Yale SM NR035 040 045AD - NDR030 ADB815 - NS040 050 AEB816

MAINTENANCE MANUAL
For Models
NR 035/040/045 AD
NDR 030 AD
(B815)
NS 040/050 AE
(B816)
For Service & Parts Contact
Authorized Dealer
Yale Materials Handling Corp

1400 Sullivan Drive
5203717-05
Caller No. 12011 1705 ©June 1998
Greenville, NC 27834-2011
Yale
Industrial Trucks
EXPLANATION OF MODEL CODE
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
2 GENERAL TRUCK AND LUBRICATION SCHEDULE
3 ELECTRICAL SYSTEM
4 DRIVE UNIT
5 BRAKE SYSTEM
6 STEERING SYSTEM
7 HYDRAULIC SYSTEM
8 MAST AND REACH ASSEMBLY
9 BATTERY AND CHARGING SYSTEM

•
- •- .
10 USER SUPPORTINFORMATION
11 ALPHABETICAL INDEX
Yale
Industrial Trucks
SECTION 1
OPERATING INSTRUCTIONS
Yale
IndustrialTrucks
-
SECTION 1 CONTENTS
INTRODUCTION
DESCRIPTION PAGE NUMBER
OPERATING INSTRUCTIONS-GENERAL 1-1

SAFETY LABELS 1-2
OPERATOR PRE-CHECKS AND INSPECTION 1-2
OPERATING PROCEDURE-GENERAL 1-3
SHUT DOWN PROCEDURE 1-3
FORK ADJUSTMENT 1-3
SAFETY AND OPERATIONAL CHECKLIST 1-4
MODEL AND OPERATING INFORMATION 1-6
SAFE MAINTENANCE PROCEDURES 1-9
MOVING A DISABLED LIFT TRUCK 1-10
......
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
OPERATING INSTRUCTIONS-GENERAL C. Truck Weight

Before attempting to operate this truck, carefully read and This is the approximate weight of the truck without a load on the
understand these operating procedures. forks. This weight plus the weight of the load to be moved must
be considered when operating on elevated floors or elevators.
Make sure the truck is in proper operating condition. Visually
inspect the entire truck for any damage that may have occurred D. Capacity Rating
during shipment.
This rating shows the maximum load capacity of this truck.
Personal injury and damage to the truck can occur if the
NOTE: Throughout this manual the terms right,Jeft, front and
capacity rating is exceeded.
rear relate to the viewpoint of an operator riding on the truck
with the forks trailing.
This truck meets all applicable mandatory requirements of
Familiarize yourself with the information contained on the ANSI B56.1 Safety Standard for Powered Industrial Trucks at
nameplate which is located in the operator's compartment. the time of manufacture. In addition, these trucks are classified
Information on this nameplate is shown in Figure 1-1 and as by Underwriters' Laboratories, Inc. and/or approved by Factory
follows: Mutual Engineering Corporation for the type designation.
Consult UL Index of Classified Products and FM Approval
A. Serial Number Guide.
This is an identification number assigned to this particular truck No additions, omissions or modifications should be made that
and should be used when ordering service parts or when will affect compliance to the previously stated requirements or
requesting any information from your Yale industrial truck in any way minimize the effectiveness of the safety devices.
dealer. The serial number is a six digit number preceded by a
letter and is stamped on the lift truck frame and on the
Safety and informational labels are located in conspicuous
nameplate. locations on this truck and should be strictly followed. Check
the nameplate of each truck before operation. These safety and
B. Model Code informational labels must be replaced immediately if missing or
The model number and the serial number should be used when defaced. Labels will vary with type of truck and equipment
requesting information. An explanation of the model code is installed. Refer to the Parts Manual for part number and
located on Page B of this manual. location for ail labels.
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
a new plate if this unit is equipped other than as >

O
—Truck Weight With Bait to
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
If a truck is shipped incomplete from

the factory, the nameplate will be
A—
—
TRAINED OPERATORS
ANO MECHANICS ONLY
a«<—i
DO NOT OVERLOAD
covered by the label shown above. Do Pt

not operate the lift truck until you obtain
a complete nameplate from your Yale
industrial truck dealer.
o —
n?T-TrrT."
s'1
» ;
cI—L.3
1
Capacities and cautions contained on

this nameplate must be strictly followed.
Figure 1-1 - Nameplate Information
1-1
Yale
IndustrialTrucks OPERATING INSTRUCTIONS
SAFETY LABELS OPERATOR PRE-CHECKS AND INSPECTION

A definition of the safety labels used on the motorized lift trucks
Before each shift, every 8 hours or before beginning truck
is listed below.
operation it is the operator's responsibility to carry out the
following checks and inspections. Do not operate the truck if it is
/j\ DANGER in need of repair, if it is in an unsafe condition, or might
contribute to an unsafe condition. Remove the key and report
the condition to the proper authority. If the truck becomes
DANGER: Identified by a Red Label, immediate hazards which unsafe in any way while you are operating it, STOP operating
WILL result in severe personal injury or death. "the lift truck and report the matter immediately to the proper
authority.
/j\ WARNING Basic maintenance information and the Recommended

Schedule of Maintenance are in the Operating Manual, Part
Number 5203717-03, located in the document holder on the
WARNING: Identified by a Orange Label, hazards or unsafe mast screen. Also refer to Section 2 of this manual.
practices which MAY result in personal injury or death.
1. Make sure overhead guard, load backrest extension, mast
A CAUTION screens and all other safety devices are attached.
2. Make sure all capacity, safety and informational plates or

CAUTION: Identified by a Yellow Label, hazards or unsafe labels are attached. This truck is not considered safe to use
practices which may result in minor personal injury, product or without a legible, properly filled out nameplate.
property damage.
Contact Yale Materials Handling Corporation or your local
THE READER MAYFINDANY OR ALL OF THE FOLLOWING dealer for Yale industrial trucks if the nameplate is not present
LABELS USED IN THIS PUBLICATION. AN UNDERSTAND¬ and legible. See parts manual for label page with label and plate
ING OF THEIR USE, AS GIVEN BELOW WILL AID THE
locations.
READER.
3. Inspect truck for any damage that might have occurred
during the previous shift.
NOTE
4. Inspect truck for any signs of external leaking of the
battery, steering system or hydraulic system.
An advisory procedure, practice, condition, etc., which is
essential to emphasize. 5. Check hydraulic hoses for leaking, chafing, cuts or
reinforcement showing through the outside of the hose.
/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
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 push loads with the truck.

OPERATING PROCEDURE-GENERAL
ÿ Read and understand the Operating Manual supplied with
the lift truck. Notify your supervisor if the manual is not
available. ÿ Watch out for pedestrians at all
times. Do not drive up to anyone
ÿ Keep hands, feet and cither parts of your body inside the standing in front of an object.
designated operator's compartment. Parts of your body
outside the truck can be injured when passing obstructions.
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
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
Figure 1-2 - Typical Narrow Aisle Electric Lift Truck
1-4
Yale
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.
Daily pre-shift inspection is an OSHA requirement. Operator's Daily Check List

We recommend that you document that these Electric Truck
Industrial Trucks inspections have been made._
Record of Fluid Added
Date Operator Battery Water
Truck Number Model Number Hydraulic Oil
Department Serial Number
Shift Drive Hour Hoist Hour
Meter Reading Meter Reading
SAFETY AND OPERATIONAL CHECKS (Prior to each shift)

Have a qualified mechanic correct all problems (O-K.ÿ) Need Maintenance
Leaks - Hydraulic Oil, Battery
Tires - Condition and Pressure
Forks, Top Clip Retaining Pin and Heel - Check Condition
Load Backrest/Extension - Securely Attached
Hydraulic Hoses, Mast Chains and Stops - Check Visually
Finger Guards - Attached
Overhead Guard - Attached
Safety Warnings - Attached (Refer to Parts Manual for Location)
Internal Checks:
Battery - Check Water/Electrolyte Level and Charge
Hydraulic Fluid Level - Check Level
Drive Unit Fluid Level - Check Level
Operator's Compartment:
Operating Manual - in Container
Nameplate - Attached and information matches model, serial number and attachments
Battery Restraint System - Adjusted and Securely Fastened
Seat Belt, Buckle and Retractors - Functioning Smoothly
Brake Fluid - Check Level
Controls (Turn Truck On) Unusual Noises Must Be Investigated Immediately:
Accelerator Linkage - Functioning Smoothly
Parking Brake - Functioning
Service Brake - Functioning Smoothly
Steering Operation - Functioning Smoothly
Drive Control - Forward/Reverse - Functioning Smoothly
Tilt Control - Forward and Back - Functioning Smoothly
Hoist and Lowering Control - Functioning Smoothly
Attachment Control - Operation
Horn and Lights - Functioning
Gauges: Hour Meter/Battery Discharge Indicator - Functioning
Instrument Monitors - Functioning
Form 944-6418-A (5/93)
© Copyright 1993 Yale Materials Handling Corporation
1-5
Yale
MODEL AND OPERATING INFORMATION

The NR-AD (reach), NDR-AD (double reach) and NS-AE
(straddle) narrow aisle electric lift trucks have lifting capacities
of 1362 kg (3,000 lbs) to 2270 kg (5,000 lbs) with a 609.6 mm
(24 in) load center.
These trucks feature operator comfort, low noise and vibration

levels and ease of brake and control handle efforts. The large
operator compartment is designed for flexible side stance
position. Vale Hi-Vis Simplex and Triplex masts provide
excellent visibility for these models.
No additions, omissions, changes or modifications should be

made that will affect compliance to the previously stated
requirements or in any way minimize the effectiveness of the
safety devices.
Before attempting to operate this truck, carefully read and

understand these operating procedures. Make sure the truck is
in proper operating condition. Be sure ail safety devices such
as the overhead guard, mast screen and the load backrest
extension are in place and properly secured.
Figure 1-4 - Operating Controls
1. The Instrument Display is located near the steering tiller

and has the following features:
A. The Battery Indicator has a 10 bar green, yellow and
red light emitting diode (LED) to indicate battery charge
status. As power is usedthe LEDs will turn off, starting with
green. The red LED, second from the bottom, will flash
indicating a nearly discharged battery. The bottom red
LED will alternately flash with the LO-Batt indicator LED (a
crossed battery symbol), indicating a discharged battery.
The lift function will be locked out at this point.
B. The Message Center is a 16 character, dot matrix,
liquid crystal display (LCD) with green back light. There are
four yellow and one red/yellow LED indicators. The 16
character, alpha-numeric display shows the hourmeter
readings, truck performance status, and a warning or fault
condition. When a warning message is received, the
warning/fault indicator will blink as a yellow light. When a
fault message is received, the warning/fault indicator will
blink as a red light.
Figure 1-3 - Narrow Aisle Electric Lift Truck
1-6
Yale
mode data. This internal battery is not serviceable and is

designed to last for the life of the instrument display.
2. Control Handle - The multi-function control handle is

used for hydraulic and traction operation. Each auxiliary
function, Reach, Tilt and Sideshift (optional) has a separate
switch. There is atso a switch for the horn. Not all functions are
used on each lift truck and the location of the functions may vary
between lift truck models. See Figure 1-6 and Table 1-1.
The handle is moved horizontally for forward and reverse

travel. Up and down movement while pressing an auxiliary
function switch, controls the auxiliary hydraulic functions. Up
and down movement without pressing an auxiliary function
switch operates the lift function, up for lift, down for lower. Once
the handle is moved from the neutral position the switch can be
released. The function will be locked until the handle is returned
to the neutral position.
Figure 1-5 - Instrument Display
NOTE: Diagonal movement of the handle will control both
C. The Instrument Display Hourmeter switch is travel and a hydraulic function simultaneously.
operator controlled and is used for on-demand display of
hourmeter information. The hourmeter data can be
displayed at any time by pressing the hourmeter switch.
The switch is marked with an hour glass symbol. Press
JUUUUUUUUUUU
once to display truck hours to 1/10 of an hour. Press twice
to display drive motor hours. Press three times to display
the hoist motor hours. Press four times to return to the
normal display. After 30 seconds the display will return to
the normal display mode, which indicates the current
operational status of the truck.
D. The Drive Mode switch allows the operator to select Handle Adjustment
the level of traction motor controller speed best suited to
the application. Operation of the drive mode switch will
cause the green indicators and corresponding drive
modes to increase from Turtle to Mid to Rabbit. Turtle Figure 1-6 - Control Handle
mode provides slower acceleration, reduced top speed
and maximized energy efficiency. It is also a valuable Truck Model
setting when training new operators. Mid mode reduces
acceleration with full travel speed. Rabbit mode provides Switch NS NR/NDR
maximum acceleration and travel speed. When the key A Horn Horn
switch is turned to off, the selected drive mode is retained.
Sideshift
When the battery is disconnected the drive mode defaults Extend
B (If so equipped)
to the Rabbit mode. The rates of acceleration and travel
speeds are programmable and can be adjusted by a Sideshift
qualified service technician. C Not Available (If so equipped)
D Not Available Tilt
E. The LED Function Selection Lights are for the
display of Status, Warning and Fault conditions. Status Table 1-1 - Control Handle Switch Locations
messages will be displayed for Lift, Reach, Tilt and
Sideshift. The indicators will display up-to-date status If the operator wants to perform an auxiliary function in one
conditions, independent of the present LCD display. There direction, immediately followed by the reverse direction,
are four yellow and one red/yellow LED indicators. (example: extend then retract), the reach auxiliary function
switch should be pressed and held until the handle is moved
The Instrument Display is powered even when the vehicle is not from the extend (up) position, through the neutral position into
being operated. When the battery is disconnected, the the retract (down) position. If the switch is not held while moving
dashboard contains an internal back-up battery, capable of through the neutral position the control will select the lowering
memory retention of the battery Indicator, hourmeter and drive function and mast lowering will occur.
1-7
Yale
5. Battery Power Disconnect - A red battery power

WARNING: Unintentional mast lowering disconnect knob is located next to the key switch. When
can cause damage or injury. pressed, battery power is shut off to all circuits in the truck.
When the battery power disconnect switch is activated, power
The operator can change the direction of travel while the lift is still supplied to the battery indicator. Power is restored by
truck is moving by moving the control handle for the opposite turning the key switch to the start position. * -
direction of travel. The lift truck will come to a stop and then
accelerate in the opposite direction. This action is called
plugging.
uuuuuuuu
3. Steering Tiller-The steering tiller controls truck direction
with 5 turns lock to lock.
WARNING: Reverse steering is available for this

truck. Operator should check steering direction
before operating truck.
Figure 1-9 - Battery Power Disconnect
6. Brake Pedal - The brake is applied when the pedal is

released. The brake is released when the pedal is depressed.
Braking force can be controlled by the operator. The brake
pedal works with the "Operator Sensing Switch". The
operator's right heel must be on the Operator Sensing Switch
and the left foot must depress the brake pedal before any truck
functions will work. After the operator is in the correct position,
the hydraulics can be operated with the left foot raised (brake
Figure 1-7 - Steering Tiller applied). The right foot can be lifted while traveling with the
brake pedal depressed (brake released). When the operator
4. Key Switch - The key switch is a three position switch. leaves the truck, the parking brake is automatically applied and
The first position is OFF (marked O). The second position is power steering is turned off.
RUN (marked I). The third position is START (marked II). The
key automatically returns to the second position, after it is
released in the third position. The key switch is located to the
right side of the control handle.
1. BRAKE PEDAL
2. OPERATOR SENSING SWITCH
Figure 1-10 - Brake Pedal

Figure 1-8 - Key Switch
1-8
Yale
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.
7. Before removing any component from the truck, such as

counterweights, mast assembly, drive unit, etc., make sure that
the lifting mechanism and slings are of the proper capacity and
in good condition.
8. When working on the hydraulic system, be sure the truck is

turned off, battery is disconnected, mast is lowered and the
hydraulic pressure is relieved in hoses and tubes.
9. When necessary to work with mast in a raised position,

Figure 1-11 - Operating Manual install a safety chain to restrain moving parts. Connect moving
parts to a part that does not move.
SAFE MAINTENANCE PROCEDURES
10. Brakes, steering mechanisms, control mechanisms,
Your Yale industrial truck, as manufactured, meets all the warning devices, guards and safety devices should be
applicable mandatory requirements of ANSI B56.1 Safety inspected regularly and maintained in a safe operating
Standard for Powered Industrial Trucks. condition.
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
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.
MOVING A DISABLED LIFT TRUCK HOW TO PUT A LIFT TRUCK ON BLOCKS

WARNING: The lift truck must be put on blocks for
WARNING: Use extra care when towing a lift
some types of maintenance and repair. The
truck if there is a problem with any of the following: removal of the following assemblies will cause
1. Brakes do not operate correctly. large changes in the center of gravity, mast, drive axle and
battery.
2. Steering does not operate correctly.
3. Tires are damaged. WARNING: Put the lift truck on blocks only if the
surface is solid, even and level. Make sure that any
4. Traction conditions are bad. blocks used to support the lift truck are solid, one
5. If the lift truck must be towed on a steep grade. piece units. Put blocks in front and back of the tires to prevent
movement of the lift truck.
Remember! There may be problems with more than one of
the above areas of the truck. Do not tow the lift truck if you have CAUTION: To prevent damage, make sure the
not identified all problem areas. reach mechanism is fully retracted before lifting the
rear of the lift truck.
If the steering pump motor does not operate steering the lift
truck can be difficult. Poor traction can cause the disabled lift
1-10
Yale
Ftrÿ
c£p!=
DRIVE/STEER & CASTER WHEELS LOAD WHEELS
Figure 1-12 - Putting a Lift Truck on Blocks

HOW TO RAISE THE LOAD WHEELS PRECAUTIONS FOR TRUCKS IN STORAGE
1. Release the brake pedal to apply the brake. Put blocks on Complications can arise as a result of improper handling of
both sides (front and back) of the drive/steer tire and the caster trucks during periods of storage.The main areas of concern are
wheels to prevent movement of the lift truck. electric motors, hydraulic components and electric truck
batteries. Electric powered trucks can best be protected by
2. Use an overhead crane and web sling under the outriggers being operated for a short exercise period each month.
at the mast, to raise the load wheels. Another lift truck can also
be used to raise the outriggers. Make sure that the crane and Before placing any truck in storage, you must choose an area
sling or other lift truck has a capacity of at least 2/3 the total which is clean, dry and free from airborne contaminants.
weight of the lift truck as shown on the nameplate.
When parking the truck, chock the wheels. The forks should be
3. Raise the outriggers only enough to suspend the wheels. fully lowered and tilted forward. For safety and increased
Install blocks under the outriggers at the rear of the wheels to usable floor area, remove the forks and tag them with the truck
support the lift truck. serial number. Coat all exposed portions of cylinder rods and lift
chains with fresh high grade SAE 30 or 40 weight engine oil.
HOW TO RAISE THE DRIVE/STEER TIRE AND CASTER
Electric trucks should be stored without batteries, therefore you
WHEELS
will have to provide a fully charged battery for the exercise
1. Put a block on each side (front and back) of the load wheels period.
to prevent movement of the lift truck.
Operate the truck for a short period of time each month. Electric
2. Use a special low clearance hydraulic jack under the rear drive motors must be exercised to keep them free of rust and
frame to raise the drive/steer tire and caster wheels. Another lift contamination caused by condensation built up over periods of
truck can also be used to raise the lift truck. Make sure that the inactivity. Operate the truck with the motor at its normal
jack or other lift truck has a capacity of at least 2/3 the total temperature for at least five minutes.
weight of the lift truck as shown on the nameplate.
All hydraulic cylinders should be cycled several times each
3. Raise the lift truck only enough to suspend the drive/steer month to keep the seals active and to coat the interior walls with
tire and the caster wheels. Install blocks under the rear of the oil. Actuate each cylinder, in both directions, until the stops are
frame to support the lift truck. reached. With the power off, actuate each control button to
relieve hydraulic pressure.
1-11
Yale
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. - •- •
,2. Neutralize and.clean the battery with a solution of 16

ounces of baking soda in one (1) gallon of water.
PRECAUTIONS FOR BATTERIES IN STORAGE
Batteries should be placed on a wooden pallet and stored in a 3. Store in a cool, dry location.
dry, moderately cool area. Lead acid batteries will slowly "self
discharge" over a period of time. This "self discharge" is due to a 4. Check each cell in the battery at least once every 30 days
chemical reaction. This chemical reaction can be accelerated and boost charge when specific gravity falls below 1.240.
by heat, resulting in a more rapid "self discharge". The average
rate of discharge results in a 0.001 drop in specific gravity per 5. Protect batteries from ambient contamination.
day. If the self discharge is left uncontrolled, excessive sulfating
can occur which is difficult to reduce and may damage the If a greasy film forms on the top of a battery, it is acid and must
plates. be neutralized with a solution of 16 ounces of baking soda in
one (1) gallon of water.
A discharged battery with a specific gravity of 1.100 will freeze
at - 8 ° C (+ 18 ° F). A fully charged battery with a specific gravity
of 1.280 will freeze at -67°C (-87* F).
1-12
Yale
IndustrialTrucks
SECTION 2
GENERAL TRUCK AND LUBRICATION SCHEDULE

Yale
IndustrialTrucks
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
GENERAL MAST SCREEN

This manual covers the repair and maintenance of the NR-AD A mast screen is provided to prevent fingers or hands from
(reach), NDR-AD (double reach) and NS-AE (straddle) narrow being placed into the mast area. The lift truck should never
aisle electric lift trucks have lifting capacities of 1362 kg (3,000 be operated without the mast screen. The mast screen may
lbs) to 2270 kg (5,000 lbs) with a 609.6 mm (24 in) load center. be removed for servicing the lift truck by removing the four
attaching capscrews. Two of the capscrews retainthe top of the
The manual has been subdivided into various sections which
mast screen to the overhead guard, while the bottom two
contain instructions for removal, disassembly, inspection,
capscrews retain the mast screen to the lift truck frame. The
assembly, installation and adjustment of the major
operating manual holder is located on the mast screen.
components. Additionally this manual includes, within this
section, the recommended schedules of maintenance and
lubrication schedule. Troubleshooting charts and ACCESS DOOR AND COVERS
recommended specifications are also included within the
The drive unit access door is mounted on a hinge and secured
sections.
by a single capscrew and latch at the rear of the lift truck. Turn
Various components that are not covered in specific sections the capscrew one-half turn to unlock the drive unit access door.
are covered in this section. Some of these components must be
The battery compartment cover is made of molded plastic. It
opened or removed to complete maintenance or repairs
covers the compartment above the battery compartment. To
covered in other sections.
remove the cover, remove the five retaining screws, one of
which is common with the drive unit compartment cover.
FRAME
The drive unit compartment cover is located over the drive unit
The lift truck frame is a sturdy one piece structure fabricated
compartment and adjacent to the steering tiller. The cover is
from steel incorporating mounting points for the mast, hydraulic
attached with a single retaining screw and one screw that is
controls, electrical controls, pumps and motors.
common with the battery compartment cover. To remove the
cover, remove the two screws and move the cover from its
LOAD BACKREST AND FORKS mounting points. To install the cover, position the cover under
the battery compartment cover and align with the mounting
Two different arrangements are used on these lift trucks for
holes. Install the two screws.
attaching the load backrest and forks. One arrangement is for
units supplied with shaft type forks (standard) while the other
arrangement has hook type forks. The removal and assembly
will depend upon the type of forks used. See Section 9, MAST
for the recommended removal and assembly for the LOAD
BACKRESTS AND FORKS.
<=>
Figure 2-2 - NS Lift Truck

Figure 2-1 - NR Lift Truck
2-1
Yale
IndustrialTrucks 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
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.
A WARNING: Batteries are heavy. Use care to

avoid injury
5. Before installing the battery, make sure the battery is
cleaned and painted. Refer to BATTERY AND CHARGING,
Section 9.
.
1 Make sure the key is in the OFF position. Disconnect the
6. When a replacement battery is installed, make sure the
battery. Move the connector and cables so that they will not be
battery fits the battery compartment. Use spacers to prevent
damaged when the battery is moved.
the battery from moving more than 0.5 in. (13 mm) in any
horizontal direction.
2. Remove the battery panel.
7. Make sure the weight of the replacement battery is within
3. Align the battery stand with the battery so that the end of the
the maximum andminimum weight shown on the nameplate.
stand is against the roller frame of the lift truck. Adjust the
capscrew legs of the battery stand so that the tops of the rollers
8. The battery must be installed so that the battery connector
are level and at the same height as the bottom of the battery.
will connect to the lift truck connector without pulling on the
Attach the puller cable to the battery case. Stand on the base of
cables.
the battery puller and pull the battery onto the battery stand.
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.
Figure 2-3 - Changing the Battery Figure 2-4 - Inspecting Tires
2-3
Yale
MODEL DRIVE/STEER TIRES CASTER WHEELS LOAD WHEELS

NR035AD 12x5.5x8 8x2 5x3.9
NR040AD Low Profile Rubber Polyurethane Polyurethane
NR045AD Plain Tread Dual Articulating Tandem Articulating
12x5.5x8 8x2 5x3.9
NDR030AD Low Profile Rubber Polyurethane Polyurethane
Plain Tread Dual Articulating Tandem Articulating _
12x5.5x8 8x2 4x3.9
NS040/050AE Low Profile Rubber Polyurethane Polyurethane
Plain Tread Dual Articulating Tandem Articulating
Table 2-2 Tire Sizes
SOLID TIRES 4. Carefully apply hydraulic pressure until the wheel hub is
forced from the old tire into the new tire. The new tire, when
Remove the One Piece Wheel and Tire
properly seated, will be flush to the inner or outer edge of the
WARNING: Wheels must be changed and tires wheel hub. See Figure 2-6 and Figure 2-7.
replaced by trained personnel only. Always wear
safety glasses.
INSTALL THE WHEELS ON THE LIFT TRUCK
NOTE: To change cushion tires, the wheel must be pressed 1. Installthe tire and wheel on the hub. Tighten the lug nuts to
out of the rim. The proper tools, equipment and press ring must 136 N»m (100 Ibf ft) torque.
be used. Do not attempt to change tires (rims) or wheels unless
you have the proper tools, equipment and experience. 2. Raise the lift truck high enough to remove the blocks.
Lower the lift truck to the floor.
1. Loosen the wheel lug nuts. Put the lift truck on blocks as
described in HOW TO PUT THE LIFT TRUCK ON BLOCKS, CAUTION: Check all wheel nuts after 2 to 5
Section 1, this manual. hours of operation: when new lift trucks begin
operation and on all lift trucks when the wheels
WARNING: The lifting and carrying of solid tires is have been removed and installed. Tighten the nuts in a cross
not recommended because their weight could be pattern to 136 N«m (100 Ibf ft) torque. When the nuts stay tight
in excess of 45 kg (100 lb). Where applicable use a for eight hours, the interval for checking the torque can be
wheel or tire dolly to assist in the removal and installation of the extended to 350 hours.
wheel.
2. Remove the wheel nuts and remove the wheel from the lift
truck.
3. The correct tools, equipment and a press ring must be

used for each size of wheel. Use a press to push the wheel hub
from the tire.
Install the Tire on the One Piece Wheel

1. Make sure the wheel hub is the correctsize for the tire. Do
not mix types of tires, types of tire treads, or wheels of different
manufacturers on any one 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
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.
SINGLE LOAD WHEELS

Figure 2-7 - 13.5 x 5.5 Solid Tire Pressed onto Wheel
Removal-Single Load Wheels
TANDEM LOAD WHEELS NOTE: Single load wheels are optional.
Removal-Tandem Load Wheels
1. Put the lift truck on blocks as described in HOW TO PUT
NOTE: The load wheels are held in place by the load wheel THE LIFT TRUCK ON BLOCKS, Section 1, this manual.
brackets. For easier installation, remove and install one load
wheel before removing the next load wheel. 2. Using a drift, drive the roll pins through the top of the base
arm, until the axle is released.
1. Put the lift truck on blocks as described in HOW TO PUT
THE LIFT TRUCK ON BLOCKS, Section 1, this manual. 3. Remove the axle, spacers and loadwheel. Removethe roll
pins from the axle. Remove the bearings from the load wheel.
2. Remove the axle nut, axle shaft, washers, bearings and
load wheel. Remove the axle sleeve from the load wheel.
SINGLE LOAD WHEELS
Installation-Tandem Load Wheels Installation-Single Load Wheels
1. Pack the new load wheel with the recommended grease 1. Install bearings in the new loadwheel. Pack the wheel with
listed in the LUBRICATION SCHEDULE, this section. Install the recommended grease listed in the LUBRICATION
the new load wheel, axle shaft, axle sleeve, bearings, washers SCHEDULE, this section.
and axle nut. See Figure 2-8.
2. Align the spacers and position the new load wheel. Install
the axle through the base arm. See Figure 2-9.
2-5
Yale
1. SWIVEL PLATE 9. LOCKWASHER

1. ROLL PIN
2. THRUST BEARING 10. SELF-LOCKING NUT
2. AXLE 3. O-RING 11. GUARD WASHER
3. SPACER 4. ROLLER BEARING 12. ROLLER BEARING
4. BEARING 5. GUARD WASHER 13. WHEEL
5. LOAD WHEEL ASSEMBLY 6. NUT 14. AXLE SHAFT
6. BASE ARM 7. COTTER PIN 15. CAPSCREW
8. LUBE FITTING 16. SWIVEL FORK
Figure 2-9 - Single Load Wheels Figure 2-10 - Caster Wheels

3. Align the slots in the axle with the roll pin holes in the base Removal-Caster
arm. Install the roll pins until they are flush with the top of the
base arm. 1. Put the rear of the lift truck on blocks. See HOW TO RAISE
THE DRIVE/STEER TIRE AND CASTER WHEELS, Section 1.
4. Remove the blocks from under the lift truck. Make sure the blocks are in a location to permit removal of the
caster from the right hand side of the lift truck.
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
Make sure the blocks are in a location to permit removal of the

MAXIMUM FORK HEIGHT
caster wheels from the right hand side of the lift truck.
STOP BELOW 6147 mm
2. Remove the cotter pin, axle nut, lockwasher and guard SETTING 6147 mm (242 in)
washers from each caster wheel. Remove each caster wheel. (242 in) AND ABOVE
InstaHation-Caster Wheels DRIVE 4.8*6.4 mm 1

4.6*3.2 mfri
SIDE (0.19-0.25 in) (0.06-0.125 in)
1. Completely fill the new bearings with the recommended
grease listed in the LUBRICATION SCHEDULE, Section 2. CASTER SIDE 4.8-6.4 mm 4.8-6.4 mm
Install the bearings in the replacement wheels. (0.19-0.25 in) (0.19-0.25 in)
2. Install the guard washers at each bearing of each wheel.

Table 2-3 - Articulation Chart
Install each wheel, lockwasher and nut. Rotate each wheel as NOTE: The articulation stop settings are also listed on the
the nut is tightened. Tighten each nut to remove all clearance. nameplate.
There will be a resistance to the rotation of the wheel. Loosen
the nutto the first alignment to installthe cotter pin. Install a new ADJUSTMENT PROCEDURE
cotter pin through each nut. 1. Position the truck on a flat, level floor.
3. Apply grease to the lube fittings on the caster with the 2. Disconnect the battery.
recommended grease listed in the LUBRICATION
SCHEDULE, this section.
3. Open the drive unit compartment door, after turning the
latch capscrew one-half of a turn to unlock the door.
4. Remove the blocks from under the lift truck.
4. Check the articulation stop clearance on both the drive and
ARTICULATION STOP ADJUSTMENT caster stop screws. If the clearance between the stops are not
within the range listed in the ARTICULATION CHART, loosen
Stability and traction will be affected if the drive unit articulation the lock nuts and adjust the stop screws to the correct setting.
stops are not adjusted properly.
5. Tighten the lock nuts and torque to 108 N«m (80 Ibf ft).
The articulation stop screws must be adjusted to the proper
setting as listed in the ARTICULATION CHART, at the following 6. Close and lock the compartment door.
times:
1. Every 350 hours during routine maintenance. CASTER SIDE ADJUSTMENT

T DRIVE SIDE ADJUSTMENT
2. When a drive and/or caster wheel is changed.
3. When any repairs are carried out on the articulation axle.
DRIVE UNIT ARTICULATION STOPS
DRIVE SIDE ADJUSTMENT
CASTER SIDE ADJUSTMENT
DRIVE/STEER WHEEL
Figure 2-11 - Drive Unit Articulation Stops Nameplate
CASTER WHEELS -
Figure 2-12 - Articulation Stop Location
2-7
Yale
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
THE OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA)

REQUIRES THAT THE USER EXAMINE THE TRUCK BEFORE EACH SHIFT TO BE SURE IT IS IN SAFE WORKING ORDER.
LUBRICATION INSTRUCTIONS Refer to both the Recommended Schedules of Maintenance

and these Lubrication Instructions when inspecting, lubricating
/\ WARNING: Yale Industrial Trucks are equipped
and servicing these models. Read and observe all safety and
/ I\ with certain safety devices as standard equipment,
for example: overhead guards, load backrest
operational precautions described in this manual before
performing any work on this truck.
extensions, and mast screens. If for any reason these safety
devices are removed when the truck is being serviced,
Refer to the appropriate charts in this section for the oils and
adjusted, repaired or overhauled, these safety devices must be
grease that are recommended for use on these models.
properly installed before testing or operation of the truck.
Failure to comply with this warning could result in serious injury
Perform all 8 hour safety and operational checks as described
to the mechanic and/or the operator.
in the Recommended Schedules of Maintenance located in this
section.
/\ CAUTION: Never use steam to clean the
I f \ electronic control or electrical parts. In dusty areas, Check all fluid levels. Hydraulic oil, brake fluid and battery
LmJ use low pressure air to blow the dust off the control. levels should be at their full marks. Add recommended fluids
In oily or greasy areas, use a mild solution of detergent and
and oils as required. A certain amount of water loss in battery
water, or denatured alcohol to wash off the control. Then blow
cells is normal. Always replace water at the end of a charge.
the control completely dry with low pressure air.
Use approved tap or distilled"water.
The following maintenance instructions are for standard
models. Trucks used for special applications may be equipped EVERY 350 HOURS
with extra lubrication fittings, covers, special oils, etc. Consult
your nearest authorized Yale industrial truck dealer when
/\ WARNING: The articulation stops must be
servicing these models.
11\ adjusted every 350 hours or whenever a drive
wheel tire or caster wheel tire is replaced. Failure
to adjust these stops properly can reduce stability as well as
IMPORTANT: The interval of time referred to in the traction. Refer to the Articulation Stop Adjustment in Section 2
maintenance chart is based on normal operating conditions. If of this manual for the adjustment procedure and proper
the vehicle is operated in areas of high contamination such as clearance settings.
dust, corrosive vapors, etc., the interval of time should be
adjusted accordingly.
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
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
Figure 2-13 - cation Points

28. Hydraulic System - Lower mast. There is no drain plug in Clean hydraulic tank with solvent and dry with compressed air.
this hydraulic tank. The hydraulic tank is drained at the supply Connect the hose to the tube and tighten the hose clamp.
hose. (The hose and tubing between the bottom of the Remove the breather cap and fill the tank with hydraulic oil.
hydraulic tank andthe main hydraulic pump.) Put a shallow pan Raise and lower mast, operate tilt control and reach
with a capacity equal to the hydraulic system of the truck under mechanism (if equipped), to expel air from hydraulic system.
the end of the hose. See hydraulic tank capacities below.
Disconnect the hose at the pump and drain the oil. Pour the oil NOTE: If hydraulic system is contaminated contact your
into a suitable container and discard in accordance with local authorized Yale industrial truck dealer for assistance.
regulations.
29. Drive Unit - Park truck on a level floor. Remove drain plug.
BATTERY OIL TANK CAPACITY Drain gear oil into a suitable container and discard in
TO FULL MARK accordance with local regulations. Replace drain plug and fill
COMPARTMENT SIZE
with gear oil through level/fill hole. Drive truck slowly to circulate
317.5 mm (12.5 in) 17.6 litres (4.64 gal) oil. Drive Unit Capacity 2.6 litres (0.69 gallons) for AD/AE
370.8 mm (14.6 in) 19.5 litres (5.16 gal) models.
421.6 mm (16.6 in) 21.5 litres (5.67 gal)
ÿNOTE: Do not expose bearings or hydraulic system to
477.5 mm (18.8 in) 25.3 litres (6.68 gal) foreign particles.
535.9 mm (21.1 in) 25.3 litres (6.68 gal)
Hydraulic System = Tank Capacity +4.01 litres
(1.06 gallons) in lines
Table 2-4 - Hydraulic Oil Tank Capacities
2-10
Yale
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
HYDRAULIC SYSTEM CHECK: A B C

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

Brake Adjustment X
Brake Drums and Linings for Wear X
Electric Motor and Drive Train Mounting Bolts (Torque to Specifications) X
Wheel Bolts or Nuts (Torque to Specifications) X
Wheel Brake Bolts (Torque to Specifications) X
Mast and Trunnion Cap Bolts (Torque to Specifications) X
2-12
Yale
ELECTRICAL SYSTEM CHECK: A B C

Clean all Controls X
Interlock Switches - Check Operation X
Accelerator Switch and Potentiometer - Check Operation X
Electronic Card - Check Operation X
Time Delay - Check Operation X
Direction Switch - Check Operation X
Drive Resistor (Magnetic Control) - Check Operation X
Valve Lift and Tilt Switches - Check Operation X
All Motors - Clean with Compressed Air X
All Motors - Check Brushes and Springs X
All Motors - Check Power Wire Terminals X
Battery Box and Connectors - Neutralize and Clean X
Battery Condition - Physical and Electrical X
All Wire Connections X
Contactors - Tips and Wire Connectors X
- -
MAST CARRIAGE ATTACHMENT CHECK: A B c
Mast and Carriage Safety Stops X
Mast Flange Wear X
Mast Rollers and Wear Plugs X
Carriage Rollers and Wear Plugs X
Chain Anchors X
Chain for Wear or Cracks (Use Wear Indicator 5180968-69) X
Pallet/Forks/Platform (Visual) X
Forks (See Note 2) X
Attachment - Sliding Surface Wear X
Attachment - Rotating Parts and Torque Bolts X
GENERAL CHECK: A B c
Steering - King Pins and Knuckles - Tightness X
Steering - Tie Rods and Wheel Alignment X
Steering - Drag Links X
Steering - Bellcrank X
All Bolts, Nuts, Cotter Pins, Etc. X
Overhead Guard and Load Backrest - Cracks, Mounting, Etc. X
Articulation Adjustment X
2-13
Yale
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
HYDRAULIC OILS
Type For All Hydraulically Actuated Equipment

