a
shims and the nut plates that fasten the bottom of the mast to level floor with the overhead guard on top.
the truck frame.
Cleaning and Inspection
4. Install safety chains to keep the mast components from
moving. Remove the capscrews, washers and clamps that WARNING: Cleaning solvents can be flammable
fasten the lift cylinder hoses to the mast weldments. Do NOT and toxic, and can cause skin irritation. Wear
disconnect any hydraulic fittings. protection for eyes and skin. When using cleaning
solvents, always follow the recommendations of the
5. Remove the safety chains installed in Step 4. Do not manufacturer.
damage hydraulic hoses as the mast lowers. Carefully operate
the LIFT/LOWER control handle to fully lower the inner 1. Clean the mast weldments with steam or solvent.
weldment. Make sure that all hydraulic pressure is removed
from the system. WARNING: Some parts can be damaged by
welding and cause an injury. Get authorization and
6. Mark the trunnion caps so they can bereassembled in the instructions from your Yale lift truck dealer before
same position and on the same trunnion from which they are welding on the mast , reach or carriage assembly.
removed. Usechain to connect a crane or other lifting device to
8-33
Yale
IndustrialTrucks mast and reach assembly
INNER WELDMENT
INTERMEDIATE WELDMENT
OUTER WELDMENT
FREE LIFT CYLINDER
MAIN LIFT CYLINDER
A. LOCK PLATE
B. RETAINER
SHEAVE SUPPORT ASSEMBLY
A. SPACER
B. SNAP RING
C. BALL BEARING
D. CHAIN SHEAVE
E. SPACER (NS ONLY)
F. SHAFT
FREE LIFT CHAIN
CHAIN ANCHOR
CLAMP
CHAIN SHEAVE ASSEMBLY (RH)
A. CHAIN SHEAVE
B. BALL BEARING
C. SNAP RING
MAIN LIFT CHAIN
LOAD ROLLER
FREE LIFT HOSE SHEAVE
FLOW REGULATOR HOUSING
HYDRAULIC TUBE (MAIN LIFT)
HYDRAULIC HOSE (MAIN LIFT)
TRUNNION STUB SHAFT
TO TRUCK CONTROL VALVE
REAR VIEW
HOSE ROUTING - LIFT
8-34
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
2. Inspect the sliding and rolling surfaces of the channels for inner weldment will lower so that the free lift hose does not have
damage (dents) and wear (grooves). Inspect all welds for tension.
cracks.
9. Disconnect the hydraulic hose from the free lift cylinder
Free Lift Cylinder-Removal and Installation and install caps on the fittings.
(See Figure 8-25, Figure 8-28 and Figure 8-28)
10. Remove the cylinder strap. Use a crane and sling to lift the
NOTE: Cylinder seals can be replaced without removing the
free lift cylinder off the locating screw and out of the inner
cylinder from the mast assembly.
weldment. If the free lift cylinder must be disassembled, see the
HYDRAULIC SECTION.
NOTE: The following procedure describes how to remove the
free lift cylinder without removing the reach or carriage and
11. Reverse the procedure to install the cylinder. Make sure
mast assembly from the lift truck. If the reach or carriage
the locating screw forthe base of the free lift cylinder is installed
assembly has been removed, do only Steps 4 through 12 to
before installingthe cylinder. Use acrane and sling to installthe
remove and install the cylinder.
cylinder on the inner weldment.
1. On NR or NDR units, operate the REACH/RETRACT
12. Adjust the main lift chains. Check for hydraulic leaks and
control handle to fully retract the forks. Use safety chains to
correct operation after the cylinder is installed. See CHECKS
fasten the parts of the reach assembly so that the forks cannot
AND ADJUSTMENTS.
extend.
Main Cylinders-Removal and Installation
2. Raise the reach approximately 60 cm (2 ft). Use safety
(See Figure 8-25)
chains between the reach assembly and inner weldment to
prevent the reach assembly from lowering. Operate the NOTE: It is necessary to remove the mast assembly from the
LIFT/LOWER control handle to retract the free lift cylinder. truck to remove the main cylinders.
3. Remove the load backrest extension as described in 1. Remove the mast assembly as described in TRIPLEX
LOAD BACKREST EXTENSION-REMOVAL AND INSTALLA¬ MAST ASSEMBLY-REMOVAL.
TION.
2. Remove the safety chains that fasten the mast weldments
4. Fasten the free lift chains so that they cannot move over together and use a prybar to carefully and slowly move the
the sheaves. Remove the cotter pins from the pins that fastens intermediate weldment approximately 75 mm (3 in) out of the
each free lift chain to the chain anchor at the free lift cylinder. outer weldment.
Carefully remove these pins. This removal procedure will not
change the chain adjustment. 3. Install a sling and crane to support the cylinder. Remove
the capscrews, washers and lock plate at the base of one main
5. If there are also hose and cable sheaves in the sheave cylinder.
support, disconnect the hoses at the free lift cylinder. Install
caps on the hydraulic fittings. Disconnectthe spring of the cable WARNING: Be careful when removing or
tension device. See Figure 8-27. installing snap rings. These snap rings are large
and can come loose during removal or installation
6. Lift the sheave support assembly out of the free lift cylinder with enough force to cause an injury. Always use the correct
and put the lift chains, hoses, cable and sheave support over snap ring pliers and wear eye and face protection during
the carriage or reach assembly or fasten them out of the way. removal or installation.
7. Hold the LIFT/LOWER control lever in the LOWER 4. Remove the snap ring, back-up washer, rubber bushing .
position for approximately five seconds to fully retract the free and shims (if applicable) that fasten the cylinder rod to the
lift cylinder rod and to remove all hydraulic pressure. It can be intermediate weldment. If shims are used, make a note of the
necessary to push the rod into the cylinder while the control shim arrangement. Normally, the shim arrangement for the
lever is in the LOWER position. replacement cylinder will besimilar.
/\ WARNING: Make sure that the power is off and 5. Remove the hose or tube between the main cylinder and
/f\ the key is removed. Put a "DO NOTOPERATE" tag the flow regulator. If necessary, use a prybar to carefully move
CJh) in the operator's compartment. Disconnect the the reach assembly or carriage assembly and mast weldments
battery and put a tag or lock on the battery connector. for access. Install a cap on the regulator fitting to prevent
leakage.
8. Loosen, but do not remove, the nuts for the main lift chains
at the chain anchors near the top of the outer weldment. The 6. Remove the main cylinder retainer, capscrews and
washers.
8-35
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
7. Repeat the Steps 2 through 7 to remove the other main 9. Push the cylinder toward the top of the mast assembly to
cylinder. move the main cylinder off the locating dowel pin. Continue to
push the cylinder so that the rod moves into the cylinder to allow
NOTE: See the HYDRAULIC SECTION to disassemble and removal from the intermediate weldment.
repair the cylinder.
RIGHT SIDE
REAR VIEW VIEW
"T
t
1. CHAIN SHEAVE
2. HOSE SHEAVE 7. MANIFOLD BLOCK
3. CABLE SHEAVE 8. TO REACH ASSEMBLY
4. CABLE TENSION DEVICE 9. HYDRAULIC HOSES
5. TO TRUCK 10. SHEAVE SUPPORT
6. ELECTRICAL CABLE FOR REACH ASSEMBLY 11. TRUNNION STUB SHAFT
8-36
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
hydraulic pressure. Holdthe control lever (for each function) in 3. Lower the carriage or reach assembly so that the safety
the forward position for approximately five seconds to release chains are the support for the carriage or reach assembly and
the pressure. Make sure the hydraulic pump does NOT inner weldment. The lift hose for the free lift cylinder must not
operate. Move the key to the OFF position. Disconnect the have tension.
battery and put a tag or lock on the battery connector.
4. -Removethe snap ringf washer, -free lift bose sheave and
NOTE: Access can be difficult for some fittings. If necessary, spacer at the bottom of the intermediate weldment.
operate the system to move mast weldments or the carriage or
reach assembly. Make sure to foMow the SAFETY 5. Follow the-reverse procedure to inslallthehose sheave for
PROCEDURES after moving components BEFORE starting the free lift cylinder.
work. Also make sure the system does not have pressure as
described in Step 1. Carriage or Reach Sheaves-Removal and Replacement
Remove the sheaves, for the hoses and cable to the carriage or
2. Disconnect hoses, drain any excess oil into a container
reach assembly as follows:
and install caps to prevent dirt from entering the hydraulic
system.
1. Fully lower the carriage or reach assembly. Fully retract
the forks if the reach assembly is installed. Install safety chains
3. Replace the hose. Operate the system to remove allthe air
between the tops of the inner and outer weldments of the reach
from the oil and to check for leaks.
assembly to prevent reach operation.
Hose and Cable Sheaves Replace
CAUTION: Do NOT use steam to clean the lift
(See Figure 8-27 and Figure 8-28)
chains, sheaves or load rollers. The sheaves and
NOTE: The following procedures describe how to replace the roller bearings are sealed and permanently
hoseandcable sheaves without removing the carriage or reach lubricated. Do not use compressed air on the bearings. The air
assembly or mast assembly from the lift truck. If the mast can force the lubricant out of the bearings.
assembly has been removed, carefully move the carriage or
reach assembly, inner or intermediate weldments using a WARNING: The mast weldments can move and
prybar as necessary. cause an injury. Make sure the mast assembly is
level with the carriage or reach assembly side on
WARNING: The mast weldments can move and top to prevent unexpected movement of the mast weldments.
cause an injury even if the mast assembly has
been removed from the lift truck. Make sure the 2. Make sure that the system does not have hydraulic
mast assembly is level to prevent the components from moving pressure. Hold the control lever (for each function) in the
without being moved. Use safety chains to prevent movement forward position for approximately five seconds to release the
after components are in the correct position. pressure. Make sure the hydraulic pump does NOT operate.
Move the key to the OFF position. Disconnect the battery and
Free Lift Hose Sheave put a tag or lock on the battery connector.
Remove the sheave, for the hose to the free lift cylinder, as
3. Fasten the carriage or reach assembly hoses. Install the
follows:
reach assembly electrical cable to the top of the sheave support
at the free lift cylinder. Disconnect or remove the hoses at the
1. Fully retract the forks if the reach assembly is installed.
carriage or reach assembly. Install caps to prevent dirt from
Move the key to the OFF position. Disconnect the battery and
entering the hydraulic system.
put a tag or lock on the battery connector. Install safety chains
between the tops of the inner and outer reach weldments of the
4. Install tags on the connectors and wires of the electrical
reach assembly to prevent reach operation.
cable at the reach assembly for correct connection later.
Disconnect the electrical cable.
2. Operate the LIFT/LOWER control lever to raise the inner
weldment. Use safety chains to fasten the reach assembly or
5. Install tags on the hydraulic hoses at the- reach assembly
carriage assembly and inner weldment so that they cannot
for correct connection later. Disconnect the hoses and install
move and the bottom of the innerweldment is approximately 60
caps to prevent dirt from entering the hydraulic system.
cm (2 ft) off the floor.
8-37
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
REAR VIEW
REAR VIEW
14
1. HOSE SHEAVE 11. HOSE AND CABLE SHEAVE ASSEMBLY AT SHEAVE SUPPORT
2. ELECTRICAL CABLE SHEAVE 12. ELECTRICAL CABLE (REACH ONLY)
3. SPACER 13. TO SHEAVE SUPPORT ANO CARRIAGE OR REACH ASSEMBLY
4. WASHER 14. TENSION DEVICE FOR ELECTRICAL CABLE
5. CAPSCREW 15. MANIFOLD BLOCK
6. CHAIN SHEAVE FOR MAIN LIFT 16. TO TRUCK
7. HOSE GUARD 17. FREE LIFT CYLINDER
8. SNAP RING 18. HYDRAULIC HOSE FROM SHEAVE SUPPORT
9. INTERMEDIATE WELDMENT 19. HYDRAULIC HOSE TO CARRIAGE
10. INNER WELDMENT
8-38
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
REAR VIEW
REACH OR CARRIAGE ASSEMBLY
SIDESHIFT ONLY
REAR VIEW
17
TO REACH OR CARRIAGE ASSEMBLY
ELECTRICAL CABLE FOR REACH ASSEMBLY
TO LIFT TRUCK
HYDRAULIC HOSE (LIFT)
LIFT TRUCK FRAME ÿ J
HOSE TO RIGHT MAIN CYLINDER
TUBE TO LEFT MAIN CYLINDER ''
FLOW REGULATOR HOUSING
REGULATOR MOUNT PLATE
MAIN LIFT CYLINDERS IjJ
/
13
OUTER WELDMENT ÿ--ÿ0
FRONT VIEW
6. Remove the two capscrews and nuts that fasten the two Main Lift Chains
halves of the hose and cable sheave together. See Figure 8-27.
1. Raise the mast until the lower chain anchors are visible on
Do not let the sheave halves fall.
the inner weidment.
7. Carefully remove the capscrews that fasten the hose and
2. Use safety chains to fasten the inner weidment so that it
cable sheaves at the top of the intermediate weidment. Do not
cannot move. Operate the LOWER control lever to lower the
let any of the parts fall. These capscrews fasten to the stub
masts until the safety chains are a support for the inner
shafts of the chain sheaves.
weidment and lift chains do not have tension.
8. Follow the reverse procedure to install the hose and cable
NOTE: Removing the pins, at the chain anchors, will
sheave for the carriage. Make sure to operate the carriage
disconnect the lift chains without changing the chain
hydraulic function(s) and check for leaks after the hoses are
adjustment. Always adjust the chains if new lift chains or other
connected.
components are installed.
Triplex Lift Chain Removal and Installation
3. Fasten both main lift chains so that they cannot move over
(See Figure 8-25)
the sheaves. Removethe chain anchor pins at each end of both
WARNING: Keep control of the lift chains when main lift chains. Hold each chain to keep it from moving too fast
disconnecting them from the chain anchor. This and carefully remove them.
procedure will prevent the lift chains from falling
and causing injury or damage. 4. Inspect the main lift chains as described in CHECKS AND
ADJUSTMENTS. Replace the main lift chains if necessary.
WARNING: Never replace just the worn section
of a lift chain. Replace the complete chain. Never 5. Reverse the procedure to install the main lift chains.
replace just one chain of a chain pair. Replace both
chains. 6. Adjust the main lift chains as described in CHECKS AND
ADJUSTMENTS.
Free Lift Chains
Triplex Chain Sheaves-Disassembly and Assembly
1. Operate the LIFT/LOWER control lever to raise the
(See Figure 8-25)
carriage. Use safety chains to fasten the carriage so that it
cannot move and the forks are approximately 60 cm (2ft) off the Free Lift Chain Sheaves
floor.
1. If necessary, remove the free lift chains as described in
TRIPLEX LIFT CHAINS-REMOVAL AND INSTALLATION.
2. Lower the carriage so that the safety chains are the
support for the carriage and the lift chains do not have tension.
WARNING: Be careful when removing or
installing snap rings. These snap rings are large
NOTE: Removing the pins, at the chain anchors, will
and can come loose during removal or installation
disconnect the lift chains without changing the chain
with enough force to cause an injury. Always use the correct
adjustment. Always adjust the chains if new lift chains or other
snap ring pliers and wear eye and face protection during
components are installed.
removal or installation.
3. Fasten both free lift chains so that they cannot move over
2. Remove the snap ring from the shaft in the sheave
the sheaves of the sheave support. Remove the chain anchor
support.
pins at each end of both free lift chains. Hold each chain to keep
it from moving too fast and carefully remove them. 3. Use a drift to tap the shaft out of the sheave support.
4. Inspect the free lift chains as described in CHECKS AND
4. Remove the sheaves and spacers as a group. Inspect all
ADJUSTMENTS. Replace the free lift chains if necessary.
components for wear or damage. Replace any part that is worn
or damaged.
5. Reverse the procedure to install the free lift chains.
5. Reverse the procedure to install the chain sheaves.
6. Adjust the free lift chains as described in CHECKS AND
ADJUSTMENTS. Main Lift Chain Sheaves
1. If necessary, remove the main lift chains as described in
TRIPLEX LfFT CHAINS-ftEMOVAL AND INSTALLATION.
8-40
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
2. Remove both pins from the chain anchors at the rear of the
free lift cylinder. Remove each lift chain from the sheaves. 4
3. Always install safety chains to prevent the weldments from 4. Use a prybar to remove the load roller from the mast
moving BEFORE starting to replace any load roller. Remove weldment.
the snap rings that fasten the load rollers.
8-41
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
5. Use a cloth to clean each load roller. Inspect the load 7. Install safety chains between the outer, intermediate and
rollers for cracks, flat spots or bearings that do not turn freely. inner weldments to keep the intermediate and inner weldments
Replace any roller that shows wear or is damaged. from moving.
6. Reverse the procedure to install the load rollers. 8. Use a prybar to align and install the four mount capscrews
andthe nutpiates thatfasten the bottom of the mast to the truck
7. Adjust the wear plugs after all load rollers and wear plugs frame. Move the bottom of the weldment in or out and add
are replaced. See CHECKS AND ADJUSTMENTS. The wear shims until the mast is adjusted between vertical to 1/2 degree
plugs are adjusted afterthe mast assembly is installed on the lift of back tilt.
truck.
9. Tighten the four mount capscrews to 203 N«m (150 Ibf ft)
Triplex Mast Assembly-Installation torque.
NOTE: If the carriage or reach assembly is installed on the
mast, it must have a safety chain installed as described in 10. Install the hose clamps and hose bracket. Operate the
SAFETY PROCEDURES. LIFT/LOWER control handle to raise the inner weldment high
enough to carefully remove the safety chains. Remove the
WARNING: Do not install the triplex mast safety chains.
assembly unless it is completely assembled. Mast
parts can move and cause an injury if not fastened 11. Tighten the four trunnion cap capscrews to 203 N«m (150
together during assembly. Ibf ft) torque. Use the crane to lower the inner and intermediate
weldments until the chain and crane are no longer the support.
NOTE: The inner and intermediate mast assemblies must be Remove the chain and crane.
in a position to allow access to the mount capscrews at the
bottom of the outer weldment. Use safety chains to keep the 12. Install the mast guard and capscrews that fasten the rear
mast assembly from moving as described in SAFETY legs to the overhead guard.