Ambient Air Temp. Normal Freezer
3
0° to+110°F 0° to -60 F
Anticipated Ambient Air Temp. Range 3 3
(-18° to +44 C) (-18° to -52 C)
3
+18° to +148°F -55° to +65 F
Actual Useable Operation Oil Temperature flange
(-8° to +65 °C) (-49° to +18"C)
ASTM Viscosity Grade Number/Index (Ref.) S-215/92 Minimum S-75/200 Minimum
3
Pour °F Maximum -75° F (-60 C)
3 3
-20 F (-29 C)
MIL-Specifications -
MIL H-5606
APPROVED SOURCES
American (Amoco) Rykon Number 21 No Product

Atlantic Richfield/Arco Duro AW-46 No Product
Burmah-Castrol Hyspin AWH-46 No Product
Chevron Oil Company Chevron AW Hyd. Oil 46 Aviation Hyd. Fluid A
Cities Service (Citco) Pacemaker XD-20 No Product
Exxon Nuto H 46 Univis J-43
Fiske Brothers Lubriplate HO-1 No Product
Gulf Harmony 48AW No Product
Houghton & Company Hydro Drive HP 200 No Product
Keystone (Pennwalt) KLC Number 5 No Product
Mobil Oil Co. (Mobil) DTE 25 AERO-HFA
Pennzoil Oil Co. Pennzoil AW 46 No Product
Phillips Petroleum Magnus A-215 No Product
Shell Tellus 46 Aeroshell Fluid 4
Solene Ind. Lubricant H-205-B No Product
Sun Oil Co. (Sunoco) Sunvis 821 WR No Product
Texaco Rando HD-46 Aircraft Hyd "BB"
Valvoline Oil Co. Anti-Wear Number 20 No Product
Field Personnel Note: The hydraulic oils, as listed herein, are approved YALE Materials Handling Corporation sources that meet or exceed the
specifications annotated. The use of hydraulic oils other than the suppliers and products listed is unauthorized.
2-15
Yalo
GEAR OILS
YALE PART NO. 3101530-34 3101530-38

Application Standard Application Special Application
SAE Grade 80W-90 75W-90
Type Multi-Purpose EP Multi-Purpose EP
Base Oil Conventional Petroleum Synthetic
MIL-Spec. No. MIL-L-2105C MIL-L-2105C
API Service Classification GL-5 GL-5
-15° to +100°F As low as -60°F (-51°C)
(-26° to +38° C) Primarily intended for cold
Most Yale lift truck operations storage and/or arctic conditions;
Anticipated Ambient Temperature will fall can be used as high as +90 °F
within this (+32°C). Note: This oil is a
temperature range. synthetic formulation.
APPROVED SOURCES
Burmah-Castrol HYPOY C80W/90 No Product
Century Hulburt Inc. No Product No Product
Chevron Universal No Product
Chevron
Gear Lube 80W/90
Exxon Gear Oil No Product
Exxon
GX 80W/90
Mobil Mobilube HD 80W/90 Mobilube SHC 75W/90
Pennzoil Pennzoil MP 4092 No Product
Philube SMP No Product
Phillips 66
Gear Oil 80W/90
Solene Lub. Inc Solene Gear Oil #905 No Product
Sunfleet GL-5
Sun No Product
Gear Lube 80W/90
Unocal MP Gear Lube No Product
Union 76
LS 80W/90
Field Personnel Note: The gear oils, as listed herein, are approved YALE Materials Handling Corporation sources that meet or
exceed the specifications annotated. The use of gear oils other than the suppliers and products listed is unauthorized.
BRAKE FLUID
YALE PART NUMBER 0227768-00

SAE Type J 1703 - FMVSS 116 (DOT 3)
Anticipated Ambient Air Temp. Range -40°to +401° F (—40°+250°C)
Type of Fluid Non-Petroleum
APPROVED SOURCES
Any Supplier whose Product Meets or Exceeds the Above Specifications.
2-16
Yale
GREASE
STANDARD FOR HIGH PRESSURE FITTINGS, PLAIN AND

ANTI-FRICTION BEARINGS AND WHEEL BEARINGS
YALE PART NUMBER 3101560-36 3101562-46
Ambient Air Temp. Normal Freezer
Type Quality Automotive Quality Automotive
Soap Type Lithium Complex - tithfeimComptex "
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.
ANTI-SEIZE LUBRICATING COMPOUND
YALE PART NUMBER 3101562-30

APPROVED SOURCES
Loctite Corporation 76764
Bostik - Division of Emhart NSBT-16
Permatex - Subsidiary of Loctite 80208
2-17
Yale
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)
Figure 2-14 - Thread Design
2-18
Yale
INCH FASTENERS METRIC FASTENERS

STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
TYPE OF FASTENER •MARKINGS NOT REQUIRED •MARKINGS NOT REQUIRED
4.6* 4.8* 5.8* 8.8
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
HEX HEAD FLANGE SCREWS

©
SAME AS ABOVE
12-POINT FLANGE SCREWS
10.9 12.9
MARKINGS NOT REQUIRED
10.9 12.9
HEX SOCKET HEAD
CAPSCREWS
4.8* 9.8
5.1
SEMS
Table 2-6 - Bolts and Screws
2-19
Yale

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

5* 5.2*
9.8 10.9 12.9

MARKINGS
FOR SIZE
8* 8.1 M5 AND
STUDS LARGER
OR
OPTIONAL GEOMETRIC SYMBOLS

FOR SIZES M5 THRU M11 ONLY.
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
HEX FLANGE NUTS
Table 2-7 - Studs and Nuts
2-20
Yale

TYPE OF FASTENER STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
iTTfl
OR
ALL METAL PREVAILING

TORQUE NUTS
OR
ALL METAL PREVAILING OR

TORQUE FLANGE NUTS
JUL JUL
Table 2-8 - Torque Nuts
2-21
Yale

TYPE OF FASTENER STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
OR

NYLON INSERT
PREVAILING
TORQUE NUTS

NYLON INSERT
PREVAILING
TORQUE NUTS
Table 2-9 - Torque Nuts with Nylon Inserts
2-22
Yale
Marking No Mark 3 Marks 6 Marks Socket Head 12 Pt. - Flanged
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
Grade JIS F4T ISO 8.8 or JIS F8T ISO 10.9 or JIS F11T ISO 12.9
8.8. .10.9 . 12.9.
Marking None 8.8 or F8T or 8T 10.9 or F11T or 11T 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.
5. Marking not required on M5 and smaller fasteners.
Table 2-11 - General Guide to Torque Values
2-24
Yale
JIC FLARED TYPE AND SAE

SWIVEL ADAPTER UNIONS
STRAIGHT THREAD O-RING FITTINGS
DASH THREAD MAXIMUM TORQUE N*m (Ibf ft) DASH MAXIMUM TORQUE N»m (Ibf ft)
PIPE SIZE
SIZE SIZE SWIVEL NUT LOCKNUT SIZE FEMALE PIPE MALE PIPE
-2 5/16"-24 8(6) 8(6) -2 1/8"-27 18(13) 16(12)
-3 3/8"-24 8(6) 8(6) - - - -
-4 7/16"-20 14(10) 11 (8) -4 1/4M8 27(20) 34 (25)
-5 1/2"-20 20 (15) 14(10) - - - -
-6 9/16"-18 27 (20) 18(13) -6 &
CO CO *r— 00 34 (25) 54 (40)
-8 3/4"- 16 41 (30) 28(21) -8 1/2"-14 64 (47) 73 (54)
-10 7/8"-14 54(40) 456 (33) - - - -
-12 1-1/16"-12 95 (70) 65 (48) -12 3/4"- 14 114(84) 106 (78)
-14 1-3/16"-12 108(80) 76 (56) - - - -
-16 1-5/16"-12 122(90) 85 (63) -16 1"-11-1/2 175 (129) 152(112)
-20 1-5/8"-12 163(120) - -20 1-1/4"- 11-1/2 206 (152) 209(154)
-24 1-7/8"-12 178(131) - -24 1-1/2"-11-1/2 206 (152) 286 (211)
-32 2-1/2"-12 407 (300) - -32 2"- 11-1/2 407 (300) 407 (300)
NOTE: Values shown are for zinc plated fittings. Values for cadmium plated fittings may vary slightly, but not enough to be of
any appreciable difference.
'Torque Values furnished by Air-Way Manufacturing Co., Olivet, Michigan
Table 2-12 - Recommended Maximum Torque Values for Hydraulic Fittings*
2-25
Yale
MULTIPLY BY TO GET MULTIPLY BY TO GET

AREA
inches2 (in2) X 6.452 = centimeters2 (cm2) centimetres2 (cm2) X 0.155 =inches2 (in2)
feet2 (ft2) X 0.093 = meters2 (m2) >* -metres2 (m2) X 10.764 = feet2 (ft2)
LINEAR
inches (in) X 25.4 millimeters (mm) millimetre (mm) -X 0.039 ÿ—
inches (in)
feet (ft) X 0.305 = meters (m) metre (m) X 3.281 = feet (ft)
yards (yd) X 0.914 = meters (m) metre (m) X 1.094 = yards (yd)
miles (mi) X 1.609 = kilometers (km) kilometre (km) X 0.621 = miles (mi)
MASS
ounces (oz) X 28.35 = grams (g) grams (g) X 0.035 = ounces (oz)
pounds (lb) X 0.454 = kilograms (kg) kilograms (kg) X 2.205 = pounds (lb)
tons (2,000 lb) X 907.18 = kilograms (kg) kilograms (kg) X 0.001 = tons (2,000 lb)
tons (2,000 lb) X 0.907 = metric ton (t) metric tonne (t) X 1.102 = tons (2,000 lb)
POWER
horsepower (hp) X 0.746 = kilowatts (kW) kilowatts (kW) X 1.34 = horsepower (hp)
PRESSURE
pounds/in2 (psi) X 6.895 = kilopascal (kPa) kilopascal (kPa) X 0.145 = pounds/in2 (psi)
pounds/in2 (psi) X 0.007 = megapascal (MPa) megapascal (MPa) X 145.04 = pounds/in2 (psi)
TEMPERATURE
(°Fahrenheit-32) X 0.56 = "Celsius (C) ("Celsius x 1.8) + 32 = "Fahrenheit
TORQUE
pound inches (Ibf in) X 0.113 = Newton meter (N»m) Newton metre (N»m) X 8.851 = pound inches (Ibf in)
pound feet (Ibf ft) X 1.356 = Newton meter (N»m) Newton metre (N«m) X 0.738 = pound feet (Ibf ft)
VELOCITY
miles/hour (mph) X 1.609 = kilometer/hour (km/h) kilometre/hr (km/h) X 0.621 = miles/hour (mph)
VOLUME
inches3 (in3) X 16.387 = centimeters3 (cm3) centimetres3 (cm3) X 0.061 = inches3 (in3)
inches3 (in3) X 0.016 = litres (I) litres (I) X 61.024 = inches3 (in3)
quarts, U.S. (qt) X 0.946 = litres (I) litres (I) X 1.057 = quarts, U.S. (qt)
quarts, U.S. (qt) X 0.83 = quarts, Imp. (qt) quarts, Imp. (qt) X 1.205 = quarts, U.S. (qt)
gallons, U.S. (gal) X 3.785 = litres (I) litres (I) X 0.264 = gallons, U.S. (gal)
gallons, U.S. (gal) X 0.83 = gallons, Imp. (gal) gallons, Imp. (gal) X 1.205 = gallons, U.S. (gal)
ounces (oz) X 29.57 = milliliter (ml) milliliter (ml) X 0.034 = ounces (oz)
Table 2-13 - Conversion Table for Metric and English Units
2-26
Yale
IndustrialTrucks
SECTION 3
ELECTRICAL SYSTEM ]
Yale
Industrial Trucks
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
AUXILIARY SWITCH .3-3
TESTING 3-4
REMOVAL 3-4
INSTALLATION 3-4
"EE" CONTACTORS 3-5
FUSES 3-5
RELAYS 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
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
SECTION 3 - CONTENTS (Continued)

ELECTRICAL SYSTEM
MAIN INTERFACE BOARD (MIB) 3-16

OPERATION 3-16
LED DISPLAY 3-16
REMOVAL 3-17
INSTALLATION 3-17
MAIN INTERFACE BOARD ADJUSTMENTS 3-18
GENERAL 3-18
DEFAULT VALUES 3-18
CHECKING THE MODEL CODE AND SET-UP STATUS 3-18
MIB CALIBRATION PROCEDURE 3-18
STEP 1 ENTER THE SET-UP MODE 3-18
.....
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
REMOVAL 3-59
TESTING 3-59
INSTALLATION 3-59
PROGRAMMER HAND SET 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
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
Yale
IndustrialTrucks

ELECTRICAL SYSTEM
PROGRAMMING THE TRACTION MOTOR CONTROLLER 3-65

TROUBLESHOOTING 3-67
STATUS LED DIAGNOSTICS 3-67
PROGRAMMER DIAGNOSTICS 3-67
TEST MENU 3-68
DIAGNOSTICS MENU 3-75
DASHDISPLAYASSEMBLY 3-79
OPERATION 3-79
REMOVAL 3-79
INSTALLATION 3-80
VOLTAGE SELECTION 3-80
ADJUSTMENT 3-80
INOPERATIVE DASH DISPLAYASSEMBLY 3-81
INOPERATIVE DRIVE MODE SELECTION 3-81
TROUBLESHOOTING WITH A PROGRAMMER HAND SET 3-81
TROUBLESHOOTING WITHOUT A PROGRAMMER HAND SET . . . 3-82
NO WARNINGS OR FAULTS DISPLAYED 3-82
LIFT INTERRUPT 3-83
LOST MIB SIGNAL DISPLAYED 3-83
HOURMETER INPUT 3-83
MOTOR MAINTENANCE-GENERAL 3-84
BRUSH AND COMMUTATOR INSPECTION 3-84
NORMAL COMMUTATOR SURFACES 3-85
COMMUTATOR PROBLEMS 3-86
BRUSH REPLACEMENT-TRACTION AND HYDRAULIC MOTORS . 3-89
COMMUTATOR REPAIRS 3-91
TESTS 3-91
DAMAGED FIELD AND ARMATURE 3-91
SHORT-CIRCUIT IN AN ARMATURE WINDING 3-92
SHORT-CIRCUIT IN THE ARMATURE 3-92
OPEN CIRCUIT IN A FIELD COIL 3-92
SHORT-CIRCUIT INA FIELD COIL 3-92
SHORT-CIRCUIT BETWEEN FIELDAND MOTOR CASE 3-92
BRUSH HOLDER 3-92
MAIN INTERFACE BOARD (MIB) FUNCTION CODE VALUES 3-93
24V NR035AD 3-93
24VNR040AD . 3-94
36V NR035AD 3-95
36V NR040AD 3-96
36V NR045AD 3-97
24V NDR030AD 3-98
36V NDR030AD 3-99
24 V NS040AE 3-100
36V NS040AE 3-101
.... 36VNS050AE 3-102
Yale
IndustrialTrucks

ELECTRICAL SYSTEM
WIRING DIAGRAMS AND SCHEMATICS 3-104

WIRING SCHEMATIC 5241353-87 3-105
OPTIONS SCHEMATIC 5241353-87 3-107
WIRING DIAGRAM 5241353-87 3-109
OPTIONS DIAGRAM 5241353-87 3-112
Yale
IndustrialTrucks ELECTRICAL SYSTEM
INTRODUCTION
GENERAL
The electrical control system consists of the following major

components: WIRING SCHEMATICS AND DIAGRAMS are located at the
end of this section.
• Main Interface Board (MIB)
• Proportional EtedrorHydraulic Valve NOTE: Throughout this manual the terms right, left, front and
• SEM Traction Motor Controller rear relate to the viewpoint of an operator standing in the truck
• Dash Display Assembly facing the forks.
• Multi-function Control Handle Assembly
• Contactor Panel Assembly
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
Figure 3-1 - Logic Diagram
3-1
Yale
Jndustrial Trucks ELECTRICAL SYSTEM
COMPONENT REPAIR AND TESTING

GENERAL WARNING: Disconnect the battery by separating
1. To check for wire connections to the frame, disconnect the
/|\ the connector before opening the compartment
cover or inspecting/repairing the electrical system.
battery connector completely and use an ohmmeter to check
If a tool causes a short-circuit, the high current flow from the
the circuits. Check for resistance of 50,000 ohms or more
battery can cause an injury or parts damage.
between each terminal of the lift truck portion of the battery
connector and a clean connection point on the frame of the lift
2. Disconnect the battery and separate the connectors.
truck. There should-beTWetectrical connections to the frame of
the lift truck. Wires or terminals without insulation can cause
3. Remove the socket head capscrews retaining the
electrical connections to the frame. Isolators used to insulate
operator's compartment cover to the frame. Remove the cover
circuit boards from the frame that are missing, broken or
for access to the contactor panel assembly.
installed incorrectly can also cause these connections.
2. Check for voltage between each terminal of the connector

on the battery and a clean metal connection on the frame of the
lift truck. It is normal to measure some voltage between the
battery and the frame even if the resistance checks are correct.
If voltage is detected, use an ammeter to measure current flow.
The current must not exceed 100 milliamperes. Current in
excess of 100 milliamperes can cause a problem.
If voltage is detected at the frame, check to be sure the battery

is clean and is not defective. Clean the battery and battery
compartment as required. A build-up of carbon dust in the
electric motors can also cause measurable voltage at the
frame. Wear appropriate safety equipment and remove carbon
dust from motors using dry compressed air.
CONTACTOR PANEL ASSEMBLY

Description/Features
The contactor panel assembly is located behind the operator's
compartment cover on the right side of the truck. The contactor
panel assembly contains the following major components:
• Traction Contactor
• Lift Pump Contactor
• Steer/Auxiliary Pump Contactor
• 3 Power Fuses
• 4 Control Fuses
• "ER" (enable relay)
• "HR" (hourmeter relay) "EE" trucks only
• Sidactor (for dash display protection)
• 6 Amp Diode (for reverse polarity protection)
Components used in the contactor panel assembly are 1. TRACTION CONTACTOR
common to both the 24 volt truck and the 36 volt truck options. 2. LIFT PUMP CONTACTOR
3. POWER FUSES
Removal 4. POWER STEER CONTACTOR
5. TRACTION CONTROL
1. Move the lift truck to a safe level area. Turn the key switch
6. ENABLE RELAY
off and remove the key. Put a "DO NOT OPERATE" tag on the
7. CONTROL FUSES
multi-function control handle. Put blocks underthe drive wheels
to keep the lift truck from moving. See Section 1 - HOW TO
PUT A LIFT TRUCK ON BLOCKS.
Figure 3-2 - Contactor Panel and Traction Controller
3-2
Yale
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.
4. Discharge the controller by connecting a load acrQss

terminals B + and B - . Disconnect the plug to the main wiring
harness.
NOTE: The contactor panel assembly does not normally

have to be removed from the lift truck. The steps listed above
must be done to service any item that is attached to the
contactor panel assembly.
T
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.
7. Remove the capscrew, flat washer, lockwasher and nut

retaining the top of the panel assembly to the frame. Remove
Figure 3-3 - Typical SPNO Contactor Assembly
the two nuts, lockwashers, and flat washers retaining the
The contactor contacts are made of special silver alloy. The
bottom of the panel assembly to the frame. Remove the
contacts will normally look black and rough from normal
contactor panel assembly.
operation. This condition does not cause problems with the
operation of the lift truck. Cleaning is not necessary. DO NOT
Installation
USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE
1. Align the contactor panel with the mounting holes in the CONTACTS. Replace the contacts when the silver alloy is worn
frame. Install the two flat washers, lockwashers and nuts on the away to the base support metal.
bottom of the panel assembly. Install the capscrew, flat washer,
lockwasher and nut to retain the top of the panel assembly. The traction, lift pump and steer pump contactors are SPNO
(single pole normally open) contactors. SPNO contactors have
2. Install the power wires and fuses. Refer to WIRING one set of normally open contacts. See Figure 3-3.
SCHEMATICS AND DIAGRAMS at the end of this section for
wiring details. Auxiliary Switch
On non "EE" rated trucks, there is an auxiliary switch mounted
3. Reconnect the control wires.
on the lift pump contactor. A mechanical connection between
the lift pump contactor and the auxiliary switch causes the
4. Connect the battery,
contacts of the auxiliary switch to close when the lift pump
contactor is closed.
5. Remove the blocks from under the drive wheels, remove
the "DO NOT OPERATE" tag and install the key.
The lift pump contactor auxiliary switch is used to send a signal
to the dash display whenever the lift pump is activated. When
CONTACTORS the signal is present, pump hours accumulate on the dash
display hourmeter.
Contactors are switches, controlled by electromagnets (coils), NOTE: The lift pump contactor auxiliary switch is not present
that close and open a power circuit. The MIB and traction motor on "EE" ratedtrucks. On "EE" rated trucks a hourmeter relay is
controller have internal electronic drivers to control the current used to send a signal to the dash display. Refer to RELAYS for
to the coils of the contactors. The electromagnetic field in the additional information on the hourmeter relay.
3-3
Yale
Testing NOTE: No external suppressors are used on contactor coils

which are controlled by the MIB or the traction motor controller.
WARNING: Parts of this procedure requires
The MIB and traction motor controller have internal
working on the lift truck with full electrical current
suppressors for these contactor coils.
present. Do not wear any rings, a watch or any
other jewelry while ÿworking around the contactor panel
9. If the contactor closes but the truck does not work properly,
assembly. When manually closing a contactor with the power
check the electrical function of the high current section of the
connected, use a properly insulated tool.
contactor (the tips and buss bars). With the lift truck battery
connected and all switches closed, connect a volt ohmmeter
1. Remove the operator's compartment cover.
across the high current terminals of the contactor.
2. Check the condition of the battery. If it is not fully charged,
Check the voltage drop across the contactor tips. Set the
charge or replace the battery with a fully charged battery before
voltage scale of the meter to the lowest range higher than
continuing.
battery voltage (50 volts for a 36 volt battery, etc.). On SPNO
contactors, read the voltage across the contactor with the tips
3. Visually check to see if the contactor closes when the
open. Battery voltage should drop to zero or near zero as the
circuit is energized. If the contactor closes, skip to Step 9. If the
tips close.
contactor does not close, proceed to Step 4.
A voltage drop of 2 volts or more across the closed tips
4. Connect a voltmeter across the coil terminal Verify that
indicates a poor contact or high resistance. Check for burned or
the correct voltage is being applied to the coil wi;h the circuit
worn tips, incorrect size or mismatched tips and for an incorrect
energized. See Table 3-1.
gap setting on contactors with adjustable point gaps.
PULL IN HOLDING Removal

CONTACTOR COIL
Approximate Approximate
WARNING: The capacitor in the traction motor
Traction 24 volts 12 volts controller can hold an electrical charge after the
Lift Pump 24 volts 12 volts shock and injury, discharge the capacitor before inspecting or
repairing any component. Wear safety glasses. Make certain
Power Steering/Aux. Pump 24 volts 12 volts the battery has been disconnected. Discharge the
NOTE: Pull in voltage occurs for only approximately 1 capacitors in the controller by connecting a load (such as a
second. Some voltmeters may not display this voltage. contactor coil or a horn) across the controller's B + and B -
terminals (center 2 terminals). DO NOT use a screwdriver to
Table 3-1 - Contactor Coil Voltages discharge the traction motor controller.
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.
2. Remove the insulator.
3. Service the contactor.
4. Install the insulator.
5. Position the enclosure shroud over the contactor and

fasten the shroud to the coil and frame assembly.
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.
WARNING: Disconnect the battery and separate

the connector before opening the compartment
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.
The fuses may be checked for continuity if it cannot be

determined visually that a fuse has failed. Make certain to
replace any failed fuse with one of the same amperage when
replacing a fuse. See Table 3-2.
1. ENCLOSURE SHROUD 7. RETURN SPRING
2. CAPSCREW 8. MOVING CONTACT
3. INSULATOR 9. BASE FUSE CIRCUIT RATING
4. FIXED CONTACT 10. PLUNGER
FU1 Traction 325 Amp
5. CAPSCREW 11. COIL AND FRAME
6. COVER FU2 Lift Pump 400 Amp
FU3 Power Steering/Auxiliary Pump 100 Amp

-
Figure 3-4 Typical "EE" Contactor
FU4 Battery Input to Dash Display+Sidactor 1 Amp
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
Table 3-2 - Fuses

3-5
Yale
Industrial Trucks ELECTRICAL SYSTEM
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
Figure 3-5 - Enclosed Fuse Box "EE" Application

SIDACTOR relay will deenergize these circuits if certain fault conditions
occur. Refer to MIB codes 70, 71, 72 and 73.
The sidactor is used to protect the dash display from voltage
spikes or excessive voltage, which can occur if a battery
Hourmeter
charger is accidently connected to the lift truck.
The "HMR" (hourmeter relay) is used to send a signal to the
The sidactor is normally open and connected between fuse dash display whenever the lift pump is activated. When the
FU4 (battery + ) and battery - . Battery + to the dash display is signal is present, pump hours accumulate on the dash display
also supplied through FU4. The sidactor is designed to hourmeter. The "HMR" (hourmeter relay) is present only on
momentarily short when higher than normal voltage is "EE" rated trucks.
detected. This will cause the 1 amp fuse (FU4) to fail before
damage to the dash display occurs. NOTE: On non "EE" rated trucks, there is an auxiliary switch
mounted on the lift pump contactor. Refer to CONTACTORS,
Always replace fuse FU4 with a 1 amp fuse. The sidactor must AUXILIARY SWITCH for additional information.
be checked whenever the 1 amp fuse has failed. Check the
sidactor by disconnecting it and measuring the resistance.
Replace the sidactor if it tests shorted.
BOSCH AND POTTER BRUMFIELD RELAYS
RELAYS
85 87A
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
The enable relay is controlled by the MIB. The enable relay

PIN ARRANGEMENT SCHEMATIC
supplies battery volts to the the lift pump contactor coil, the
power steering contactor coil, the hydraulic control valve coils,
the selector valve coils and to certain MIB input switches. The Figure 3-6 - "ER" and "HMR" Relays
3-6
Y&fe
COIL RESISTANCE
COIL LOCATION MANUFACTURER @ 21 °C (70° F) TEST POINTS
"LIFT and "LOWER" coils 6.5 ± 0.5 ohms Coil leads

"AUX UP" (auxiliary up) Hydraulic Control
and Vickers
Valve 1.8 ± 0.2 ohms Coil leads
"AUX DOWN" (auxiliary down)
coils
Robert Bosch Corp. 305 ±15 ohms
"ER" (enable relay) coil Contactor Panel Terminals 85 and 86
Potter & Brumfield Co. 360 ± 35 ohms
"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)
are both single pole, double throw (SPDT) type relays.They are
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
Removal and Installation
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.
3-7
Yale
5. If the switch must be replaced, tag and disconnect the WARNING: Disconnect the battery and separate
wires. the connector before opening the compartment
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.
Testing 2. Disconnect the battery and separate the connectors.

1. Remove wires #56«nd #74 from the switch and check the
3. Remove the hydraulic tank dipstick.
resistance between switch terminals 7 and 8.
4. Remove the battery compartment cover for access to the
2. Replace any switch that does not read continuity between
wiring to the key switch.
switch terminals 7 and 8 with the switch not activated and no
continuity with the switch activated.
5. Tag and disconnect the electrical wires to the key switch.
NOTE: The switch is not activated (switch arm out) when the
6. Remove the nut retaining the key switch to the mounting
inner mast is elevated. The switch is activated (switch arm
bracket and remove the key switch.
depressed) when the inner mast is lowered.
Installation
Installation
1. Position the new switch in the mounting bracket. Install the
1. Position the new switch on the bracket. Install the
nut to retain the key switch.
mounting capscrews, lockwashers and nuts.
2. Install the electrical wires to the key switch. Refer to
2. Connect wire #56 to terminal 8 and wire #74 to terminal 7.
WIRING SCHEMATICS AND DIAGRAMS at the end of this
section for wiring details.
3. Install the cover using the two capscrews.
3. Install the battery compartment cover.
4. Connect the X-11 plug.
4. Install the hydraulic tank dipstick.
5. Remove the safety chains from the mast. Connect the
battery, install the key and check the mast for proper operation.
5. Connect the battery.
6. Remove the blocks from under the drive wheels. Remove
the "DO NOT OPERATE" tag from the multi-function control
handle.
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
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.
WARNING: Disconnect the battery and separate

KEY SWITCH
the connector before opening the compartment
Removal cover or inspecting/repairing the electrical system.
multi-function control handle. Put blocks underthe drive wheels
4. Remove the battery compartment cover for access to the

wiring to the battery disconnect switch.
3-8
Yale
5. Tag and disconnect the electrical wires to the battery

disconnect switch.
6. Pull the battery disconnect switch up to the "ON" position.
7. Rotate the red knob to align the hole in the housing with the
hole in the shaft.
8. Insert a 4.0 mm (0. 15 in) diameter rod through the hole in

the housing and into the hole in the shaft, to prevent the shaft
from rotating. Figure 3-7 - Proportional Electro-Hydraulic Valve
9. Rotate the red knob counterclockwise to remove it. Manual Lowering
WARNING: Always verify that no one is under or
10. Remove the two screws retaining the battery disconnect near the lift mechanism or load during the manual
switch to the mounting bracket and remove the switch. lowering procedure. Verify that there are no
obstructions beneath the lift mechanism or load. If the mast
Installation does not lower when the manual lowering valve is activated,
1. Ensure the replacement battery disconnect switch is in the deactivate the valve immediately and determine the cause.
"ON" (up) position and that the red knob is removed.
A provision is provided on the lowering valve to allow manual
2. Positionthe new battery disconnect switch in the mounting lowering of the forks if necessary. Manual lowering is
bracket. Installthe two screws retaining the battery disconnect accomplished by inserting a 1/8 inch alien wrench into the
switch to the mounting bracket. manual lowering screw (located in the center of the lowering
valvistor) and slowly turning it clockwise until the forks begin to
3. Install the red knob by threading it clockwise. Insert a 4.0 lower. See Figure 3-8. Be sure to return the screw to the original
position once the manual lowering process is complete by
mm (0.15 in) diameter rod through the hole in the housing and
slowly turning the screw counterclockwise until it stops.
into the hole in the shaft, to prevent the shaft from rotating while
installing the knob. Remove the rod from the housing once the
red knob is tightened securely. WARNING: Failure to return the manual lowering
screw to the full counterclockwise position will
4. Install the electrical wires to the battery disconnect switch. cause the forks to lower unexpectedly.

PROPORTIONAL ELECTRO-HYDRAULIC SOLENOIDS
6. Install the hydraulic tank dipstick. 1. AUXILIARY UP 3. LIFT
2. AUXILIARY DOWN 4. LOWER
7. Connect the battery.

o
PROPORTIONAL ELECTRO-HYDRAULIC CONTROL
VALVES
There are four electrically operated proportional valves located
on the main hydraulic control valve. These proportional valves
are controlled by solenoids. Valve openings are controlled by
varying the electrical current in the valve coils.
The instructions for testing, removal and replacement of the

proportional valves is covered in Section 7 - HYDRAULIC
SYSTEM.
MANUAL LOWERING SCREW
Figure 3-8 - Hydraulic Control Valve
3-9
Yale
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.
If a reading other than those listed are obtained, replace the

solenoid. See 'SectioffTfcfr' information on removing and
installing the solenoids.
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.
When tilt is selected by the operator at the multi-function control

handle, neither of the two selector valve assemblies is
energized. When reach is selected, the coils are energized on 1. HYDRAULIC FITTING
the reach selector valve. When sideshift is selected the coils on 2. SOLENOID
the optional sideshift selector valve are energized. 3. VALVE BODY
4. HOSE
Testing/Removai/lnstallation 5. INNER FRAME
6. PORT
Solenoids can be checked for resistance by removing the leads 7. TUBES
to the solenoids and tested using a volt ohmmeter. See 8. CHECK VALVE ASSEMBLY
Table 3-3, Page 3-7 for coil resistance values. If a reading
other than those listed are obtained, replace the solenoid. See Figure 3-9 - Reach Selector Valve
Section 8 for information on removing the sideshift and reach
solenoids.
1. SOLENOID
2. VALVE BODY
Figure 3-10 - Sideshifter Selector Valve
3-10
Yale
MULTI-FUNCTION CONTROL HANDLE

Description/Features left to cause the lift truck to travel in a forward direction. Move
the handle to the right to cause the lift truck to travel in the
The multi-function control handle is located in the operator's
reverse direction.
compartment. The handle is spring-loaded to return to the
center (neutral position) when pressure on the handle is
Disassembly
removed. The traction and hydraulic functions of the truck are
controlled with the multi-function handle. The traction functions 1. Move the lift truck to a safe level area. Turn the key switch
are selected by moving.the multi-function control handle from off and remove the key. Put a "DO NOT OPERATE" tag on the
side to side. The hydraulic functions are controlled by moving multi-function control handle. Put blocks under the drive wheels
the multi-function control handle from front to rear. See to keep the lift truck from moving. See Section 1 - HOW TO
Figure 3-11. The handle is equipped with a horn button and can PUT A LIFT TRUCK ON BLOCKS.
be equipped with up to three auxiliary selection buttons. The
auxiliary selection buttons operate the extend/retract, tilt and WARNING: Disconnect the battery and separate
sideshift, depending on how the truck is equipped. See the connector before opening the compartment
Figure 3-11 for the location of the components on the cover or inspecting/repairing the electrical system.
multi-function control handle. If a tool causes a short-circuit, the high current flow from the
Operation
The handle can be adjusted to three different positions for
operator comfort. The handle is adjusted by pressing the 3. Remove the hydraulic tank dipstick and the battery
handle downward on the shaft and turning the handle to the compartment cover.
desired position. Move the multi-function control handle to the
SIDESHIFT SELECT FORWARD REVERSE

BUTTON TRAVEL TRAVEL
TILT SELECT TRACTION CONTROL

BUTTON
LIFT
REACH SELECT
TILT UP
BUTTON
SIDESHIFT RIGHT
EXTEND
LOWER
1 HORN TILT DOWN
I BUTTON SIDESHIFT LEFT
RETRACT
Figure 3-11 - Operation of the Multi-Function Control Handle
3-11
Yale
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.
3-12
Yale
industrial Tmcks ELECTRICAL SYSTEM
6. Adjust each switch so it activates when the multi-function

control handle is moved in the appropriate direction and does
not activate when in neutral. When the switches are activated,
the switch arm must not bottom out against the body of the
switch or bind the multi-function control handle assembly.
Properly adjusted switches will activate when the end of the
multi-function control handle is moved approximately V2 inch to
3A inch from the neutral position. See Figure 3-12.
SWITCH ACTIVATION % INCH TO %

INCH FROM NEUTRAL POSITION
MEASURE AT TOP OF HANDLE
Figure 3-12 - Multi-function Control Handle Switch

Adjustment
/\ CAUTION: If the forward, reverse or hydraulic

/|\ neutral switch is not adjusted properly, the MIB
may not allow the set up of the corresponding
potentiometer. All switches must be open when the
multi-function control handle is in neutral and the appropriate
switch must close when the multi-function control handle is
moved V2 inch to 3A inch from the neutral position.
7. Install and adjust the potentiometers. Refer to TRACTION

AND HYDRAULIC POTENTIOMETER, INSTALLATION and
ADJUSTMENT, Page 3-15. 1. COVER
2. MEMBRANE
8. Installall the electrical wires and connect the X-7, X-8 and 3. BUTTON
X-9 plugs to the connectors. Refer to WIRING SCHEMATICS 4. SWITCH ASSEMBLY
AND DIAGRAMS at the end of this section for wiring details. 5. SWITCH RETAINER
Make certain that the switches and potentiometers work 6. BODY AND SLEEVE
properly when 1he multi-function control handle is moved. 7. TOLERANCE RING
8. SCREW
9. Calibrate the MIB to the potentiometer. Refer to MIB 9. HORN SWITCH
CALIBRATION. . 10. SCREW
A CAUTION: Whenever adjusting or replacing a

_«
I\ potentiometer the MIB must be calibrated to the

potentiometer. Figure 3-13 - Multi-function Handle - Exploded View
3-13
Yale
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
Figure 3-14 - Multi-Function Control Handle Assembly - Exploded View
3-14
Yale
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
Test Points Resistance Value Table 3-5 - Potentiometer Wiring

Between pot terminals 1 and 3 10KQ ± 10% 3. Calibrate the MIB to the potentiometer. Refer to MIB
CALIBRATION.
Between pot terminals 1 and 2 0-10KQ ± 10%
.
A
Between pot terminals 2 and 3 0-10KQ ± 10% CAUTION: Whenever adjusting or replacing a
f\ potentiometer the MIB must be calibrated to the
NOTE: Potentiometers can be supplied with or without potentiometer.
rotational stops.
Table 3-4 - Potentiometer Specifications
Installation
TERMINAL 3
1. Install the potentiometer through the mounting hole
aligning the locating pin into the slot in the mounting bracket.
See Figure 3-15. Fastenthe potentiometer to the bracket using 0>-TERMINAL 2
the lockwasher and nut.
TERMINAL 1
A CAUTION: Potentiometers can be supplied with
/ I\ or without rotational stops. Potentiometers with LOCATING
internal rotational stops will be damaged if they are PIN
10KQ ± 10%
rotated beyond the stops.
2. Install the gear on the potentiometer. Do not tighten the

setscrew in the gear at this time. If the setscrew is tightened
before the potentiometer is centered, the potentiometer can be
damaged. TERMINAL 1 CW TERMINAL 3
Adjustment
A CAUTION: The wires to the potentiometer must

be disconnected during Step 1.
1. Adjust the potentiometer for mid-range. Compare the Figure 3-15

TERMINAL 2 (WIPER)
- Traction and Hydraulic Pot Specifications

resistance measured between terminals 1 and 2 with the
resistance measured between terminals 2 and 3. The
potentiometer is ayhetnid-range position when the resistance
readings are equal within 100 ohms. Rotate the potentiometer
shaft while holding the gear in the neutral position for the correct
resistance readings. Tighten the setscrew in the gear at this
time.
NOTE: Failure to properly center the potentiometer can

cause a fault code to occur. The fault code may occur
immediately or intermittently.
3-15
Yale
MAIN INTERFACE BOARD (MIB)