PROCEDURES.
13. Make all adjustments and test the operation of the mast
1. Usethe crane or lifting device to lift the mast assembly and assembly before returning the truck to service. See CHECKS
move it close enough to the truck to make the necessary AND ADJUSTMENTS.
connections. Make sure the truck and mast assembly cannot
move. REACH CYLINDERS
2. Install and tighten the mast and carriage or reach Removal
assembly hoses on their correct bulkhead fittings according to (See Figure 8-30)
the labels installed during removal. NOTE: Fully extend the reach mechanism. If the scissor
arms and outer frame are installed, use clamps and blocks to
3. Move the mast assembly into position. Lower the mast prevent the scissor arms from retracting. Install the clamps and
assembly so that the outer weldment is aligned with the blocks on the channels of the inner frame and the outer frame
trunnion blocks on the lift truck frame. or apron. Install the blocks under the load bearings. See
Figure 8-30. Tighten the clamps so that the blocks cannot
NOTE: Make sure all hoses and the electrical cable are not move.
between a mast crossmember and the truck.
1. If necessary, remove the cable bracket and manifold block.
4. Align the trunnion caps according to the marks made
during removal. Install the capscrews, but leave them loose. 2. If necessary, remove the stops, shims and stop supports.
Install labels for correct installation of the shims sets in the
5. Connect all the wires of the electrical cable according to same positions. When the new stops are installed, the shim
the labels made during removal. arrangement will normally be the same or similar.
CAUTION: Install tape on all electrical wires for Cleaning and Inspection
the reach assembly if the wires are not connected
to the reach assembly. If the wires are not WARNING: Cleaning solvents can be flammable
connected, they can make a short-circuit and cause damage. and toxic, and can cause skin irritation. Wear
protection for eyes and skin. When using cleaning
6. Operate the LIFT/LOWER control handle to raise the inner solvents, always follow the recommendations of the
and intermediate weldments high enough for access to the manufacturer.
bottom of the outer weldment.
8-42
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
CAUTION: Do NOT operate the tilt or sideshift 5. Use a punch or small drift to remove the roll pin from the
functions if the outer frame has been removed. mount at each end of each reach cylinder. Make a mark on each
Hydraulic oil can come out of the hoses. rod end of the reach cylinders for correct installation. There is a
right hand and a left hand rod end.
1. Operate the LIFT/LOWER control handle to raise the
reach assembly for access to the. reach cylinders tram the 6. Have a helper,holdthe reachcylinder to keep it from falling.
operator compartment of the lift truck. Use a drift to remove the pins that fasten each end of cylinder to
the frame. Remove the other reach cylinder using the same
2. Move the key to the OFF position and disconnect the procedure.
battery. Remove the mast guard from the mast assembly.
7. Remove the bushings from each mount of the inner frame
3. Install safety chains to fasten the carriage and mast and each scissor arm.
weldments so that they cannot move. Install the safety chains
as described in SAFETY PROCEDURES. Disassembly
(See Figure 8-31)
1. Loosenthe capscrew at the rod end. Hold the rod to keep it
from turning and remove the rod end from the cylinder rod.
1. INNER FRAME MOUNT Clean all of the parts of the reach cylinder with solvent. Dry the
2. BUSHING parts with compressed air. Inspect the parts of the reach
3. PIN cylinder for damage and wear. Replace all parts that are worn or
4. ROLL PIN damaged. Replace all parts included in the cylinder repair kit.
5. REACH CYLINDER
6. ROD END Assembly
2 7. SCISSOR ARM MOUNT (See Figure 8-31)
1. Install the parts of the rod assembly as shown in
Figure 8-30 - Reach Cylinder Mounts Figure 8-31. Make sure to replace all seals and other parts
included in the cylinder repair kit. Use Loctite No. 242 on the rod
NOTE: It is normally not necessary to remove the hydraulic and nut for the piston. Install the piston seal and piston rings. If
tube from the reach cylinder. removed, tighten the piston nut to 95 N*m (70 Ibf ft) torque.
4. Install labels on the hydraulic lines for correct connection CAUTION: Do not cut or damage seals during
during installation. Disconnect the hydraulic lines at the reach installation. Be especially careful when moving
cylinders. Install caps on the hydraulic lines and cylinder ports seals across threads or edges of parts. Install tape
to prevent dirt from entering the system. over the rod threadslo protect the seals.
NOTE: If disassembly of a reach cylinder is necessary, 2. Install the rod seal, back-up ring, O-ring and wiper on the
loosen the retainer in the cylinder shell while the cylinder is retainer. Put a thin coat of hydraulic fluid on the inside of the
installed in the reach assembly. It is possible that reach shell and all parts of the piston and rod. Use O-ring lubricant
adjustments will not be necessary. If disassembly is NOT and install the rod assembly in the shell. Carefully install the
necessary and the rod ends will NOT be1replaced, mark the retainer on the rod and in lhe shell. Use a spannerwrenCh to
reach cylinders for installation in the same position. tighten the retainer to 129 to 142 N«m (95 to 105 Ibf ft) torque.
8-43
Yale
Industrial Trucks mast and reach assembly
1. LOCKNUT
2. PISTON RINGS
3. PISTON PACKING
4. PISTON
5. CYLINDER TUBE
6. PISTON ROD
7. O-RING
8. BACK-UP RING
9. ROD SEAL
10. WIPER RING
11. PACKING GLAND
8-44
Yale
Industrial Trucks JWAST AND REACH ASSEMBLY
b. The outer frame is stable so that it cannot tip. NOTE: Make sure the tilt cylinder rod is fully extended.
WARNING: The outer frame is heavy and can 1. If this unit has the sideshift function, remove the outer
cause an injury if it tips or falls. If the frame is not frame as described in OUTER FRAME-REMOVAL. Read the
installed, make sure the frame is stable. If the WARNING and make sure the frame cannot tip or fall.
frame is NOT on the floor with the fork side down for stability,
use a crane and chains to raise the frame. Install a solid 100 mm NOTE: If disassembly of the tilt cylinder is necessary, loosen
(4 in) block under each fork heel and near each fork tip. Lower the retainer while the cylinder is installed in the frame. If
the frame so that the forks are on the blocks and install a disassembly is NOT necessary and the -rod end wtH NOT be
capacity load on the forks. You can also use safety chains to removed, it is possible that tilt adjustments will not be
fasten the frame to an object that cannot tip or fall. necessary.
5. Remove the locknuts that fasten the two tilt pivots and the
rod end of the tilt cylinder together. Separate the two tilt pivots
and remove the bushings from the rod end.
Removal-without Sideshifter
NOTE: if the outer frame is installed on the scissor arms, fully
1. INNER FRAME OF REACH ASSEMBLY
extend the reach mechanism. Use clamps and blocks to
2. LOAD BEARING
3. WOOD BLOCK prevent the scissor arms from retracting. Installthe clamps and
4. CLAMP blocks on the channels of the inner frame and the outer frame.
Install the clamps and blocks under the load bearings. See
Figure 8-32 - Install Blocks and Clamps Figure 8-32. Tighten the clamps so that the blocks cannot
move.
8-45
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
1. CAPSCREW
2. LOCKWASHER
3. COTTER PIN
4. PIN
5. TILT PIVOT SHAFT
6. HOSE ASSEMBLY
7. FITTING
8. O-RING
9. TILT CYLINDER
10. LOCKNUT
11. LOCKWASHER
12. BUSHING
13. TILT PIVOT RH.
14. LOCKNUT
15. TILT CYLINDER PIN
16. ROD END
17. TILT PIVOT L.H.
18. TILT SLIDER
19. POLY BEARING BLOCK
20. END CAP
21. CAPSCREW
22. TILT SLIDER SHAFT
-
Figure 8-33 Tilt Pivot Mechanism With Sideshifter
NOTE: If the outer frame is not installed on the scissor arms 1. If this unit has the sideshift function, remove the outer
make sure of the following: frame as described in OUTER FRAME-REMOVAL. Read the
WARNING and make sure the frame cannot tip or fall.
a. There is access to the reach assembly side of the
frame.
2. install labels for correct connection during installation and
b. The outer frame is stable so that it cannot tip. disconnect the hydraulic lines at the tilt cylinder. Install caps on
the hydraulic lines and cylinder ports to prevent dirt from
/\ WARNING: The outer frame is heavy and can entering the system.
I cause an injury if it tips or falls. If the frame is not
I\
Cm) installed, make sure the frame is stable. If the NOTE: If disassembly of the tilt cylinderis necessary, loosen
frame is NOT on the floor with the fork side down for stability, the retainer while the cylinder is installed in the frame. If
use a crane andchains to raisethe frame. Install a solid 100 mm disassembly is NOT necessary and the rod end will NOT be
(4 in) block under each fork heel and near each fork tip. Lower removed, it is possible that tilt adjustments will not be
the frame so that the forks are on the blocks and install a necessary.
capacity load on the forks. You can also use safety chains to
fasten the frame to an object that cannot tip or fall. 3. Remove the two capscrews, lockwashers and cotter.pins
that fasten the top two tilt roller shafts for the left and right hand
NOTE: Make sure the tilt cylinder rod is fully extended. tilt pivots. Remove the two tilt roller shafts. Hold the tilt cylinder
so that the cylinder and tilt pivots cannot fall.