DESCRIPTION/FEATURES opened at any one time as long as both switches are not
opened simultaneously.
The main interface board (MIB) is a printed circuit board that
directs communication between the electrical components of
If the operator steps off the truck, and the key switch remains in
the truck. The MIB provides inputs and outputs to the
the "ON" position, the MIB will display "0200" and the dash
multi-function control handle, variable valves, solenoid valves,
display will read "POWER ON" (after a 3 second delay).
contactor coils, relay coils, throttle, speed limit switch, brake
switch, operator sensing-., switch and the dash display.
Pushbuttons on the MIB provide for service level diagnostics LED DISPLAY
and set-up capability. A four-digit LED display on the MIB
The four digit LED display is capable of displaying two truck
shows real-time truck function "STATUS", "WARNINGS" and
function status, warning, or fault codes simultaneously. Referto
"FAULTS". See STATUS, WARNING AND FAULT CODE
MIB STATUS, WARNING, AND FAULT CODES for a
TROUBLESHOOTING.
comprehensive explanation of each code. One code is
displayed by the left two digits and the other code is displayed
by the right two digits. It is important to readthe left two digits as
one code and the right two digits as a separate code. The LED
display is also used during the calibration procedure. Refer to
MIB ADJUSTMENTS.
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
Fjgure 3-17 - MIB Pushbuttons A, B, C, and D and LED Display
3-16
Yale
MIB REMOVAL MIB INSTALLATION

The main interface board (MIB) is located under the battery WARNING: Disconnect the battery and separate
compartment cover. For access to the MIB, remove the battery the connector before opening the compartment
compartment cover. The MIB is not a repairable item and must cover or inspecting/repairing the electrical system.
be replaced if troubleshooting determines the MIB to be faulty. If a tool causes a short circuit, the high current flow from the
J\ WARNING: Disconnect the battery and separate
/ 1\ the connector before opening the compartment 1. Move the lift truck to a safe level area. Turn the key switch
Uÿl cover orlnspecting/repairing the electrical system. off and remove the key. Put a "DO NOT OPERATE" tag on the
If a tool causes a short circuit, the high current flow from the multi-function control handle. Put blocks underthe drive wheels
battery can cause an injury or parts damage. to keep the lift truck from moving. See Section 1 - HOW TO
off and remove the key. Put a "DO NOT OPERATE" tag on the 2. Disconnect the battery and separate the connectors.
multi-function control handle. Put blocks under the drivewheels
to keep the lift truck from moving. See Section 1 - HOW TO 3. Align the plugs with the connectors located on the bottom
PUT A LIFT TRUCK ON BLOCKS. of the MIB. Connect the two plugs J 1 and J2 to the bottom of the
main interface board. Make certain that the lock on each plug is
2. Disconnect the battery and separate the connectors. engaged with the latch.
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.
4. Discharge the controller by connecting a load across

terminals B + and B - . Disconnect the two plugs from the main
interface board (MIB).
5. Remove the capscrews and lockwashers retaining the PULL

MIB to the lift truck frame.
6. Lift the MIB high enough to access the connectors on the

bottom of the MIB.
7. Use a screwdriver in the slot of the lock on the connector to

release the male plug. Pull and hold the lock away from the
latch while pulling the J plug from the MIB. See Figure 3-18.
Disconnect boththe J 1 and J2 plugs fromtheMIB.TheMIBcan
now be removed from the lift truck.
NOTE: The MIB is not a repairable item and must be replaced

INSERT SCREWDRIVER INTO SLOT
if there is a problem with the board itself.
PULL LOCK AWAY FROM THE
CONNECTOR TO DISCONNECT
Figure 3-18 - MIB "J" Connector
3-17
Yale
MAIN INTERFACE BOARD (MIB) ADJUSTMENTS

GENERAL MIB CALIBRATION PROCEDURE
The MIB must be calibrated whenever any of the following The four digit LED display on the MIB is used during the
occur calibration procedure to display the function number and the
function value.
• A new MIB is installed or a MIB is transferred frorrfone truck
to another. • The function number is displayed by the left two digits.
• Traction potentiometer is adjusted or replaced. • The function value is displayed by the right two digits.
• Hydraulic potentiometer fS adjusted or replaced.
During normal operation, the left two digits show the status
• Troubleshooting indicates that any of the above code of the truck and the right two digits show 00, or a warning
components may be out of adjustment.
or fault code, as applicable. During the set-up procedure, the
CAUTION: Turning the key switch off or LED is used to display function number and function value
disconnecting the battery when the MIB is being information.
calibrated will result in the MIB returning to the run
mode without saving any new values. Step 1 Entering the Set-up Mode
NOTE: To exit the set-up procedure at any time without
DEFAULT VALUES
saving new values, turn the key switch to the "OFF position.
Every MIB installed in a new truck by the factory is programmed
with the recommended factory default values for that model 1. Turn the key switch to the "ON" position.
truck. In addition, the MIB is calibrated to the specific traction
and hydraulic potentiometers on the truck. 2. Refer to Figure 3-17 for the location of the MIB buttons.
Press and hold buttons "A" and "C" simultaneously until the
Whenever a replacement MIB is installed in a truck, the
LED display shows a series of dashes then release.
appropriate model code must be programmed into the MIB.
Upon release, the left two digits will display function number
This automatically sets the recommended factory default "01" and the right two digits will display the corresponding
values for all functions except functions 30 through 34.
function value. Function number "01" is the truck model code
Functions 30 and 31 are programming utilities and do not
function. The function value shown should correspond to one of
require value entries. Function 33 is not used. Functions 32 and
the truck model code values shown in Table 3-6.
34 are used to calibrate the traction and hydraulic
potentiometers. The replacement MIB must be manually
calibrated to the specific traction and hydraulic potentiometers Function Value Truck Model Battery Voltage
installed on the truck.
00 NONE -
NOTE: The MIB must be calibrated to the traction and/or
hydraulic potentiometer whenever a traction or hydraulic 10 NR035AD 24
potentiometer is adjusted, repaired or replaced.
11 NR040AD 24
CHECKING THE MODEL CODE AND SET-UP STATUS 12 NR035AD 36

Turn the key switch to the "ON" position. Press button "A" on the 13 NR040AD 36
MIB. Refer to Figure 3-17. The LED display will show either
"FnnO" or "FnnA", where 'nn' indicates the model code number 14 NR045AD 36
currently programmed into the MIB and the "0" or "A" indicates
15 NDR030AD 24
the MIB program status. A model code of "00" indicates that the
MIB has not been programmed for any truck model. See 16 NDR030AD 36
Table 3-6 for model code information.
17 NS040AE 24
The MIB program status is shown as "0" or "A". The "0"
indicates that the settings.correspond to the default values for 18 NS040AE 36
the truck model listed ('nn'). The "A" stands for "altered", and
indicates that one or more of the function values have been set 19 NS050AE 36
to a value other than the default value for the truck model listed.
Table 3-6 - Truck Model Code Function Values
NOTE: A fault code can occur if the truck model is not
selected properly or if the traction and/or hydraulic NOTE: A value of 00 indicates a new MIB with no program or
potentiometers are not properly calibrated to the MIB. a MIB which has had the program erased.
Pressing button "C" or "D" will show the software version (i.e.
3. If the model code is incorrect or the MlB is to be reset to the
"C500" for version 5.00).
factory default settings, proceed to Step 2, ERASING THE
3-18
Yale
MODELCODE. If the model code is correct, proceed to Step 4, 8. Repeat Step 6.

CALIBRATING THE HYDRAULIC POTENTIOMETER
RANGE. 9. Return the multi-function control handle to the neutral
position.
Step 2 Erasing the Model Code
10. Press button "C" to increase the function value (the right
1. Select function number 31 by pressing and holding button
two digits) to any value greater than "00".
"A", then pressing button "C" or "D" until the left two digits of the
LED show 31. Release button "A" when the desired function
11. Press and hold button "B". Move the multi-function control
number is reached.
handle through the full range of full speed lift to full speed lower
while holding button "B". Notice that the function value digits
CAUTION: After erasing the model code it will be
(right two digits) remain at the value set in Step 10. above,
necessary to perform Steps 3 through Step 6
but that the left two digits change as the control handle is
before the lift truck will be operational.
moved. Notice also that the decimal point between each digit
will light to indicate that the neutral switch has closed.
2. Verify that the LED display shows "3150".
Check the calibration by watching the left two digits, while
3. Change the function value (the right two digits) to a value of
holding button "B" and cycling the control handle through the full
75. The function value is changed by pressing either button "C"
range of lift and lower. The left two digits should be nearly zero
or "D" until the desired value is obtained.
in the neutral position. When the handle is moved to the full
speed lift position, the left two digits should increase to a value
4. Press and hold button "B". Press button "D" to erase the
of at least 94, ideally 99 (the value "AO" represents a value of
model code and all programmed values. Release both buttons.
100 and is acceptable). Similarly, when the handle is moved to
The MIB display will show "0110" to indicate that Function 01
the full speed lower position, the left two digits should increase
has reset to the starting value of 10 corresponding to the first
to a value of at least 94, ideally 99 (the value "AO" represents a
model code function value in sequence (NR035AD). Proceed
value of 100 and is acceptable). If the left two digits do not
to STEP 3 to change the model code function value, as
exceed 94 when the control handle is moved to the full speed
required.
(lift or lower) position, the calibration must be repeated. If the
proper values cannot be obtained, check the potentiometer or
Step 3 Setting the Model Code
switch. See Table 3-4 and Figure 3-15 for potentiometer
1. Change the function value (the right two digits) to the value specifications.
assigned for the correct truck model, as required. See
Table 3-6. The function value is changed by pressing either Step 5 Calibrating the Traction Potentiometer Range
button "C" or "D" until the desired value is displayed.
1. Put blocks under the drive wheels to keep the lift truck from
moving. See Section 1 - HOW TO PUT A LIFT TRUCK ON
Step 4 Calibrating the Hydraulic Potentiometer Range
BLOCKS.
1. Center the hydraulic potentiometer manually using an
ohmmeter before proceeding. Refer to HYDRAULIC 2. Center the traction potentiometer manually using an
POTENTIOMETER, ADJUSTMENT, Page 3-15. ohmmeter before proceeding. Refer to TRACTION
POTENTIOMETER, ADJUSTMENT, Page 3-15.
"A", then pressing button "C" or "D" until the left two digits of the 3. Select function number 34 by pressing and holding button
LED show 32. Release button "A" when the desired function "A", then pressing button "C" or "D" until the left two digits of the
number is reached. The MIB display should show "3210". LED show 34. Release button "A" when the desired function
number is reached. The MIB display should show "341 0".
3. Press button "D" until the function value is decreased to
zero. Once the value reaches zero, press button "D" at least 4. Press button "D" until the function value is decreased to
one more time. zero. Once the value reaches zero, press button "D" at least
one more time.
4. Verify that the MIB display shows "3200".
5. Move the multi-function control handle to the full speed lift
position. Hold for 2 seconds. 6. Press the brake pedal.
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.
3-19
Yale
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. • •
5. Verify the correct operation of all traction and hydraulic

11. Return the multi-function control handle to the neutral functions.
position.
CUSTOMIZING MIB FUNCTIONS
12. Press button "C" to increase the function value (the right
two digits) to any value greater than "00". Certain function values can be customized, as required. The
following pages contain detailed descriptions of each function
13. Press and hold button "B". Move the multi-function control number.
handle through the full range of full speed forward to full speed
reverse while holding button "B". Notice that the function Refer to Table 3-19 through Table 3-28 for specific minimum
value digits (right two digits) remain at the value set in Step and maximum values available for each function,
12. above, but that the lefttwo digits change as the control corresponding to the specific truck model.
handle is moved. Notice also that the decimal point on the far
left of the display will light to indicatethat the reverse switch has Settings can be returned to the existing values by exiting
closed, and that the decimal point in the center will light to without saving the new values. To exit without saving new
indicate that the forward switch has closed. values, turn the key switch to the "OFF position. The settings
can be returned to the factory default values by setting Function
Check the calibration by watching the left two digits, while 01 to the correct value for the specific lift truck model. Refer to
holding button "B" and cycling the control handle through the full MIB CALIBRATION PROCEDURE.
range of forward and reverse. The left two digits should be
nearly zero in the neutral position. When the handle is moved to WARNING: Program changes will affect lift truck
the full speed forward position, the left two digits should performance and operation. If function values are
increase to a value of at least 89, ideally 99 (the value "AO" changed, make sure all operators of the lift truck
represents a value of 100 and is acceptable). Similarly, when know that the truck may now operate differently.
the handle is moved to the full speed reverse position, the left
two digits should increase to a value of at least 89, ideally 99 WARNING: Each function has a range of values
(the value "AO" represents a value of 100 and is acceptable). If (minimum/maximum), specific to each model
the left two digits do not exceed 89 when the control handle is truck. Adjustment of functions to a value outside
moved to the full speed (forward or reverse) position, the the specific range for the truck model can cause the truck to
calibration must be repeated. If the proper values cannot be operate differently than normal. Do not set any function to a
obtained, check the potentiometer or the switches. See value outside the minimum/maximum range for the truck.
Table 3-4 and Figure 3-15 for potentiometer specifications. Function values set incorrectly can cause personal injury or
damage to the truck.
Step 6 Exiting the Set-up Mode and Saving the New
Values Function values are customized as follows:
1. Turn the key switch to the "ON" position.

CAUTION: Failure to perform this step will result
in the loss of all new settings.
2. Refer to Figure 3-17 for the location of the MIB buttons.
Press and hold buttons "A" and "C" simultaneously until the
LED display shows a series of dashes then release.
"A", then pressing button "C" or "D" until the left two digits of the
Upon release, the left two digits will display function number
LED show 30. Release button "A" when the desired function
"01" and the right two digits will display the corresponding
number is reached. The MIB display should show "3050".
function value. Function number "01" is the truck model code
function. The function value for function number "01" should
correspond to the value for the specific truck model, as shown
in Table 3-6.
3. Press and hold button "B", then press button "C".
3-20
Yale
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
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.
extend. Decreasing this value will decrease the slowest speed
the forks extend. Decreasing this value below the default value
3-21
Yale
can increase the distance the multi-function control handle has -

Function 12 Tilt Down Minimum Rate
to be moved to start extend.
This function adjusts the slowest speed the forks tilt down with
the multi-function control handle in the slow tilt down position
-
Function 07 Extend Maximum Rate
(auxiliary valve is first activated).
This function adjusts the fastest speed the forks extend with the
multi-function control handle in the fast extend position. Increasing this value will increase the slowest speed the forks
tilt down. Decreasing this value will decrease the slowest speed
Increasing this value .wjlj.provide faster speeds. Decreasing the forks tilt down. Decreasing this value below the default
this value will provide slower speeds. After programming the value can increase the distance the multi-function control
minimum value allowed, an additional reduction in extend handle has to be moved to start tilt down.
speed can be realized by decreasing the value of Function 06, if
desired. Function 13 Tilt Down - Maximum Rate
This function adjusts the fastest speed the forks tilt down with
Function 08 Retract - Minimum Rate
the multi-function control handle in the fast tilt down position.
This function adjusts the slowest speed the forks retract with
the multi-function control handle in the slow retract position Increasing this value will provide faster speeds. Decreasing
(auxiliary valve is first activated). this value will provide slower speeds. After programming the
minimum value allowed, an additional reduction in tilt down
Increasing this value will increase the slowest speed the forks speed can be realized by decreasing the value of Function 12, if
retract. Decreasing this value will decrease the slowest speed desired.
the forks retract. Decreasing this value below the default value
can increase the distance the multi-function control handle has Function 14 Sideshift Right - Minimum Rate
to be moved to start retract.
This function adjusts the slowest speed the forks sideshift to the
right with the multi-function control handle in the slow sideshift
Function 09 Retract - Maximum Rate
right position (auxiliary valve is first activated).
This function adjusts the fastest speed the forks retract with the
multi-function control handle in the fast retract position. Increasing this value will increase the slowest speed the
sideshift moves right. Decreasing this value will decrease the
Increasing this value will provide faster speeds. Decreasing slowest speed the sideshifter moves right. Decreasing this
this value will provide slower speeds. After programming the value below the default value can increase the distance the
minimum value allowed, an additional reduction in extend multi-function control handle has to be moved before sideshift
speed can be realized by decreasing the value of Function 08, if right occurs.
desired.
Function 15 Sideshift Right - Maximum Rate
Function 10 Tilt Up - Minimum Rate
This function adjusts the fastest speed the forks sideshift to the
This function adjusts the slowest speed the forks tilt up with the right with the multi-function control handle in the
multi-function control handle in the slow tilt up position maximum-speed, sideshift right position.
(auxiliary valve is first activated).
Increasing this value will provide faster speeds. Decreasing
Increasing this value will increase the slowest speed the forks this value will provide slower speeds. After programming the
tilt up. Decreasing this value will decrease the slowest speed minimum value allowed, an additional reduction in sideshift
the forks tilt up. Decreasing this value below the default value right speed can be realized by decreasing the value of Function
can increase the distance the multi-function control handle has 14, if desired.
to be moved to start tilt Lip.
Function 16 Sideshift Left - Minimum Rate
Function 11 Tilt Up - Maximum Rate
This function adjusts the slowest speed the forks sideshift to the
This function adjusts the fastest speed the forks tilt up with the left with the multi-function control handle in the slow sideshift
multi-function control handle in the fast tilt up position. left position (auxiliary valve is first activated).
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.
3-22
Yale
Function 17 Sideshift Left - Maximum Rate Function 22 Model Code - MTVRD

This function adjusts the fastest speed the forks sideshift left WARNING: Do not customize this function. This
with the multi-function control handle in the maximum-speed, function must remain at the default value. Values
sideshift left position. other than the default value can cause improper
operation of the lift truck. Improper lift truck operation can cause
Increasing this value will provide faster speeds. Decreasing personal injury or property damage.
this value will provide slower speeds. After programming the
minimum value allowed, an additional reduction in sideshift left Function 23 Power Steering Contactor - Minimum
speed can be realized by decreasing the value of Function 16, if Current
desired.
WARNING: Do not customize this function. This
function must remain at the default value. Values
-
Function 18 Hydraulic Function Starting Rate
other than the default value can cause improper
This function adjusts the starting rate, or rate of acceleration, of operation of the lift truck. Improper lift truck operation can cause
the hydraulic valve for all hydraulic functions. personal injury or property damage.
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
decreases the time it takes for the hydraulic function to
accelerate (accelerates more quickly).
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
Increasing the stopping rate value increases the time it takes
for a hydraulic function to stop (decelerates more slowly).
Decreasing the stopping rate value decreases the time it takes
for the hydraulic function to stop (decelerates more quickly).
Function 20 Maximum Travel Speed - Mast Elevated
Function 26 Lift Pump Contactor - Maximum Current
This function adjusts the maximum travel speed (speed limit) of
the truck with the mast elevated above free lift.
WARNING: Never adjust Function 20 to a value
greater than the value specified for the truck
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.
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
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
3-23
Yale
Function 29 Steering Pump Time Delay Functions 35-56 NOT USED

/\ WARNING: Do not customize this function. This
Function 57 Hydraulic Auxiliary Function Damping
II\ function must remain at the default value. Values
wJLbJ other than the default value can cause improper This function is used as a utility for timing hydraulic auxiliary
operation of the lift truck. Improper lift truck operation can cause function damping.
Function 30 Exit and Save New Values
This function is used as a utility for saving changes made to MIB
settings and exiting from the MIB set-up mode. No
4ÿ function must remain at the default value. Values
of the lift truck. Improper lift truck operation can cause
Dperationof
operation
customization for this function is applicable. personal injury or property damage.
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
Figure 3-19 - MIB Plug - Pin Identification

3-24
Yale
MIB STATUS, WARNING AND FAULT CODES

GENERAL For example, if an operator tries to use the sideshift and there is
an open sideshift solenoid on the mast, the red fault icon on the
During normal operation, the left two digits show the "STATUS"
dash will light and CHECK FAULT CODE. NO SIDESHIFT will
code of the truck andthe right two digits show "00". Whenever a
be displayed.
truck function is selected, the left two digits are updated to
display the selected function.
To repair the problem, remove the cover for access to the MIB
and perform the function (sideshift) which caused the fault to
The two digits on the right side of the display are used to display
occur. Fault code "43" would be displayed on the right two digits
either a "WARNING" code or a "FAULT" code. If neither a
of the MIB when the sideshift function was attempted. The
"WARNING" code nor a "FAULT code is present, the right two
digits continue to display "00". If multiple faults are present, the
serviceperson would refer to MIB Code "43" on the following
pages to diagnose and repair the cause of the problem.
highest priority "FAULT code is displayed. After the highest
priority fault is repaired, the next highest priority "FAULT code
NOTE: The fault code, fault message and fault icon for most
will be displayed.
faults are displayed only when the operator attempts to perform
the affected function.
If a "WARNING" code and a "FAULT code are received at the
same time, the left two digits will display the "WARNING" code,
the right two digits will display the "FAULT code, and the TROUBLESHOOTING CHARTS
"STATUS" code will not be displayed. Always troubleshoot the
The sample chart below explains the format for the information
code shown on the right side of the display first.
provided on the following pages. Note that an "X" in the MIB
CODE section represents a placeholder character and can be
Codes are displayed as follows:
any number. The priority level is provided to show the relative
• "STATUS" codes -+ numbers 01 to 16. order codes would be displayed in the event of more than one
• "WARNING" codes-* numbers 34 to 38. simultaneous status, warning or fault condition.
• "FAULT codes — numbers 40 to 85.
ÿ
MIB CODE DASH DISPLAY MESSAGE PRIORITY LEVEL CODE TYPE SIGNAL SOURCE
Code Priority Origin of

displayed on assigned in Status, message sent
Message displayed on dash
MIB. "X" the software Warning, or to dash
display
represents (relative to Fault display (MIB
any number other codes) or Traction)
CONDITION
TRUCK RESPONSE
POSSIBLE CAUSES AND TEST PROCEDURES
CORRRESPONDING SCHEMATIC OR DIAGRAM
LOGIC
3-25
Yale
IndustrialTrucks electrical system
BLANK OR UNDEFINED CODE CONDITIONS
"Blank
"Blank Display"
Display"
CONDITION
No display on MIB or dash display.
15 15
TRUCK RESPONSE
Travel and hydraulic functions are disabled. 1 -
• B + and/or B - missing at the MIB and dash display. 01 OASH
C\i
Check to ensure battery disconnect switch is closed by MIB DISPLAY
measuring for battery voltage on both sides of the switch.

("POS" connection and bus bar connection to power fuses).
s S|
I
!«]
*"!
o,
Check fuses 4, 5, and 6 for open condition, if open replace

1 3- ;
them. *--
1 3-3
J2-15 and J2-23 (wire #15) at the MIB should measure near 1 3-6
battery voltage, J2-7 and J2-8 (wire #13) should be B - . X4-2
(wire #15) at the dash display should measure near battery
voltage, and X4-8 and X4-10 should be B-.
LOGIC
• Defective MIB and/or dash display. Displayed if any of the following conditions are not satisfied:
Replace MIB and/or dash display.
J2-15 and J2-23 (wire #15) at the MIB should measure near
battery voltage and J2-7 and J2-8 (wire #13) should be B - .
X4-2 (wire #15) at the dash display should measure near
battery voltage and X4-8 and X4-1 0 should be B - .
xxxx "Blank Display"

CONDITION
Dash display blank.
TRUCK RESPONSE
"LIFT' function is disabled, traction and auxiliary functions are
normal.
trj
OASH
DISPLAY
J

• B + and/or B - missing at the dash display. FF
!v' Ui
X4-2 at the dash display should measure near battery 1
voltage, and X4-8 and X4-1 0 should be B - . 13-1
• Defective dash display. 13-5
Verify B + and B - as detailed above, if these measurements
are correct replace the dash display.
LOGIC
Displayed if any of the following conditions are not satisfied:
X4-2 (wire #15) at the dash display should measure near
battery voltage. X4-8 (wire #13-1) and X4-10 (wire #13-5)
should be B-.
3-26
Yale
LOST MIB SIGNAL

"Blank Display" NO LIFT OR DRIVE
CONDITION
MIB display is blank.
i
truck response 15
Travel and hydraulic functions are disabled.

• B + or B - missing at the MIB.
J2-15 and J2-23 (wire #15) should measure near battery
voltage. J2-7 and J2-8 should be B - . MIB
• Defective MIB.
Verify B + and B - as detailed above, if these measurements
are correct replace the MIB.
NOTE: This fault occurs when there is a loss of communication
between the MIB and display. This may be due to a loose wire or
from total failure of the electronics board. If the board fails, the MIB
will disable traction and hydraulics. If a wire is loose only the
display will be disabled. LOGIC
Displayed if any of the following conditions are not satisfied:
J2-15 and J2-23 (wire #15) should measure near battery
voltage. J2-7 and J2-8 should be B - .
xxxx LOST MIB SIGNAL

NO LIFT OR DRIVE
CONDITION
Communication between MIB and dash display is not functioning
properly.
TRUCK RESPONSE
"LIFT" function is disabled. Travel and "AUXILIARY HYDRAULIC"
functions may or may not be disabled.

• Open in wire 81 , 82, or 83.
Disconnectthe plug J1 at the MIB and plug X-6 at the dash
display.
Check continuity from J1-7 (wire #81) to X6-8 (wire #81).
Locate and repair any open circuits.
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).
3-27
Yale
xxxx DRIVE CTRL HOT

SPEED REDUCED
26 WARNING
TRACTION
CONTROLLER
NOTE
Warning and Fault messages originating from the traction
controller are NOT shown as codes on the MIB, but will be
displayed on the dash display.
CONDITION
Traction controller too hot. Determine and correct cause.
TRUCK RESPONSE
Yellow "WARNING" indicator illuminates.
Traction controller goes into thermal cutback.
Reduced travel speeds.

SYMPTOM
\
• See TRACTION MOTOR CONTROLLER, TEST/ DIAGNOS¬
TICS, thermal cutback fault.
LOGIC
Displayed when the internal temperature of the traction motor
controller is beyond the operating range of -25 to + 85 ° C
(- 13 to 185 °F). The internal temperature can be read by
accessing the test menu on the hand set.
DRIVE CTRL FAULT TRACTION

XXXX THROTTLE FAULT
20 FAULT CONTROLLER
NOTE
displayed on the dash display.
CONDITION
Traction controller fault.
TRUCK RESPONSE
Red "FAULT" indicator illuminates.
Traction is disabled until fault condition is corrected.

Traction controller fault. Determine and correct cause.
\ ÿ
• See TRACTION MOTOR CONTROLLER, TEST/ DIAGNOS¬
TICS, THROTTLE FAULT.
LOGIC
Displayed when the traction motor controller determines that
the throttle input is out of range.
3-28
Yale
Industrial Tmcks ELECTRICAL SYSTEM
xxxx DRIVE CTRL FAULT 19 FAULT TRACTION

CONTROLLER
NOTE
displayed on the.dash display.
CONDITION
Traction controller fault.
TRUCK RESPONSE
Red "FAULT indicator illuminates.

Traction controller fault. Determine and correct cause.
• See TRACTION MOTOR CONTROLLER, TEST / DIAGNOS¬
TICS, DRIVE CONTROL FAULT.
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.
See MIB CODE

MIB SET-UP MODE 21 WARNING MIB
Below
MIB CODE
The two digits on the left will display the current function number
and the two digits on the right will display the current function
value.
CONDITION
MIB was placed in SET-UP MODE by simultaneously pressing the
A and C buttons located on top of the MIB. Refer to MIB
CALIBRATION PROCEDURE.
TRUCK RESPONSE
Yellow "WARNING' indicator illuminates.

• MIB is in the SET-UP MODE.
Turn the key switch to the "OFF position. Restart the truck
using the normal procedure
or
exit the MIB SET-UP mode. LOGIC
Refer to MIB CALIBRATION procedure. Displayed when MIB is in SET-UP MODE.
3-29
Yale
STATUS CODES
02XX POWER ON 30 STATUS MIB

CONDITION
Operator is not on the truck, key is on.
15 24 15
TRUCK RESPONSE
Main contactor, MIB, and dash display are energized. Traction
and hydraulic functions are not available until the operator steps
onto the truck. nU-
fr aaDASH
MI 3 a 1SPLAY
Jl_i [®"I j~2

HU
13-1
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-.
03XX READY 29 STATUS MIB

CONDITION
Key is on and traction contactor is energized. Operator enters the 15
truck and presses both the operator sensing pedal and the brake
pedal. BRAKE
SWITCH
OPERATOR
TRUCK RESPONSE SENS ING
"PS" (power steering) pump starts. Traction and hydraulic SWITCH
functions are enabled.
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.
both switches for proper operation.
3-30
Yale
04XX FORWARD MODE 28 STATUS MIB

CONDITION
Multi-function control handle positioned for "FORWARD" travel.
TRUCK RESPONSE
rr
56 56
Truck travels in the-forward direction.
FWD REV 6 21 22 23
1 chi) —VVVV1—'3 clou)
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.
05XX REVERSE MODE 28 STATUS MIB

CONDITION
Multi-function control handle positioned for "REVERSE" travel.
TRUCK RESPONSE 56 56
Truck travels in the reverse direction.
c c
pWDx 6 REV 22 23
l CHI) —VW V"—1 3cl0'j:
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
06XX LIFT 27 STATUS MIB

CONDITION
Multi-function control handle positioned for "LIFTING"
TRUCK RESPONSE
Yellow "LIFT/LOWER" indicator illuminates.
Lift pump starts and forks lift. 10
NEUTRAL SWITCH
31 32 33
40 I CHI) -\A/Wÿ '3 (LOU)

HYDRAULIC POT
LOGIC
07XX LOWER 27 STATUS MIB

CONDITION
Multi-function control handle positioned for "LOWERING"
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
3-32
Yale
08XX REACH 27 STATUS MIB

CONDITION
"REACH" button is pressed on the multi-function control handle.
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.
09XX EXTEND 27 STATUS MIB

CONDITION
"REACH" button is pressed and the multi-function control handle
is positioned for "EXTEND".
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.
3-33
Yale
10XX RETRACT 27 STATUS MIB

CONDITION
is positioned for "RETRACT".
TRUCK RESPONSE
Forks retract. T
REACH
10
A
NEUTRAL
SWITCH 31 32 33
44 40 1 CHI) -'VVW -'3 (LOW)

hydraulic pot
Lki a
LOGIC
voltage.
11XX TILT 27 STATUS MIB

CONDITION
"TILT" button is pressed on the multi-function control handle.
TRUCK RESPONSE
Yellow TILT indicator illuminates.
10 10
tilt! 31 32 33
NEUTRAL
SWITCH
—WWN—
hydraulic pot
3 (LOW)
42 40
I ~i
LOGIC
the neutral value.
3-34
Yale
12XX TILT UP 27 STATUS MIB

CONDITION
"TILT" button is pressed and the multi-function control handle is
positioned for TILT UP".
TRUCK RESPONSE
Forks tilt up.
NEUTRAL
SWITCH
3 CLOW)
HYDRAULIC PO
LOGIC
voltage.
13XX TILT DOWN 27 STATUS MIB

CONDITION
TILT" button is pressed and the multi-function control handle is
positioned for TILT DOWN".
TRUCK RESPONSE
Forks tilt down. 10
TIL
NEUTRAL
SWITCH 31 32 33
42 uhiJ-WnX/—
HYDRAULIC POT
Lkl
LOGIC
voltage.
3-35
Yale
14XX SIDESHIFT 27 STATUS MIB

CONDITION
"SIDESHIFT button is pressed on the multi-function control
handle.
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
the neutral value.
15XX SIDESHIFT RIGHT 27 STATUS MIB

CONDITION
"SIDESHIFT button is pressed and the multi-function control
handle is positioned for "SIDESHIFT RIGHT.
TRUCK RESPONSE
Forks sideshift to the right. 10
I
SSI
NEUTRAL
SWITCH 32 33
46 1 (HI) -'VVVV-'3 (LOW)

!
HYDRAULIC POT
id 0
LOGIC
voltage.
3-36
Yale
16XX SIDESHIFT LEFT 27 STATUS MIB

CONDITION
"SIDESHIFT" button is pressed and the multi-function control
handle is positioned for "SIDESHIFT LEFT".
TRUCK RESPONSE
Forks sideshift to the left. IfN |_ |rvj
NEUTRAL
SWITCH
31 32 33
HYDRAULIC POT
LOGIC
voltage.
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).
34 MAST UP SPEED REDUCED 27 WARNING MIB

CONDITION
Mast elevated while traveling "FORWARD" or "REVERSE".
TRUCK RESPONSE
Yellow "WARNING" indicator illuminates. 56 56 55 56
Maximum travel speed is reduced.
POSSIBLE CAUSES AND TEST PROCEDURES 56
• Mast elevated.
IF THE MAST IS NOT ELEVATED: HEiGHT
• Height limit switch damaged or out of adjustment. LIMIT
PUD REV O FWDs 6 REV 0
Adjust height limit switch. Verify proper operation of switch. SW I TCH
• Height limit switch shorted.
Remove wires #56 and #74 from the switch. Check 74
resistance between switch terminals 7 and 8. Replace any
switch that does not read continuity with mast primary 60 80 50
elevated and no continuity with mast primary lowered.
• Shorted height limit switch circuit.
Disconnect the battery. Disconnect the J1 plug from MIB.
¥ inr or O
Check resistance between wires #56 and #74. There should
not be continuity. If continuity (low ohms) is measured, wires LOGIC
#56 and #74 are shorted together somewhere in the harness. Displayed when voltage at MIB terminal J1-4 is near battery
Locate and rejftalf the short. voltage and voltage at MIB terminal J1-13 or J1-10 is near
Reconnect wire #56 to terminal 8 and wire #74 to terminal 7. battery voltage.
3-37
Yale
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
• Multi-function control handle not in "NEUTRAL".
Reset multi-function control handle to "NEUTRAL".
H.
ills
„
*
TT1T
IF MULTI-FUNCTION CONTROL HANDLE IS IN "NEUTRAL": a a a

Big i 0
• FORWARD, REVERSE or NEUTRAL (hydraulic) switch signal zt 11 11
V
JT
i
3Z
!
53
to MIB is inappropriate in relation to multi-function control I /
handle position. — >« 1 run
—
' TRACTION ROT — 111 -'•/" /ÿ/ fROT-
111*
I-TORIU.;:
15
TT0RRW.IC ROT
Check forward, reverse and neutral switch adjustment.

Check forward, reverse and neutral switches for shorted LOGIC
condition. Displayed when greater than 14 volts is present at J 1-2 before
Check for short circuit in forward, reverse or neutral switch battery voltage is present at J 1-1 and J 1-9.
circuit. Displayed when battery voltage is simultaneously supplied to
• Traction, or hydraulic potentiometer defective or out of J 1-9 and J1-10 or J1-9 and J 1-13 with battery voltage present at
adjustment. J 1-1. (Forward or reverse switch closed before brake switch.)
Displayed when the voltage at J2-16 or J2-21 is above or below
Check, replace and/or adjust potentiometers.
approximately 2.5 volts (neutral voltage) before battery voltage
is present at J1-1 andJ1-9.
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
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
37 BRAKE PEDAL UP 23 WARNING MIB

CONDITION
Brake switch not closed and operator moves the multi-function £- '
,s
control handle to travel or perform a hydraulic function. 10

c I 1 «
NEUTRAL
TRUCK RESPONSE 1
switch
I
Yellow "WARNING" indicator illuminates. 40
60 SO 55

• Brake switch not closed.
Ii 0 i
Stand on the platform and press the brake pedal to close the
a is a 13 13 Hp a
brake switch. Reset the multi-function control handle to
neutral.
f+4 11 37 33
13 i!l
• Brake switch out of adjustment or defective. ml — — 5MM5 (Mil

—iVÿW—ÿ1.
-MV0MMJ.1C - -VÿA/V*POT-i'lC
5..I
BUT ------ i5.) 1
HlBWULi:
Adjust or replace the brake switch.

• Open in the brake switch circuit.
Disconnect the battery and MIB J plugs. Check continuity LOGIC
between MIB plug terminal J1-9 and wire #56 at the brake Displayed when greater than 14 volts is present at J 1-2 with
switch. Check continuity between wire #15 at fuse FU6 and battery voltage present at J1-1 and near 0 volts present at J1-9.
the brake switch. Repair any open circuits in the brakeswitch Displayed when the voltage at J2-16 or J2-21 is above or below
circuit. approximately 2.5 volts (neutral voltage) with battery voltage
present at J1-1 and near 0 volts present at J 1-9.
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
NEUTRAL
Travel and hydraulic functions are disabled. SWITCH
NO !
POSSIBLE CAUSES AND TEST PROCEDURES 40
• Operator sensing switch and brake switch are not closed. 50 30 56 11

Stand in the operator compartment to close operator sensing
10 0 0
-
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
• Open in operator sensing switch and brake switch circuit. '-AA/llv*-

II 1 - y--
-n' lyT/i/ 155—
- 55-Vÿl/A- l il ImM Mil'
i 15.1
Disconnect the battery and MIB J plugs.