8-46
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
7. FITTING
8. O-RING
9. TILT CYLINDER
10. LOCKNUT
11. LOCKWASHER
12. BUSHING
13. TILT PIVOT R H.
14. LOCKNUT
15. TILT CYLINDER PIN
HI Jll
111 16. ROD END
ill 17.
18.
TILT PIVOT L.H.
TILT ROLLER
19. TILT ROLLER SHAFT
\
12
V
\
1. CAPSCREW
2. LOCKWASHER
3. COTTER PIN
4. PIN
5. TILT PIVOT SHAFT
6. HOSE ASSEMBLY
-
Figure 8-34 Tilt Pivot Mechanism Without Sideshifter
8-47
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
Cleaning And Inspection and nut for the piston. Install the piston seal and tighten the
piston nut to 149 N«m (110 Ibf ft) torque.
/\ WARNING: Cleaning solvents can be flammable
/ 1\ and toxic, and can cause skin irritation. Wear
A
_« CAUTION: Do not cut or damage seals during
protection for eyes and skin. When using cleaning
solvents, always follow the recommendations of the I\ installation. Be especially careful when moving
i seals across threads or edges of parts. Install.tape
manufacturer.
over the rod threads to protect the seals.
Clean all of the parts of the tilt cylinder with solvent. Dry the
2. Install the rod seal, back-up ring, O-ring and wiper on the
parts with compressed air. Inspect the parts of theirlt cyiinder
retainer. Put a thin coat of hydraulic fluid on the inside of the
for damage and wear. Replace ail parts that are worn or
shell and all parts of the piston and rod. Use O-ring lubricant
damaged. Replace all parts included in the cylinder repair kit.
and install the rod assembly in the shell. Carefully install the
retainer on the rod and in the shell. Use a spanner wrench to
Assembly
tighten the retainer to 167 to176 N*m (123 to 130 Ibf ft) torque.
1. Install the parts of the rod assembly as shown in
Figure 8-35. Make sure to replace all seals and other parts 3. Install a new bushing in the mount hole at the shell end of
included in the cylinder repair kit. Use Loctite No. 242 on the rod the tilt cylinder.
1. LOCKNUT
2. PISTON
3. PISTON PACKING
4. PISTON ROD
5. CYLINDER TUBE
6. ROD PACKING
7. O-RING
8. BACK-UP RING
9. GLAND
10. WIPER RING
11. BUSHING
8-48
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
5. Align and install the right hand and left hand tilt pivots and 3. Install new bushings for all pivot points of the tilt assembly.
spacer pins in the rod end of the tilt cylinder. Install four new Lubricate all bushings with multi-purpose grease.
locknuts. See Figure 8-34. Tighten all four locknuts to 136 N*m
(100 Ibf ft) torque. 4. Installthe tilt roller shafts for the tilt roller assemblies in the
tilt pivots. Install the cotter pins and secure with the capscrews
6. Install the tilt pivot assemblies in the outer frame using the and lockwashers.
shafts, cotter pins, lockwashers and capscrews.
5. Align and install the right hand and left hand tilt pivots and
7. Connect the hydraulic lines to the tilt cylinder as marked spacer pins in the rod end of the tilt cylinder. Install four new
during removal and disassembly. Always use new O-rings on locknuts. See Figure 8-34.'Tighten all four locknuts to 136~N*m
the O-ring fittings. (100 Ibf ft) torque.
CAUTION: The outer frame assembly must be 6. Install the tilt pivot assemblies in the outer frame using the
installed on the apron as described in OUTER shafts, cotter pins, lockwashers and capscrews.
FRAME. The reach assembly must also be
installed on the mast before doing Step 8. 7. Connect the hydraulic lines to the tilt cylinder as marked
during removal and disassembly. Always use new O-rings on
8. After all hydraulic lines are connected, operate the the O-ring fittings.
functions to check for leaks and correct operation.
CAUTION: The outer frame assembly must be
Installation-without Sideshifter installed on the apron as described in OUTER
FRAME. The reach assembly must also be
NOTE: If the outer frame is not installed on the scissor arms
installed on the mast before doing Step 8.
make sure of the following:
a. There is access to the reach assembly side of the 8. After all hydraulic lines are connected, operate the
frame. functions to check for leaks and correct operation.
b. The outer frame is stable so that it cannot tip.
SIDESHIFT CYLINDER
WARNING: The outer frame is heavy and can
Removal
cause an injury if it tips or falls. If the frame is not
installed, make sure the frame is stable. If the NOTE: If the outer frame is not installed on the scissor arms,
frame is NOT on the floor with the fork side down for stability, make sure the frame is stable so that it cannot tip.
use a crane and chains to raise the frame. Install a solid 100 mm
(4 in) block under each fork heel and near each fork tip. Lower WARNING: The outer frame is heavy and can
the frame so that the forks are on the blocks and install a cause an injury if it tips or falls. If the frame is not
capacity load on the forks. You can also use safety chains to installed, make sure the frame is stable. If the
fasten the frame to an object that cannot tip or fall. frame is NOT on the floor with the fork side down for stability,
use a crane and chains to raise the frame. Install a solid 100 mm
1. Installthe nut, special lockwashers and rod end on the rod. (4 in) block under each fork heel and near each fork tip. Lower
Make sure the flat sides of the special lockwashers are both the frame so that the forks are on the blocks and install a
facing out. Install new bushings in the anchor end of the tilt capacity load on the forks. You can also use safety chains to
cylinder and in the rod end. Lubricate the bushings with fasten the frame to an object that cannot tip or fall.
multi-purpose grease.
1. Install labels for correct connection during installation and
2. Align the anchor end of the cylinder on the cylinder mount disconnect the hydraulic lines from the sideshift cylinder. Install
(ports to the rear). Install the pin, cotter pin, lockwasher and caps on the hydraulic lines and cylinder ports to prevent dirt
capscrew to fasten the cylinder to the outer frame. from entering the system.
8-49
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
NOTE: If disassembly of a sideshift cylinder is necessary, cylinder for damage and wear. Replace ail parts that are worn or
loosen the retainer while the cylinder is installed. damaged. Replace all parts included in the cylinder repair kit.
Assembly
1. HOSE ASSEMBLY
2. FITTING 1. Install the parts of the rod assembly as shown in
3. O-RING Figure 8-37. Make sure to replace all seals and -other parts
4. ROLL PIN included in the cylinder repair kit. Use Loctite No. 242 on the rod
5. CLEVIS PIN and nut for the piston. Install the piston seal and tighten the
6.
7.
COTTER PIN
WASHER
piston nut to 149 N»m (110 Ibf ft) torque. . . . . „
2. install the rod seal, back-up ring, O-ring and wiper on the
retainer. Put a thin coat of hydraulic fluid on the inside of the
shell and all parts of the piston and rod. Use O-ring lubricant
and install the rod assembly in the shell. Carefully install the
retainer on the rod and in the shell. Use a spanner wrench to
tighten the retainer to 129 to 142 N»m (95 to 105 Ibf ft) torque.
rKjpf
Installation
10. ROD END NOTE: If the outer frame is not installed on the apron, make
11. LOCKNUT sure the frame is stable so that it cannot tip.
12. SIDESHIFT CYLINDER
WARNING: The outer frame is heavy and can
cause an injury if it tips or falls. If the frame is not
Figure 8-36 - Sideshift Cylinder Mounting installed, make sure the frame is stable. If the
frame is NOT on the floor with the fork side down for stability,
2. Remove the roll pin from the stationary end of the sideshift use a crane and chains to raise the frame. Install a solid 100 mm
cylinder. Remove the cotter pin from the clevis pin at the (4 in) block under each fork heel and near each fork tip. Lower
opposite end. the frame so that the forks are on the blocks and install a
capacity load on the forks. You can also use safety chains to
3. Support the cylinder and remove the clevis pins. Remove fasten the frame to an object that cannot tip or fall.
the cylinder.
1. Hold the sideshift cylinder in the correct position on the
Disassembly outer frame. Align the cylinder for installation on the outer frame
1. Loosen the locknut at the rod end. Remove the rod end and the apron.
and locknut from the cylinder rod.
2. Install the clevis pins at both cylinder mounts. Install the
2. Carefully remove the retainer and rod assembly from the washers and a new cotter pin in the moveable end of the
cylinder shell. sideshift cylinder. Install a roll pin in the stationary end of the
sideshift cylinder.
3. Carefully remove the parts of the rod assembly as shown
in Figure 8-37. 3. Connect the hydraulic lines to the sideshift cylinder as
marked during removal. Always use new O-rings on the O-ring
Cleaning and inspection fittings. If necessary to connect the hydraulic lines, see
Figure 8-36. Operate the sideshift function to check for leaks
WARNING: Cleaning solvents can be flammable and correct operation.
and toxic, and can cause skin irritation. Wear
protection for eyes and skin. When using cleaning 4. Remove the air from the system as described in CHECKS
solvents, always follow the recommendations of the AND ADJUSTMENTS.
manufacturer.
Clean all of the parts of the sideshift cylinder with solvent. Dry
the parts with compressed air. Inspect the parts of the sideshift
8-50
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
1. LOCKNUT
2. PISTON
3. PISTON PACKING
4. PISTON ROD
5. CYLINDER TUBE
6. ROD PACKING
7. O-RING
8. BACK-UP RING
9. PACKING GLAND
10. WIPER RING
1. Operate the LIFT/LOWER control handle to raise the 5. Install labels on all hoses, hydraulic lines and electrical
reach or inner frame assembly for access to the selector valve wires connected to the selector valve for correct connections
from the operator's compartment. during installation. Make a note of the location of all cable ties
for correct installation of new cable ties during installation.
WARNING: There are pinch points on the mast
and reach assembly that can cause an injury. Use WARNING: Hoses and cables can roll over the
safety chains on the inner frame and mast sheaves to fall and cause an injury if the ends are
weldments to keep the inner frame and mast weldments from not fastened. Keep control of the ends of the hoses
moving. Install the safety chains as described in SAFETY and cables as they are removed. Use wire to temporarily fasten
PROCEDURES. the ends of the hoses or cables.
2. If the scissor arm assembly is installed, operate the 6. Remove the hydraulic lines, electrical cables and hoses.
REACH/RETRACT control handle to fully retract the forks. See Figure 8-38. Install caps on all hydraulic fines and valve
ports to prevent dirt from entering the system.
3. Move the key to the OFF position and disconnect the
battery. Use safety chains to fasten the parts of the reach 7. Remove the hose and cable sheave.assembly from the
assembly so that the forks cannot extend. bottom of the selector valve.
8-51
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
Disassembly
1. Remove all fittings from the selector valve. See
Figure 8-38.
3. Remove and discard all O-rings from the valve and fitting
parts.
Clean all of the parts of the selector valve with solvent. Dry the
parts with compressed air. Inspect the parts of the selector
valve for damage and wear. Replace all parts that are worn or
damaged. Replace all O-rings.
8-52
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
WARNING: There are pinch points on the mast valve for damage and wear. Replace all parts that are worn or
that can cause an injury. Use safety chains on the damaged. Replace all O-rings.
inner frame and mast weldments to keep the inner
frame and mast weldments from moving. Install the safety Assembly
chains as described in SAFETY PROCEDURES.
1. Use O-ring lubricant andinstall new O-rings on the parts of
the selector valve.
1. If the outer frame is installed, operate the
REACH/RETRACT control handle to fully extend the forks.
2. Install the parts in the valve block as shown in Figure 8-39.
2. Move the key to the OFF position and disconnect the
battery.
5. Remove the hose and cable guide and the solenoid valve
body. 6
Disassembly
1. Remove all fittings from the selector valve.
3. Remove and discard all O-rings from the valve and fitting
parts.
1. HOSE AND CABLE GUIDE
Cleaning and Inspection 2. VALVE BODY
3. SOLENOID (1 OF 2) (SIDESHIFT ONLY)
WARNING: Cleaning solvents can be flammable 4. PLUG
and toxic, and can cause skin irritation. Wear
protection for eyes and skin. When using cleaning
solvents, always follow the recommendations of the
5.
6.
OUTER FRAME
TILT CYLINDER _
manufacturer. -
Figure 8-39 Titt/Sideshift Selector Valve
Clean all of the parts of the selector valve with solvent. Dry the
parts with compressed air. Inspect the parts of the selector
8-53
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
WARNING: There are pinch points on the outer CAUTION: The reach assembly must be
frame that can cause an injury. Use clamps and completely assembled and installed on the lift truck
blocks to prevent the scissor arms from moving. before doing this procedure.
Installthe clamps and blocks at the channels of the inner frame
to make sure that the load bearings cannot move in the Operate the reach, the tilt and the sideshift functions to remove
channel. See Figure 8-32. the air from the hydraulic system. Fully extend and retract each
cylinder rod. When the cylinder rod reaches the end of its
2. Move the key to the OFF position and disconnect the stroke, hold the control handle for approximately two seconds.
battery. Repeat the procedure as many times as necessary for each
cylinder until the operation of all cylinders is smooth.
3. Holdthe hose and cable guide and the selector valve in the
correct position on the frame and install the two capscrews and Check for Leaks in Hydraulic System
lockwashers.
1. Slowly raise and lower the mast several times without a
load. On NR or NDR trucks, operate the reach assembly
4. Connect the hydraulic lines as marked during
functions several times. Put a capacity (see the Nameplate)
disassembly. Always use new O-rings on the O-ring fittings. If
load on the forks and raise and lower the load several times. On
necessary to connect the hydraulic lines, see Figure 8-39.
NR or NDR trucks, operate the reach assembly functions
several times. Lower the load. Check for leaks and repair as
5. Operate the TILT and SIDESHIFT functions to check for
necessary.
leaks and correct operation.
2. On all models, raise the reach or carriage assembly and
6. Remove the clamps and blocks from all channels for the
the capacity load one metre (3 ft). If the reach or carriage
load bearings. Remove the air from the system as described in
assembly lowers slowly with the control handle in a NEUTRAL
CHECKS AND ADJUSTMENTS.
position, there are leaks inside the hydraulic system. The
maximum speed that the reach or carriage assembly is allowed
CHECKS AND ADJUSTMENTS to lower is 50 mm (2 in) in 10 minutes when the hydraulic oil is
Check Mast Operation 30° C (90° F). If the oil temperature is 70° C (160° F), the
maximum speed that the reach or carriage assembly can lower
WARNING: Do not try to locate hydraulic leaks by is 150 mm (6 in) per 10 minutes.
putting hands on pressurized hydraulic
components. Hydraulic oil can be injected into the 3. Check the lift cylinders for internal leaks. Remove the load
body by pressure. from the forks. Install a gate valve in each of the supply lines
between the electro-mechanical control valve and the mast.
1. Check for leaks in the hydraulic system. Check the Put a capacity load on the forks again. Raise the carriage one
condition of the hydraulic hoses and tubes. meter (3 ft). Close both gate valves. If the reach or carriage
assembly or inner mast lowers slowly, the seals in the lift
2. Slowly raise and lower the mast several times without a cylinders have leaks.
load. The mast components must raise and lower smoothly in
the correct sequence. 4. If the reach or carriage assembly does not move, open
both gate valves and check the movement again. If the reach or
NOTE: Some parts of the mast move at different speeds carriage assembly lowers when the gate valves are open,
during raising and lowering. check for leaks in the hydraulic lines and fittings. If no leaks are
found, the electro-mechanical control valve can have a defect.
3. The weldments and the carriage or reach assembly must Remove the load from the forks.
lower completely.
5. On NR or NDR trucks, slowly tilt the forks forward, if the
4. Check that the controls for the carriage and reach forks continue to slowly tilt forward when the control handle is in
assembly operate the functions installed on the lift truck. See
8-54
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
7. If the forks do not move, open the gate valve andcheck for
movement again. If the forks move forward when the gate valve
is open, check for leaks in the hydraulic lines or fittings. If no
leaks are found, the electro-mechanical control valve or
Valvistors can be damaged. Remove the load from the forks.
2. Inspect the chain anchors and pins. Replace any parts that
are worn or damaged.
6705
1. WORN PIN
3. Inspect the chain sheaves. Replace any parts that are 5. LOOSE LEAVES
2. CRACKS
worn or damaged. 6. DAMAGED PIN
3. .EDGE WEAR
4. HOLE WEAR 7. CORROSION
8-55
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
1. Loosen the jam nut on the wear plug using the special tool
5062050-00 available from your Yale lift truck dealer. See
Figure 8-41. Also see Figure 8-42. Raise and lower the mast
weldments several times to find the point of minimum clearance
of the weldment.
1. LOAD ROLLER
2. WEAR PLUG 7
2. Adjust the wear plugs to attain zero clearance between the 3. SNAP RING
wear plug and the weldment channel at the tightest point.
4. SET SCREW
Adjust wear plugs on opposite sides to keep the weldment in
5. JAM NUT
the center. 6. STUB SHAFT
7. MAST OR CARRIAGE WELDMENT
3. Adjust the clearance to approximately 0.5 mm (0.02 in) by 8. WELDMENT CHANNEL
turning the adjustment handle 1/8 turn counter clockwise. Keep
Figure 8-41 - Load Roller and Wear Plug Assembly
8-56
Yalo
IndustrialTrucks MAST AND REACH ASSEMBLY
2. If the distance is correct, the free lift chains are adjusted for
the correct height. Do Step 5 next. If the distance is NOT
correct, do all of the steps.
1. SPECIAL TOOL 5062050-00 3. Raise the carriage or reach assembly for access to the
2. ADJUSTMENT HANDLE
3. WELDMENT chain anchors near the top of the free lift cylinder. Install safety
chains as described in SAFETY PROCEDURES on Page 2.
Remove the mast guard. See Figure 8-19. Loosen both
Figure 8-42 - Wear Plugs-Adjustment
locknuts at the chain anchors to make any adjustments.
Adjust Wear Strips
4. Adjust the nuts of the chain anchors equal amounts for the
(See Figure 8-43)
correct distance (Step 1).
NOTE: The wear plugs and lift chains must be adjusted
before the wear strips are checked for wear, replaced and
adjusted.