Check continuity between MIB plug terminal J1-1 and wire
#11 at switch connector X-13. Check continuity between wire
#15 at switch connector X-13 and wire 15 at fuse FU6. Repair LOGIC
any opens in the operator sensing switch circuit. Displayed when greater than 14 volts is present at J 1-2 with
Check continuity between MIB plug terminal J1-9 and wire near 0 volts present at J 1-1 and J1-9.
#56 at the-brake switch. Check continuity between wire #15 Displayed when the voltage at J2-16 or J2-21 is above or below
at fuse FU6 and the brake switch. Repair any open circuits in approximately 2.5 volts (neutral voltage) with near 0 volts
the brake switch circuit. present at J1-1 and J1-9.
3-39
Yale
FAULT CODES
CHECK FAULT CODE

XX40 NO REACH
18 FAULT MIB
CONDITION
i0
is moved to the "EXTEND" or "RETRACT" position.
i1 -
TRUCK RESPONSE EX EX
Red "FAULT indicator illuminates. "REACH" is disabled. A B
ÿ
• 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-
resistance measures outside of specifications, replace the

coil. Coil resistance @ 21°C (70°F) = 39 ±4 ohms. 92
• Shorted "EX" (reach) solenoid coil circuit.
Disconnect the battery. Disconnect the J2 plug from the MIB.
Disconnect wires #10 and #92 from the "EX" (reach)
i
solenoids. Check resistance between wires #10 and #92. LOGIC
There should not be continuity. If continuity (low ohms) is Displayed when higher than normal current is sensed in the
measured, wires #10 and #92 are shorted together "EX" (reach) solenoid circuit.
somewhere in the harness. Locate and repair the short.
CHECK FAULT CODE

XX41 NO REACH
18 FAULT MIB
CONDITION
is moved to the "EXTEND" or "RETRACT" position. 1o
TRUCK RESPONSE
Red "FAULT indicator illuminates. "REACH" is disabled.
i
" ÿ EX
• Open "EX" (reach) solenoid coil. > B
<:-v y
"EX" (reach) solenoids located on the mast. Measure the
resistance of each, "EX" (reach) solenoid coil. If the coil
coil. Coil resistance @ 2TC (70°F) = 39 ±4 ohms.
• Open "EX" (reach) solenoid coil circuit. »
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
CHECK FAULT CODE

XX42 NO SIDESHIFT
17 FAULT MIB
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

• Shorted "SIDESHIFT solenoid coil.
Disconnect the battery. Remove wires #10 and #91 from the
sideshift solenoids located on the mast. Measure the
resistance of each solenoid coil. If the coil resistance
measures outside of specifications, replace the coil. Coil
resistance @ 21°C (70°F) = 39 ±4 ohms. 31
• Shorted "SIDESHIFT solenoid coil circuit.
Disconnect wires #10 and #91 from the sideshift solenoids.
Check resistance between wires #10 and #91 . There should
not be continuity. If continuity (low ohms) is measured, wires LOGIC
#10 and #91 are shorted together somewhere in the harness. Displayed when higher than normal current is sensed in the
Locate and repair the short. "SIDESHIFT solenoid circuit.
CHECK FAULT CODE

XX43 NO SIDESHIFT
17 FAULT MIB
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.
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
3-41
Yale
CHECK FAULT CODE

XX44 NO AUX FUNCTIONS
16 FAULT MIB
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.
• 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 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.
CHECK FAULT CODE

16 FAULT MIB
CONDITION
multi-function control handle is moved up.
TRUCK RESPONSE
Red "FAULT indicator illuminates. "EXTEND", "TILT UP" and 10
"SIDESHIFT RIGHT functions are disabled.
• Open "AUX UP" (auxiliary up) solenoid coil.
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
I1
• 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.
3-42
Yale
CHECK FAULT CODE

15 FAULT MIB
CONDITION
multi-function control handle is moved down.
TRUCK RESPONSE 10
Red "FAULT indicator illuminates. "RETRACT, TILT DOWN",
and "SIDESHIFT LEFT functions are disabled.
• Shorted "AUX DOWN" (auxiliary down) solenoid coil. AUX
Disconnect the battery. Remove wires #10 and #73 from the DOWN
"AUX DOWN" solenoid. Measure the resistance of the "AUX
DOWN" 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 DOWN" solenoid coil circuit. 73
Disconnect wires #10 and #73 from the solenoid. Check
resistance between wires #10 and #73. There should not be ÿI
continuity. If continuity (low ohms) is measured, wires #10
and #73 are shorted together somewhere in the harness. LOGIC
Locate and repair the short. Displayed when higher than normal current is sensed in the
"AUX DOWN" (auxiliary down) solenoid circuit.
CHECK FAULT CODE

15 FAULT MIB
CONDITION
multi-function control handle is moved down.
TRUCK RESPONSE
Red "FAULT indicator illuminates. "RETRACT, TILT DOWN", 10
and "SIDESHIFT LEFT functions are disabled.
• Open "AUX DOWN" (auxiliary down) solenoid coil.
d
AUX
"AUX DOWN" solenoid. Measure the resistance of the DOWN
yj
(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
be reportedÿs acode XX47. Troubleshoot as in MIB CODE "AUX DOWN" (auxiliary down) solenoid circuit.
3-43
Yale
CHECK FAULT CODE

0648 NO LIFT
14 FAULT MIB
CONDITION
Multi-function control handle positioned for "LIFTING".
TRUCK RESPONSE 10
Red "FAULT indicator illuminates. "LIFT function is disabled.

• Shorted "LIFT solenoid coil.
"LIFT solenoid. Measure the resistance of the "LIFT j) LIFT

(70°F) = 6.5 ±0.5 ohms.
• Shorted "LIFT solenoid coil circuit. 71
resistance between wires #10 and #71 . There should not be
continuity. If continuity (low ohms) is measured, wires #10
lijj
and #71 are shorted together somewhere in the harness. LOGIC

Locate and repair the short. Displayed when higher than normal current is sensed in the
"LIFT solenoid circuit.
CHECK FAULT CODE

0649 NO LIFT
14 FAULT MIB
CONDITION
TRUCK RESPONSE
Red "FAULT indicator illuminates. "LIFT function is disabled. 10
• Open "LIFT solenoid coil.
"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
• Open "LIFT solenoid coil circuit.

Check continuity from pin J2-6 to wire #71 at the "LIFT 7i
• Failed MIB (open power FET in "LIFT circuit). LOGIC
A short in the "LIFT solenoid coil circuit can cause a power Displayed when lower than normal current is sensed in the
FET to fail open. If the FET fails open the condition will be "LIFT solenoid circuit.
reported as a code XX49. Troubleshoot as in MIB CODE
3-44
Yale
CHECK FAULT CODE

0750 NO LIFT/LOWER
13 FAULT MIB
CONDITION
Multi-function control handle positioned for "LOWERING".
TRUCK RESPONSE 10
Red "FAULT" indicator illuminates. "LIFT" and "LOWER" functions
are disabled.

LOWER
• Shorted "LOWER" solenoid coil.
"LOWER" solenoid. Measure the resistance of the "LOWER"
solenoid coil. If the coii resistance measures outside of
(70°F) = 6.5 ±0.5 ohms. 70
• Shorted "LOWER" solenoid coil circuit.
resistance between wires #10 and #70. There should not be
continuity. If continuity (low ohms) is measured, wires #10 LOGIC
and #70 are shorted together somewhere in the harness. Displayed when higher than normal current is sensed in the
Locate and repair the short. "LOWER" solenoid circuit.
CHECK FAULT CODE

0751 NO LIFT/LOWER
13 FAULT MIB
CONDITION
Muiti-function control handle positioned for "LOWERING".
TRUCK RESPONSE
Red"FAULT" indicator illuminates. "LIFT" and "LOWER" functions 10
are disabled.
• Open "LOWER" solenoid coil.
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.
Check continuity from pin J2-14 to wire #70 at the "LOWER" 70
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
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
CHECK FAULT CODE

0652 NO LIFT
12 FAULT MIB
CONDITION
TRUCK RESPONSE
• 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).
"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 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.
CHECK FAULT CODE

0653 NO LIFT
12 FAULT MIB
CONDITION
TRUCK RESPONSE 10
• 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
¥
• Failed MIB (open power FET in "LIFT PUMP" / "HMR" circuit).
A short in the "LIFT PUMP" / "HMR" coil circuit can cause a LOGIC
be reported as a code XX53. Troubleshoot as in MIB CODE "LIFT PUMP" /"HMR" (hourmeter relay) coil circuit.
3-46
Yale
IndustrialTmcks electrical system
CHECK FAULT CODE

XX54 NO HYD FUNCTIONS
11 FAULT MIB
......... CONDITION
Multi-function handle is positioned for any hydraulic function.
TRUCK RESPONSE
Red "FAULT indicator illuminates. All hydraulic functions are
disabled.
• "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).
CHECK FAULT CODE

11 FAULT MIB
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
CHECK FAULT CODE

10 FAULT MIB
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.
• 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
#32 and #33 from the hydraulic potentiometer. Measure the

resistance from pin J2-16 to J2-17. 0 ohms indicates a short. With Multi-Function Control Handle in neutral:
Locate and repair any shorts. Low side: J2-17 (wire # 33) should be approximately 0.5 volts
• Hydraulic potentiometer defective or out of adjustment. Wiper: J2-16 (wire # 32) should be approximately 2.5 volts
Check, replace and/or adjust pot. Disconnect the wires from High side: J2-2 (wire #31) should be approximately 4.5 volts
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 J2-17 is equal and less than 1.0 volt. MIB
terminals 1 and 2 or 2 and 3. reference voltage at pin J2-16 (wiper) is too low.
CHECK FAULT CODE

10 FAULT MIB
CONDITION
Key switch is on and battery disconnect switch is closed.
TRUCK RESPONSE
Ei m i
disabled.

• Hydraulic potentiometer circuit shorted between wiper and
1 CHI) -VVW -3 CLOW)
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
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.
3-48
Yale
CHECK FAULT CODE

10 FAULT MIB
CONDITION
Key switch is.onandbattery disconnect switch is closed.
TRUCK RESPONSE
a i a
disabled. 31 32

• Hydraulic potentiometer circuit open on the high side (wire
1 (HI) - VVVV -'3
HYDRAULIC POT
CLOW)
#31).
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
an open. Locate and repair any open circuits.
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.
CHECK FAULT CODE

10 FAULT MIB
CONDITION
TRUCK RESPONSE
a in i
disabled.
• Hydraulic potentiometer circuit open on the low side (wire #33)
or on the wiper side (wire #32).
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.
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.
3-49
Yale
XX60 CHECK FAULT CODE 9 FAULT MIB

CONDITION
Key switch is on and battery disconnect switch is closed. c
TRUCK RESPONSE
Red "FAULT" indicator illuminates. Travel, auxiliary and power
steering functions are disabled.

• Shorted "PS" (power steering) contactor coil.
<!
"PS" coil. Measure the resistance of the coil. If the coil
coil. Coil resistance @ 21°C (70°F) = 52 ±4 ohms. 36
• Shorted "PS" coil circuit.
Disconnect wires #10 and #36 from the coil. Check
resistance between wires #1 0 and #36. There should not be
EJi
continuity. If continuity (low ohms) is measured, wires #10 LOGIC
and #36 are shorted together somewhere in the harness. Displayed when higher than normal current is sensed in the
Locate and repair the short. "PS" (power steering) circuit.

CONDITION
Key switch is on and battery disconnect switch is closed. ic
TRUCK RESPONSE
Red "FAULT" indicator illuminates. Travel, auxiliary and power
steering functions are disabled.
• Open "PS" (power steering) coil.
"PS" coil. Measure the resistance of the coil. If the coil
<!i>K
coil. Coil resistance M 21 °C (70°F) = 52 ±4 ohms.
• Open "PS" coil circuit.
3s
Check continuity from pin J2-12 to wire #36 at the "PS" coil
and from wire #10 at the "PS" coil to wire #10 at the "ER"
(enable relay) on the contactor panel. All circuits should test
near 0 ohms. Greater than 0 ohms indicates an open. Locate
E
and repair any open circuits.
• Failed MIB (open power FET in "PS" circuit). LOGIC
A short in the "PS" coil circuit can cause a power FET to fail Displayed when lower than normal current is sensed in the "PS"
open. If the FET-fails open the condition will be reported as (power steering) circuit.
a code XX61. Troubleshoot as in MIB CODE XX60. If the
XX61 fault does not clear replace the MIB.
3-50
Yale
CHECK FAULT CODE

XX62 NO DRIVE
8 FAULT MIB
CONDITION
HUH
TRUCK RESPONSE 21 22 23
Red "FAULT indicator illuminates. Travel functions are disabled.
POSSIBLE CAUSES AND TEST PROCEDURES 1 (HI) -TRACTION

AV/VWA-
POT
3 CLOW)
• Traction potentiometer circuit shorted between wiper and low

side.
Disconnect the J2 plug from the MIB. Disconnect wires #21 , With Multi-Function Control Handle in neutral:
#22 and #23 from the traction potentiometer. Measure the Low side: J2-1 (wire # 23) should be approximately 0.5 volts
resistance from pin J2-21 to J2-1. 0 ohms indicates a short. Wiper: J2-21 (wire # 22) should be approximately 2.5 volts
Locate and repair any shorts.
• Traction potentiometer defective or out of adjustment.
ohmmeter to check the potentiometer. Resistance should be Displayed when the MIB detects that the voltage at MIB
10K ohms ± 10% between pot terminals 1 and 3, and 0-1OK terminals J2-21 and J2-1 is equal and less than 1.0 volt. MIB
ohms ±10%, depending on wiper position, between pot reference voltage at pin J2-21 (wiper) is too low.
CHECK FAULT CODE

XX63 NO DRIVE
8 FAULT MIB
CONDITION
TRUCK RESPONSE
Iÿl (1 3
21 22 23
• 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
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.
3-51
Yale
CHECK FAULT CODE

XX64 NO DRIVE
8 FAULT MIB
CONDITION
TRUCK RESPONSE
S~ i 3
21 22 23
• 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
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.
CHECK FAULT CODE

XX65 NO DRIVE
FAULT MIB
CONDITION
r
TRUCK RESPONSE
jl Ij1 Is]
22 23
• 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.
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.
3-52
Yale
CHECK FAULT CODE

0466 NO DRIVE
8 FAULT MIB
CONDITION
Multi-function control handle is in the "NEUTRAL" position.
vwB-. TRUCK RESPONSE
Red "FAULT indicator illuminates. Travel functions are disabled. 56

• "FORWARD" switch out of adjustment or shorted. !?]
H
fTi
iAi_ H_
Fj
Check operation of the "FORWARD" switch, adjust or replace FWD
as necessary.
21 22 23
IFTHE "FORWARD" SWITCH TESTS GOOD, CONTINUE:
• "FORWARD" switch circuitry shorted.
Disconnect the battery and J1 plug at the MIB. Check 50
continuity between wire #60 and wire #56. If continuity exists TRACTION POT
wire #60 andwire #56 are shorted together. Locate and repair
the short.
¥
Check, replace and/or adjust pot. Disconnect the wires from LOGIC
the potentiometer and remove it from the truck. Use an Displayed when MIB terminal J1-13 (wire #60) is near battery
ohmmeterto check the potentiometer. Resistance should be voltage with the multi-function control handle in the "NEUTRAL"
10K ohms ± 10% between pot terminals 1 and 3, and 0-1OK position (traction potentiometer wiper voltage is at
ohms ±10%, depending on wiper position, between pot approximately 2.5 volts (neutral voltage)).
CHECK FAULT CODE

0467 NO DRIVE
8 FAULT MIB
CONDITION
Multi-function control handle is in the "FORWARD" travel position.
TRUCK RESPONSE

FW0
J_ n
• "FORWARD" switch failed open.
Replace any switch that does not read continuity between C
and NO with the switch activated.
• "FORWARD" switch out of adjustment.
Adjust the "FORWARD" switch. 60 1 CHI) - WW -
TRACT ON POT
[
3 CLCW)
• Open in the "FORWARD" switch circuit.

Check continuity between J1-13 and wire #60 at the switch, I
and wire #56 at the forward switch and wire #56 at the brake
switch. Both circuits should test near 0 ohms. Greater than 0
ohms indicates an open. Locate and repair any open circuits.
LOGIC
Displayed when MIB terminal J1-13 (wire #60) is not near
battery voltage with the multi-function control handle positioned
for "FORWARD" travel.
3-53
Yale
Industrial Trucks electrical system
CHECK FAULT CODE

0568 NO DRIVE
8 FAULT MIB
CONDITION
Multi-function control handle is in the "REVERSE" travel position.
TRUCK RESPONSE 55

_Ji| inI P
si
r
• "REVERSE" switch out of adjustment or shorted.
Check operation of the "REVERSE" switch, adjust or replace c 2i 22 23
as necessary. REV (
IF THE "REVERSE" SWITCH TESTS GOOD, CONTINUE:
• "REVERSE" switch circuitry shorted. NO 1 CHI)
TRACT ! ON
KaA-
30T
3 CLOW)
Disconnect the battery and J1 plug at the MIB. Check

continuity between wire #80 and wire #56. If continuity exists 80
wire #80 and wire #56 are shorted together. Locate and repair
the short.
• Traction potentiometer defective or out of adjustment. t
ohmmeter to check the potentiometer. Resistance should be Displayed when MIB terminal J1-10 (wire #80) is near battery
10K ohms ± 10% between pot terminals 1 and 3, and 0-1OK voltage with the multi-function control handle in the "NEUTRAL"
ohms ±10%, depending on wiper position, between pot position (traction potentiometer wiper voltage is at
terminals 1 and 2 or 2 and 3. approximately 2.5 volts (neutral voltage)).
CHECK FAULT CODE

0569 NO DRIVE
8 FAULT MIB
CONDITION
Multi-function control handle is in the "REVERSE" travel position.
TRUCK RESPONSE
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
• "REVERSE" switch out of adjustment.

Adjust the "REVERSE" switch. 30 1 (HI) —'v\aXa-
TRACTION POT
3 (LOW)
• Open in the "REVERSE" switch circuit.

Check continuity between J1-10 and wire #80 at the switch, l!
and wire #56 at the reverse switch and wire #56 at the brake
switch. Both circuits should test near 0 ohms. Greater than 0
ohms indicates an open. Locate and repair any open circuits.
LOGIC
Displayed when MIB terminal J1-10 (wire #80) is not near
battery voltage with the multi-function control handle positioned
for "REVERSE" travel (traction potentiometer wiper voltage is
less than approximately 2.5 volts (neutral voltage)).
3-54
Yale
Industrial Tmcks electrical system

CONDITION
l5
TRUCK RESPONSE
Red "FAULT indicator illuminates. Travel and hydraulic functions ER
! 86
are disabled.

d
• Shorted "ER" (enable relay) coil.
"ER" (enable relay). Measure the resistance of the relay coil 15
(relay terminals #85 and #86). If the coil resistance measures
outside of specifications, replace the relay. Coil resistance @
•
2TC (70° F) = 305 ± 15 ohms.
Shorted "ER" (enable relay) coil circuit.
li±1
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.

CONDITION
TRUCK RESPONSE
i5
Red "FAULT indicator illuminates. Travel and hydraulic functions
are disabled.
• Open "ER" (enable relay) coil. ER
k
86
Disconnect the battery. Remove wires #15 and #16 from the j
"ER" (enable relay). Measure the resistance of the relay coil

(relay terminals #85 and #86). If the coil resistance measures
outside of specifications, replace the coil. Coil resistance @
21°C (70°F) = 305 ± 15 ohms.
• Open "ER" (enable relay) coil circuit. iS
Check continuity from pin J2-11 to wire #16 at the "ER"
(enable relay) and from wire #1 5 at the "ER" (enable relay) to
wire #15 at fuse #6 on the contactor panel. Both circuits I:j
open. Locate and repair any open circuits. LOGIC
• Failed MIB (open power FET in "ER" (enable relay) circuit). Displayed when lower than normal current is sensed in the
A short in the "ER" (enable relay) coil circuit can cause a
,
"ER" (enable relay) coil circuit.
power FET to fail open. If the FET fails open the condition will
be reported as a code XX71 . Troubleshoot as in MIB CODE
3-55
Yale
MIB FAILURE
XX72 TRUCK DISABLED
2 FAULT MIB
CONDITION
TRUCK RESPONSE i
Red"FAULT" indicator illuminates. Travel and hydraulic functions
are disabled.

• Power FET is shorted in the MIB.
Replace the MIB.
LOGIC
Displayed when the internal logic of the MIB detects a shorted
power FET.

CONDITION
TRUCK RESPONSE
NONE (traction and hydraulic functions are disabled).

• Voltage spike/Electrical "noise".
Verify if the fault can be cleared by turning the key switch to
the "OFF' position. Wait 10 seconds and restart the truck ©
using the normal procedure.
Check for unsuppressed accessories, strobe light, etc.
Check all connections and wiring for loose or intermittent
connections. Mil
• Defective MIB.
Replace the MIB.
Tfl f*-
"
LOGIC
Displayed when the internal logic of the MIB detects a shorted
suppression zener diode.
3-56
Yale
XX82 CHECK FAULT CODE FAULT MIB

CONDITION
TRUCK RESPONSE

•Truck model not programmed into new MIB board.
Program truck model into MIB. Refer to MIB CALIBRATION
procedure.
• Truck model was erased from a previously programmed MIB
by selecting Function 31 and entering a value of 75.
Program truck model into MIB. Refer to MIB CALIBRATION
procedure.
• Truck model was erased from a previously programmed MIB
by turning the key switch off while the MIB was in the Set-up
mode and Function 31 was selected. LOGIC
Program truck model into MIB. Refer to MIB CALIBRATION Displayed when MIB function "01" has a value of 00.
procedure. (New MIB board with no program or a previously programmed
board which has had the model code erased.)
CHECK FAULT CODE

XX83 NO DRIVE
FAULT MIB
CONDITION
TRUCK RESPONSE
Travel functions are disabled.

• MIB not calibrated to traction potentiometer.
Calibrate MIB to traction potentiometer. Refer to MIB
CALIBRATION procedure.
• Traction potentiometer not adjusted properly.
Adjust traction potentiometer. Refer to TRACTION AND
HYDRAULIC POTENTIOMETER, ADJUSTMENT.
Calibrate MIB to traction potentiometer. Refer to MIB
• Forward and/or reverse switch not adjusted properly.
Adjust forward and/or reverse switch. Refer to LOGIC
MULTI-FUNCTION CONTROL HANDLE, ASSEMBLY. Displayed if the traction potentiometer set-up procedure has not
Calibrate MIB to hydraulic potentiometer. Refer to MIB been performed.
CALIBRATION procedure. (Model code has been programmed into the MIB.)
3-57
Yale

CONDITION
Key switch is on and battery disconnect switch is closed. ÿ l$L
TRUCK RESPONSE
Red "FAULT indicator illuminates.
Hydraulic functions are disabled. oI
jPÿ !
POSSIBLE CAUSES AND TEST PROCEDURES IT i
i
• MIB not calibrated to hydraulic potentiometer. ! ÿ
Calibrate MIB to hydraulic potentiometer. Refer to MIB @

• Hydraulic potentiometer not adjusted properly.
Adjust hydraulic potentiometer. Refer to TRACTION AND
HYDRAULIC POTENTIOMETER, ADJUSTMENT.
Calibrate MIB to hydraulic potentiometer. Refer to MIB
• Neutral switch not adjusted properly.
Adjust neutral switch. Refer to MULTI-FUNCTION LOGIC
CONTROL HANDLE, ASSEMBLY. Displayed if the hydraulic potentiometer set-up procedure has
Calibrate MIB to hydraulic potentiometer. Refer to MIB not been performed.
CALIBRATION procedure. (Model code has been programmed into the MIB.)
3-58
Yale

Description/Features Removal
The Curtis Model 1244-4405 traction motor controller uses a 1. Move the lift truck to a safe level area. Turn the key switch
sophisticated microprocessor to control the logic and operation to the off position and remove the key. Put a "DO NOT
of the high frequency MOSFET technology, eliminating the OPERATE" tag on the multi-function control handle. Put blocks
need for forward and reverse contactors. The controller under the drive wheels to keep the lift truck from moving. See
operates on the principle of independentlycontrolling the motor Section 1 - HOW TO PUT A LIFT TRUCK ON BLOCKS.
field and armatureoircuits. This is accomplished through the
use of a full bridge configuration on the field circuitry and a half WARNING: Disconnect the battery and separate
bridge configuration on the armature circuitry. Pulse width the connector before opening the compartment
modulation (PWM) allows the field and armature circuitry to be cover or inspecting/repairing the electrical system .
controlled accurately and independently. The motor controller If a tool causes a short-circuit, the high current flow from the
has many programmable features that allow for multi-mode battery can cause an injury or parts damage.
user selectable control, including acceleration rates, maximum
speed, braking current limit, and neutral braking current limit. 2. Disconnect and separate the battery connector.
The controller also includes a wide range of built-in safety
features and full diagnostic and set-up capability for safe 3. Remove the socket head capscrews retaining the
reliable operation. operator's compartment cover. Remove the cover.

controller can hold an electrical charge after the
shock and injury, discharge the capacitor before inspecting or
capacitors in the controller by connecting a load (such as a
contactor coil or a horn) across the controller's B + and B -
4. Discharge the controller by connecting a load across

terminals B + and B - .
5. Unplug the connector from the traction motor controller.

Tag and disconnect the wires to the terminals.
6. Remove the four capscrews, lockwashers and L brackets

-
Figure 3-20 Traction Motor Controller retaining the controller within the mounting brackets. Carefully
remove the traction motor controller from the lift truck.
The Curtis Model 1307 Programmer Hand Set (Yale P/N
1500359-08) is used to program and troubleshoot the traction Testing
motor controller. Refer to PROGRAMMER HAND SET.
See PROGRAMMER HAND SET for complete testing and
The traction motor controller communicates with the dash troubleshooting procedures for the Traction Motor Controller.
display for selection-of performance modes and for diagnostic The traction motor controller cannot be repaired. The traction
information. The performance-mode selection feature allows motor controller is sealed and contains no serviceable parts, if
the operator to choose from three different motor controller testing has determined the traction motor controller to be faulty,
performance levels by pushing a button on the dash display. it must be replaced.
The rate of acceleration, maximum top speed, and braking rate
can be specifically assigned for each mode using the Installation
programmer hand set.
1. Make certain that the mounting surface for the traction
Simplified diagnostic information is communicated to the dash motor controller is clean. There should be no dirt between the
display to alert the operator to adverse conditions such as frame and the traction motor controller. Align the traction motor
controller over temperature, operator sequence error or motor controller in the lift truck between the upper and lower mounting
controller malfunction. brackets. Verify that the captive nuts are in place on the
mounting brackets. Install the L brackets, capscrews and
3-59
Yale
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
Figure 3-21 - Traction Motor Controller Pin Arrangement
3-60
Yale
PROGRAMMER HAND SET

Description/Features To the left of the PROGRAM, TEST and DIAGNOSTICS menu,
a small scroll bar is displayed. The scroll bar gives a rough
The Programmer Hand Set is a hand held tool that allows the
indication of the position of the four displayed items within the
userto PROGRAM, TEST and DIAGNOSE the Traction Motor
entire menu. That is, when the scroll bar is at the top of the
Controller. It has been designed for ease of use with eight keys
window, the top of the menu is displayed. When scrolling
to control all functions. A MORE INFO key is included to provide
more detail on any display item. through the menu, the bar will move downward. Whenthe bar is
at the bottom, the end of the menu has been reached.
The programmer is powered by the controller. When the
CHANGE VALUE Keys
programmer is plugged into the controller, it will acquire ail the
controller function values and display the model number, date The CHANGE VALUE arrow keys increase or decrease the
of manufacture and revision code. After the initial display, the value of theselected menu item.There is an LED on each arrow
programmer will prompt the user with further instructions. key to indicate when the key is active and a change is
permissible. When the LED is off, the limit setting (maximum or
minimum) of the function has been reached.
FOUR LINE LCD
DISPLAY WINDOW
The CHANGE VALUE keys may be pressed repeatedly or held
in the same manner as the SCROLL DISPLAY keys. The longer
SELECTS the key is held the faster the value changes. This allows rapid
TEST changing of any function value.
/MENU MORE INFO Key
The MORE INFO key is used to display additional information
about the selected item and to access the SPECIAL
SELECTS PROGRAM MENU andthe DIAGNOSTICS HISTORY MENU.
SELECTS DIAGNOSTICS
When the programmer is in any of the operating modes, the
MENU
MORE INFO key may be pressed to display additional
information aboutthe selected item. Pressthe MORE INFO key
CHANGES again to return to the original list. In the PROGRAM menu, a bar
VALUE OF graph is displayed along with the minimum and maximum
SCROLLS
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.
3-61
Yale
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.
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.
3. Discharge the capacitors in the traction motor controller by

connecting a load (such as a contactor coil or a horn) across the
controller's B + and B - terminals (center 2 terminals).
SCROLL
DISPLAY
i ' $%s / nil

*
0 1 23 4 5 6 789: ; <= >?||ll
®ABC0E FGH I JKLMNOllll
PQRSTUVWXYZx-»tr IIII
Figure 3-23 - Programmer Hand Set Self Test
3-62
Yale
OPERATING MODES Test Menu

Program Menu Press the TEST key to enter the TEST mode. The LED in the
comer of the TEST key illuminates to indicate that the
Press the PROGRAM key to enter the PROGRAM mode. The
LED in the comer of the PROGRAM key illuminates to indicate programmer has been placed in the TEST mode. The TEST
that the programmer has been placed in the PROGRAM mode.
menu displays real time information about the status of the
inputs, outputs and controller temperature. In the TEST mode,
All of the adjustable functions and features are shown in the
the item of interest does not need to be the top item in the
display window, four at a time, with the corresponding settings.
window; it only needs to be one of the four items displayed in the
The setting of the' selected item (the item at the top of the
window. The TEST mode is useful for checking out the
display with the flashing arrow) can be changed using the
CHANGE VALUE keys.The CHANGE VALUE keys have LEDs operation of the controller during initial installation. The MORE
to indicate whetherthe key can be used to increase or decrease
INFO key, when used in the TEST mode, displays additional
information about the top item in the window.
the value any further. When the LED is no longer lit, the limit for
the key direction has been reached.
TEST
Press the MORE INFO key to display more detailed information DESCRIPTION
MENU DISPLAY
for the setting selected, including a bar graph indicating the
position of the current setting relative to the range for the THROTTLE % Throttle reading, as % of full throttle.
setting, the unit of measure, and the specific minimum and ARM CURRENT Motor armature current, in amps.
maximum values for the setting. If the range is limited by the
values assigned for a different function, the name of the limiting FIELD CURRENT Motor field current, in amps.
function is displayed in place of the minimum and maximum
values. BATT VOLTAGE Battery voltage across the capacitors.
HEATSINK °C Heatsink temperature in °C.
PROGRAM
DESCRIPTION FORWARD
MENU DISPLAY Forward switch on or off.
INPUT
M3 Brake C/L Mode 3 braking current, in amps
REVERSE INPUT Reverse switch on or off.
M2 Brake C/L Mode 2 braking current, in amps
INTERLOCK
Brake switch on or off.
M1 Brake C/L Mode 1 braking current, in amps INPUT.
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
Taper Rate Regen braking decrease rate, when

transitioning to plug, in 1/32 seconds DRIVE MODE
TEST MENU
Mode 3 maximum speed, as % of top TURTLE MIDDLE RABBIT
M3 Max Speed
'speed
MODE SELECT
OFF ON OFF
M2 Max Speed Mode 2 maximum speed, as % of top INPUT 1
speed
MODE SELECT
ON OFF OFF
M1 Max Speed Mode 1 maximum speed, as % of top INPUT 2
speed
Table 3-9 - Dash Display Drive Mode Inputs
Table 3-7 - Program Menu
3-63
Yale
Diagnostics Menu Diagnostic History

Press the DIAGNOSTIC key to enter the DIAGNOSTIC mode. Press the DIAGNOSTICS key and the MORE INFO key
The LED in the corner of the DIAGNOSTIC key illuminates to simultaneously to enter the DIAGNOSTIC HISTORY menu.
indicate that the programmer has been placed in the The DIAGNOSTIC HISTORY lists all of the faults observed and
DIAGNOSTIC mode. The DIAGNOSTICS menu displays all recorded by the controller since the history was last cleared.
currently active faults detected by the controller. It is capable of Press the SCROLL DOWN key to display any recorded faults.
displaying 19 different faults, four at a time. Each fault will be listed only once, regardless of the number of
times the fault may have occurred.
DIAGNOSTICS The diagnostic history can be cleared from the controller using
DEFINITION
MENU DISPLAY the SPECIAL PROGRAM MENU function, "CLEAR DIAG
HISTORY". Press the PROGRAM key while holding the MORE
ARM SENSOR Armature sensor fault INFO key. Press the SCROLL DOWN key until CLEAR DIAG
CONT DRVR OC Contactor driver overcurrent HISTORY appears in the top line of the display. Press the
MORE INFO key again, and then press the VALUE UP key to
FIELD OPEN Field winding open or disconnected clear the history, or VALUE DOWN to cancel the operation.
FLD SENSOR Field sensor fault Special Program Menu
HPD High Pedal Disable activated Press and hold the MORE INFO key, then press the
PROGRAM key to enter the SPECIAL PROGRAM menu. The
HW FAILSAFE 1 Power-on self test fault
SPECIAL PROGRAM menu allows the user to: revert the
HW FAILSAFE 2 External watchdog fault controller to previous settings, save controller settings to the
programmer memory, load controller settings from the
HW FAILSAFE 3 Internal watchdog fault programmer memory, clear diagnostic history, adjust the
contrast of the programmer display, select language, and
LOW BATTERY
Battery voltage too low display basic controller and programmer information. Press the
VOLTAGE
SCROLL DISPLAY key until the desired function is on the top
M- SHORTED M - output shorted (Controller M - line. Press the MORE INFO key for information on how to make
Terminal) to B- the desired adjustment.
MAIN CONT DNC Traction contactor did not close The SPECIAL PROGRAM menu also allows the userto "clone"
controllers. After one controller is programmed with all of the
MAIN CONT desired values, the values can be saved to the programmer
Traction contactor welded
WELDED memory. The programmer can then be used to load the saved
MISSING values to other similar controllers (same model number).
Missing Contactor
CONTACTOR
NO KNOWN SPECIAL PROGRAM DEFINITION
No known faults have occurred MENU DISPLAY
FAULTS
OVERVOLTAGE Battery voltage too high RESET ALL
Revert to previous settings
SETTINGS
SRO Static Return to Off activated
CONT Save controller settings to
THERMAL Cutback, due to over/under SETTINGS— PROG programmer
CUTBACK temperature
PROG Load programmer settings to
THROTTLE SETTINGS—CONT controller
Throttle out of range
FAULT 1
CLEAR DIAG Clear DIAGNOSTIC HISTORY
THROTTLE HISTORY memory
Throttle low fault
FAULT 2
CONTRAST Adjust programmer display
Table 3-10 - Diagnostic and Diagnostic History Display ADJUSTMENT contrast
LANGUAGE Select displayed language

NOTE: The DIAGNOSTIC and DIAGNOSTIC HISTORY
SELECTION
display shown in Table 3-10 is not a menu as such, but simply
a list of the possible messages displayed when the PROGRAMMER INFO Display programmer information
programmer is operating in the DIAGNOSTICS or
DIAGNOSTIC HISTORY modes. The messages are listed in CONTROLLER INFO Display controller information
alphabetical order for easy reference. Table 3-11 - Special Program Menu
3-64
Yale
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.
15. Disconnect and separate the battery connector.
NOTE: The brake pedal must be released (up position)
during Step 7.
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
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.
3-65
Yale
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.
MENU DISPLAY MIN./MAX. UNITS OF

FUNCTION DESCRIPTION FACTORY VALUE
VALUES ALLOWED MEASURE
M3 BRAKE C/L •• •
24 volt trucks only 320 100 to 450
ÿ
M2 BRAKE C/L Brake Current Limit Amps

M1 BRAKE C/L 36 volt trucks only 280 100 to 450
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


End Regen Taper 24 volt trucks only 25 1 to 64

TAPER RATE 1/32 second
Rate 36 volt trucks only 27 1 to 64
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 100 Oto 100

24 volt trucks only
"EE" 85 Oto 85
M3 MAX SPEED M3 Speed Limit % of Throttle
36 volt trucks only
"EE" 75 Oto 75

24 volt trucks only
"EE" 85 Oto 85
36 volt trucks only
"EE" 75 Oto 75
Standard 65 0 to 65
24 volt trucks only
"EE" 65 0 to 65
Standard 65 0 to 65
36 volt trucks only
"EE" 65 0 to 65
Table 3-12 - NR/NDR/NS Program Menu Range and Default Values
3-66
Yale
TROUBLESHOOTING Programmer Diagnostics

The traction motor controller provides diagnostic information to The programmer presents complete diagnostic information in
the programmer hand set, the dash display and the Status LED plain language. Faults are displayed in the DIAGNOSTIC
on the controller. The following four-step process is menu. The status of the controller inputs and outputs is
recommended for diagnosing and troubleshooting an displayed in the TEST menu. The DIAGNOSTIC HISTORY
inoperative vehicle: menu provides a list of the faults that have occured since the
1. Visually inspect the truck for obvious problems.
diagnostic history file was last cleared. Checking (and clearing)
the diagnostic history file is recommended each time the truck
2. Diagnose the problem using the DIAGNOSTIC menu in is serviced.
the programmerhand set.
3. Test the circuitry (inputs/outputs) using the TEST menu in Press the DIAGNOSTIC key to enter the DIAGNOSTIC mode.
the programmer hand set. The LED in the comer of the DIAGNOSTIC key illuminates to
4. Correct the problem. indicate that the programmer has been placed in the
DIAGNOSTIC mode. The DIAGNOSTICS menu displays ail
Status LED Diagnostics currently active faults detected by the controller. It is capable of
displaying 16 different faults, four at a time.
A Status LED is built into the traction motor controller. It is
visible through a window in the label on the top of the controller.
Press the DIAGNOSTICS key and the MORE INFO key
The Status LED displays fault codes when there is a problem
with the controller or with the inputs to the controller. During
simultaneously to enter the DIAGNOSTIC HISTORY menu.
The DIAGNOSTIC HISTORY lists ail of the faults observed and
normal operation, with no faults present, the Status LED
recorded by the controller since the history was last cleared.
flashes steadily on and off. If the controller detects a fault, a
Press the SCROLL DOWN key to display any recorded faults.
2-digit fault identification code is flashed continuously until the
Each fault will be listed only once, regardless of the number of
fault is corrected. For example: code "3,2" - welded traction
times the fault may have occurred.
contactor - appears as three flashes, pause, two flashes, long
pause, three flashes, pause, two flashes, long pause...and so
Press the TEST key to enter the TEST mode. The LED in the
on continuously until the problem is corrected.
corner of the TEST key illuminates to indicate that the
NOTE: Only one LED fault code is indicated at a time, and programmer has been placed in the TEST mode. The TEST
faults are not queued up. Operational faults - such as a fault in menu displays real time information about the status of the
SRO sequencing - are cleared by cycling the keyswitch. inputs, outputs and controller temperature. In the TEST mode,
the item of interest does not need to be the top item in the
LED CODE EXPLANATION window: it only needs to be one of the four items displayed in the
window. The MORE INFO key, when used in the TEST mode,
OFF (no flashes) No power or defective controller displays additional information about the top item in the
ON (continuously) Controller or microprocessor fault window.
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
3,4 Missing contactor, or traction

contactor did not close
4,1 Low battery voltage
4,2 Overvoltage
4,3 Thermal cutback; over/under temp
Table 3-13 - Status LED Fault Codes
3-67
Yale
Diagnostics Menu
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.
TRUCK RESPONSE
Traction may or may not function normally.