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:
5. Check chain tension by pushing on both chains at the NOTE: When the chain adjustments are complete, make
same time. If the tension is not the same, adjust the nuts on the sure that the cotter pin at the bottom of the chain anchor, can
chain anchors until the tension is the same and the distance be installed under the adjustment nut. If there is no room to
(Step 1) is also correct. When the tension is equal on both install the cotter pin, the chains are too short. Installthe correct
chains, the chain sheave assembly will be level. Tighten the chains. Make sure that the locknuts on the chain anchors are
locknuts. tight against the mount plate. If there are not enough threads
on the chain anchor for correct adjustment, new chains are too
NOTE: When the chain adjustments are complete, make long or old chains are too worn. Links can be removed from old
sure that the cotter pin at the bottom of the chain anchor can be chains if the chains are less than 3% longer than the correct
installed under the adjustment nut. If there is no room to install new chain. Replace of d chamsthat are too long er newchains
the cotter pin, the chains are too short. Install the correct that are not the correct length.
chains. Make sure that the locknuts on the chain anchors are
tight against the mount plate. If there are not enough threads 6. Tighten the chain anchor jam nuts.
on the chain anchor for correct adjustment, new chains are too
long or old chains are too worn. Links can be removed from old 7. Check the mast operation described at the beginning of
chains if the chains are less than 3% longer than the correct this CHECKS AND ADJUSTMENTS section.
new chain. Replace old chains that are too long or new chains
that are not the correct length. 8. Install the mast guard if removed.
8-58
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
8-59
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
7. Raise and lower the carriage with a load. Check that there
is minimum clearance with free movement. If the carriage does O
not move smoothly, during lowering, follow the WARNING and
adjust the wear plugs equally for more clearance.
NOTE: Make sure the total shim thickness for each side is the
same for each set of side rollers. Equal shim thickness will keep
the clearance equal between the carriage or reach assembly
and mast weldment on both sides.
3. If the distance "B" is more than 4 mm (0. 16 in) less than the
maximum measurement of Step A, install smaller size thrust
rollers. If the distance "B" is more than 4mm (0.16 in) greater
than the maximum measurement of Step A, install larger size Figure 8-45 - Measuring Channel Width
thrust rollers. Install the same size rollers on each side for a
minimum clearance at the maximum measurement point (Step
1). Thrust rollers have outside diameters of 74, 76 or 78 mm
(2.88, 2.96 or 3.04 in).
8-60
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
5. Fully retract the forks, check each stop on the inner frame.
8-61
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
maximum height of the fork tips. Tighten the locknutto 81 to 156 Operate the sideshift function for full movement of the outer
N»m (60 to 115 Ibf ft) torque without rotating the rod. frame. Move the key to the OFF position and disconnect the
battery. Make a measurement of the total movement of the
Adjustment for the Sideshift Cylinder outer frame (total stroke of the cylinder). Operate the sideshift
function to move the outer frame to one end of the stroke then
WARNING: The points between the scissor arms -
half way back. The cylinder rod will now be at the center of the
and the inner frame, outer frame, apron or outer
stroke. Move the key to the OFF position and disconnect the
frame are pinch points and can cause an injury. Do
battery. Loosen the locknut at the rod end of the sideshift
NOT put any part of your body between these assemblies if
cytinder<ar>d usea wrench to rotate the cylmder rod. Rotate the
they can move. Always move the key to the OFF position and
rod to move the center of the outer frame to the center of the
disconnect the battery.
apron. Tighten the lock nut without rotating the rod.
Remove the air from the sideshift system as described in
REMOVE AIR FROM THE HYDRAULIC SYSTEM. Operate
the sideshift mechanism to move the forks to the full right and
full left for several cycles.
8-62
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
TROUBLESHOOTING-MAST
Bad hydraulic leaks, bad pump or pump drive, relief valve set too low,
bad check valve
Bad cylinder seal(s). Check for seal leaks inside the cylinder by install¬
ing a gate valve in the hydraulic line. See Checks and Adjustments.
The forks will not extend and there is no power The steering and auxiliary pump is not operating
steering Check:
Power fuse for pump motor
Auxiliary contactor, driver and timer
Pump motor
The forks will not extend and there is no power Selector valve is damaged or not operating
steering
Auxiliary relief valve is damaged
The forks will not tilt Selector valve is damaged or not operating
The forks will not sideshift Selector valve is damaged or not operating
8-63
Yale
IndustrialTrucks MAST AND REACH ASSEMBLY
SPECIFICATIONS
8-64
Yale
Industrial Trucks
SECTION 9
SECTION 9 - CONTENTS
BATTERY AND CHARGING SYSTEM
_
cigarette lighter or match. USE A FLASHLIGHT
useful characteristics.
OR PERMANENT LIGHT. Do not smoke or create sparks.
-
Why The space between the underside of the cover and the
top of the electrolyte in the cell usually contains a hydrogen
oxygen mixture which is explosive when ignited.
CELL COVER
POSITIVE NEGATIVE
PLATE ' PLATE
SEPARATOR
CONTAINER
7. Remove vent caps from nearby cells when preparing to 13. Allow only authorized personnel (qualified by training and
assemble a repaired cell into the battery. Cover the vent holes experience) in the battery room.
with layers of damp cloth before using lead burning equipment
on the intercell connectors in order to integrate the cell into the -
Why An untrained or inexperienced person may unknowingly
battery circuit. Also, use dark glasses to protect the eyes. break normal rules for proper handling, causing injury to
themselves and damage to batteries and equipment.
-
Why To prevent a possible hydrogen oxygen concentration
from exploding when a flame is lit. 14. Enclose all bare wires and buss bars in the battery room by
wire guards, guard rails orotber means of isolation from
8. Be sure to shut off the power when changing or repairing general plant traffic.
plugs or receptacles that are connected to the charging
equipment. This will prevent a short circuit and arcing. -
Why Any open high current transmission equipment is a
possible hazard to you, other workers and equipment.
Why - A short circuit may injure you. Arcing may cause
explosion and fire. 15. Never lay metal tools such as wrenches or other material
on top of an open battery.
9. Before removing the terminal lugs from the receptacle
when repairing a damaged or dirty plug or receptacle Why - Sparking and short circuiting will occur and the battery
connected to a battery, the battery circuit must be opened or will quickly be discharged or may explode.
"broken".
16. Check batteries for cracks or leaks. Repair at once.
Why - The leads which terminate in the receptacle are live or
"hot" with the total voltage of the battery existing across the Why - Electrolyte will spill on floor or equipment, causing
terminals. If the terminal lugs are accidentally touched together corrosion of the steel tray and related equipment. Continuous
a short circuit or arcing will occur with its attendant danger. flow of leakingelectrolyte cancause a ground baththat reduces
battery life and capacity.
Why - If water should beadded to acid it will not readily mix and -
Why Even an old battery no longer capable of useful life may
will splash the acid due to the great difference in the specific have enough residual voltage left to cause a spark if filled with
gravity of the two liquids. The effect of splashed acid is electrolyte.
dangerous.
18. Familiarize yourself as completely as possible with
-
Why Full knowledge of batteries and the dangers of improper
handling will pay dividends in the elimination of injuries and
battery with rubber mat or other insulating material to prevent damage.
external short circuits from chains or cables falling on top of
battery. /\ CAUTION: Keep vent plugs in the cells at all
/| \ times, except when taking hydrometer readings,
Why - Batteries are a heavy concentrated load and might adjusting specific gravity and electrolyte levels,
easily cause painful strains or injury to your feet or hands. troubleshooting or assembling a repaired cell.
Batteries may be seriously damaged or electrolyte spilled if the
battery is dropped. -NOTE: ••Ybor company, industry and -government safety
regulations should be reviewed to help reduce accidents and
12. Make sure that charging plugs and receptacle are properly damage to equipment.
locked and all other connections tight, secure and free from
friction. NOTE: If batteries are not in use, keep them charged. Check
specific gravities monthly and give a freshening charge (3 to 4
-
Why A loose connection may mean sparking or even arcing hours at the finish rate) if the gravities have fallen 30 points
with attendant danger of gas explosion. (.030) or more, otherwise, give freshening charge every three
months.
9-2
Yale
IndustrialTrucks BATTERY AND CHARGING SYSTEM
BATTERY TROUBLESHOOTING
9-3
Yale
IndustrialTrucks BATTERY AND CHARGING SYSTEM
BATTERY TROUBLESHOOTING
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.
9-4
Yale
Industrial Trucks BATTERY AND CHARGING SYSTEM
Specific Gravity
The strength of the electrolyte is measured in points of specific
gravity. For example, a solution of sulfuric acid has a specific LESS THAN
gravity of 1.835. Water has a specific gravity of 1.000. 2.06 VOLTS
Electrolyte is 27% acid and 73% water and has a specific
gravity of 1.275.
=5n F3X
DECREASED
/\ CAUTION: NEVER pour water into acid. The
SULFURIC
/ 1\ quick production of heat can cause the acid to boil ACID
# '1
CmJ and splash out of the container. ALWAYS pour acid 1
r
into water when making a dilute solution of acid.
INCREASED •i
,* .
WATER i#
L5±'
s
2.06
VOLTS
DECREASED DECREASED
LEAD LEAD
SPONGE PEROXIDE
9-5
Yale
IndustrialTrucks BATTERY AND CHARGING SYSTEM
t
\. i\
MAXIMUM \ • If you have more than one lift truck in operation, do the
WATER battery voltages need to be the same?
2.33
VOLTS
INCREASED
SULFURIC
ACID
DECREASED
S
N
WATER .' s
INCREASED INCREASED
SPONGE LEAD
LEAD PEROXIDE
DECREASED LEAD SULFATE
__
not installed, the electrolyte will leak, causing corrosion of the
(vol———
ts x ampere x hours
1,000
\ ,
I = kilowatt hours of KWH
J
battery case and in the battery compartment.
--
STRAPS
9-7
Yale
IndustrialTrucks BATTERY AND CHARGING SYSTEM
1. Keep batteries clean and free of acid spills. 8. Do not charge a battery with a charger that has an
ampere-hour rating higher than that of the battery. This will give
2. Do not over-discharge. Excessive discharge shortens too high a charging current and excessive heating. Charging
battery life. with a lower ampere-hour charger will cause no harm, but may
require longer than 8 hours to fully charge.
3. Do not overcharge. Overcharging produces corrosion of
positive grids and excessive gassing, which loosens the active Maintenance Records
material of the plates.
Always complete the Battery Inspection Report and the Daily
Battery Report.
4. Charge batteries in a well ventilated area to remove the
explosive gases and acid fumes.
NOTE: Follow the same sequence when you record the cell
number. Always begin the record with a positive cell. Follow a
5. Maintain electrolyte at the proper level. If low, add water.
sequence so that the last cell is always the cell for the
Before charging, make sure tops of plates are covered; after
negative cable.
charge, fill to recommended level. Do not add acid.
Record the beginning ampere reading of the charger each time
6. Keep batteries from freezing.
the battery is charged. Any difference in the daily ampere
reading can indicate a problem with the battery or the charger.
7. Keep batteries in a charged state.
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2 22
3 23
4 24
S 23
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20
27
• 20
9
10
11
13
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31
32 _ . --
-- .
9-8
Yale
IndustrialTrucks BATTERY AND CHARGING SYSTEM
o* am
MT(
Adding Water
Some water is lost from the electrolyte of each cell during the
charge and discharge cycle when the battery is in service. ELECTROLYTE
Check the electrolyte level daily. Some service persons check
some of the cells each day so that all of the cells are checked PLATE PROTECTOR TOP OF SEPARATORS
each week. If the level of the electrolyte goesbetowthelevel of
the top of the separators for the plates, the cell can be
damaged.
Figure 9-10 - Electrolyte Level
NOTE: Keeping the electrolyte level within the correct limits
Hydrometer
is the most important item of battery maintenance. Always use
distilled water, if you add distilled water, wait five minutes Use a hydrometerto measure thespecific gravity of thebattery.
before measuring the specific gravity with a hydrometer. Do not Make sure there is enough electrolyte in the battery cells. A
add distilled water to a cell during the charging cycle. The high level or low level of the electrolyte can change the specific
electrolyte can flow out of the cell through the fill hole. Figure gravity measurement. When the electrolyte level is low, the
9-9
Yale
Industrial Trucks BATTERY AND CHARGING SYSTEM
LIQUID
SPECIFIC GRAVITY LEVEL
SCALE-
FLOAT
9-10
Yale
Industrial Tmcks BATTERY AND CHARGING SYSTEM
average additional charge is 12%. When the battery is nearly resistor. When the charging current decreases, the voltage
charged, the final charging must be at a low rate. A charging across the resistor causes an increasing voltage at the battery
rate that is too high will cause heating in the battery and a high terminals. The charging is similar to the gradual charge. The
loss of water from the electrolyte. The charging of the battery resistor must be correctly set or the charging rate will be wrong.
must be done correctly or the service life of the battery will be
decreased. 3. TWO-RATE CHARGE - This method also uses a high
charging rate at the beginning followed by a lower rate. Two
NEVER discharge a battery below 1.130 to 1.110. Discharging resistors control the charging rate. One resistor controls the
a batterybeyond the design limits will decrease.the service life charging rate at the beginning of the cycle-and a seGond
of the battery. resistor reduces the charging rate when the voltage in the cells
reach 2.37 volts. A relay automatically controls the second
If lift truck operation results in only partial discharges (50% or resistor.
less) and specific gravities are 1.210 to 1.220 or more at the end
of the shift, recharging may be deferred andthe battery used for Troubleshooting the Charger
another shift providing the work load is not expected to
Battery chargers normally operate automatically without
increase. Hydrometer readings and experience will disclose
constant attention. It is necessary to make a periodic check to
the frequency of charge intervals under these circumstances.
determine if the charger is operating correctly. Check for the
following conditions:
CAUTION: A battery should always be recharged
immediately following a complete discharge.
1. Battery temperature is too high - The temperature in a
Never allow it to remain in a discharged condition,
battery will not normally rise more than 14° C (25° F) during an
since permanent damage may result.
eight hour charging period. Higher temperatures indicate that
the charging rate needs adjustment.
Types of Battery Charges
1. DAILY CHARGE -This charge is normally eight hours and 2. Continuous operation of the charger - Check the
will keep the battery fully charged if the battery is not automatic controls on the charger. Check the charging rate. A
discharged below the limit. low charging rate can be the problem.
2. EQUALIZING CHARGE - This charge is at a low rate and 3. Continuous operation of a charger at a high rate -
balances the charge in all of the cells. The equalizing charge is Normally, the charging rate begins at a high rate and decreases
normally given approximately once per week and isthree hours as the battery becomes charged. If the rate does not decrease,
at a low rate in addition to the regular charging cycle. The most the control need repair or adjustment.
accurate specific gravity measurements for a charged battery
will be after an equalizing charge. WARNING: Always connect the positive cable to
the positive terminal and connect the negative
NOTE: Sometimes the capacity of a battery is not enough to terminal. Any other connection will cause injury
complete a work period. Check for the following conditions: and damage.
• The battery is too small for the job. WARNING: Always charge the battery at the end
• The battery is not fully charged. of the work period (shift). Never let the specific
gravity reach a level less than the limits shown in
• The battery charger is not operating correctly. the manual.
• The battery is near the end of its service life.
/\ WARNING: Always deenergize the charger
Methods of Charging 11\ before you connect or disconnect the charger from
the battery.
There are three methods of charging a battery.
How to Know when the Battery is Fully Charged
1. GRADUAL CHARGE - This method uses a solid state
automatic battery charger. The charging rate begins at 20-25 1. During charging, the voltage increases slowly. When the
amps/100 amp-hours and decreases to less than 5 amps/100 battery is fully charged, the voltage level is constant.
amp-hours when the battery is 80% charged. The charging
current decreases when the voltage across the cell increases 2. Remove a vent cap and look in the opening. If you see
during the charging cycle. The increase in the voltage from the bubbles in the electrolyte, the battery is either fully charged
charger is approximately the same as the increase in the or in the final stage of charging.
specific gravity in the cells.
3. The specific gravity reading is constant and within the
2. MODIFIED CONSTANT VOLTAGE - This method uses a limits of a charged battery. If the temperature increases after
generator to generate a constant voltage that is controlled by a
9-11
Yale
Industrial Trucks BATTERY AND CHARGING SYSTEM
the battery is charged, the specific gravity will decrease a small Equipment Needed
amount.
• A lifting device to remove the battery from the lift truck.
4. Constant meter indications on the charger will indicate the • Racks to hold the batteries during charging and
end of the charging cycle. storage. These racks must be made of wood and must not
be metal unless the metal racks are covered with an
Battery Charging Area insulating material.
To increase the service life and reduce maintenance, a special • A battery charger that will charge your batteries.
area is needed for charging the batteries. The following
information should be considered when setting up an area.
• Tools for maintenance.
• An area with a drain for cleaning batteries and battery
1. Location of power supply. compartments.
9-12
Yale
IndustrialTrucks
SECTION 10
SECTION 10 - CONTENTS
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 "Guide to Lift Truck Useand Maintenance", which addresses lift truck safety in the workplace, good maintenance practices and training
programs, is available from your Yale industrial truck dealer. Order manual #2020.
The following information and programs are intended to help you to achieve your investment objectives.
OPERATING MANUAL - 1703 (5203717-03) 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 the Yale Materials Handling Corporation, 15
Industrial Trucks, each truck is equipped with an Operating
Junction Road, Flemington, New Jersey 08822-9499.
Manual.
10-1
Yale
IndustrialTrucks user support information
NOTES
10-2
Yale
IndustrialTrucks
SECTION 11
11 ALPHABETICAL INDEX
Yale
IndustrialTrucks ALPHABETICAL INDEX
11-1
Yale
IndustrialTrucks ALPHABETICAL INDEX
F K
Fork Adjustment 1-3 Key Switch
Fork Replacement 8-5 Installation 3-8
Hook Forks-NS 8-5 Removal 3-8
Pin Forks-NR or NDR 8-5
Free Lift Chains 8-40 L
Free Lift Cylinder Lift Cylinders
Removal and Installation 8-35 Removal and Installation 8-26
Fuses 3-5 Lift Truck on Blocks 1-10
Load Backrest and Forks 2-1
Load Backrest Extension
G Removal and Installation 8-5
Gear Oils 2-17 Load Rollers and Wear Plugs
Grease 2-18 Removal and Installation 8-31 & 8-41
Lubrication Instructions 2-9
H M
Height Limit Switch 3-7 Main Cylinders
Installation 3-8
Removal and Installation 8-35
Removal 3-7 Main Interface Board (MIB) 3-16
Testing 3-8
Adjustments 3-18
......