"g cg
• Brake pedal is pressed when programmer handset is
connected.
! ai
Turn key switch to the "OFF position. Release the brake
pedal. Turn the key switch to the "ON" position. y f
• Interface cable between traction motor controller and
programmer hand set is defective.
o
CURTIS. •-
Replace the interface cable.
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
is in the "ON" position. Diagnostic menu is selected.
TRUCK RESPONSE
Traction functions normally.
POSSIBLE-CAUSES AND TEST PROCEDURES

• No faults that are diagnosable by the traction motor controller
exist.
LOGIC
Displayed when no known faults are present.
3-68
Yale
RAMME
"Any LED Code"
CONDITION
Hand set is plugged nto the traction motor controller. Key switch
TRUCK RESPONSE
Traction may or may not function normally.
POSSIBLE CAUSES AND TEST PROCEDURES ÿ ÿ ÿ.

• Caused by a defective hand set.
Replace the hand set. A A
V W
LOGIC
Displayed when the internal check logic of the traction motor
controller does not get the correct communication from the
programmer hand set.
RMAL CUTBACK
ERMAL CUTBACK DUE
OVER/UNDER TEMP
CONDITION
TRUCK RESPONSE
Traction speed is reduced.

• Temperature of the traction motor controller is greater than 85 °
C (185 °F) or less than -25° C (- 13°F).
Determine thecause of the out of range temperature and
correct (low battery, overloading etc.).
Can be caused by excessive load on vehicle, operation in
extreme environments, or improper mounting of controller.
When controller cools off or warms up normal operation will
resume.
If controller is improperly mounted, remount according to
specifications. See TRACTION MOTOR CONTROLLER LOGIC
INSTALLATION. Displayed when the internal temperature of the traction motor
controller is beyond the operating range of -25° to +85° C.
The internal temperature can be read by accessing the test
menu on the hand set.
3-69
Yale
wmm
VATED
CONDITION
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
Check direction switches for proper operation, a shorted

direction switch can also cause this fault. lil
NOTE: The brake can be released while traveling, if the
operator presses the brake pedal within three seconds SRO
will not be activated. If the operator waits more than three LOGIC
seconds, SRO will be activated and the handle will have to be Displayed when battery volts is simultaneously supplied to
returned to neutral to resume normal operation of the truck. terminals 2 and 10 or terminals 2 and 11.
r .r, •
-"iV J
CONDITION
15
TRUCK RESPONSE
Traction is disabled until fault condition is corrected. (The HPD
3RAKE
function has a three second delay during normal operation.) SWITCH
• 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
Check for approximately 0.2 volts at pin 14 and pin 15 at the

traction motorcontroller with the multi-function control handle
in neutral. MIB
III if!
• Traction potentiometer out of adjustment.
Check traction potentiometer adjustment. Refer to
TRACTION POTENTIOMETER SET-UP.
• MIB failed.
Check the MIB for proper operation. The MIB provides the LOGIC
throttle position signal to the traction motor controller via wire Displayed when voltage at pin 14 or pin 15 is above about 1.25
#29 (J1-20) and a throttle reference voltage via wire #30 volts with 0 volts at pin 2.
(J1-16). With the multi-function control handle in neutral pin [5.00 volts (full speed throttle voltage) x 25% =1 .25 volts]
15 and pin 14 should measure approximately 0.2 volts.
3-70
Yale
MM aSBHWRI
mmm
CONDITION
is in the "ON" position; Diagnostic menu is selected.
56 56
TRUCK RESPONSE
• 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.
-mm
CONDITION
BATTERY
(-) o
U
I
TRUCK RESPONSE
POSSIBLE CAUSES AND TEST PROCEDURES T T

• Truck voltage greater than 45 volts. NEG POS
Check to ensure proper battery is in the truck.
• Plugging the charger into the truck instead of the battery can
also cause this fault.
Check to ensure the proper battery charging procedure is
followed.
LOGIC
Traction controller is designed to operate with 24 and 36 volt
batteries only.
3-71
Yale
LEO CODE DASH DISPLAY MESSAGE PROGRAMMER HAND SET DISPLAY MESSAGE
QVEBCQRREN&
CONDITION
ih*v.i iun
TRUCK RESPONSE
15 -c@>-
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.
CONDITION
TRUCK RESPONSE

• Defective traction motor controller.
Replace traction motor controller.
LOGIC
Displayed when the internal check logic of the traction motor
controller determines an internal failure of the traction motor
controller.
3-72
Yale
CONDITION
BATTERY
TRUCK RESPONSE

• Battery voltage less than 16 volts.
i
Check battery voltage to ensure proper voltage for truck.
Check for loose or corroded connections between the battery
and the traction motor controller.
LOGIC
B + bus bar on traction motor controller should measure near
truck battery voltage. Connections should be tight and
corrosion free.
"Any or No LED
FAULT
Code" K3
'*</' TTi* "'V? < * ' * '
CONDITION
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
Yale
,«i> ste « - : ., v.--. - .
3,4
CONDITION
TRUCK RESPONSE 15

• Traction contactor missing or contactor coil open.
Check traction contactor coil for open condition. Contactor
coil should measure approximately 17 T 1 ohms. If contactor
coil is open, replace it.
• Open wire between the traction motor controller and the
¥ PMC IBACT ION
CONTROLLER
[rnj
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.
FAI
-
CONDITION
TRUCK RESPONSE 29

• Throttle input voltage (pin 15, wire #29) out of range.
Check wire #29 for short to B - or B + .
Check for continuity between J1-20 (wire #29) at the MIB and
pin 15 (wire #29) at the traction motor controller. You should
read near zero ohms, if this wire is open find the open and
repair it.
• MIB failed.
Check the MIB for proper operation. The MIB provides the
throttle position signal to the traction motor controller via wire LOGIC
#29 (J1-20). With multi-function control handle in neutral pin Pin 15 at the traction motor controller is above (approximately)
15 (wire #29) should measure approximately 0.2 volts. As the 5.0 volts (full speed reference voltage) or below (approximately)
handle is moved in a "FORWARD" or "REVERSE" direction 0.2 volts (neutral reference voltage).
the voltage should increase to near 5 volts.
3-74
Yale
CONDITION
TRUCK RESPONSE
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
Menu TEST MENU

OPERATING RANGE
Item (Neutral position shown)
Scroll display until For Additional Information: 0% to 100%

THROTTLE % is shown on Press 0 with multi-function control handle in neutral.
the top line MORE INFO 100 with multi-function control handle positioned for full
speed travel (forward or reverse).
Throttle % should gradually increase as the multi-function
control handle is moved from the neutral position to the
full speed position (forward and reverse).
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 ARM For Additional Information:

CURRENT is shown on the Press
top line MORE INFO
Indicates traction.motor armature current.

3-75
Yale
Menu OPERATING RANGE

TEST MENU
Item
Scroll display until FIELD For Additional Information:

CURRENT is shown on the Press
top line MORE INFO
Indicates traction motor field current.
Menu TEST MENU

OPERATING RANGE
Item (24 volt truck shown)
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)
ÿgBiBBjjg V " ' ft- ' * V ~
Indicates actual battery voltage to the traction motor controller.
Menu TEST MENU

OPERATING RANGE
Item 22°C (71.5T) shown
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.
Menu TEST MENU

OPERATING RANGE
Item (Multi-function control handle positioned for forward travel.)
Scroll display Until For Additional Information: Forward switch "OPEN" OFF
FORWARD INPUTis shown Press
on the top line MORE INFO Forward switch "CLOSED" ON
6 FORWARD INPUT OH FORWARD INPUT; ,

,s
ggj|Mgili|B|iagpi! ON
Shows status of forward switch input at traction motor controller. Output of MIB.
3-76
Yale
IndustrialTrucks
Menu
Item
Item
Item
Item
10
on the top line
REVERSE 1nru
Scroll display until

INTRLCK INPUTis shown
on the top line
INTRLCK 'NPUT
Shows status of interlock (brake) switch.
Menu
Scroll display until MAIN

CONT is shown on the top
MAIN CONT
l(plw®lw
ISSIIi
33X8?$ * --
line
..
;:::;;5r >1;

FAULT 1 OUTPUT is shown
on the top line
FAULT 1OUTPUT
f§f||ph*
Shows status of fault 1 output.

i
M
>
Shows status of main (traction) contactor.
Menu
upi i-r
Press
MORE INFO
i
,
1
ijyrg.-*- •*—'*
*Lÿ -
TEST MENU
(Multi-function control handle positioned for reverse travel.)

REVERSE INPUTis shown
ni.[
ON
ÿ»— t
TEST MENU
OPEN
TEST MENU
.
For Additional Information: Fault 1 output low
Fault 1 output high

-ON
||
-
'.
Shows status of reverse switch input at traction motor controller. Output of MIB.
Menu
TEST MENU
ÿ
'
Press
MORE INFO
REVERSE INPUT
For Additional Information:
MAIN CONTACTOR
DB.VEH.S
FAULT 1 OUTPUT
Press
MORE INFO
Qÿ|
ON
Reverse switch "CLOSED"
.
ELECTRICAL SYSTEM
OPERATING RANGE
For Additional Information: Reverse switch "OPEN"
OPERATING RANGE
For Additional Information: Interlock (brake switch) input

Press
MORE INFO
INTERLOCK INPUT
OPERATING RANGE
OPERATING RANGE
OFF
. ON
ON
ON
OFF
3-77
Yale
Menu
TEST MENU OPERATING RANGE
Item
Scroll display until For Additional Information: Fault 2 output low ON

FAULT 2 OUTPUT is shown Press
on the top line MORE INFO Fault 2 output high OFF
11 SBfcutlaoOTPtnfÿm- FAULT 2 OUTPUT IK

/ÿlyl
HHP * - ÿ
HK ' '* K#X , s ÿ
Shows status of fault 1 output.
Menu TEST MENU OPERATING RANGE

Item (Rabbit mode shown)
Scroll display until For Additional Information: Turtle Mode ON

MODSEL 1 is shown on the Press
top line MORE INFO Mid Mode OFF
12 'MODSEL 1 MODSEL 1 Rabbit Mode OFF

h
.......
-- ÿ ÿÿ
- . ÿ
Controlled by the drive mode switch on the dash display.
Menu TEST MENU OPERATING RANGE

Item (Rabbit mode shown)
Scroll display until For Additional Information: Turtle Mode OFF

MODSEL 2 is shown on the Press
top line MORE INFO Mid Mode ON
13 MODSEL 2 MODSEL 2 Rabbit Mode OFF

* IS- /\ra|l
":T "
'1®; >r f*::.'.'
'
*. '
'
Controlled by the drive mode switch on the dash display.
3-78
Yale
DASH DISPLAY ASSEMBLY

Description/Features When the battery is disconnected, the drive mode defaults to
the Rabbit mode when battery power is restored.
The dash display interfaces with the MIB and the traction
......
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
Figure 3-24 - Dash Display Assembly REMOVAL

The dash display is located on the panel adjacent to the
Operation steering tiller in the operator's compartment. The dash display
The Dash Display is energized when the key switch is on and assembly cannot be repaired and must be replaced if defective.
the battery disconnect switch is closed. An internal back-up
battery provides memory retention of the battery indicator and
hourmeter readings when the battery is disconnected from the
truck.
The Drive Mode Switch allows the operator to select the level of
traction motor controller performance most suited to the WARNING: Disconnect the battery and separate
application. Indicator!" on the dash display change to the connector before opening the compartment
correspond to the level of performance selected. The three cover or inspecting/repairing the electrical system.
indicators are as follows: The Turtle" indicates slowest If a tool causes a short-circuit, the high current flow from the
acceleration, reduced top speed, and maximized energy battery can cause an injury or parts damage.
efficiency. The "Rabbit" indicates maximum acceleration and
maximum top speed. The middle setting is a compromise 2. Disconnect and separate the battery connector.
between the turtle and rabbit settings and indicates reduced
acceleration, but with maximum top speed. When the key
switch is turned to off, the selected drive mode is retained.
3-79
Yale
FRONT VIEW
DASH DISPLAY WIRE HARNESS DM1
FM1
ÿBARE
1 SB 3-5
JT -3
J1 -3- J1-1 ÿJl-4
X-1 5 CONNECTOR
TO DASH DISPLAY
l® -J 1-2
FRONT VIEW FRONT VIEW
X-15A JUMPER ASSEMBLY

USED 24 VOLT TRUCKS ONLY
Figure 3-25 - Dash Display Voltage Selection Jumper Location

4. Remove the socket head capscrews retaining the battery only. No jumper is used for 36 volt battery operation. The
compartment cover and the drive unit cover. Remove the jumper assembly, when used, is located in the main truck wire
covers. Open the drive unit compartment door. harness beneath the dash display assembly. See Figure 3-25.
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.
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.
3-80
Yale
DOT screwdriver
SLOT
r. A
16 9
0.QD.QLO,OQ0
oooonona
RESET DISCHARGE
EXPLODED VIEW
V Y)
Figure 3-26 - Battery Indicator Adjustment
Approximate Average Approximate Average

RESET DISCHARGE
Volts per Cell Required for Volts per Cell at Lift
Pot Position Pot Position
Reset Interrupt
- 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
Table 3-14 - Battery Indicator RESET Potentiometer -

Table 3-15 Battery Indicator DISCHARGE
Adjustment Potentiometer Adjustment
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.
3-81
Yale
The voltages should be as follows:

DRIVE MODE
TEST MENU
TURTLE MIDDLE RABBIT DRIVE MODE
TEST
MODE SELECT POINT TURTLE MIDDLE RABBIT UNDEFINED
OFF ON OFF
INPUT 1
DM1/Pin 4 Low High Low High
MODE SELECT
ON OFF OFF
INPUT 2 . DM2/Pin 3 High Low Low High
Table 3-16 - Dash Display Drive Mode Inputs High is anything greater than + 10.0 volts.
Low is anything less than + 5.0 volts.
If the communication is occurring as shown in Table 3-16, but
truck operation is still incorrect, verify the programming of the NOTE: If DM1 and DM2 are both open, pins 3 and 4 at the
traction motor controller as follows: traction motor controller will both be high and the drive mode
will be undefined. When the drive mode is undefined, the
1. Enter the PROGRAM MENU on the programmer. See mode defaults to the turtle mode.
PROGRAMMING THE TRACTION MOTOR CONTROLLER. Table 3-17 - Dash Display Drive Mode Test Voltages
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
performed with all connections in place. FM 1 Low High Low High
FM 2 Low Low High High

CAUTION: Use only a digital volt ohm meter
during this test procedure. Use of other test High is anything greater than + 10.0 volts.
equipment can cause the internal components of Low is anything less than + 5.0 volts.
the dash display and/or traction motor controller to malfunction.
Table 3-18 - Dash Display Status/Waming/Fault Test
Voltages
3-82
Yale
Lift interrupt Hourmeter Input

Wire #85 transmits the lift interrupt signal from the dash to the The lift pump hourmeter input is transmitted by wire #37 from
MIB. Normally, (when the BDI is not flashing), the signal is less the HMR (Hourmeter Relay). The contacts of the HMR are
.
than + 5.0 volts When the BDI is in the red flashing zone (lift closedwhen the lift pump contactor is energized. If the lift pump
interrupt), the signal is greater than +10.0 volts. hourmeter is not functioning properly, check for battery voltage
with the lift pump operating at wire #37, plug X-4, at the dash
To check a dash display/lift interrupt circuit malfunction, display. Check for battery voltage at the HMR, wires #10 and 37
by-pass the lift interrupt function by connecting a jumper wire (lift pump contactor energized). Check for battery voltage
from battery- to#36 wire of the X-6 plug at the dash display across wires #85 and #87 (lift pump contactor energized). If the
assembly. If the lift does not operate, disconnectthe battery and voltages test correctly, but the hourmeter does not function
check the continuity of wire #85 from the dash display X-6 plug correctly, replace the dash display.
to the MIB J1 plug. Check the MIB for fault or warning codes.
The traction motor hourmeter input is transmitted by wires #6
If lift interrupt does not occur when the BDI is in the red flashing and #8. If the drive hourmeter is not functioning properly, check
zone, wire #85 may be shorted to battery - .Check the MIB for for battery voltage during travel at the dash display. During
fault or warning codes forward travel, check wire #6, at dash display pin 4-6. During
reverse travel, check wire #8, at dash display pin 4-7.
Lost MIB Signal Displayed
Wires #81, #82, and #83 also transfer status, warning and fault
information to the dash display. If "LOST MIB SIGNAL" is
displayed on the dash display, check the continuity of these
wires. If the wires test OK, verify proper operation of the dash
display and MIB.
3-83
Yale
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.
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
V\ capacitors in the controller by connecting a load (such as a
contactor coil or a horn) across the controller's B + and B -
Jul discharge the traction motor controller.
4. Removethe operator's compartment cover. Discharge the

capacitor in the traction motor controller.
5. If used, remove the brush covers to the motor. Wear eye

protection. Use a vacuum cleaner or compressed air to remove
dirt and "brush dust" from the commutator area.
NOTE: Vacuum cleaning, when possible, is the

recommendation of manufacturers of electric motors. The use
of compressed air can send dirt particles into the bearings and
other areas of the motor that can cause possible damage.
6. Visually inspect the commutator surface. See Figure 3-28

through Figure 3-36. The commutator wears slowly in normal
service. The mica must be cut below the surface of the
commutator bars after a long service period or after a
1337 commutator has been turned in a iathe. Carefully rotate the
TTTT armature. DO NOT damage the commutator if you use a tool to
rotate the armature.
7. Inspect the white or gray insulation (mica) between the

commutator bars. The mica must not touch the brushes or the
brushes will wear very rapidly.
-
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.
3-84
Yale
Normal Commutator Surfaces

A commutator that has been in service will have a smooth and surface condition is the lubrication between the commutator
polished surface with a darker brown color where it rotates and the brushes. The brushes will wear rapidly if this surface
under the brushes. A variation of color on the commutator condition does not develop during the first six to ten hours of
surface between light brown and darker brown is normal. This operation after a commutator with a new surface is installed.
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.
A CONDITION CALLED "SLOT BAR MARKING" A VERY DARK SURFACE IS ALSO A

6939
IS ALSO NORMAL IF THE COMMUTATOR NORMAL AND ACCEPTABLE CONDITION
SURFACE IS SMOOTH. THE VARIABLE IF THE COMMUTATOR SURFACE IS
COLOR OCCURS IN A PATTERN ACCORDING SMOOTH.
TO THE NUMBER OF CONDUCTORS PER
SLOT.
Figure 3-28 - Normal Commutator Surfaces

3-85
Yale
Industrial Trucks electrical system
Commutator Problems
Commutator problems and motor problems are shown in Figure 3-29 through Figure 3-36. See COMMUTATOR REPAIRS, this section.
HEAVY STREAKS AND FINE GROOVES INDICATE THE

BEGINNING OF DAMAGE TO THE COMMUTATOR.
POSSIBLE CAUSES:
• OPERATION OF THE MOTOR IN DIRTY AND ABRASIVE
CONDITIONS
• CONTINUOUS OPERATION OF A MOTOR WITH A LIGHT
mujhHhHÿfil
LOAD
• BRUSH PRESSURE IS TOO LOW
• WORN BRUSHES
6939
Figure 3-29 - Commutator Problems
GROOVES AND LINES THAT HAVE FOLLOWED THE HEAVY

STREAKS AND FINE GROOVES AS SHOWN. THE ARMATURE
MUST BE REMOVED FROM THE MOTOR SO THAT THE
COMMUTATOR CAN BE REPAIRED. A COMMUTATOR WITH
THIS CONDITION WILL CAUSE THE BRUSHES TO WEAR
RAPIDLY.
POSSIBLE CAUSES:
CONDITIONS
• CONTINUOUS OPERATION OF A MOTOR WITH A LIGHT
I
1 LOAD
• BRUSH PRESSURE IS TOO LOW
• WORN BRUSHES
3-86
Yale
I h H|P|
M i
ÿ
iiiT I GROOVES THAT ARE THE WIDTH OF THE BRUSHES.
-----
POSSIBLE CAUSES:
——— —
"H- o- < CONDITIONS
• WRONG TYPE OF BRUSHES FOR THIS MOTOR AND
OPERATION
• BRUSH PRESSURE IS TOO HIGH
6940
A CONDITION CALLED "COPPER DRAG" OCCURS WHEN

COPPER FROM THE COMMUTATOR BAR IS PULLED INTO THE
SLOT BETWEEN THE COMMUTATOR BARS. THIS CONDITION
B&iHiXiil WILL CAUSE A SHORT-CIRCUIT BETWEENTHE COMMUTATOR

BARS IF IT IS NOT CORRECTED. THE BRUSHES WILL WEAR
RAPIDLY.
POSSIBLE CAUSES:
ÿÿIErl&Ili3S0Sf3IHBO
ÿÿ
6946
CONDITIONS
OPERATION
• BRUSH PRESSURE IS WRONG (TOO HIGH OR TOO LOW)
. . --v
ELECTRICAL BURNS ON COMMUTATOR BARS ON OPPOSITE

SIDES OF THE COMMUTATOR.
POSSIBLE CAUSES:
• OPEN ARMATURE WINDING
ijÿ| • MOTOR HAS BEEN STALLED
6939
3-87
Yale
COPPER WEARS RAPIDLY AT THE EDGE OF THE

COMMUTATOR BARS.
POSSIBLE CAUSES:
CONDITIONS
OPERATION
693!
1. FLASHOVER CAUSES BURNING OF ENDS OF

COMMUTATOR BAR
2. OPEN CIRCUIT IN WINDING CAUSES DEEP
BURNING OF ADJACENT COMMUTATOR BARS
3. OVERHEATING CAUSES DAMAGE TO VARNISH
INSULATION
T-T ft". .1
POSSIBLE CAUSES:
• MOTOR HAS BEEN TOO HOT
(WRONG LIFT TRUCK FOR THE APPLICATION)
• MOTOR HAS BEEN STALLED
• OPEN ARMATURE WINDING
• OPEN FIELD COIL
6943
CHECK FOR LOOSE OR HIGH COMMUTATOR BARS.

POSSIBLE CAUSES:
• MOTOR HAS BEEN STALLED
• MOTOR HAS BEEN TOO HOT
HIGH COMMUTATOR BARS RAPID BRUSH WEAR

AT EACH BRUSH POSITION FROM HIGH
CAN OCCUR IF THE COMMUTATOR BARS.
MOTOR IS STALLED.
3-88
Yale
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.
A WARNING: Disconnect the battery and separate

X|\ the connector before opening the compartment
3. Open the drive unit compartment cover.
/\ WARNING: The capacitor in the traction motor

/ 1\ controller can hold an electrical charge after the
the battery has been disconnected. Use a screwdriver or
jumper wire to make a short-circuit across the B + and B-
terminais of the traction motor controller.
4. Remove the brush covers to the motor. Wear eye

protection. Use a vacuum cleaner or compressed air to remove
dirt and "brush dust" from the commutator area.
MINIMUM
5. Make a note of the arrangement and connections of the 14 mm
(0.55 in) BRUSH
brush assembly. The replacement brushes must be installed in LENGTH
the same positions as they were removed.
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
3-89
Yale
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.
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
A brush for a hydraulic pump motor has an area of

approximately 1.74x0.375 in. = 0.653 in.2 (4.42x0.95 cm = -
Figure 3-39 Check Brush Spring Pressure
4.21 cm2'. Brush springs for the hydraulic pump motor normally
have a spring force of approximately 1 Ibf and 8 ozf±4 ozf TRACTION MOTOR - REMOVAL
(6.3 ±1.1 Newtons) when measured with a spring scale as
The procedure for removing the traction motor from the lift truck
shown in Figure 3-39. (Look for a reading of approximately and for disassembly of the traction motor from the drive unit is
1.5±.25 pounds on the spring scale.) The minimum length of outlined in Section 4.
the hydraulic motor brushes is 15.9 mm (0.625 in). Replace all
brushes if any one of the brushes are less than the minimum
brush length. TRACTION MOTOR - INSTALLATION
The procedure for assembly to the drive unit and for installing
NOTE: The brush springs used in motors made by Yale have the traction motor in the lift truck is outlined in Section 4.
a constant force design. The force of the brush spring against
the brush stays almost constant as the brush wears and
becomes shorter in its brush holder. LIFT PUMP AND MOTOR - REMOVAL
The procedure for assembly of the motor to the pump and for
10. New brushes must be made to fit the surface of the installing the lift pump and motor is outlined in Section 7.
commutator by an abrasive procedure called "stoning the
commutator". Use a Brush Seater and Commutator Stone
(No. 23-007M from the Ideal Company or an equivalent brush LIFT PUMP AND MOTOR - INSTALLATION
seater stone). See STONING THE COMMUTATOR, this The procedure for installing the lift pump and motor and
section. disassembly of the motor from the pump isoutlined in Section 7.
If new brushes are not fitted to the commutator by stoning, the
contact surface can be small until the brushes wear to fit the STEERING PUMP AND MOTOR - REMOVAL
commutator. This small surface can cause burns and a rough The procedure for removing the steering pump and motor and
surface on the commutator. "Stoning the Commutator" is most disassembly of the steering pump from the motor is outlined in
easily done when the motor rotates slowly. When the motor Section 6.
rotates at higher speeds, the centrifugal force removes the
abrasive particles from the commutator more quickly. See
Figure 3-40.
3-90
Yale
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
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
1. BRUSH SEATER STONE
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.
Figure 3-40 - SI the Commutator

3. Turn the key switch to the OFF position and disconnect the resistance checks will not normally indicate a short-circuit in a
battery. Check all brush contact surfaces. The brushes fit motor winding. A resistance greater than 1 to 2 ohms can
correctly when 85% of the brush contact surface touches the indicate a damaged winding. The motor must be removed from
commutator. This procedure normally requires approximately the lift truck and disassembled as shown in the illustrations
15 to 45 minutes. before the tests can be done.
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.
3-91
Yale
Short-Circuit in an Armature Winding

1. FIELD COIL TERMINAL 1
A short-circuit in a motor winding is difficult to test because of
the normal low resistance (less than one ohm) of a good 2. OHMMETER
armature. Use a Meggar to check for a short-circuit in a motor
winding. A motor with a short-circuit in an armature winding will
have a different sound when it begins to operate, but a service
person must have experience to hear and understand the
difference in sound. A winding with a short-circuit will also run
hotter than a good winding and can have indications of heat
damage. A winding that shows heat damage when the other
windings are normal can have a short-circuit.
Another indication of a short-circuit will be a higher than normal

current draw by the motor. A higher than normal current draw
can also indicate other problems or needed adjustments and
11415
does not always indicate a short-circuit in a motor winding.
Figure 3-42 - Test for an Open Field Circuit
Short-Circuit in a Field Coil

A short-circuit in a motor field winding is difficult to test because
of the normal low resistance (less than one ohm) of a good field.
A Meggar can be used to check for a short-circuit in a motor
winding. A motor with a short-circuit in a field winding will have a
different sound when it begins to operate, but a service person
must have experience to hear and understand the difference in
sound. A winding with a short-circuit will also run hotter than a
good winding and can have indications of heat damage.
Another indication of a short-circuit will be a higher than normal

current draw by the motor. A higher than normal current draw
ARMATURE SHAFT can also indicate other problems or needed adjustments and
COMMUTATOR does not always indicate a short-circuit in a motor winding.
PROBES TO OHMMETER
Short-Circuit Between Field and Motor Case
Figure 3-41 - Test for an Armature Short-Circuit A volt ohmmeter (R x 10,000 scale) can be used to test for a
short-circuit between the field and the motor case. Put one
Short-Circuit in the Armature probe on the motor case and the other probe on a field terminal.
A volt ohmmeter (R x 10,000 scale) can be used to test for a Check the resistance between the field terminal and the motor
short-circuit between an armature winding and the armature case. A resistance of less than one megohm indicates a
shaft. Put one probe on the armature shaft and the other probe problem between the field terminal and the motor case. Make
on a commutator bar. See Figure 3-41. A resistance of less sure that carbon dust has been cleaned from the motor before
than one megohm indicates a problem between a winding and making this test.
the armature shaft.
Brush Holder
NOTE: Clean the dirt and "brush dust" from the commutator Make sure the carbon dust has been removed from the brush
area before making a test for a short-circuit. holders. Use a volt ohmmeter (R x 10,000 scale) to measure
the resistance between the brush holder and the motor case.
Open Circuit in a Field Coil The correct resistance should be infinity (~).
The field windings in large electric motors normally have less
than one ohm of resistance. If a volt ohmmeter (R x 1 scale) is
used to check the resistance between the two terminals of the
winding, a resistance greater than one ohm indicates a problem
in that winding or corrosion ,in the terminal connection. See
Figure 3-42.
3-92
Yale
FUNCTION RECOMMENDATION ALLOWED RANGE

Default Min./ Min./Max.
No. Description Function Circuit Range Max. Range
Value Amps (Approximate) Value (Approximate)
01 Model Code Default Values 10 - 24 volt NR035AD 110/10 10/10

02 Lift-Minimum Rate 20 .66 0% to 1% 2/22 -
03 Lift-Maximum Rate 08 1.41 100% lift speed ' 2/10 -
04 Lower-Minimum Rate 15 .46 0% to 1% t' 2/17 -
05 Lower-Maximum Rate 09 1.32 100% lower speed 2/10 -
06 Extend-Minimum Rate 41 1.33 0% to 1% 37/46 -
07 Extend-Maximum Rate 23 2.23 3.0 seconds 15/35 2.5 to 6.0 seconds
08 Retract-Minimum Rate 40 1.26 0% to 1% 36/45 -
09 Retract-Maximum Rate 26 2.33 3.0 seconds 15/35 2.5 to 6.0 seconds
10 Tilt Up-Minimum Rate 42 1.33 0% to 1% 38/47 -
11 Tilt Up-Maximum Rate 25 2.29 3.0 seconds 15/35 2.0 to 6.0 seconds
12 Tilt Down-Minimum Rate 43 1.35 0% to 1% 39/48 -
13 Tilt Down-Maximum Rate 24 2.26 2.0 seconds 15/25 2.0 to 6.0 seconds
14 Sideshift Right-Minimum Rate 43 1.35 0% to 1% 39/48 -
15 Sideshift Right-Maximum Rate 25 2.29 2.0 seconds 15/30 2.0 to 6.0 seconds
16 Sideshift Left-Minimum Rate 43 1.35 0% to 1% 40/49 -
17 Sideshift Left-Maximum Rate 25 2.29 2.0 seconds 15/30 2.0 to 6.0 seconds
18 Hydraulic Function-Starting Rate 10 - - 5/20 -
19 Hydraulic Function-Stopping Rate 10 - - 5/20 -
20 Maximum Travel Speed-Mast Elevated 70 - 70% max. speed 25/70 25% to 70%
21 Model Code-MTVFD 89 - - 89/89 Do Not Adjust
22 Model Code-MTVRD 99 - - 99/99 Do Not Adjust
23 Power Steering Contactor-Minimum Current 03 0.10 - 03/03 Do Not Adjust
24 Power Steering Contactor-Maximum Current 60 2.04 - 60/60 Do Not Adjust
25 Lift Pump Contactor-Minimum Current 03 0.10 - 03/03 Do Not Adjust
26 Lift Pump Contactor-Maximum Current 60 2.04 - f 60/60 Do Not Adjust
. . . . . . . . . . . . . . . . . . . .
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
3-93
Yale

Default Min. / MinVMax.

02 Lift-Minimum Rate 20 .66 0% to 1% 1' 2/22 -
03 Lift-Maximum Rate 08 1.41 100% lift speed 2/10 -
04 Lower-Minimum Rate 15 .46 0% to 1% r 2/17 -
05 Lower-Maximum Rate 09 1.32 100% lower speed 1 2/10 -
12 Tilt Down-Minimum Rate 43 1.35 0% to 1% , 39/48 -
14 Sideshift Right-Minimum Rate 43 1.35 0% to 1% , 39/48 -
17 Sideshift Left-Maximum Rate 25 2.29 2.0 seconds . 15/30 2.0 to 6.0 seconds
20 Maximum Travel Speed-Mast Elevated 70 - 70% max. speed ' 25/70 25% to 70%
21 Model Code-MTVFD 84 - - [84/84 Do Not Adjust
25 Lift Pump Contactor-Minimum Current 03 0.10 - s 03/03 . Do Not Adjust
26 Lift Pump Contactor-Maximum Current 60 2.04 - 60/60 Do Not Adjust
. . . . . . . . . . . . . . . . . . . .
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.
57 Hydraulic Auxiliary Function Damping Sets delay for fine-tuning auxiliary hydraulic functions; do not adjust.
3-94
Yale

Default Min./ MinVMax.

02 Lift-Minimum Rate 20 .66 0% to 1% 2/22 -
04 Lower-Minimum Rate 15 .46 0% to 1% 2/17 -
. . . . . . . . . . . . . . . . . . . .
.......................
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
3-95
Yale

Default Min. / Min./Max.
No. Description Function Circuit Max. Range
Range

02 Lift-Minimum Rate 20 .66 0% to 1% i 2122 -
07 Extend-Maximum Rate 27 2.37 3.0 seconds -15/35 2.5 to 6.0 seconds
09 Retr-.ct-Maximum Rate 26 2.33 3.0 seconds 15/35 2.5 to 6.0 seconds
10 Tilt lo-Minimum Rate 42 1.33 0% to 1% 38/47 -
24 Power Steering Contactor-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
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.
3-22 - MIB Function Code Values - 36 Volt NR040AD Model Trucks
3-96
Yale

Default Min./ MinVMax.

02 Lift-Minimum Rate 20 .66 0% to 1% . 2/22 —
03 Lift-Maximum Rate 08 1.41 100% lift speed I 2/10 -
04 Lower-Minimum Rate 15 .46 0% to 1% | 2/17 -
06 Extend-Minimum Rate 45 1.40 0% to 1% ; 41/50 -
07 Extend-Maximum Rate 27 2.37 3.0 seconds , 15/35 2.5 to 6.0 seconds
12 Tilt Down-Minimum Rate 43 1.35 0% to 1% : 39/48 -
13 Tilt Down-Maximum Rate 24 2.26 2.0 seconds ; 15/25 2.0 to 6.0 seconds
14 Sideshift Right-Minimum Rate 43 1.35 0% to 1% ; 39/48 •
-
16 Sideshift Left-Minimum Rate 44 1.36 0% to 1% '
40/49 -
17 Sideshift Left-Maximum Rate 25 2.29 2.0 seconds : 15/30 2.0 to 6.0 seconds
20 Maximum Travel Speed-Mast Elevated 50 - 50% max. speed I25/50 25% to 50%
23 Power Steering Contactor-Minimum Current 03 0.10 - l; 03/03 Do Not Adjust
. . . . . . . . . . . . . . . . . . . .
28 Auxiliary Function Coiis-Maximum Current 60 2.04 - 60/60 Do Not Adjust
29
30
31
32
34
......
................
ERASE
3-97
Yale

Default Min./ Min./Max.
01 Model Code Default Values 15 - 24 volt NDR030AD ! 15/15 15/15

02 Lift-Minimum Rate 20 .66 0%to 1% 2/22 -
09 Retract-Maximum Rate 31 2.33 3.0 seconds 1&/35 2.5 to 6.0 seconds
. . . . . . . . . . . . . . . . . . . .
-
.......................
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
34 Traction Potentiofheter Set-up Calibrates the MIB to the traction potentiometer.
3.24 - MIB Function Code Values - 24 Volt NDR030AD Model Trucks
3-98
Yale

Default Min./ MinJMax.
No. Description Function Max. Range
Circuit Range
01 Model Code Default Values 16 - 36 volt NDR030AD 16/16 16/16

02 Lift-Minimum Rate 20 .66 0% to 1% 2/22
20 Maximum Travel Speed-Mast Elevated 50 - 50% max. speed f 25/50 25% to 50%
. . . . . . . . . . . . . . . . . . . .
.......................
29 Steer Pump Time Delay 30 - 3.0 seconds 30/30 Do Not Adjust
Table 3-25 - MIB Function Code Values - 36 Volt NDR030AD Model Trucks
3-99
Yale

Default Min. / MinJMax.
01 Model Code Default Values 17 - 24 volt NS040AE 17/17 17/17

02 Lift-Minimum,Sate 20 .66 0% to 1% 2/22 —
04 Lower-Minimum Rate 15 .46 0% to 1% r 2/17 -

06 Extend-Minimum Rate Not Used NS
07 Extend-Maximum Rate Not Used NS
08 Retract-Minimum Rate Not Used NS
09 Retract-Maximum Rate Not Used NS
10 Tilt Up-Minimum Rate Not Used NS
11 Tilt Up-Maximum Rate Not Used NS
12 Tilt Down-Minimum Rate Not Used NS
13 Tilt Down-Maximum Rate Not Used NS
. . . . . . . . . . . . . . . . . . . .
27 Auxiliary Furlctfdtt Coils-Minimum Current 00 - - I 00/00 Do Not Adjust
29
30
31
32
34
ERASE .......................

Table 3-26 - MIB Function Code Values - 24 Volt NS040AE Model Trucks
3-100
Yale


02 Lift-Minimum_Rate 20 .66 0% to 1% 2/22 -
05 Lower-Maximum Rate 09 1.32 100% lower speed 2/10 I -
13
14
15
Tilt Down-Maximum Rate
Sideshift Right-Minimum Rate
Sideshift Right-Maximum Rate
43
25
1.35
2.29
Not Used NS
0% to 1%
2.0 seconds
39/48
- 15/30
......
2.0 to 6.0 seconds
16 Sideshift Left-Minimum Rate 44 1.36 0% to 1% ; 40/49
19 Hydraulic Function-Stopping Rate 10 - - 5/2Q -
22 Model Code-MTV RD 99 - - 99/99 Do Not Adjust
....................
27 Auxiliary Function Coils-Minimum Current 00 - - 00/00 Do Not Adjust
29
30
31
32
34
ERASE .......................

3-101
Yale

No. Description Function Circuit Max. Range
Range

02 Lift-MinimurrrRate 20 .66 0% to 1% f- 2/22
13 Tilt Down-Maximum Rate Not Used NS
16 Sideshift Left-Minimum Rate 44 1.36 0% to 1% 40/49 ; -
24 Power Steering Contactor-Maximum Current 60 2.04 - 60/60 T Do Not Adjust
. . . . . . . . . . . . . . . . . . . .
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
3-102
Yale
NOTES
3-103
Yale
8RAKE SW
5I0ACT0R
PS LIFT
PUMP
S-XJ MOTOR
ARM PUMP
MOTOR
SHIELD
FOR ALL OTHER NOTES SEE SHEET 3 OF 7
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
r if-
hrr-ti
ALY PUSH IPUSH PUSH *EE' PUHP PUHP SOL SOL L oown '9 aoi
j 4 19 9 9
SOL
Ft)"
COIL 90T BOT I
ws -C Ho h: 'EE'
OM.Y <3
|
80 74 56 11 IS 16
I S i
i 1—
9 71 70 72 73 43
SO 30 74 56 11 IS IS 16 42 46 23 36 91 70 77 73
E(|-
MI | 1999
L0CX-0UT ppp s§h
p s§hs*hs*hs*Sh
ijlJ p uj
'jSh'ahÿh
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
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.
E> SHIELDED CABLE.

S> CONNECTOR X-I5A (JUMPER ASSY) T0 3E
USED ON 24 VOLTS TRUCKS ONLY.
g> SIDE SHIFT ANO REACH SELECTOR VALVES ARE NOT
USED ON NS-AO MODEL TRUCK.
7. BROKEN LINES ARE FOR OPTIONS ONLY.
0. ABBREVIATIONS FOR COMPONENT ARE SHOWN
IN PARENTHESES IN WIRING DIAGRAM.
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
NOTES
3-107
Yale
0A5H30AR0
<2
IS I I I-1SA
DISPLAY
U COQW BA«
CONNECTOR X-1 2 FOR

THERMOSTAT A NO FAN
WHEN USEO
SEE SHEET 7 OF 7
13 A3
-MAiN TÿUCK WIRE HARNESS -
SEE SHEET S OF 7
d® —13
-3—010
Hi
sa—KUO
PUMP
MOTOR
cRONT VIEW OF CONNECTOR

X-4 AMI X-S ARE ENLARGED
FOR CLARITY
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
5241353-87
Sheet 4 of 7
Figure 3-45 - Wiring Diagram 5241353-87 — NR/NDR/NS Revision 2
3-108
ELECTRICAL SYSTEM
JHL •oi oCrr.p

iv ikftrÿOL r-1 i REACH <H
jCtJ sioe shift ycd. SELECTOR
I fl SELECTOR VALVE fl 8 O| VALVE
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
AUX U TRACTION SWITCHES ANO POT
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
• OPERATOR FLOOR • OPERATOR FLOOR ÿ

OPERATOR FLOOR
FOR all OTHEa NOTES SEE SHEET 3 OF 7
5241353-87
Sheet 5 of 7
"Figure 3-45 - Wiring Diagram 5241353-87 - NR/NDR/NS (Continued) Revision 2
3-109
Yale
MAIN TRUCK HARNESS
a'j-rfia&a
PROM
SHEET S OF 7
BATTERY
ONTACTOR PANEL
SAT POS
5HEET 5 OF 7
TOR VIEW OF AUX SWITCH'

QOJWM FOR CLARE TV)
POWER STEER
CONTACTOR
5 lOACTOR
IFUS !OAMP| (ia<

,0tnr
ENABLE RELAY
CER>
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
TO HA IN
TRUCK HIRE HARNESS
SEE SHEET <CF 7
X-'2
SLACK
THERMOSTAT AND rAN

TO MAIN
TRUCK HIRE HARNESS
ACCESSORY
SEE SHEET S OF 7
HA IN TRUCK HARNESS
is FAN FAN SHEET S CP 7

CONTACTOR PANEL
FAN SWITCH
f1
LIGHT SWITCH
T—T f!
CONTACTOR
~EE* CONTACTOR PANEL POWER STEER
— —
9SA- T 5I0ACT0R
r— 98-
— 98-
LAMP cNASLE relay

(ER)
=J HOUR METER
RELAY
(HN)
FAN ANO LIGHTS

TO TRACTION nOTCR TO OPERATOR SENSING SH
CONTROLLER PMC -SEN "EE* 5HCHN FOR *5* SEE SHEET S OF 7 ANO TRACT -ON CONTROLLER
SEE SHEET 6 OF 7 SEE SHEET S OF 7
SHEET S OF 7

5241353-87
Sheet 7 of 7
-'Figure 3-46 - Options Diagram 5241353-87 - NR/NDR/NS Revision 2
3-777
Yale
IndustrialTrucks electr.cal system
NOTES
3-112
Yale
IndustrialTrucks
SECTION 4
DRIVE UNIT
Yale
IndustrialTrucks
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
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.
The traction motor fastens to an adapter ring that is attached to

an articulating axle. This adapter ring is part of the large ball
bearing and allows the MDU to turn on the axis of the traction
motor. The traction motor does not turn with the MDU.
The articulating axle is fabricated from metal components and

provides the proper spacing between the MDU, caster wheels
and axle shaft locations. A pivot pin passes through the center
of the articulating axle weldment and is supported by two
trunnion blocks, the upper halves of which are welded to the lift
truck frame. This mounting provides the articulating capability
to allow for floor variations between the drive wheel and the
caster wheel. The amount of variation is limited by the
adjustable articulation stops. Both articulation stops are
located in the drive unit compartment, providing for easy
access.
NOTE: The manufacturer recommends draining and refilling

the drive unit oil afterthefirst 500 hours of use on all new trucks.
See LUBRICATION INSTRUCTIONS, Section 2, this manual.
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.
The articulation stop screws must be adjusted to the proper

setting as listed in the ARTICULATION CHART, at the following
times:
1. Every 350 hours during routine maintenance.
2. When a drive and/or caster wheel is changed. Figure 4-2 - Drive Unit Articulation Stops Nameplate
3. When any repairs are carried out on the articulation axle.
4-1
Yale
MAX. FORK HEIGHT
6147 mm
a
BELOW (242 in)
STOP 6147 mm AND
SETTING (242 in) ABOVE
DRIVE 4.8-6.4 mm 1.6-3.2 mm

SIDE (0.19-0.25 in) (0.06-0.125 in)
CASTER SIDE 4.8-6.4 mm 4.8-6.4 mm
(0.19-0.25 in) (0.19-0.25 in)
Table 4-1 - Articulation Chart
NOTE: The articulation stop settings are also listed on the
nameplate.
ARTICULATION ADJUSTMENT PROCEDURE

1. Position the truck on a flat, level floor.
2. Disconnect the battery. X\\\\\Vf
3. Open the drive unit compartment door, after turning the

latch capscrew one-half of a turn to unlock the door.
4. Check the articulation stop clearance on boththe drive and

caster stop screws. If the clearance between the stops are not
within the range listed in the ARTICULATION CHART, loosen
the locknuts and adjust the stop screws to the correct setting.
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
TRACTION MOTOR Figure 4-3 - Traction Motor and MDU

The traction motor is not part of the steering system. The motor 2. Tag the power cables of the traction motor for correct
is part of the MDU assembly and must be removed to remove installation during installation. The motor terminals are
the axle assembly from the lift truck. identified on the motor as A1, A2, F1 and F2. Remove the
power cables from the terminals of the traction motor. Fasten
Removal the cables in a location to prevent damage during motor
1. Disconnect the battery. Open the drive unit compartment removal.
door.
3. Tag and disconnect the wires to the brake switch.
4-2
Yale
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.
5. Make an identification mark on the motor housing and the

HYDRAULIC STEERING MOTOR
axle weldment for correct motor alignment during installation.
Remove the six M8 capscrews and lockwashers retaining the Description
flange of the traction motor to the MDU upper housing.
Lift truck steering is achieved when the hydraulic steering
motor rotates the master drive unit (MDU) using a steering
WARNING: The traction motor is heavy. Be sure
chain. See Figure 4-4. The hydraulic steering motor uses a
that all lifting devices (hoists, cables, chains,
rotor assembly to change hydraulic energy into mechanical
slings, etc.) are suitable and of adequate capacity
energy. The rotor assembly has a fixed rotor with seven vanes
to lift the traction motor. The traction motor can weigh
and a stator. There is hydraulic pressure between the vanes
approximately 40 kg (85 lbs).
and stator. The pressure makes the stator rotate in the rotor.
6. Use a sling around the traction motor and an overhead
crane to carefully lift the traction motor. Do not damage the drive
gear on the motor shaft or the brake assembly on the top of the
motor. Position the motor on its side so that the gear and the
brake assembly are not damaged.
Installation
1. Install a new O-ring on the traction motor housing. Use 2
O-ring lubricant on the O-ring.
WARNING: The traction motor is heavy. Be sure

that all lifting devices (hoists, cables, chains,
to lift the traction motor. The traction motor can weigh
approximately 40 kg (85 lbs).
2. Use an overhead crane and a sling to carefully lift the

traction motor into the correct position on the MDU upper
housing. Do not damage the drive gear or the brake assembly.
Make sure that the motor and the MDU are aligned with the
mark made during removal before the motor is completely 1. HYDRAULIC STEERING MOTOR
lowered onto the upper housing. 2. MASTER DRIVE UNIT (MDU)
3. STEERING CHAIN
3. Install and tighten the six capscrews and lockwashers
using a crisscross pattern to 20 N«m (15 Ibf ft) torque. Figure 4-4 - Hydraulic Steering System
4. Connect the power cables to the motor terminals. Removal
CAUTION: See Section 5 of this manual to 1. Use the steering system to move the master drive unit for
remove the air from the brake system. Do not access to the chain anchor of the steering chain. Disconnect
operate the lift truck without removing the air from the battery and open the drive unit compartment cover.
the brake system.
2. Remove the steering chain from the sprocket of the
CAUTION: Brake fluid damages paint. Immedi¬ hydraulic motor. To remove the chain, first make a mark on the
ately remove any brake fluid that is on a painted chain anchor and the MDU upper housing at the chain anchor.
surface. Remove the cotter pin from the end of one offset pin at the chain
anchor. Remove the link pin and chain. Remove the chain from
5. Remove the cap from the brake line from the master the sprocket of the hydraulic motor. Use wire to fasten the chain
cylinder and attach the line to the slave cylinder. Add brake fluid so that it does not fall.
4-3
Yale
3. Remove the capscrews and lockwashers that retain the REPAIR

hydraulic motor to the articulating axle weldment. Remove the
Removal - Articulating Axle Weldment
shims and motor. Wire the shims together for use at assembly.
1. Make sure the key is in the OFF position. Disconnect the
4. Install labels on the hydraulic lines for proper installation at battery. Raise and block the drive/steering wheel off the floor.
assembly. Disconnect the hydraulic lines and install caps on See Section 1 - HOW TO RAISE THE DRIVE/STEER TIRE
the lines and fittings or ports of the motor. AND CASTER WHEELS.
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,
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
1. SHIMS
2. BUSHINGS
3. PIVOT PIN
4. CAPSCREW
5. NUT
6. ARTICULATING AXLE WELDMENT
Figure 4-5 - Art ting Axle installed
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
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
Disassembly 3. The upper housing is retained to the lower housing with

(See Figure 4-6 and Figure 4-7) two dowel pins. Use a plastic hammer against the lower portion
of the upper housing to separate the upper housing from the
NOTE: Before disassembling the drive unit make certain the
lower housing. Carefully slide the upper housing for clearance
work area is clean and ail the necessary tools are available.
betweenthe upper housing and helical gear. Removethe upper
The nuts retaining the drive axle and upper gear on the pinion
housing.
shaft are staked in place and the staked portion must be
removed before attempting any disassembly.
/\ CAUTION: The helical gear and pinion shaft
If\ assembly can only be removed afterthe bevel gear
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
A WARNING: Toxic vapors may be generated by

II\ heating the axle shaft to remove the Loctite. Wear
a protective mask during this operation. Use
gloves to remove the bevel gear if it has been heated.
NOTE: The bevel gear is secured to the axle shaft using

Loctite 270. It may be necessary to use a welding torch to heat
the bevel gearto 100 to 120° C (212 to 248° F) to free the bevel
gear from the axle shaft.
A CAUTION: Be careful not to damage the threads

or splines on the axle shaft.
6. Use a strap wrench or place a wood wedge under the

helical gear to keep the gear from rotating. Remove the nut
retaining the helical spur gear. Use a gear puller to remove the
helical gear from the pinion shaft. Carefully remove the pinion
shaft and bearing cone from the lower housing. Use a plastic
hammer, if necessary. Remove the spacer bushing from the
pinion shaft.
7. Use a copper mandrel and a plastic hammer to drive the

1. UPPER HOUSING 4 axle shaft out of the lower housing. Remove the bevel pinion out
2. CAPSCREWS INSIDE TOP CASE of the lower housing.
3. HOUSING
4.
5.
CAPSCREWS
DOWEL
Figure 4-6 - Separating Upper and Lower Housing
A CAUTION: Keep all shim sets together and
labeled for correct location and installation during
assembly.
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
Figure 4-7 - Master Drive Unit Parts
4-8
Yale
8. If necessary, remove the bearing cones from the axle 5 1

shaft, from the bevel gear and from the bevel pinion shaft. To
remove the bearing cone from the axle shaft, it is necessary to
cut the bearing cage, open the cage and remove the rollers.
Use a puller to remove the cage from the axle shaft.
9. Remove the bearing shield from the lower housing using a
plastic hammer. See Figure 4-8.
10. If necessary, remove the motor nut, lockwasher, bevel

pinion and key from the motor shaft. Remove the O-ring from
the motor.
Figure 4-8 - Removing Bearing Shield

1. UPPER PINION BEARING CUP
11. Remove the wheel bolts from the axle shaft, using a 2. LOWER PINION BEARING CUP
hydraulic press, if necessary. 3. INNER AXLE SHAFT BEARING CUP
4. OUTER AXLE SHAFT BEARING CUP
12. If necessary, remove the bearing cups. Use a puller or 5. SHIMS-UPPER PINION BEARING
copper mandreland a plastic hammer. Do NOT damage or lose 6. SHIMS-LOWER PINION BEARING
the shims between the cups and the bore in the case. Keep 7. SHIMS-INNER AXLE SHAFT
each set of shims together and separate from the other sets of 8. SHIMS-OUTER AXLE SHAFT
shims. Put a label on each set so that the sets can be installed in 9. INNER SEAL RING
the correct position during assembly. Measure the distance 10. BEARING SHIELD
betweenthe edge of the case andthe inner seal ring at the axle
bore. The replacement seal ring MUST be installed in the same
Figure 4-9 - Bearing and Shim Location
position as the old seal. Remove the seal ring.
Assembly 1. Clean all components thoroughly. Remove all traces of

Loctite. Use Loctite Fast Cleaner No. 706 to remove Loctite
NOTE: If neither the bevel pinion shaft and gear set nor the from the lower housing in the area where the thread protecting
lower case are being replaced, use the upper bearing shim set shield had been located. Spray the cleaner from a distance of
and lower bearing shim set removed during disassembly. approximately 30 cm (0.50 in), while holding the can upright.
Allow the cleaner to work, then thoroughly remove the
NOTE: There are two numbers stamped on the bevel pinion dissolved dirt from the lower housing using a clean cloth. Spray
shaft. There are also two numbers stamped on the bevel gear. the surface with the cleaner again and allow to air dry.
One number on each part is the set number. These numbers
MUST be the same. Check that the bevel pinion shaft and the 2. Check all parts for damage or cracks. Replace any
bevel gear are a matched set by comparing the set numbers. damaged parts.
The second number on the bevel pinion shaft is the assembly
dimension of the shaft (dimension B, Figure 4-10). The second CAUTION: The axle and gear assemblies are
number on the bevel gear is the gear clearance number. installed and removed several times during this
procedure. Be careful not to damage the seals.
WARNING: Cleaning solvents can be flammable
and toxic, and can cause skin irritation. When NOTE: The large ball bearing is part of the upper housing.
using cleaning solvents, always follow the The upper housing and the ball bearing are replaced as a unit.
recommendations of the manufacturer. Wear eye protection.
4-9
Yale
1. BEVEL PINION SHAFT

2. SPACER
3. SPECIAL MEASURING TOOL
4. LOWER CASE
5. LOWER BEARING
6. LOWER BEARING SHIM SET
7. UPPER BEARING SHIM SET
8. UPPER BEARING
DIMENSION "B" (mm) stamped

on end of bevel pinion shaft.
Figure 4-10 - Installing Bevel Pinion Shaft
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
1. BEVEL PINION SHAFT

2. SPACER
3. UPPER BEARING SHIM SET
4. BEARING CUP
5. BEARING CONE
BEARING
CUP
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.
8. Lubricate the bearing cup with transmission oil. Installthe

pinion shaft into the housing and preload it against the bearing
cup with the special clamping tool or a piece of wood.
9. Place the spacer bushing on the pinion shaft.
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).
11. Add 0.02 mm (0.00078 in) to the value of dimension A and

install a shim set equal to that sum into the bearing bore.
Shim set (mm) = A + 0.02 mm.
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
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
amount of additional shims, add 0.07 mm (0.0028 in) to the

clearance value measured in Step 16. Install shims equal to
that sum into the bearing bore with the shims installed earlier.
Additional shim set (mm) = value measured on dial
indicator + 0.07 mm.
If no clearance was measured, add a total of 0.02 mm (0.00078
in) to the shims installed earlier.
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.
27. Use a dial indicator to check the backlash between the

bevel gear and the pinion. The backlash is the clearance
between the teeth of the bevel gear and the teeth of the pinion
gear. See Figure 4-14. Position the dial indicator on the
housing so that the dial indicator foot is as close as possible to
being perpendicularto the tooth flank of the bevel gear. Install a
wood wedge under the large gear at the top of the MDU to keep
the gear and pinion from moving. -
Figure 4-15 Checking Wheel Shaft Bearing Clearance
4-12
Yale
STEP 1 . Apply a colored dye or grease to approximately

12 of the teeth of the spiral bevel gear. CORRECT CONTACT PATTERN
STEP 2. Apply a small friction load to the edge of the gear , ÿ
so that the gear does not turn easily. Rotate the

gear one revolution by turning the large gear on
the spiral bevel pinion. y//
STEP 3. Check the tooth contact pattern on the spiral / \ / \ / \
bevel gear. Make sure that the pattern is checked V \_»
on the side of the tooth where the pinion teeth ap¬
ply the force.
WRONG TOOTH CONTACT PATTERN
TIP CONTACT r-1 } ÿ

The spiral bevel pinion is too far from the center of the
spiral bevel gear.
/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
—.
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.
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.
Figure 4-16 - Tooth Contact Pattern
4-13
Yale
1. SPIRAL BEVEL GEAR

2. DIAL INDICATOR
3. WOOD WEDGE
RADIAL SHAFT
SEAL
THREAD
PROTECTIVE
SHIELD
2
11411
1.8mm (0.071 in)
Figure 4-17 - Checking Backlash Figure 4-18 - Inner Seal Installation
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
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.
53. Lubricate trunnion bearing using the recommended

grease listed in Section 2. Add the grease through both fittings.
Slowly rotate the MDU while filling the fittings with grease. A dry
bearing will take approximately 55 g (0. 12 lb) of grease to fill the
bearing completely.
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
PROBLEM POSSIBLE CAUSE
Lift truck will not move. Traction motor not operating.
Damaged gears or bearings.

Master drive unit makes noise. There is not enough lubricant or the wrong lubricant has been
used.
Dry or damaged bearings.
Wrong bearing or gear adjustment.
Worn or damaged gears.
Oil leaks at the housing cover. Housing cover is not sealed or properly seated.
Capscrews not sealed off or not tightened to specified torque.

Oil leaks at the wheel shaft. Shaft seal incorrectly mounted or damaged.
Surface of axle shaft damaged.
Oil leaks at the filler plug or drain plug. Dirt between sealing ring and housing.
Plugs not tightened to specified torque.
Oil leakage between lower and upper housings. Sealing surface not sealed off.
Capscrews not tightened to specified torque.
Oil leaks in motor compartment. Too much oil in MDU.
Breather defective.
Traction motor seal defective.
Banging noise at helical gears. Teeth on the helical gear or helical pinion damaged.
Ringing noise. Helical gear and pinion running without lubrication.
Grinding noise. Bearing preload or backlash not properly adjusted.
Trunnion bearing difficult to turn, binds or exceeds maximum The centering ring has separated and dirt has penetrated into
clearance. the bearing.
Cage segments are damaged.

Deformation of the balls or ball races.
Bearing not properly lubricated.
4-16
Yale
IndustrialTrucks
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
ASSEMBLY AND INSTALLATION 5-4
FLOOR PLATE ASSEMBLY 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
GENERAL Removal and Disassembly

This section has the description and the repair procedures for
the brake assembly. NOTE: The complete brake assembly normally does not
need to be removed to make repairs. Remove only the parts
NOTE: Many,of the procedures need the compartment door necessary to make the repair.
open. To open the door, turn the capscrew that fastens the door
one quarter turn and open the door. 1. Disconnect the battery. Putblocks on each side of the drive
wheel to prevent movement of the lift truck. Open the motor
The brake assembly is a mechanical brake mechanism that is compartment door for access to the brake assembly.
installed on the top of the traction motor. The brake assembly
has a brake drum, two brake shoes, a cam and cam lever and
the return spring for the brake shoes. The cam moves the brake
shoes against the brake drum. A spring and linkage operates
the cam lever to apply the brake. A hydraulic slave cylinder
I !
moves this same linkage to release the brake. The brake drum
rotates with the armature of the traction motor. The brake shoe
assembly and the linkage are fastened to the traction motor
housing.
q
A master cylinder and brake pedal assembly is fastened to the
frame under the operator compartment. The brake pedal
extends through the floor plate and is foot operated. There is a
hydraulic line between the master cylinder and the slave
cylinder. The master cylinder assembly operates the slave
A In. u i,
i
cylinder using hydraulic pressure from the master cylinder and
pedal operation. A reservoir for the brake fluid is mounted on
the traction motor compartment door.
The brake is a normally ON type of mechanism. The brake is

fully applied when the brake pedal is in the UP position.
Releasing the brake pedal permits a spring to move the cam
lever and apply the brake shoes against the brake drum. A
brake switch prevents the operation of the traction system
when the brake pedal is released to apply the brake.
To RELEASE the brake, the operator must step on the brake

pedal. The brake pedal moves the push rod of the master
cylinder to apply hydraulic pressure to the slave cylinder. The
push rod pushes the control bar against the brake spring to
release the brake shoes. The shoe springs move the brake
shoes away from the brake drum. The brake shoes will be
gradually released as the brake pedal is depressed. The brake
pedal must be depressed as far as possible to completely
release the brake. Movement of the control bar operates the
brake switch whence brake pedal is depressed to release the
brake.The brake switch must be ON before the traction system
can operate.
BRAKE ASSEMBLY 1. BRAKE RESERVOIR

2. BRAKE ASSEMBLY
NOTE: Turn the screw that fastens the door one-half turn and 3. BRAKE PEDAL AND MASTER CYLINDER
open the door. 4. TRACTION MOTOR
Figure 5-1 - Brake Arrangement
5-1
Yale
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.
8. Remove the lockout, tube, bearing and actuation rod from

the control bar.
9. Removethe shoulder screw, bushings, flat washer and nut

to remove the control bar from the brake mounting bracket.
10. Remove the four socket head capscrews and lockwashers

retaining the brake mounting bracket to the traction motor.
Remove the brake mounting bracket, brake drum spacer and
the brake assembly spacer.
12087 11. Check for damaged or broken parts. Replace any

damaged or broken parts.
6
Assembly and Installation
1. CAM LEVER 4. SHOE RETURN SPRING (See Figure 5-3 and Figure 5-4)
2. CAM 5. SUPPORT PLATE
3. BRAKE SHOE 6. BRAKE LINING 1. Align the brake assembly spacer and brake mounting
bracket on the traction motor. Position the brake assembly on
the spacer and install the four socket head capscrews and
-
Figure 5-2 Brake Assembly
lockwashers. Tighten the capscrews to 23 N«m (17 Ibf ft ) dry.
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
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
Figure 5-3 - Assembly

4. Install the bushing for the actuation rod in the control rod. brake mounting bracket. Align the cam lever of the brake
Install the actuation rod in the control rod. Install the tube and assembly and the actuation rod and install the jam nut and
locknut on the actuation rod. Install the two socket head lockwasher.
capscrews andTockwashers to retainthe brake assembly to the
5-3
Yale
Industrial Trucks BRAKE SYSTEM
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.
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.
3. Install the brake pedal pad on the brake pedal weldment.
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.
6. Install the floor plate assembly in the operators

Figure 5-4 - Brake Assembly Installation compartment.
7. Adjust the brakes as described in CHECKS AND

MASTER CYLINDER AND PEDAL ASSEMBLY
ADJUSTMENTS.
Removal and Disassembly
(See Figure 5-5) 8. Remove the air from the brake system as described in
1. Remove the floor plate assembly from the operator's CHECKS AND ADJUSTMENTS.
compartment.
CAUTION: Brake fluid damages paint. Immedi¬

surface.
5-4
Yale
FLOOR PLATE ASSEMBLY Assembly and Installation

Removal and Disassembly 1. Position the operator sensing switch on the floor plate.
Pass the wire leads through the hole in the plate.
1. Lift the floor plate assembly from the operator's
compartment.
2. Remove the liner to expose the adhesive backing on the
new floor pad. Install the floor pad on the floor plate.
2. Disconnect plug X13. Remove the floor plate assembly
from the truck.
3. Connect plug X13. Install the floor plate in the operator's
compartment.
NOTE: To replace the operator sensing switch, the floor pad
must be removed. The floor pad has an adhesive backing. It
must be replaced with a new pad after removal.
BRAKE PEDAL PAD

COTTER PIN
FLAT WASHER
BUSHING
GROOVE PIN
BRAKE PEDAL WELDMENT
ROD END PIN
HOSE ASSEMBLY
BRAKE FLUID FEED HOSE
MASTER CYLINDER
FLOOR PAD
SWITCH-OPERATOR SENSING
FLOOR PLATE WELDMENT
Figure 5-5 - Master Cylinder and Pedal Assembly

5-5
Yale
MASTER CYLINDER WARNING: Do NOT use mineral oil solvent to

clean the master cylinder or brake system parts.
Disassembly
Mineral oil will damage rubber seals. Damage to
(See Figure 5-6) the seal can cause brake failure. Clean the master cylinder
CAUTION: Brake fluid damages paint. Immedi¬ using isopropyl alcohol, or a solvent approved for cleaning
ately remove any brake fluid that is on a painted brake parts.
surface.
3. Remove the parts shown in Figure 5-6. Remove the valve
1. Remove the cupand ttre boot from the end of the piston of seal from the valve stem. Clean the cylinder body and all metal
the master cylinder. parts. Check the bore for wear and damage (scratches or
holes). If the bore is worn or has damage, replace the master
2. Use a pair of internal snap ring pliers and remove the cylinder.
retaining ring.
4 5 ,6
ALL PARTS MARKED * ARE PART OF THE

REPAIR KIT.
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
Figure 5-6 - Master Cylinder
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.
3. Installthe retaining ring in the cylinder body. Installthe boot

and cup. ÿ
..
4. Install caps in both ports if the master cylinder is not being FEr
installed on the lift truck immediately.
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
(See Figure 5-7)

BRAKE SWITCH-REPLACE
CAUTION: Brake fluid damages paint. Immedi¬ (SEE FIGURE 5-3 AND FIGURE 5-8)
surface. 1. Disconnect the battery. Put blocks on each side of the drive
wheel to prevent movement of the lift truck. Open the door for
1. Remove the rubber boot from the slave cylinder. access to the brake assembly.
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.
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
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.
5. The brakes must hotel a lift truck with a ratedload on a 15%

grade with the pedal in the up position.
6. Fill the brake reservoir with the recommended brake fluid

and remove air from the brake system. See REMOVE AIR
FROM THE BRAKE SYSTEM.
Remove Air from the Brake System

1. Before the air is removed from the brake system, make
sure the brake is correctly adjusted. Make sure the master
cylinder reservoir is filled with the recommended brake fluid.
See Section 2 for the recommended brake fluid and the
quantity of brake fluid for the brake system.
BLEED
PUSH ROD
SCREW
2. Put one end of a rubber hose on the bleed screw at the top
of the slave cylinder. Put the other end of the hose into a clear JAM NUT
container of brake fluid. X
3. Loosen the bleed screw one turn. Slowly push the brake c- -
pedal and hold it at the end of its stroke. Close the bleed screw
and release the brake pedal. Repeat the procedure until there
are no air bubbles from the rubber hose. Visually check the
level of the brake fluid in the reservoir for the master cylinder
during this procedure to make sure not to drain the reservoir
and put air into the brake system. ACTUATION ROD
ADJUSTING 63.5 ±0.8 mm

NUT (2.50 ±0.03 in)
BRAKE SWITCH
Figure 5-8 - Brake Assembly Adjustments
5-8
Yale
IndustrialTmcks BRAKE SYSTEM
TROUBLESHOOTING

The brake will not release. The brake system is not adjusted correctly.
There is air in the brake system.
The master or slave cylinder needs repair.
The brake will not stop the lift truck. The brake system is not adjusted correctly.
The brake shoes are worn or damaged.
There is oil or grease on the lining material.
5-9
Yale
IndustrialTrucks brake system
NOTES
5-10
Yale
IndustrialTrucks
SECTION 6
STEERING SYSTEM
Yale
Industrial Trucks
STEERING SYSTEM
STEERING SYSTEM-INTRODUCTION 6-1

HYDRAULIC STEERING MOTOR 6-1
DESCRIPTION 6-1
REMOVAL 6-3
INSTALLATION 6-3
STEERING CONTROL UNIT 6-4
REMOVAL 6-4
INSTALLATION 6-4
DISASSEMBLY 6-4
CLEANING 6-7
ASSEMBLY 6-7
STEERING TILLER MOUNTING BRACKET ASSEMBLY 6-11
STEERING PUMP AND MOTOR 6-11
STEERING PUMP SPECIFICATIONS 6-11
REMOVAL-PUMP AND MOTOR 6-11
ASSEMBLY AND INSTALLATION-PUMP AND MOTOR 6-12
DISASSEMBLY-STEERING PUMP 6-13
ASSEMBLY-STEERING PUMP 6-14
REMOVE AIR FROM STEERING SYSTEM 6-14
STEERING PRESSURE ADJUSTMENT 6-15
Yale
IndustrialTrucks 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.
WARNING: THE NARROW AISLE SERIES

LIFT TRUCK MAY BE FURNISHED WITH
EITHER AUTOMOTIVE OR REVERSE
STEERING. BEFORE WORKING ON ANY OF THESE LIFT
TRUCKS, BE SURE OF THE TYPE OF STEERING BEING
USED.
The steering system draws hydraulic oil from the same

hydraulic tank used by the mast and reach assembly. The
hydraulic oil is directed to the SCU by a power steering and
auxiliary gear pump. The pump has a priority flow valve, which
will provide hydraulic oil for power steering first if boththe power
steering and auxiliary functions are being used at the same
time. The gear pump is driven by a permanent magnet motor.
The motor can either be 24 or 36 volts.
£n
Refer to Section 7 for information on the HYDRAULIC
SYSTEM.
HYDRAULIC STEERING MOTOR

Description
Lift truck steering is achieved when the hydraulic steering
motor rotates the master drive unit (MDU) using a steering
1. STEERING TILLER
chain. The hydraulic motor rotates the MDU for steering the lift
2. STEERING CONTROL UNIT (SCU)
truck.
3. HYDRAULIC STEERING MOTOR
The hydraulic steering motor uses a rotor assembly to change
hydraulic energy into mechanical energy. The rotor assembly Figure 6-1 - Steering System
6-7
Yale
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
Figure 6-2 - Steering System
6-2
Yale
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.
2. Remove the steering chain from the sprocket of the

hydraulic motor. To remove the chain, first make a mark on the
chain anchor and the MDU housing at the chain anchor.
Remove the cotter pin from the end of one offset pin at the chain
anchor. Remove the link pin and chain. Remove the chain from
the sprocket of the hydraulic motor. Use wire to fasten the chain
so that it does not fall.
3. Remove the capscrews and lockwashers that retain the

hydraulic motor to the articulating axle weldment. Remove the 1. HOSE 4. LOCKWASHER
shims and motor. Wire the shims together for use at assembly. 2. STEERING MOTOR 5. SPROCKET
3. CAPSCREW 6. NUT
4. Install labels on the hydraulic lines for proper installation at
Figure 6-3 - Hydraulic Steering Motor
assembly. Disconnect the hydraulic lines and install caps on
the lines and fittings. Plug the ports of the motor. NOTE: If the chain anchor came off the MDU housing, install
the chain anchor at the mark made during removal.
5. Put the flange of the motor in a soft jawed vise. Hold the
sprocket and remove the nut and washer. Do not damage the 4. Install the shims and motor on the articulating axle
sprocket teeth. weldment. Use the steering chain to check that the sprocket is
aligned with the chain flange on the master drive unit. If
6. Carefully remove the sprocket and woodruff key. Do not let necessary, add or remove shims between the motor and axle
the woodruff key fall. The woodruff key is located between the weldment for correct alignment. Install the capscrews and
sprocket and shaft. lockwashers. Tighten the capscrews to 68 N*m (50 Ibf ft)
torque.
NOTE: Most service personnel do not repair the hydraulic
motor. The cost of repairs can be greater than the cost of a 5. Install the steering chain on the chain anchor. Install the
replacement motor. offset link and link pin on the chain anchor. Use a new cotter pin
to complete the assembly. The chain should be adjusted to
Installation obtain a chain deflection of 3.05 mm (0. 12 in) at the center of the
span using a force of 9 to 11 kg (20 to 25 lbs).
1. If the hydraulic motor is a new replacement, remove the
nut, washer and tape used to retain the woodruff key in the
NOTE: An alternative method to adjust the steering chain is
shaft. Do not use the washer, use the washer removed from the
to use a torque wrench to tighten the chain adjusting capscrew
original motor.
to obtain a 1.24 N*m (11 Ibf in) torque. The steering chain must
not be tight.
2. Install the woodruff key in the shaft for the hydraulic
steering motor. Align the slot of the sprocket with the woodruff
6. Remove the block from under the wheels. Close the drive
key and carefully install the sprocket in the shaft. Install the
unit compartment door. Connect the battery.
washer removed during the removal procedure. Install and
tighten the nut. Do not damage the sprocket teeth when
7. Operate the steering system to check that the system is
tightening the nut.
operating correctly. Check for hydraulic leaks.
6-3
Yale
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.
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.
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.
2. Installlabels on the hydraulic lines for proper installation at

assembly. Disconnect the hydraulic lines and install caps on
the lines and fittings.
3. Use a drift pin to remove the spring pin retaining the

sprocket to the shaft of the steering column assembly. Remove
the chain and sprocket.
CCD
4. Remove the two capscrews and lockwashers retaining the
steering column and steering control unit to the mounting
bracket.
5. Removethe two capscrews and lockwashers retaining the

steering column to the steering control unit.
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.
4. It may be necessary to loosen the capscrews and nuts

_
5. STEERING COLUMN AND
STEERING CONTROL UNIT _
retaining the mounting bracket to the lift truck frame to adjust Figure 6-4 - Steering Tiller, Steering Column and
the steering chain. Then use a 3/8 drive ratchet placed in the Steering Control Unit
mounting bracket slot and rotate clockwise to adjust the Disassembly
steering chain. The steering chain should have a 4.06 to 3.05
mm (0.16 to 0.12 in) deflection on the slack side at midpoint. 1. Put the control unit in a vise with soft jaws. Make an
After the proper adjustment has been made, tighten the identification mark on the length of the control unit.
capscrews to 31 N«m (23 Ibf ft) torque.
6-4
IndustrialTrucks steering system
1. CAPSCREW
11876 2. COVER
3. O-RING
Figure 6-6 - Cover Removal

1. STEERING CONTROL UNIT
3. Remove the spacer (if used), the stator, rotor and port
2. VISE plate. Put a mark on the stator so that the same side is toward
Figure 6-5 - Steering Control Unit in Vise the body of the control unit. Remove the O-rings. Remove the
center shaft.
2. Remove the cover on the bottom of the steering control
unit.
1. STATOR
2. ROTOR
3. PORT PLATE
4. O-RING
5. CENTER SHAFT
11877
-
Figure 6-7 Stator and Rotor Removal
6-5
Yale
4. Remove the screw for the check valve assembly. Remove

the parts for the check valve. For some units the check ball is in
the opposite end of the control unit.
11875
1. SCREW
2. CHECK VALVE ASSEMBLY
3. CHECK BALL
Figure 6-8 - Check Valve Removal

5. Remove the spool and sleeve assembly. Remove the (Rotate the spool slowly during removal.) Remove the ring from
thrust bearing assembly from the spool. Push the center pin the sleeve. Remove the neutral position springs from the spool.
from the sleeve. Carefully remove the spool from the sleeve.
1. SPOOL AND SLEEVE ASSEMBLY

2. THRUST WASHER
3. THRUST BEARING
4. CENTER PIN
5. SLEEVE
6. SPOOL
7. RING
8. NEUTRAL POSITION SPRINGS
11876
Figure 6-9 - Spool and Sleeve Assembly Removal

6. When installed,*remove the snap ring, bushing, O-ring and
seal ring. Remove the oil seal from the bushing or housing.
6-6
Yale
11876
1. SNAP RING
2. SEAL
3. BUSHING
4. O-RING
5. OIL SEAL
Figure 6-10 - Oil Seal and Bushing Removal

Cleaning 2. Put the spool (3) on the work bench then put the housing
(6) onto the spool as shown. Install the guide ring (2) with the
O-ring (1) on the end of the spool. Put a large thrust washer (4,
and toxic, and can cause skin irritation. When
see STEP 4) on top of the guide ring and O-ring assembly. Use
using cleaning solvents, always follow the solvent
a socket or tube (5) to push on the washer and install the O-ring
manufacturer's recommended safety precautions.
and guide ring in the housing. Carefully remove the washer,
tube and spool from the housing. Install the housing as
Clean all the parts in solvent. Dry the parts with compressed air.
described in the FRAME Section.
Do not dry the parts with a cloth. Make sure all surfaces are free
of scratches and sharp edges.
1. O-RING
Assembly
2. GUIDE RING
Use new seals, O-rings and neutral position springs during 3. SPOOL
assembly. Lubricate all parts with clean hydraulic oil. 4. WASHER
5. TUBE
1. Install the dust seal. 6. HOUSING
12650
1. HOUSING
2. DUST SEAL
Figure 6-11 - Seal Installation Figure 6-12 - O-ring Installation
6-7
Yale
3. Carefully assemble the spool and sleeve. Make sure the

spool rotates freely in the sleeve.
Figure 6-13 - Spool and Sleeve Assembly

4. Assemble the neutral position springs then push them into
position in the spool (4). Make sure the flat springs (1) are
installed to the outside of the curved springs (2). Install the
center pin (3). Installthe ring (5) on the sleeve (over the neutral
position springs). The ring must turn freely on the sleeve.
2
1. NEUTRAL POSITION SPRINGS (FLAT)
2. NEUTRAL POSITION SPRINGS (CURVED)
3. CENTER PIN
4. SPOOL
5. RING
Figure 6-14 -Spring Installation
6-8
Yale
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.
1. CHECK BALL SLEEVE

2. HOUSING
3. O-RING
4. PORT PLATE
i(i>\
11885
Figure 6-16 -Check Ball and Port Plate Installation
6-9
Yale
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
Figure 6-17 - Stator and Rotor Assembly

8. Install the spacer plate (1). Install the O-ring (2) and the N»m (265 Ibf in). Make sure the capscrew (4) with the pin fits in
end cap (3). Tighten the capscrews for the end cap in the the hole for the check ball (5).
sequence shown to 17 N»m (150 Ibf in), then tighten them to 30
1. SPACER PLATE
2. O-RING
3. END CAP
4. CAPSCREW
5. CHECK BALL
(D ©
1
11886
Figure 6-18 - End Cap Installation
6-10
Yak*
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.
6. It may be necessary to loosen the capscrews retaining the

STEERING TILLER MOUNTING BRACKET ASSEMBLY
steering column and steering control unit mounting bracket to
Removal and Disassembly the lift truck frame to adjust the steering chain. Then use a 3/8
drive ratchet placed in the mounting bracket slot and rotate
clockwise to adjust the steering chain. The steering chain
should have a 4.06 to 3.05 mm (0.16 to 0.12 in) deflection on the
both sides {front and back) of the drive/steer tire
slack side at midpoint. Tighten the capscrews to 31 N«m (23 Ibf
andthe caster wheels to prevent movement of the lift truck. Put
ft) torque after the steering chain has been properly adjusted.
7. Install the drive unit cover and the battery compartment
cover. Remove the blocks from the tires and wheels. Connect
.
1 Disconnect the battery. Block the drive/steer tires, caster
the battery and test the steering control unit. Close the drive unit
wheels and load wheels on both sides to prevent movement of
compartment cover.
the lift truck. Open the drive unit compartment cover. Remove
the battery compartment cover and the drive unit cover.
8. Install the center shaft (1) so that it engages with the center
pin (2) in spool and sleeve assembly. Make sure the center pin
2. Remove the socket head capscrew, lockwasher and nut
is still parallel to the surface with the ports. Installthe rotor (3) on
retaining the steering tiller to the shaft. Remove the tiller.
the center shaft. Make sure that a valley in the rotor aligns with
the slot (center pin) in the center shaft. Installthe O-ring (5) and
3. Remove the capscrews, hardened washers and nut plate
stator (4). Make sure to align the marks made during
retaining the steering tiller mounting bracket assembly to the lift
disassembly.
truck frame.
WARNING: Be careful when removing or STEERING PUMP AND MOTOR

Steering Pump Specifications
force to cause an injury. Always use the correct snap ring pliers Pump Relief Valve Setting: 8.4 ±0.35 MPa (1200 ±50 psi)
installation. Hydraulic Steering Pump Flow Rate: 11.7 l/min (3.1 gpm) at
2000 rpm
4. Remove the snap ring retaining the socket to the tiller
shaft. Remove the sprocket and woodruff key from the tiller Removal-Pump and Motor
shaft. Remove the second snap ring and remove the back-up
washer. Remove the tiller shaft.
released (in the UP position) and the brake is
applied. Put blocks on both sides (front and back)
5. Remove the bearings from the bracket.
of the drive/steer tire and the caster wheels. Put a block on each
side (front and back) of the load wheels to prevent movement of
the lift truck.
1. Install the bearings in the mounting bracket.
NOTE: The recommended maintenance and repairs for the
2. Install the tiller shaft through the mounting bracket and steering pump motor is covered in MOTOR MAINTENANCE,
bearings. Section 3, this manual.
/\ 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.
4. Installthe sprocket, woodruff key and the second snap ring

to retain the.sprocket on the tiller shaft
6-11
Yale
Industrial Tmcks STEERING SYSTEM
3. Align the pump shaft with the opening in the motor. Align
the marks made during disassembly.
4. Installthe pump on the motor using the two capscrews and

lockwashers.
WARNING: The motor and pump assembly has a

weight of approximately 27 kg (60 lb). The steering
pump motor has ceramic magnets. Do not let the
motor fall. The magnets can be damaged.
5. Install the mounting plate on the motor.
6. Install the pump and motor assembly in the truck using the
four capscrews, lockwashers, brackets and rubber channel
mounts.
7. Remove the caps from the hydraulic lines ana fittings.