Hoist Pump
Calibration Procedure 3-18
Assembly 7-6
Hydraulic Potentiometer 3-19
Disassembly 7-5
Traction Potentiometer 3-19
Hoist Pump and Motor 7-4
Checking the Model Code and Set-Up Status 3-18
Installation 7-5
Customizing MIB Functions 3-20
Removal 7-4 Default Values 3-18
Hose and Cable Sheaves Description/Features 3-16
Replace 8-29 & 8-37
Function Code Values
Hoses NDR030AD 24V 3-98
Replace 8-28 & 8-36 NDR030AD 36V 3-99
Hydraulic Control Valve 7-6 NR035AD 24V 3-93
Assembly 7-8
NR035AD 36V 3-95
Disassembly 7-6 NR040AD 24V 3-94
Installation 7-6 3-96
NR040AD 36V
Removal 7-6 3-97
NR045AD 36V
Hydraulic Oils 2-16 NS040AE 24V 3-100
Hydraulic Pump Motor NS040AE 36V 3-101
Tests 3-91 NS050AE 36V 3-102
Hydraulic Schematic 7-2 Function Descriptions 3-21
Hydraulic Steering Motor 4-3 & 6-1 Installation 3-17
Installation 4-4 & 6-3 LED Display 3-16
Removal 4-3 & 6-3 Operation 3-16
Hydraulic System-Introduction 7-1
Plug-Pin Identification 3-24
Hydraulic Tank 7-8 3-17
Removal
Installation 7-9 3-25
Status, Warning and Fault Codes
Removal 7-8 Troubleshooting Charts 3-25
Hydrometer 9-9 Blank or Undefined Code Conditions 3-26
Fault Codes 3-40
I Status Codes 3-30
Inner and Intermediate Mast Assemblies Warning Codes 3-37
Removal and Installation 8-36 Main Lift Chains 8-40
Inner Frame Assembly 8-22 Maintenance Schedules 2-9
Assembly 8-24 Drive Unit Check 2-13
Disassembly 8-23 Electrical System Check 2-14
Installation 8-24 General Check 2-14
Removal 8-22 Hydraulic System Check 2-13
Inner Mast Assembly Lubrication Check 2-13
Removal and Installation 8-28 Mast/Carriage/Attachment Check 2-14
11-2
Yale
IndustrialTrucks ALPHABETICAL INDEX
......
Adjust Wear Plugs 8-56
Diagnostics Menu 3-64
Adjust Wear Strips 8-57
Program Menu 3-63
Simplex 8-58
Special Program Menu 3-64
Triplex 8-58
Mast Screen 2-1 Test Menu . 3-63
Master Cylinder 5-6 Operation 3-61
Assembly 5-7 Program Menu 3-63
Disassembly 5-6 Programmer Self Test 3-62
Master Cylinder and Pedal Assembly 5-4 Scroll Display Keys 3-61
Assembly and Installation 5-4 Special Program Menu 3-64
Removal and Disassembly 5-4 Test Menu 3-63
Master Drive Unit 4-5 Proportional Electro-Hydraulic Valves 3-9
Assembly 4-9 Manual Lowering 3-9
Disassembly 4-7
Installation 4-6
Removal 4-5 R
Masts 8-1 Reach Assemblies 8-1
MIB Function Descriptions 3-23 Removal and Installation 8-7
Model and Operating Information 1-6 Reach Assembly Outer Frame 8-10
Model Code 1-1 Assembly 8-11
Motor Maintenance-General 3-84 Cleaning and Inspection 8-11
Brush and Commutator Inspection 3-84 Disassembly 8-11
Brush Replacement-Traction and Hydraulic Motors 3-89 Disassembly without Sideshifter 8-12
Commutator Problems 3-86
Installation 8-11
Commutator Repairs 3-91
Removal with Sideshifter 8-10
Normal Commutator Surfaces 3-85
Reach Cylinders 8-42
Tests 3-91
3-92 Assembly 8-43
Armature
Brush Holder 3-92 Cleaning and Inspection 8-42
Field 3-92 Disassembly 8-43
Moving a Disabled Lift Truck 1-10 Installation 8-44
Multi-Function Control Handle 3-11 Removal 8-42
Assembly 3-12 Reach Outer Frame Assembly
Description/Features 3-11 Assembly without Sideshifter 8-15
Disassembly 3-11 Cleaning and Inspection 8-15
Operation 3-11 Installation without Sideshifter 8-15
Traction and Hydraulic Potentiometer 3-15 Removal without Sideshifter 8-11
O Reach/Tilt Selector Valve 8-51
Overhead Guard 2-2 Assembly 8-52
Cleaning and Inspection 8-52
P Disassembly 8-52
Parts Ordering Instructions 10-1 8-52
Installation
Potentiometers-Traction and Hydraulic 3-15 8-51
Removal
Adjustment 3-15
Relays 3-6
Installation 3-15
Coil Testing 3-7
Testing 3-15
3-61 Contact Testing 3-7
Programmer Hand Set
Change Value Keys 3-61 Description/Features 3-6
Connecting the Hand Set to the Enable 3-6
Traction Motor Controller 3-61 Hourmeter 3-6
Description/Features 3-61 Removal and Installation 3-7
11-3
Yale
IndustrialTrucks ALPHABETICAL INDEX
S T
Safe Maintenance Procedures 1-9 Technical Publications 10-1
Safety and Operational Check List 1-4 Tilt Cylinder and Tilt Mechanism
Safety Labels 1-2 Disassembly 8-47
Safety Tips - Industrial Batteries 9-1 Tilt Cylinder and Tilt Pivot Mechanism 8-44
Selector Valve 3-10 Assembly 8-48
Testing/Removal/Installation 3-10 Installation with Sideshifter 8-48
Serial Number 1-1 Installation without Sideshifter 8-49
Service Courses 10-1 Removal with Sideshifter 8-44
Shut Down Procedure 1-3 Removal without Sideshifter 8-45
Sidactor 3-6 Tilt/Sideshift Selector Valve 8-52
Cleaning and Inspection 8-53
Side Rollers
Disassembly 8-53
Disassembly and Assembly 8-9
Installation 8-54
Sideshift Cylinder 8-49
Removal 8-52
Assembly 8-50
Tires and Wheels 2-4
Cleaning and Inspection 8-50
Torque Nuts 2-22
Disassembly 8-50 Torque Nuts with Nylon Inserts 2-23
Installation 8-50 Torque Value Guide 2-24
Removal 8-49 Torque Values, Hydraulic Fittings 2-26
Simplex Chain Sheave Traction Motor 4-2
Removal and Installation 8-29 Installation 4-3
Simplex Lift Chains Removal 4-2
Removal and Installation 8-29 Traction Motor Controller 3-59
Simplex Mast Assembly 8-25 Description/Features 3-59
Cleaning and Inspection 8-26 Installation 3-59
Installation 8-32 Programming 3-65
Removal 8-25 Removal 3-59
Single Reach Scissor Arms 8-16 Testing 3-59
Assembly and Installation 8-18 Troubleshooting 3-67
Cleaning and Inspection 8-16 Programmer Hand Set 3-67
Removal and Disassembly 8-16 Diagnostics Menu 3-68
Slave Cylinder 5-7 Test Menu 3-75
Assembly 5-7 Status LED 3-67
Disassembly 5-7 Training 10-1
Specific Gravity 9-5 Materials 10-1
7-4 Operator Courses 10-1
Specifications
Electro-hydraulic Control Valve 7-4 Triplex Chain Sheaves
Disassembly and Assembly 8-40
Hoist Pump 7-4
Free Lift Chain Sheaves 8-40
Steer Pump 7-4
Main Lift Chain Sheaves 8-40
Steering Control Unit 6-4
Triplex Lift Chain
Assembly 6-7
Removal and Installation 8-40
Disassembly 6-4 8-33
Triplex Mast Assembly
Installation 6-4 8-33
Cleaning and Inspection
Removal 6-4 8-42
Installation
Steering Pump and Motor 6-11 Removal 8-33
Assembly 6-14 Troubleshooting
Disassembly 6-13 Battery 9-3
Removal 6-11 Brakes 5-9
Specifications 6-11 Drive Unit 4-16
Steering System Hydraulic System 7-10
Introduction 6-1 Mast 8-63
Steering Tiller and Mounting Bracket Reach and Carriage 8-63
Assembly and Installation 6-11 Steering System 6-15
Removal and Disassembly 6-11 Truck Weight 1-1
Studs and Nuts 2-21 Trucks in Storage 1-11
11-4
Yale
IndustrialTrucks ALPHABETICAL INDEX
V
Valve Manual Lowering 7-4
W
Warranty Information 2-9
Wirings and Schematics 3-104
Wiring Schematic 3-105
Options Schematic 3-107
Wiring Diagram 3-109
Options Diagram 3-112
11-5