1. BATTERY COMPARTMENT COVER Connect the hydraulic lines to the fittings identified during
2. CAPSCREW removal.
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.
6. Remove and inspect the motor brushes. Refer to MOTOR

MAINTENANCE, Section 3, this manual.
NOTE: If the motor must be disassembled for cleaning or

repairs, remove the pump so a new oil seal can be installed in
the motor.
7. Remove the mounting plate from the motor.
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.
9. Removethe two capscrews and lockwashers retaining the

pump to the motor. 1. PUMP AND MOTOR ASSEMBLY
2. CAPSCREW
Assembly and Installation-Pump and Motor 3. LOCKWASHER
4. BRACKET
1. Install a new seal in the motor end housing. 5. NUT
6. RUBBER CHANNEL MOUNT
2. Coat the splines of the pump shaft with the recommended 7. MOUNTING PLATE
multi-purpose grease listed in the LUBRICATION SCHEDULE, 8. FLAT WASHER
Section 2, this manual. . .
Figure 6-20 - Steering Pump and Motor Mounting
6-12
Yale
1. CAPSCREW 5. ELBOW
2. O-RING 6. ELBOW
3. FITTING 7. PUMP
4. ELBOW 8. MOTOR
Figure 6-21 - St Pump and 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.
6. Inspect the drive gear, idler gear and the pump body for
damage. If any of these parts are damaged, the pump must be
replaced with a new pump. All seals, O-rings, back-up rings,
and snap ring must be replaced if the present pump is to be
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.
3. Mark the flange; pump body and load sensing valve

assembly for orientation during assembly.
6-13
Yale
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
Figure 6-22 - Steering Pump
Assembly-Steering Pump 6. Install a new snap ring.

1. Apply clean hydraulic oil to all the pump components
7. Install new O-rings on the fittings and elbows. Install the
before assembly.
fittings and elbows in the pump. Install the pressure relief valve
in the pump body. Make sure the valve is properly adjusted.
2. Align and install the idler gear and drive gear in the pump
body. Install new O-rings in the pump body.
8. Align the pump shaft with the opening in the motor. Align
the marks made during disassembly.
3. Install both bushings on the shafts. Install the seals and
back-up rings in the body of each of the bushings.
9. Installthe pump on the motor using the two capscrews and
lockwashers.
4. Align the load sensing valve assembly, pump body and
mounting flange. Install the four capscrews. Tighten the
capscrews to 68-74 N«m (50-55 Ibf ft) torque. CHECKS AND ADJUSTMENTS
Remove Air from Steering System
5. Install a new shaft seal on the drive gear shaft.
Air can enter the system when a hydraulic line is disconnected.
WARNING: Be careful when removing or If the operation is rough, turn the key on and rotate the steering
installing snap rings. These snap rings can come tiller from stop to stop several times in each direction. The air
loose during removal or installation with enough will be removed without disconnecting any lines. If the
force to cause an injury. Always use the correct snap ring pliers operation is still rough, check if air is entering the system at a
and wear eye and face protection during removal and loose fitting.
installation.
6-14
Yale
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
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
Yale
NOTES
6-16
Yale
IndustrialTrucks
SECTION 7
HYDRAULIC SYSTEM
Yale
IndustrialTrucks
-
SECTION 7 CONTENTS
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM-INTRODUCTION 7-1

SPECIFICATIONS 7-4
ELECTRO-HYDRAULIC CONTROL VALVE 7-4
ELECTRO-HYDRAULIC CONTROL VALVE-MANUAL LOWERING ..... 7-4
HOIST PUMP ,7-4
STEER PUMP 7-4
HOIST PUMP AND MOTOR 7-4
REMOVAL 7-4
INSTALLATION 7-5
HOIST PUMP 7-5
DISASSEMBLY 7-5
ASSEMBLY 7-6
HYDRAULIC CONTROL VALVE 7-6
REMOVAL 7-6
INSTALLATION 7-6
DISASSEMBLY 7-6
ASSEMBLY 7-8
HYDRAULIC TANK 7-8
REMOVAL 7-8
INSTALLATION 7-9
Yale
IndustrialTrucks 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:
• Main Hydraulic - Lift and Lower

• Auxiliary Hydraulic - Reach, Tilt and Optional Sideshift
• Power Steering
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
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.
FREE LIFT CYLINDER
REACH TRUCK
EXTEND
REACH CYL. HOIST CYUNOER HOIST CYLINDER
TILT UP
JB2 RIGHT SIDE HOSE
C2 C2 LEFT SIDE HOSE

TILT
CYL GAUGE PORT A2
REACH/TILT CV1
SIDESHIFT
SELECTOR VALVE SELECTOR VALVE KDG4V-3
(OPTIONAL)
SHIFT LEFT 2100

PSI
SIDESHIFT CYLINDER 2800
PSI
STRADDLE TRUCK
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
Figure 7-2 - Hydraulic Schematic
7-2
Yale
IndustrialTnicks hydraulic system
1. HOSE CLAMP
2. HOSE
3. HOSE
4. HOSE
5. CAPSCREW
6. LOCKWASHER
7. SPACER BLOCK
8. 90° HOSE FITTING

9. 45° HOSE FITTING
10. FILTER HEAD
11. FILTER ELEMENT
12. HOSE ASSEMBLY
13. HOSE CLAMP
14. HOSE
15. TUBE-SUCTION
16. HOSE-MOLDED ELBOW
17. HOSE CLAMP
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.
Figure 7-3 - Hydraulic System

7-3
Yale
SPECIFICATIONS Steering Pump

Electro-hydraulic Control Valve Pump Relief Valve Setting: 8.4 ±0.35 MPa (1200 ±50 psi)
Hoist Relief Valve Setting ........

NOTE: The port identification for all the ports is stamped on
Auxiliary Relief Valve Setting.....

the body of the Electro-Hydraulic Control Valve.
2800 ± 100 psi

2100 ±50 psi
HOIST PUMP AND MOTOR
Removal
released (in the UP position) and the brake is
PROPORTIONAL ELECTRO-HYDRAULIC SOLENOIDS of the drive/steer tire and the caster wheels to prevent
movement of the lift truck. Put a block on each side (front and
1. AUXILIARY UP 3. LIFT
back) of the load wheels to prevent movement of the lift truck.
2. AUXILIARY DOWN 4. LOWER
1. Turn the key switch to OFF. Disconnect the battery.
2. Open the drive unit compartment door. Position a drain

pan under the hoist pump. Loosen and disconnect the feed and
return lines to the hoist pump. Install plugs in the hydraulic lines
to prevent dirt from entering the system and to prevent
hydraulic oil from draining out.
MANUAL LOWERING SCREW

Figure 7-4 - Electro-Hydraulic Control Valve
Electro-hydraulic Control Valve-Manual Lowering

WARNING: Allow no one under or near the lift
mechanism or load during the manual lowering
procedure.
A provision is provided on the lowering valve to allow manual

lowering of the forks if necessary. Manual lowering is
accomplished by inserting an 1/8 inch alien wrench into the
manual lowering screw (located in the center of the lowering
Valvistor) and slowly turning it clockwise until the forks begin to
lower. See Figure 7-4. Be sure to return the screw to the original MOTOR
position once the manual lowering process is complete by PUMP
slowly turning the screw counterclockwise until it stops. O-RING
90° ELBOW
WARNING: Failure to return the manual lowering CAPSCREW
screw to the full counterclockwise positioh will LOCKWASHER
cause the forks to lower unexpectedly. 45° ELBOW
Hoist Pump Figure 7-5 - Hoist Pump and Motor

The rated flow for the hoist pump for the 24 volt lift trucks is 26.8
l/min (7.1 gpm) at 2000 rpm. WARNING: The hoist pump and motor is heavy.
Be sure that all lifting devices (lifts, cables, chains,
The rated flow for the hoist pump for the 36 volt lift trucks is 42.4 or slings) are suitable and of adequate capacity to
l/min (11.2 gpm) at 2000 rpm. lift the hoist pump and motor. The hoist pump and motor
assembly can weigh approximately 253.6 kg (115 lb).
7-4
Yale
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
Figure 7-6 - Hoist Pump Disassembled

3. Position a lifting device around the hoist pump motor. 4. Remove the blocks from under the drive/steer wheel,
Remove the four capscrews, lockwashers, flat washers and caster wheels and load wheels. Check the hydraulic level.
isolator mounts retaining the hoist pump and motor to the lift Connect the battery.
truck frame.
HOIST PUMP
4. Move the hoist pump and motor to a clean work area to
disassemble the hoist pump and motor.
Disassembly
NOTE: The recommended maintenance and repairs of the 1. Remove the two capscrews and lockwashers that retain
hoist pump motor is covered in Section 3. the hoist pump to the motor. Separate the pump from the hoist
motor. See Section 3 for repairs on the hoist pump motor.
Installation
2. Disassemble the elbows and O-rings from the pump body.
/\ WARNING: The hoist pump and motor is heavy.
1
/ \ Be sure that all lifting devices (lifts, cables, chains, /\ WARNING: Be careful when removing or
CmmJLmm* or slings) are suitable and of adequate capacity to 11\ installing snap rings. These snap rings can come
lift the hoist pump and motor. The hoist pump and motor
assembly can weigh approximately 253.6 kg (115 lb).
1. Align the hoist pump and motor with the mounting holes in
installation.
the frame using a lifting device.
3. Use snap ring pliers and remove the snap ring from the
2. Install the four isolator mounts, flat washers, lockwashers
pump drive gear shaft. Remove the shaft seal.
and capscrews.
4. Remove the four capscrews from the pump body.
3. Remove the plugs from the hydraulic lines. Install the
Separate the mounting flange and the end cover from the pump
hydraulic lines on the hoist pump.
body. Remove the back-up rings, seals, bushings and O-rings.
5. Remove the idler gear and drive gear.
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.
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.
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).
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,
caster wheels and load wheels. Connect the battery.
released (in the up position) and the brake is
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
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
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
Figure 7-7 - Electro-Hydraulic Control Valve

7-7
Yale
Industrial Trucks HYDRAULIC SYSTEM
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
so the valve plug will not be released with excessive force.
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
6. Remove the Auxiliary Relief Valve. Use a 1 inch open end
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
Figure 7-8 -h aulic Tank

8. Inspect all components for damage and replace any O-rings and six flat washers nuts to retain the tank, gasket and
defective item. top cover.
Installation 4. Install the strainer in the tank cover.

1. Locate the hydraulic tank in the lift truck.
5. Remove the plugs from the hydraulic lines. Connect all the
hydraulic lines to the hydraulic tank.
2. Install the baffle plate in the hydraulic tank.
6. Fill the hydraulic tank to the recommended level with the
3. Apply sealant (Yale P/N 5200498-31 or equivalent) to the
recommended hydraulic oil. See Section 2 for the
mating surfaceof the hydraulic tank. Install a new gasket on the
hydraulic tank. Align the top cover with the hydraulic tank and • . recommended hydraulic oil.
the gasket. Install the three capscrews, lockwashers and
7-9
Yale
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.

Low hydraulic pressure Pump is worn or damaged.
Relief valve needs adjustment.
Hydraulic system relief valve opens frequently Relief valve needs adjustment or relief valve is defective.
Restriction in the system.
The pump noise is not normal Oil in the hydraulic tank is low.
Restriction in the iniet hose.
Inlet fitting or inlet hose clamp is loose.
The bearings or gears are damaged.
The housing is damaged.
Loose capscrews holding the pump housing together.
Loose capscrews in the pump mounting.
Pump motor is damaged or worn.
The pump has low output The pump is worn.
Seals or gaskets are damaged and cause leaks.
The fitting at the pump leaks.
The pump has leaks Fittings are loose or defective.
Loose capscrews holding the pump housing together.
Seals are defective.
7-10
Yale
IndustrialTrucks
SECTION 8
8 MAST AND REACH ASSEMBLY

Yale
IndustrialTrucks
MASTS AND REACH ASSEMBLY
MASTS 8-1
CARRIAGEASSEMBLY 8-1
REACHASSEMBLIES 8-1
LOAD BACKREST EXTENSION-
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-
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
ASSEMBLY WITHOUT SIDESHIFTER 8-15
INSTALLATION WITHOUT SIDESHIFTER 8-15
SINGLE REACH SCISSOR ARMS 8-16
DOUBLE REACH SCISSOR ARMS 8-18
INNER FRAME ASSEMBLY 8-22
REMOVAL 8-22
DISASSEMBLY 8-23
ASSEMBLY 8-24
INSTALLATION 8-24
SIMPLEX MASTASSEMBLY 8-25
REMOVAL 8-25
LIFT CYLINDERS-REMOVAL AND INSTALLATION 8-26
INNER MAST ASSEMBLY-REMOVAL AND INSTALLATION 8-28

Yale
IndustrialTrucks
SECTION 8- CONTENTS (Continued)

MAST AND REACH ASSEMBLY
HOSES-REPLACE 8-28
HOSE AND CABLE SHEAVES-REPLACE 8-29
SIMPLEX LIFT CHAINS-REMOVAL AND INSTALLATION 8-29
SIMPLEX CHAIN SHEAVE-REMOVAL AND INSTALLATION 8-29
LOAD ROLLERS AND WEAR PLUGS-
INSTALLATION 8-32
TRIPLEX MASTASSEMBLY 8-33
REMOVAL 8-33
FREE LIFT CYLINDER-REMOVAL AND INSTALLATION 8-35
MAIN CYLINDERS-REMOVAL AND INSTALLATION 8-35
INNER AND INTERMEDIATE MASTASSEMBLIES-
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-
TRIPLEX MAST ASSEMBLY-INSTALLATION 8-42
REACH CYLINDERS 8-42
REMOVAL 8-42
DISASSEMBLY 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

Y&fe
IndustrialTrucks
SECTION 8- CONTENTS (Continued)

MAST AND REACH ASSEMBLY
REMOVAL 8-49
DISASSEMBLY 8-50
ASSEMBLY 8-50
INSTALLATION 8-50
REACH/TILT SELECTOR VALVE 8-51
REMOVAL 8-51
DISASSEMBLY 8-52
ASSEMBLY . . : 8-52
INSTALLATION 8-52
TILT/SIDESHIFT SELECTOR VALVE 8-52
REMOVAL 8-52
DISASSEMBLY 8-53
ASSEMBLY 8-53
INSTALLATION 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
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.
These mast assemblies, carriages and reach assemblies have

wear plugs and wear strips to allow for adjustment due to wear.
The wear plugs arein the stub shaftsofthe toad rollersandslide
against the center part of the channel. A set screw and jam nut
keep each wear plug in the correct position. The load rollers
take the forward and back loads during operation of the mast.
The loadrollers have ball bearings with grease seals. The wear
strips are made of a friction material and slide against the
outside edge of the channel flange.
The mast weldments must be parallel with equal clearance on

each side. Correct operation depends on periodic cleaning,
lubrication and adjustment of the clearance between
weldments. See CHECKS AND ADJUSTMENTS at the rear of
this section.
NOTE: See the GENERAL TRUCK AND LUBRICATION

SECTION for the correct maintenance and inspection 1. FORK
ÿ
procedures for the masts, hydraulic cylinders, forks, chains and 2. CARRIAGE
carriages. 3. LOAD BACKREST EXTENSION
WARNING: The mast, reach assemblies,

Figure 8-1 - Carriage Assembly
carriage assemblies and their components, are
heavy. To help prevent damage or an injury, a lifting
device must be used during all service procedures. REACH ASSEMBLIES
The reach assembly is used to extend the reach of the forks.
NOTE: The reach assembly or carriage assembly can be
There are two types of reach assemblies. There is a single
removed from the mast assembly with the load backrest reach assembly with one set of scissor arms. The other reach
extension and forks attached. Both the simplex and triplex mast
assembly has two sets of scissor arms for double reach. Both
assembly can also be removed with the carriage or reach reach assemblies have a tilt cylinder to tilt the forks. Each reach
assembly installed. Do only those procedures necessary for
assembly can also have an optional sideshift function. The
repair.
parts of the reach assemblies are shown in Figure 8-2. The
inner and outer frame assemblies are connected by a scissor
CARRIAGE ASSEMBLY linkage. The top of the scissor arm weldment at the inner frame
is fastened to the top of the inner frame by pins. The top of each
A carriage assembly is standard on the NS series of lift trucks. scissor arm at the outer frame or apron is fastened to the top of
The carriage is a part of the mast assembly and moves within the frame or apron by pins. On double reach units, the ends of
the vertical channels of the inner weldment. Load rollers, each set of scissor arms and scissor arm weldments are
attached to the carriage, travel in the channels of the inner fastened together by studs with bearings. The bearings on
weldment. Forks or other types of load handling equipment are
each pin or stud permit the arms to pivot. Large bearings at the
attached to the carriage. A load backrest extension is attached
center pivot of each scissor arm and scissor arm weldment also
to the carriage and adds support for a load that has multiple
permit the linkage to pivot.
pieces. See Figure 8-1.
Two hydraulic cylinders control the reach movement of the
The lift truck may be furnished with an optional sideshift scissor arms. The tilt cylinder controls the tilt action of the pivot
carriage which allows the operator to move the forks and load assemblies at the heel of the forks. The forks pivot on a large pin
from side-to-side. This function makes it easier forthe operator that connects the forks to the frame. The sideshift cylinder
to align the forks with a load or align the load with a stack. The controls the movement of the outer frame assembly and forks.
sideshift carriage is installed on the fork bars of the standard
carriage. Special bushings fit between the sideshift carriage
and the fork bars. A sideshift cylinder is installed on a plate that
8-1
Yale
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.
The flow of oil to and from the cylinders is controlled by the

elecro-hydraulic control valve and Valvistors. The Valvistors on
SINGLE REACH WITHOUT

SIDESHIFT 8. REACH CYLINDER
9. LOAD BACKREST EXTENSION
10. OUTER FRAME
11. APRON
12. LOAD ROLLER
DOUBLE REACH WITH

SIDESHIFT
11
1. INNER FRAME
2. SCISSOR ARM
3. OUTER FRAME
4. FORKS
5. TILT CYLINDER
6. SCISSOR ARM WELDMENT
7. LOAD BEARING
Figure 8-2 - Reach Assemblies
8-2
Yale
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)
Figure 8-3 - Hydraulic Schematic, Reach Assembly Functions
•REACH ASSEMBLY TUBE ASSEMBLIES FOR SIMPLEX AND TRIPLEX ARE DIFFERENT.
WITHOUT
SIDESHIFT
1. REACH/TILT SELECTOR VALVE

2. OUTER FRAME
3. TILT CYLINDER
4. OUTER FRAME
5. TILT/SIDESHIFT SELECTOR VALVE
6. FOR APRON MOUNT
7. SIDESHIFT CYLINDER
8. TO TRUCK THROUGH MAST
9. CABLE BRACKET
10. MANIFOLD BLOCK
11. FOR SCISSOR ARM MOUNT
12. REACH CYLINDER (ONE OF TWO)
13. HOSE AND- GABLE SHEAVE ASSEMBLY
14. INNER FRAME
15. MOUNT FOR REACH CYLINDER
WITH SIDESHIFT 12151
Figure 8-4 - Hydraulic Parts for Reach Assembly

8-3
Yale
Industrial Trucks MAST AND REACH ASSEMBLY
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.
Follow the repair procedures in this section.
WHEN WORKING NEAR THE MAST ALWAYS:

Lower the mast and carriage or reach assembly completely. Push
the lift/lower control lever forward and make sure there is no
movement in the mast. Make sure that all parts of the mast that
move are fully lowered.
OR
If parts of the mast must be in a raised position, install a safety

chain to restrain the moving parts of the mast. Connect moving
parts to a part that does not move. Follow these procedures:
a. Raise the mast to align the bottom crossmember of the weld-

ment that moves within the outer weldment, with a crossmember SIMPLEX
on the outer weldment (1). On the simplex mast, the moving part MAST
is the inner weldment (2). On the triplex mast it is the intermediate
weldment (3).
b. Use a 3/8 inch minimum safety chain with a hook (4) to fasten
the crossmembers together so that the movable member cannot
lower. Put the hook on the back side of the mast. Make sure the
hook is completely engaged with a link in the chain. Make sure the
safety chain does not touch lift chains or chain sheaves, tubes,
hoses, fittings or other parts on the mast.
c. Lowerthe mast untilthere is tension in the safety chain and the
free lift cylinder (5) ( triplex mast only) is completely retracted.
Move the key to the OFF position and remove the key from the key
switch. Put a "DO NOT OPERATE" tag in the operator's compart¬
ment. Disconnect the battery and put a tag or lock on the battery
connector. Install a "DO NOT REMOVE" tag on the safety
chain(s).
d. Install another safety chain (3/8 inchTtimrrnurn) between the
top or bottom crossmember of the carriage or reach assembly (6)
and a crossmember on the outer weldment (1).
NOTE: MAST GUARD MUST BE REMOVED TO INSTALL

SAFETY CHAIN. REMOVE SAFETY CHAIN AND
INSTALL THE GUARD AFTER REPAIRS ARE TRIPLEX
COMPLETE. MAST
8-4
Yale
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
1. LATCH ASSEMBLY 4. WASHER

2. LEVER 5. SPRING
3. ROLL PIN 6. LATCH PIN
Figure 8-5 - Forks
8-5
Yale
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
8. Use the crane to move the load backrest into position on

the frame. Install the capscrews that fasten the load backrest 3. Use safety chains to fasten the movable member of the
on the frame. mast to the outer weldment so that it cannot move.
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.
5. On triplex masts, remove the safety chains installed in

Step 3. Lower the carriage assembly for access to the chain
anchors at the back of the free lift cylinder. Use safety chains to
fasten the movable member of the mast to the outer weldment
so that it cannot move. Move the key to the OFF position and
disconnect the battery.
6. Fasten the chains or slings to the carriage frame. Use the

crane to raise the carriage assembly so that the lift chains
become loose.
7. Disconnect the sideshift hydraulic lines at the carriage. Put

tags on the fittings for correct connection during installation.
Make sure to put caps on the open fittings to keep dirt out of the
system.
Figure 8-6 - Fork Removal-Reach Assembly
NOTE: Removing the pins, at the chain anchors, will
disconnect the lift chains without changing the chain
CARRIAGE ASSEMBLY-REMOVAL AND INSTALLATION adjustment. Always adjust the chains1if newliftctrains'or other
(SEE FIGURE 8-7 AND FIGURE 8-8) components are installed.
NOTE: The carriage assembly can be removed with the forks
and load backrest extension attached, or with the forks and 8. Hold the lift chains to keep them from falling. Remove the
load backrest removed. Do only those procedures necessary pins in the chain anchors at the back of the outer weldment of
for your repair. See FORK REPLACEMENT to remove the simplex masts. Remove the pins in the chain anchors at the
forks. See LOAD BACKREST EXTENSION-REMOVAL AND back of the free-lift cylinder of triplex masts. Disconnect the lift
INSTALLATION to remove the load backrest extension. chains. Carefully move the lift chains through the sheaves and
lay the lift chains over the carriage.
8-6
Yale
IndustrialTrucks mast and reach assembly
1. CARRIAGE FRAME 8. GREASE FITTING 15. SCREW

2. SCREW 9. LOAD ROLLER 16. GREASE FITTING
3. NUT 10. SNAP RING 17. SNAP RING
4. STUD 11. WEAR PLUG 18. CHAIN ANCHOR
5. THRUST ROLLER 12. SHIM 19. COTTER PIN
6. WASHER 13. SIDE ROLLER 20. FORK REMOVAL NOTCH
7. SNAP RING 14. LOCKWASHER
Figure 8-7 - NS Carriage Assembly

WARNING: The carriage assembly is heavy and 10. To install the carriage assembly, reverse the removal
can cause an injury if it tips or falls. Make sure the procedures. Always use new cotter pins when installing the lift
carriage assembly is stable during and after chains. Apply Loctite to the studs of the thrust rollers during
removal. If the forks are removed, put the carriage assembly on installation.
the floor so that the load rollers are up.
11. Adjust the carriage assembly. See ADJUSTMENTS in
CAUTION: Do not damage lift chains, hoses or CHECKS AND ADJUSTMENTS. Test the carriage assembly
electrical cables as the carriage assembly is lifted for correct operation.
out of the mast weldment.
REACH ASSEMBLY-REMOVAL AND INSTALLATION
9. Carefully lift the carriage assembly out of the channels Of
the inner weldment. Carefully lower the carriage assembly to 1. Operate the LIFT/LOWER control handle to raise the
the floor. reach assembly until the thrust rollers of the inner frame (reach)
are above the top of the outer weldment.
NOTE: The carriage side rollers must be adjusted while the
carriage is out of the mast. Adjust the side rollers as described 2. Operate the REACH/RETRACT control handle to fully
in CHECKS AND ADJUSTMENTS before installing the retract the forks. Install safety chains so that the forks cannot
carriage assembly. extend. Installthe safety chains around the center plates of the
scissor arm weldment and the reach frame. Make sure a safety
8-7
Yale
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.
4. Use safety chains to fasten the movable member of the

mast to the outer weldment so that it cannot move.
WARNING: Be careful when -removing or

f f\ installing snap rings. These snap rings are large
and can come loose during removal or installation
5. Remove the snap rings, washers, thrust rollers and

spacers.
6. Disconnect the hydraulic lines (sideshift or reach only) at

the outer frame. Put tags on the fittings for correct connection
during installation. Make sure to put caps on the open fittings to
keep dirt out of the system. Disconnect the electrical
connections (reach only) at the selector valve.

adjustment. Always adjust the chains if new lift chains or other
components are installed.
1 LOAD ROLLER (4 OR 6)
7. Hold the lift chains to keep them from falling. Remove the 2. CHAIN ANCHORS
pins in the chain anchors at the back of the outer weldment of 3. INNER FRAME
simplex masts. Remove the pins in the chain anchors at the 4. SHIMS
back of the free lift cylinder of triplex masts. Disconnect the lift 5. SNAP RING
chains. Carefully move the lift chains through the sheaves and 6. SIDE ROLLER
lay the lift chains over the reach assembly. 7. THRUST ROLLER
8. SPACER
/\ WARNING: The reach assembly is heavy and 9. WASHER
If \ can cause an injury if it tips or falls. Make sure the 10. GREASE FITTING
CmJ reach assembly is stable during and after removal. 11. WEAR PLUG
If the forks are removed, put the reach assembly on the floor so
that the load rollers are up. Figure 8-8 - Reach Assembly
A CAUTION: Do not damage lift chains, hoses or

electrical cables as the reach assembly is lifted out
of the mast weldment.
CARRIAGE LOAD ROLLERS-
REMOVAL AND INSTALLATION
(SEE FIGURE 8-9 AND FIGURE 8-10)
8. Carefully lift the reach assembly out of the channels of the 1. Remove the carriage or reach assembly from the mast
inner weldment. Carefully lower the reach assembly to the floor. assembly to remove and install the carriage load rollers. See
CARRIAGE ASSEMBLY or REACH ASSEMBLY-REMOVAL
NOTE: The reach assembly side rollers must be adjusted AND INSTALLATION.
while the reach assembly is out of the mast. Adjust the side
rollers as described in CHECKS AND ADJUSTMENTS before 2. Remove the jam nuts and set screws for the load rollers.
installing the reach assembly.
3. If necessary, replace the wear plugs by pushing at the
9. To install the reach assembly, reverse the removal back of the wear plug.
procedures. Always use new cotter pins when installing the lift
chains. Apply Loctite to the studs of the thrust rollers during
installation.
8-8
Yale
4 WARNING: Lift chains, hoses and cables can roll

over the sheaves to fall and cause an injury if the
ends are not fastened. Keep control of the ends of
the lift chains, hoses and cables as they are removed. Usewire
to temporarily connect the ends of the lift chains, hoses or cable
to the masts.
4. On triplex masts, remove the safety chains installed in

Step 4.. Lower the reach assembly for access to the chain
anchors at the back of the free lift cylinder. Use safety chains to
fasten the movable member of the mast to the outer weldment
so that it cannot move. Move the key to the OFF position and
5. Install lifting eyes in the reach assembly for chains or

slings. Fasten chains or slings to the reach assembly so that the
reach assembly cannot tip as it is removed from the mast
weldment. Fasten the chains to the lifting eyes. Use the crane
to raise the reach assembly so that the lift chains become
loose.
LOAD ROLLER
2. WEAR PLUG
3. SNAP RING
installing snap rings. These snap rings are large
4. SET SCREW
5. JAM NUT with enough force to cause an injury. Always use the correct
6. STUB SHAFT
7. MAST, REACH OR CARRIAGE COMPONENT removal or installation.
Figure 8-9 - Load Roller and Wear Plug Assembly 6. Remove the snap rings from the stub shaft for the load
roller.
7. Use a prybar to remove the load roller from the stub shaft
for the load roller. See Figure 8-10.
8. Use a cloth to clean each load roller. Inspect the load

rollers for cracks, flat spots or bearings that do not turn freely.
Replace any roller that shows wear or is damaged.
9. Install the carriage or reach assembly. See CARRIAGE

ASSEMBLY or REACH ASSEMBLY-REMOVAL AND IN¬
STALLATION.
10. Adjust the carriage or reach assembly. See

ADJUSTMENTS in CHECKS AND ADJUSTMENTS.
SIDE ROLLERS-DISASSEMBLY AND ASSEMBLY

(SEE FIGURE 8-10)
3 1. Remove the carriage assembly from the mast to .replace
1. LOAD ROLLER WITH SNAP RING REMOVED the side rollers. See CARRIAGE ASSEMBLY REMOVAL AND
2. PRYBAR INSTALLATION to remove the carriage.
3. MAST, REACH OR CARRIAGE COMPONENT
4. SIDE ROLLER 2. Remove the capscrews that fasten the side roller bracket.
Figure 8-10 - Removing Load Roller NOTE: Observe the position of the shims.
3. Inspect and replace all damaged or worn parts.
8-9
Yale
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.
NOTE: It is usually not necessary to completely disassemble

the reach assembly. Do only the steps of the procedures
necessary to make the required repairs.
1
WARNING: Hydraulic oil is hot after system
operation and can cause bums. Do not disconnect 00,
any hydraulic lines of the system until the oil for the
system is cool.
CAUTION: Make sure the lift truck is in a location

that is level and has access to a crane or other
lifting device before doing any repairs on the reach
assembly.
REACH ASSEMBLY OUTER FRAME

12754
Removal with Sideshifter
(See Figure 8-12)
NOTE: Use safety chains on the inner frame and mast
weldments to keep the reach assembly and mast weldments
from moving. Installthe safety chains as described in SAFETY
PROCEDURES.
1. INNER FRAME OF REACH ASSEMBLY
2. LOAD BEARING
NOTE: Make sure that the reach assembly is in the fully
3. WOODBLOCK
extended position. The outer frame can be removed with the CLAMP
4.
forks installed or removed.
Figure 8-11 - Install Blocks and Clamps
WARNING: There are pinch points on the reach
assembly that can cause an injury. Use clamps 5. Remove the roll pins that retain the pivot pins in the outer
and blocks to prevent the scissor arms from frame to the inner scissor arms. Remove the pivot pins.
moving. Install the clamps and blocks at the channels of the
inner frame to make sure that the load bearings cannot move in 6. Use a crane to lift the outer frame high enough to allow the
the channel. See Figure 8-11. inner extend arm rollers to come out of the bottom of the outer
8-10
Yale
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
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
/\ 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
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
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
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
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
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
Figure 8-13 - Outer Frame without Sideshifter
8-14
Yale
IndustrialTrucks IWIAST AND REACH ASSEMBLY

CAUTION: Do not let the load bearings or shims
bearings. Do not use compressed air on the
2. Make sure the shims and load bearings are installed in the
correct positions on the scissor arms. If necessary, use tape to
the bearings.
keep the load bearings on the scissor arms. Do not let the load
bearings fall during installation of the outer frame.
NOTE: Inspect the load bearings of the scissor arms for wear
or damage. If necessary, replace the load bearings before
CAUTION: Do NOT operate the tilt or sideshift
installing the outer frame.
functions if the outer frame has been removed.
weldments to keep the inner frame and mast weldments from
moving. Install the safety chains as described in SAFETY
manufacturer.
PROCEDURES.
Clean all of the parts of the outer frame or apron with solvent.
Dry the parts with compressed air. Inspect the parts of the outer
assembly that can cause an injury. Use clamps
frame for damage and wear.
and blocks to prevent the scissor arms from
Assembly without Sideshifter
inner frame to make sure that the load bearings cannot move in
(See Figure 8-13)
the channel. See Figure 8-11.
NOTE: The bearings for the outer frame are normally
removed and installed with the outer frame. The selector valve 3. Use the crane to move the outer frame for alignment with
and tilt assembly are installed on the outer frame. the scissor arms. Tip the outer frame forward and align the
channels with the load bearings of the scissor arms. Slowly lift
1. If removed, installthe solenoid valve and hose guide on the the outer frame to install the load bearings in the channels.
outer frame.
NOTE: Another removal method forthe outerframe is to raise
2. Installthe tilt cylinder and tilt pivot assemblies as described the scissor arms and inner frame as a unit. Remove the safety
in TILT CYLINDER AND TILT PIVOT ASSEMBLIES. chains and operate the lift system of the lift truck to raise the
scissor arms and inner frame off the outer frame.
Installation without Sideshifter
(See Figure 8-13) 4. The load bearings must move in the channels and have
minimum clearance with free movement. Keep the outerframe
NOTE: Make all repairs for the scissor arm assembly before
in vertical alignment and move it up and down on the load
installing the outer frame. See SCISSOR ARMS to repair the
bearings. If necessary, add or remove shims for free movement
scissor arm assembly. If necessary, install new load bearings
and minimum clearance. Each shim set must have the same
using the same shims as marked during removal of the outer
thickness.
frame. When new load bearings are installed, the shim
arrangement will normally be the same or similar.
5. Install new bushings in the top end of each scissor arm.
Lubricatethe bushings with multi-purpose grease. Tip the outer
NOTE: The outer frame can be installed with the forks
frame back and align the holes for the pivot pins with the
installed.
bushings in the top scissor arms.
WARNING: The outer frame is heavy and can
6. Keep the pivot pins (Item 9, Figure 8-12) (Item 7,
cause an injury during installation. NEVER put any
Figure 8-13) in alignment to install the roll pins. Install the pins
part of your body between the outer frame and the
and roll pins.
scissor arm assembly. Tipping is even more possible if the forks
are installed. Make sure to install the chains or slings between
7. Install the hoses at the top of the outer or outer frame as
the crane and outer frame to prevent tipping.
marked during removal. For units without sideshift, see
Figure 8-13. For units with sideshift, see Figure 8-12.
1. Use a crane as a support for the outer frame. Move the
outer frame into the approximateposition for installation on the
scissor arm assembly.
air from the system as described in CHECKS AND
8-15
Yale
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.
(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.
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
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
hand scissor arms. Carefully remove the three capscrews, the
lockwashers, the end cap and the two thrust washers at the
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
other two thrust washers. Remove the other scissor arm
following this same procedure.
6. Remove the roll pins and anchor pins that fasten the
scissor arm weldment to the inner frame. Move the scissor arm
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.
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
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
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
Figure 8-14 - Single Reach Scissor Arms
8-17
Yale
Assembly and Installation arm assembly so that the load bearings move into the
channels.
5. Slowly raise the scissor arm assembly to align the mounts
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
WARNING: The points between the scissor arms
andthe inner frame are pinch points and cancause
an injury. Do NOT put your finger in the hole when
you install the pins at the reach cylinders or scissor arm
weldment.
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.
person help you support the scissor arm during DOUBLE REACH SCISSOR ARMS
(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.
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
1. SCISSOR ARM 11. SNAP RING

2. REACH CYLINDER 12. TWO THRUST WASHERS
3. -SCISSOR ARM WELDMENT 13. END CAP
4. LOAD BEARING 14. SPECIAL LOCKWASHER
5. PIN 15. CAPSCREW
6. ROLL PIN 16. LOCKWASHER
7. BUSHING 17. ROD END
8. SHIM 18. INNER FRAME
9. HOSE SHEAVE 19. REMOVAL NOTCH
10. MOUNT 20. INSTALL CLAMPS AND BLOCKS HERE
Figure 8-15 - Double Reach Scissor Arms

8-19
Yale
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.
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.
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
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
/\ 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.
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
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
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
special lockwasher against the flat of each capscrew.
the bearings.
/\
11\
Clean all of the parts of the scissor arm assembly with solvent.
Dry the parts with compressed air. Inspect the parts of the
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
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
/\
/ I\
WARNING: The points between the scissor arms
and the inner frame are pinchpoints and cancause
WARNING: The scissor arm assembly is heavy

an injury. Do NOT put your finger in the hole when and can cause an injury during installation.
you remove the pins at the scissor arm weldment. Use a brass NEVER put any part of your body between the
drift to remove the pins. innerframe andthe scissor arm assembly. NEVER put any part
of your body between the parts of the scissor arm assembly.
1. Use a crane and chains or slings as a support for scissor
arm weldment "B". Do not damage the hose sheave mount. 6. Slowly raise the weldment so you can install the shim sets
Move the weldment into a position of alignment to install the and load bearings on scissor arms "1B" and "2B" as marked
pins that fasten the weldment to the inner frame. Install the during removal. If necessary, use tape to keep the load
bushings, pins and roll pins. See Items 5, 6 and 7 of bearings on the scissor arms.
Figure 8-15. Slowly lower the weldment so that it hangs from
the pins. Remove the crane and chains or slings. 7. Use the crane to slowly raisascissor arm weldmentÿB" by :
lifting weldment "A" to align the load bearings with the removal
notches in the inner frame. Use the crane to move the scissor
arm assembly so that the load bearings move into the
channels.
8-21
Yale
8. Slowly raise scissor arm assembly to align the mounts with

the rod ends of the reach cylinders. Install the bushings, pins
and roll pins to fasten the reach cylinders to the scissor arm
weldment.
A I \
1. If the scissor arm assembly is installed, operate the

WARNING: The scissor arms are heavy and can REACH/RETRAGT control handle to fullyretract the forks. Use
cause an injury if allowed to fall. Have another safety chains to fasten the parts of the reach assembly so that
person help you support the scissor arm during the forks cannot extend.
2. Operate the LIFT/LOWER control handle to raise" the
9. Move scissor arm weldment "A" for alignment and install reach assembly or inner frame assembly until the thrust rollers
scissor arm "2A" on scissor arm weldments "A" and "B" as of the inner frame are above the top of the outer weldment.
shown in Figure 8-15. Make sure there are two thrust washers
on each side of the scissor arm at the center pivot. Tighten the 3. Move the key to the OFF position and disconnect the
three capscrews at the center pivot to 41 N«m (30 Ibf ft) torque. battery.
Also make sure there are two thrust washers on each side of
the arm of scissor arm weldment "B". Tighten the two NOTE: Use safety chains on the inner frame and mast
capscrews at the end pivots to 39 N*m (29 Ibf ft) torque. Bend weldments to keep the inner frame and mast weldments from
the comers of the special iockwashers against the flat of each moving. Install the safety chains as described in SAFETY
capscrew. Install scissor arm "1A" using the same procedure. PROCEDURES.

4. Use safety chains to fasten the reach assembly or inner
frame assembly and inner weldment of the mast so that they
cannot move.
/V WARNING: Be careful when removing or /\ WARNING: Be careful when removing or

I I\ installing snap rings. These snap rings are large / 1\ installing snap rings. These snap rings are large
UhJ and can come loose during removal or installation and can come loose during removal or installation
with enough force to cause an injury. Always use the correct with enough force to cause an injury. Always use the correct
snap ring pliers and wear eye and face protection during snap ring pliers and wear eye and face protection during
removal or installation. removal or installation.
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.
Removal A WARNING: Lift chains, hoses and cables can roll

(See Figure 8-16) II\ over the sheaves to fall and cause an injury if the
NOTE: Remove the inner frame to replace the reach
ULJ ends are not fastened. Keep control of the ends of
the lift chains, hoses and cables as they are removed. Use wire
assembly load rollers or side rollers. Other repairs to the inner
to temporarily connect the ends of the lift chains, hoses or cable
frame can be done without removing the inner frame. The inner
to the masts.
frame can be removed by removing the complete reach
assembly from the mast as one assembly. The inner frame 7. Hold the lift chains to keep them from falling and remove
assembly can also be removed after the scissor assembly has
the pins in the chain anchors of the inner frame. Disconnect the
been removed. lift chains. Carefully fasten the ends of the lift chains so that they
do not move over the chain sheaves.
8-22
Yale
9. Carefully lift the reach assembly or inner frame assembly

out of the inner weldment. Carefully lower the reach assembly
or inner frame assembly to the floor.
WARNING: Make sure that the reach assembly is

V |\ stable and cannotfall to cause an injury. Make sure
the safety chains are still installed (Step 1). If the
forks are removed, put the reach assembly (or inner frame
. assembly) on theitaonso that the mast side is on top. — - •
NOTE: The side rollers must be adjusted while the reach

assembly is out of the mast channels. Adjust the side rollers as
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.
1. If necessary, remove the reach cylinders. See REACH

CYLINDERS.
2. Remove the jam nuts and set screws for the load rollers.
3. If necessary, replace the wear plugs by pushing at the

back of the wear plug. See Figure 8-17.
1. INNER FRAME
2. COVER 10. LOCKWASHER WARNING: Be careful when removing or
3. STOP 11. CAPSCREW installing snap rings. These snap rings are large
4. SHIM 12. SPACER and can come loose during removal or installation
5. BUSHING 13. THRUST ROLLER with enough force to cause an injury. Always use the correct
6. LOAD ROLLER 14. WASHER snap ring pliers and wear eye and face protection during
7. SNAP RING 15. STOP SUPPORT removal or installation.
8. WEAR PLUG 16. ADJUSTMENT SCREW
9. SIDE ROLLER 17. JAM NUT 4. Remove the snap rings from the stub shaft for the load
roller.
Figure 8-16 - Inner Frame Parts
5. Use a prybar to remove the load roller from the stub shaft
WARNING: The reach assembly or inner frame for the load roller. See Figure 8-18.
assembly is heavy and can cause an injury if it tips
or falls. Make sure the reach assembly is stable 6. Removethe capscrews that fasten the side roller brackets.
during and after removal. Remove the side rollers and shim sets. Install labels for correct
installation of the shim sets in the same positions. When the
8. Install lifting eyes in the reach assembly or inner frame new side rollers are installed, the shim arrangement will
assembly for chains or slings. Fasten chains or slings to the normally be the same or similar.
lifting eyes. Use a crane to raise the reach assembly or inner
frame assembly high enough to disconnect the hydraulic lines 7. If necessary, remove the cover for the REACH/TILT
at the manifold block. Put tags on the fittings for correct selector valve.
connection during installation. Make sure to put caps on the
open fittings and ports to keep dirt out of the system. Install 8. If necessary, remove the hydraulic lines and hoses.
labels for correct connection of the wires and disconnect the
electrical connections at the selector valve. 9. If necessary, remove the REACH/TILT selector valve. See
REACH/TILT SELECTOR VALVE to repair the valve.
CAUTION: Do not damage lift chains, hoses or
electrical cables as the reach assembly is lifted out
of the mast weldment.
8-23
Yale
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: The inner frame assembly is heavy Installation

and can cause an injury if it tips or falls. Make sure (See Figure 8-16)
the innerframe assembly is stable before installing
any parts. NOTE: If the scissor arm assembly will be installed in the
innerframe, it is easier to install after the inner frame is installed
NOTE: If the scissor arms are not installed, install the inner in the mast. See SINGLE REACH SCISSOR ARMS or
frame in the mast before installing the scissor arm assembly. DOUBLE REACH SCISSOR ARMS to install the scissor arm
See INNER FRAME ASSEMBLY-INSTALLATION. assembly.
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.
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
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
5. Install the thrust rollers as marked during removal. If the

thrust rollers are replaced, install the correct size (74, 76 or 78
mm (2.88, 2.96 or 3.04 in) O.D.) thrust rollers. See CHECKS
AND ADJUSTMENTS at the end of this section.
6. Remove the safety chains and the lifting eyes from the
carriage or inner frame.


1. OVERHEAD GUARD
2. LEG, LEFT HAND
air from the system as described in CHECKS AND
3. LEG, RIGHT HAND
ADJUSTMENTS.
4. MASTCAPSCREW
5. LEGCAPSCREW
SIMPLEX MAST ASSEMBLY 6. MAST GUARD
7. CAPSCREW
Removal
NOTE: If the mast assembly will be disassembled after it is
-
Figure 8-19 Overhead Guard and Mast Guard
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
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
6. Mark the trunnion caps so they can be assembled in the

/ ?\ welding. Get authorization and instructions from
CbIhJi your Yale lift truck dealer before doing any welding
same position and on the same trunnion from which they are on the mast, reach or carriage assembly.
removed. Use chain to connect a crane or other lifting device to
the top of the mast assembly. Make sure the chains will not 2. Inspect the sliding and rolling surfaces of the channels for
damage the sheaves or other parts of the mast assembly. Make damage (dents) and wear (grooves). Inspect all welds for
sure the chains and crane have the capacity to lift cracks.
approximately 2000 kg (4500 lbs). Use safety chains to fasten
all the mast weldments together so that they cannot move. If Lift Cylinders-Removal and Installation
installed, install a chain or sling to the reach or carriage (See Figure 8-21)
assembly to keep the mast assembly from tipping during
NOTE: It is necessary to remove the mast assembly from the
removal.
truck to remove the lift cylinders.
7. Operate the crane until it gives support to the weight of the
1. Remove the mast assembly as described in SIMPLEX
mast assembly. Move the crane to a position so that the mast
MAST ASSEMBLY-REMOVAL.
assembly will be lifted vertically. Mark the trunnion caps for
proper installation at assembly. Remove the four capscrews
WARNING: The mast weldments can move and
that fasten the trunnion caps. Raise the mast assembly high
enough to clear the trunnions. Move the mast assembly
II\ cause an injury even if the mast assembly has
approximately 30 cm (1 ft) away from the truck for access to the been removed from the lift truck. Make sure the
mast assembly is level to prevent the components from moving
hoses.
without being moved. Use safety chains to prevent movement
8. Install labels on all plugs and wires for the electrical cable
after components are in the correct position.
for correct connection during installation. Disconnect the plugs
2. Remove the safety chains that fasten the mast weldments
and wires so that the cable is completely disconnected from the
together and use a prybar to carefully and slowly move the
truck. The plugs are near the cable tension device inside the
inner weldment approximately 75 mm (3 in) out of the outer
electrical compartment above the battery.
weldment.
9. Move the mast assembly away from the truck.
3. Install a sling and crane to support the cylinder. Remove
the capscrews, washers and lock plate at the base of the lift
10. If the mast will be disassembled, put the mast on a level
cylinder.
floorwith the overhead guard on the bottom as a support. Install
a support under the other end. Make sure the mast is level.
Keep the safety chains on the mast assembly that were
installed in Step 6.
II\ installing snap rings. These snap rings are large
11. If the mast will NOT be disassembled, put the mast on a
level floor with the overhead guard on top.
4. Remove the snap ring, back-up washer, rubber bushing
/\ CAUTION: Do NOT use steam to clean the lift and shims (if applicable) that fasten one cylinder rod to the inner
I\ chains, sheaves or load rollers. The sheaves and
f weldment. See Figure 8-21. If shims are used, make a note of
roller bearings are sealed and permanently the shim arrangement. Normally, the shim arrangement for the
lubricated. Do not use compressed air on the bearings. The air replacement cylinder will be similar.
can force the lubricant out of the bearings.
5. Remove the hose or tube between the lift cylinder and the
/\ WARNING: Cleaning solvents can be flammable flow regulator. See Figure 8-22. Install a cap on the regulator
11\ and toxic, and can cause skin irritation. Wear fitting to prevent leakage.
solvents, always follow the recommendations of the 6. Remove the lift cylinder retainer, capscrews and washers.
manufacturer.
8-26
Yale
BACK VIEW
9. FLOW REGULATOR HOUSING

10. HYDRAULIC TUBE (LIFT)
11. LOCK PLATE
12. NUT PLATE
13. SHIM PLATE
1. INNER WELDMENT 14. CAPSCREWS FOR MOUNTING MAST ASSEMBLY
2. CHAIN SHEAVE 15. REGULATOR MOUNTING BRACKET
3. CYLINDER RETAINER 16. DOWEL PIN
4. LOAD ROLLER 17. TRUNNION STUB SHAFT
5. LIFT CYLINDER 18. ELECT. CABLE FOR REACH ASSEMBLY
6. OUTER WELDMENT 19. HOSES FOR REACH OR SIDESHIFT
7. LIFT TRUCK FRAME 20. WEAR STRIP
8. HYDRAULIC HOSE (LIFT) 21. WEAR STRIP SHIM
Figure 8-20 - Simplex Mast Assembly
8-27
Yale
7. Push the cylinder toward the top of the mast assembly to

move the lift cylinder off the locating dowel pin. Continue to
push the cylinder so that the rod moves intothe cylinder to allow
removal from the inner weldment.
8. Repeat the Steps 2 through 7 to remove the other lift

cylinder.
NOTE: See the HYDRAULIC SYSTEM, Section 7, for

disassembly and repair the lift cylinders.
9. Reverse the procedure to install the lift cylinders.
Inner Mast Assembly-Removal And Installation

To remove the inner weldment from the mast assembly, the
mast assembly must be removed from the lift truck. The lift
cylinders and chain sheaves must also be removed.

MAST ASSEMBLY-REMOVAL. Remove the lift cylinders. See
LIFT CYLINDERS-REMOVAL AND INSTALLATION. Remove
the chain sheaves. See SIMPLEX CHAIN SHEAVE-RE¬
MOVAL AND INSTALLATION.
2. If it is necessary to repair the inner mast assembly, the load

rollers and wear plugs must be removed. See LOAD ROLLERS
AND WEAR PLUGS-REMOVAL AND INSTALLATION.
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
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
A
chains.
WARNING: Never replace just the worn section
of a lift chain. Replace the complete chain. Never

4. Clean and. inspect the lift chains. See CHECK LIFT
CHAINS-Cleaning and Inspection in CHECKS AND
1. To replace any hydraulic hoses, fully lower the reach or
ADJUSTMENTS. Replace the lift chains if necessary.
carriage assembly. Make sure that the system does not have
hydraulic pressure. Hold the control lever (for each function) in
5. To install the lift chains reverse the removal procedure.
the forward position for approximately five seconds to release
the pressure. Make sure the hydraulic pump does not operate.
6. Adjust and test the lift chains for correct operation as
Move the key to the OFF position. Disconnect the battery and
put a tag or lock on the battery connector. described in CHECKS AND ADJUSTMENTS.
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
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
NOTE: COMPONENTS IN BOXES - NS

WITH SIDESHIFT NR AND NDR
1. TO SHEAVE AND REACH OR

CARRIAGE (1 OF 2) HOSE AND CABLE SHEAVE
2. OUTER MAST SHIM (AS REQUIRED)
3. TO TRUCK (1 OF 2) HOSE SHEAVE
4. ELECTRICAL CABLE & TENSION LIFT TRUCK FRAME
DEVICE (REACH ONLY) HYDRAULIC HOSE-LIFT
5. CAPSCREW HYDRAULIC TUBE-LIFT
6. SHEAVE SUPPORT FLOW REGULATOR HOUSING
7. SHAFT REGULATOR MOUNT PLATE
8. COTTER PIN INNER WELDMENT
Figure 8-22 - Hose and Cable Assemblies - Simplex Mast
8-30
Yale
10. Operate the truck and test for correct operation of the chain
sheave. Check and adjust lift chains. Refer to CHECKS AND
ADJUSTMENTS.
Load Rollers and Wear Plugs-Removal and Installation

(See Figure 8-24)
ri MAST ASSEMBLY-REMOVAL. Remove the lift cylinders as

described in LIFT CYLINDERS-REMOVAL AND INSTALLA¬
TION. Remove the chain sheaves as described in SIMPLEX
CHAIN SHEAVE-REMOVAL AND INSTALLATION. The mast
assembly must be horizontal with the carriage or reach
assembly side on top.
A
weldments.
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.
/\ WARNING: Be careful when removing or

/f\ installing snap rings. These snap rings are large
NOTE: Reach assembly shown. Chain anchor on NS with enough force to cause an injury. Always use the correct
carriage assembly similar.
1. INNER WELDMENT 6. COTTER PIN removal or installation.
2. CHAIN SHEAVE 7. PIN
3. BEARING 8. CHAIN ANCHOR 3. Always install the safety chains to prevent the weldments
4. SNAP RING 9. ADJUSTMENT NUTS from moving BEFORE starting to replace any load roller.
5. LIFT CHAIN 10. OUTER WELDMENT Remove the snap rings that fasten the load rollers.
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
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.
2. Install and tighten the mast and carriage or reach hoses on

their correct bulkhead fittings according to the labels installed
during removal.
3. Move the mast assembly into position. Lower the mast

assembly so that the outer weldment is aligned with the
trunnion blocks on the lift truck frame.
NOTE: Make sure all hoses and the electrical cable are not
between a mast crossmember and the truck.
4. Align the trunnion caps according to the marks made

during removal. Install the capscrews, but leave them loose.
5. Connect all the wires of the electrical cable according to

the labels made during removal. Connect the hydraulic hoses.
CAUTION: Install tape on all electrical wires for

the reach assembly if the wires are not connected.
If the wires are not connected, they can make a
short-circuit and cause damage.
6. Operate the LIFT/LOWER control handle to raise the inner

weldment for access to the bottom of the outer weldment.
1. INNER WELDMENT
2. OUTER WELDMENT 7. Install safety chains between the outer and inner
3. LOAD ROLLER weldments to keep the inner weldment from moving.
4. SNAP RING
5. WEAR PLUG 8. Use a prybar to align and install the four mount capscrews
6. SET SCREW and the nut plates that fasten the bottom of the mast to the truck
7. JAM NUT frame. Move the bottom of the weldment in or out and add
shims until the mast is adjusted between vertical to 1/2 degree
Figure 8-24 - Mast Load Rollers of back tilt.
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
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.
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
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
Figure 8-25 -Triplex Mast Assembly
8-34
Yale
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.
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
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
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.
8. Reverse the procedure to install the main cylinders.
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
Figure 8-26 - Triplex Hose Ro for Sideshift or Reach Carriage

Inner and Intermediate Mast Assemblies-Removal and inner weldment while sliding it out of the intermediate
Installation weldment.
(See Figure 8-25, Figure 8-27, and Figure 8-28)
4. Remove the safety chains that fasten the intermediate
1. The load rollers and wear plugs must be removed to
weldment tothe outer wetdment. Use acrane or lifting device to
remove the inner or intermediate weldments. See LOAD
support the intermediate weldment while sliding it out of the
ROLLERS AND WEAR PLUGS-REMOVAL AND INSTALLA¬
outer weldment.
TION.
5. Reverse the removal procedure to install both the
2. The lift chains, hoses and electrical cable must also be
intermediate and inner weldments into the outer weldment.
removed to remove the inner or intermediate weldments. To
install the load rollers and wear plugs during assembly of the
remove the lift chains, hoses and sheaves, see TRIPLEX LIFT
mast weldments.
CHAINS-REMOVAL AND INSTALLATION, HOSES-RE-
PLACE, TRIPLEX CHAIN SHEAVES-DISASSEMBLY AND
Hoses-Replace
ASSEMBLY and HOSES AND CABLE SHEAVES-REPLACE. (See Figure 8-27 and Figure 8-28)
3. Use safety chains to fasten the intermediate weldment to 1. To replace any hydraulic hoses, fully lower the carriage or
the outer weldment. Use a crane or lifting device to support the reach assembly. Make sure that the system does not have
8-36
Yale
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
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.
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
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
NOTE: COMPONENTS IN BOXES-NS

WITH SIDESHIFT NR AND NDR
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
Figure 8-27 - Hose and Cable Assemblies-Inner and Intermediate Weldments
8-38
Yale
1. HOSE BRACKET (NR OR NDR)

2. HOSE BRACKET (NS)
3. TO FLOW REGULATOR
4. TO FREE LIFT CYLINDER
5. TENSION DEVICE
6. HOSE TO MANIFOLD BLOCK (EACH SIDE OF WELDMENT)
7. HOSE BRACKET (EACH SIDE OF WELDMENT)
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
Figure 8-28 - Hose and Cable Assemblies-Outer Weidment

8-39
Yale
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
sheave for the carriage. Make sure to operate the carriage
hydraulic function(s) and check for leaks after the hoses are
connected.
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.
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.
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
2. Remove both pins from the chain anchors at the rear of the
free lift cylinder. Remove each lift chain from the sheaves. 4
WARNING: Be careful when removing or 7

3. Remove the snap ring from the chain sheave bracket. 4
4. Use a prybar to remove the chain sheave from the bracket. 7

Inspect all components for wear or damage. Replace any item
that is worn or damaged.
Load Rollers and Wear Plugs-Removal and Installation

(See Figure 8-29)
1. Remove the mast assembly as described in TRIPLEX
MAST ASSEMBLY REMOVAL. Removethe free lift cylinder as
described in FREE LIFT CYLINDER-REMOVAL AND
INSTALLATION. Remove the main lift cylinders as described in
MAIN CYLINDERS-REMOVAL AND INSTALLATION. The
mast assembly must be horizontal with the carriage or reach
assembly side on top.

cause an injury even if the mast assembly has
been removed from the lift truck. Make sure the

correct mast weldment for access to the load rollers. The inner
weldment load rollers are at the bottom. The load rollers for the
outer weldment are at the top. The load rollers for the
intermediate weldment are at the top and the bottom of the
weldment. Use safety chains to fasten the inner weldment to 8
the outer weldment so that they do not separate completely.
4. LOAD ROLLER
NOTE: If the inner weldment and the intermediate weldment 1. OUTER WELDMENT 5. SNAP RING
will be disassembled from the outer weldment, do not install the 2. INTERMEDIATE 6. WEAR PLUG
load rollers at this time. WELDMENT 7. SET SCREW
3. INNER WELDMENT 8. JAM NUT
installing snap rings. These snap rings are large Figure 8-29 - Triplex Load Rollers
with enough force to cause an injury. Always use the correct NOTE: Replace wear plugs at this time to save the cost of
snap ring pliers and wear eye and face protection during removal and disassembly of the mast assembly for wear plug
removal or installation. replacement.
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
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
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
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.
2. Carefully remove the retainer and rod assembly from the

cylinder shell.
3. Carefully remove the parts of the rod assembly as shown

in Figure 8-31 .

manufacturer.
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
Figure 8-31 - Cylinder Parts

Installation 6. If the rod ends were NOT removed, install the roll pins at
each mount pin. If the rod ends were removed, reach
NOTE: It can be necessary to loosen the hydraulic fittings to
adjustment IS necessary. Make sure the adjustment is
allow movement of the rods. The rods need to move for correct
complete before installing the roll pins.
alignment at the mounts for the scissor arms.
7. Make sure the hydraulic fittings are tightened and remove
1. If removed, installthe correct rod end on the rod as marked
the clamps and blocks under the load bearings.
during removal. Install new bushings in all four mounts for the
reach cylinders. Lubricate the bushings with multi-purpose
grease. If necessary, install the hydraulic tube on each reach
cylinder.
2. Align the anchor end of the cylinders on the cylinder mount
8. Operate the REACH control lever to operate the function to
of the inner frame of the reach assembly. See Figure 8-30.
check for leaks and correct operation.
Install the mount pins and roll pins to fasten the cylinders to the
inner frame. Use a hammer with a "soft" metal (brass or copper)
9. Remove the air from the system and adjust the stroke of
or a plastic face to install the pins.
each reach cylinder as described in CHECKS AND
ADJUSTMENTS.
3. Connect the hydraulic lines to the reach cylinders as
marked during removal. Always use new O-rings on the O-ring
fittings. TILT CYLINDER AND TILT PIVOT MECHANISM
Removal-with Sideshifter
4. Install labels for correct connection during installation and
disconnect the hydraulic lines at the tilt cylinder. Install caps on NOTE: If the outer frame is installed on the scissor arms, fully
the hydraulic lines and cylinder ports to prevent dirt from extend the reach mechanism. Use clamps and blocks to
entering the system. prevent the scissor arms from retracting. Install the clamps and
blocks on the channels of the inner frame and the outer frame.
5. Hold each reach cylinder to align the rod endto the scissor Install the ctamps and blocks under the load bearings. See
arm mounts. Use a hammer with a "soft" metal (brass or Figure 8-32. Tighten the clamps so that the blocks cannot
copper) or a plastic face to install the mount pins to fasten the move.
rod end of each reach cylinder. Align the holes for the roll pins.
Install the roll pins. NOTE: If the outer frame is not installed on the scissor arms
make sure of the following:
NOTE: If the rod ends were not removed and the cylinders a. There is access to the reach assembly side of the
are installed in the same positions, reach adjustment is frame.
normally not necessary.
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.
2. Remove the two capscrews, lockwashers and cotter pins

that fasten the top two tilt roller shafts for the left and right hand
tilt pivots. Remove the two tilt roller shafts. Hold the tilt cylinder
so that the cylinder and tilt pivots cannot fall.
3. Carefully remove the capscrew, lockwasher and cotter pin

that fastens the tilt cylinder pin. Remove the tilt cylinder pin that
1
fastens the tilt cylinder to the outer frame. Do not let the cylinder
and tilt pivots fall. See Figure 8-33.
00,
4. Carefully remove the tilt cylinder and the tilt pivot
assemblies. Remove the four bushings for the two pivot shafts.
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.
6. Remove the two capscrews, lockwashers and cotter pins

that fasten the tilt roller shafts in each tilt pivot. Remove the
12754
shafts and the tilt slider assemblies. Remove the bushings from
the tilt slider shafts.
7. Disassemble the tilt slider assemblies by removing the six

capscrews, end caps and poly bearing blocks.
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
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
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
4. Carefully remove the capscrew, lockwasher and cotter pin Disassembly

that fastens the tilt cylinder pin. Removethe tilt cylinder pin that
1. Loosen the locknut at the rod end. Remove the rod end,
fastens the tilt cylinder to the outer frame. Do not let the cylinder
special lockwashers and nut from the cylinder rod.
and tilt pivots fall. See Figure 8-34.
2. Carefully remove the retainer and rod assembly from the
5. Carefully remove the tilt cylinder and the tilt pivot cylinder shell.
assemblies. Removethe four bushings forthe two pivot shafts.
6. Removethe locknuts that fasten the two tilt pivots and the
rod end of the tilt cylinder together. Separate the two tilt pivots —in Rgure8-35.
and remove the bushings from the rod end.
7. Remove the capscrew and lockwashers retaining the

cotter pin and tilt roller assemblies to the left and right hand tilt
pivots. Remove the bushings from the tilt rollers.
7. FITTING
8. O-RING
9. TILT CYLINDER
10. LOCKNUT
11. LOCKWASHER
12. BUSHING
13. TILT PIVOT R H.
14. LOCKNUT
HI Jll
111 16. ROD END
ill 17.
18.
TILT PIVOT L.H.
TILT ROLLER
\
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
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
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
Figure 8-35 - Cylinder Parts

Installation-with Sideshifter 1. Installthe nut, special lockwashers and rod end on the rod.
Make sure the flat sides of the special lockwashers are both
NOTE: If the outer frame is not installed on the scissor arms
facing out. Install new bushings in the anchor end of the tilt
cylinder and in the rod end. Lubricate the bushings with
a. There is access to the reach assembly side of the multi-purpose grease.
frame.
b. The outer frame is stable so that it cannot tip.
2. Align the anchor end of the cylinder on the cylinder mount
(ports .to the rear). Install the pin, cotter pin, lookwasher and
capscrew to fasten the cylinder to the outer frame.
cause an injury if it tips or falls. If the frame is not
installed, make sure the frame is stable. If the
3. Install new bushings for all pivot points of the tilt assembly.
Lubricate all bushings with multi-purpose grease.
use acrane andchains to raisethe frame. Install a solid 100 mm
(4 in) block under each fork heel and near each fork tip. Lower 4. Install the poly bearing block in the tilt slider assemblies.
the frame so that the forks are on the blocks and install a
Align the end cap and install the capscrews. Install the shafts
for the tilt slider assemblies in the tilt pivots. Install the cotter
fasten the frame to an object that cannot tip or fall. pins and secure with the capscrews and lockwashers.
8-48
Yale
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.
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
Removal
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
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. . . . . „
8. CLEVIS PIN CAUTION: Do not cut or damage seals during

9. FLAT WASHER installation. Be especially careful when moving
seals across threads or edges of parts. Install tape
over the rod threads to protect the seals.
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.
Figure 8-36 - Sideshift Cylinder Mounting installed, make sure the frame is stable. If the
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
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.
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.
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
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
Figure 8-37 - Sii lift Cylinder Parts

REACH/TILT SELECTOR VALVE WARNING: The outer frame is heavy and can
Removal
installed, make sure the frame is stable. If the
NOTE: The selector valve can be removed with the inner frame is NOT on the floor with the fork side down for stability,
frame installed or removed from the mast. It is easier to remove use a crane and chains to raise the frame. Install a solid 100 mm
the selector valve with the inner frame or reach assembly (4 in) block under each fork heel and near each fork tip. Lower
removed from the mast. If the inner frame must be removed for the frame so that the forks are on the blocks and install a
other repairs, remove the selector valve after the inner frame capacity load on the forks. You can also use safety chains to
is removed. Do all the steps of the procedure if the inner frame fasten the frame to an object that cannot tip or fall.
is installed in the mast. If the inner frame is removed from the
mast, do Steps 4 through 8. 4. Remove the cover for the REACH/TILT selector valve.
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.
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.

snap ring pliers and wear eye ana face protection during
8-51
Yale
8. If necessary, remove the snap rings that fasten the

sheaves to the shafts.
9. Holdthe selector valve and remove the two capscrews and

lockwashers that fasten the selector valve to the inner frame.
Disassembly
1. Remove all fittings from the selector valve. See
Figure 8-38.
2. If necessary, carefully remove the solenoids, check

valves, relief valve and spools.
3. Remove and discard all O-rings from the valve and fitting
parts.

manufacturer.
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.
Assembly 1. HYDRAULIC FITTING

1. Use O-ring lubricant and install new O-rings on the parts of 2. SOLENOID
the selector valve. 3. VALVE BODY
4. HOSE
2. Install the parts in the valve block as shown in Figure 8-38. 5. INNER FRAME
6. PORT
Installation 7. TUBES
8. CHECK VALVE ASSEMBLY
1. Hold the selector valve in the correct position on the frame
and install the two capscrews and lockwashers. Figure 8-38 - Reach/Tilt Selector Valve
2. Connect the hydraulic lines as marked during TILT/SIDESHIFT SELECTOR VALVE

disassembly. Always use new O-rings on the O-ring fittings. If
necessary to connect the hydraulic lines, see Figure 8-38. Removal
Connect the electrical wires to the solenoids. Install new cable NOTE: The tilt/sideshift selector valve is installed even if
ties at the original locations for clearance of hoses and there is no sideshift function. If there is no sideshift function
electrical cables during operation. there is no electrical cable or solenoids. Plugs are installed at
the solenoid and cylinder ports.
/\ CAUTION: Do NOT operate the tilt or sideshift
I* \ functions if the outer frame has been removed. WOTE: The selector valve can be removed with the outer
Hydraulic oil can come out of the hoses. frame installed or removed from the scissor arms. Do Steps 1
through 4 only if the outer frame is installed. The outer frame
3. Remove the safety chains from the scissor arms of the must be removed to remove the selector valve from the outer
reach assembly. Operate the REACH, TILT and SIDESHIFT frame. Remove the outer frame as described in OUTER
functions to check for leaks and correct operation. FRAME-REMOVAL.
4. Remove the air from the system as described in CHECKS

AND ADJUSTMENTS.
8-52
Yale
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.
battery.
WARNING: There are pinch points on the outer

SS>
frame that can cause an injury. Use clamps and
blocks to prevent the scissor arms from moving.
Install the clamps and blocks at the channels of the inner frame
to make sure that the load bearings cannot move in the
channel. See Figure 8-32.
3. If necessary, install labels for correct connection during

installation and remove the hoses at the top of the outer frame.
5 3
See Figure 8-39. Install caps on the hydraulic lines of the
solenoid valve to prevent dirt from entering the system.

cause an injury if it tips orfalls. Make sure the frame
is stable. If the 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 (4 in) block under each fork heel
and near each fork tip. Lower 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 fasten the frame to an object that cannot tip
or fall.
4. Install labels on all hoses connected to the selector valve

for correct connections during installation.
5. Remove the hose and cable guide and the solenoid valve
body. 6
Disassembly
1. Remove all fittings from the selector valve.
2. If necessary, carefully remove the solenoids, check

valves, relief valve and spools.
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
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
Installation the symbols by each of the controls and refer to the

OPERATING MANUAL for your lift truck. Make sure all of the
WARNING: There are pinch points on the mast
hydraulic lines are connected correctly and do not leak.
that can cause an injury. Use safety chains on the
inner frame and mast weldments to keep the inner
Remove Air from Hydraulic System
frame and mast weldments from moving. Install the safety
chains as described in SAFETY PROCEDURES. NOTE: When you are removing the air from the hydraulic
system, make sure that all of the hydraulic fittings are tight and
1. If the outer frame or outer frame are installed, operate the do not leak. Also make sure that the level of the oil in the
.REACH/RETRACT control handle to fully extend the forks. hydraulic lank is correct.
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
a neutral position, there are leaks inside the hydraulic system.

The maximum speed that the forks are allowed to tilt forward is Total length of WEAR LIMIT
13 mm (0.50 in) per 10 minutes (measured at the tilt cylinder). 20 links (pitch) The maximum
This maximum speed is measured when the hydraulic oil is of new chain length of 20 links
30°C (90°F). If the oil temperature is 70"C (160°F), the
maximum,speed is 39 mm (1.5 in) per 10 minutes.
12.7 (0.50) 254.0 (10.0) 261.6 (10.3)
6. If the leak rate for the tilt function is greater than 15.9 0.625) 317.5 (12.5) 327.0 12.88)
19.1 (0.75) 381.0 (15.0) 392.4 (15.45)
specifications, remove the load from the forks. Install a gate
valve betweenthe port at the rod end of the tilt cylinder and the 508.0 (20.0) 523.25 (20.6)
635.0 (25.0) 654.1 (25.75)
hydraulic line. Put the load on the forks again. Close the valve. 889.0 (35.0) 915.7 (36.05)
Tilt the forks approximately half way back. If the forks tilt slowly 1016.0 (40.0) 1046.5 (41.2)
forward, the piston seals are leaking.
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.
Check Lift Chains

NOTE: These procedures are for boththe simplex and triplex
mast assemblies.

CAUTION: Do NOT use steam to clean the lift
chains, sheaves or load rollers. The sheaves and
bearings are sealed and permanently lubricated. 12174
Do not use compressed air on the bearings. The air can force
the lubricant out of the bearings.

solvents, always follow the recommendations of the 1. CHAIN WEAR SCALE 5180968-69
manufacturer. NOTE: The instructions for measuring chain wear
are shown on the chain wear scale.
1. Clean the lift chains using solvent. Inspect the lift chains for
wear or damage. A lift chain becomes longer when it is worn. If a
lift chain is 3% longer than a new lift chain, the lift chain must be
replaced. Use a chain scale to measure the chains. If a chain
scale is not available, check the lift chains with the
measurements given in Figure 8-40.
WARNING : Never replace just the worn, section

of a lift chain. Replace the complete chain. Never
replace just one chain of a chain pair. Replace both
chains.
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
Figure 8-40 - Inspect the Lift Chains
8-55
Yale
Lubrication the clearance between the weldments equal on both sides.

Keep the weldments parallel to each other.
Clean and inspect the chains before lubrication. Use SAE 30
engine oil as a lubricant for the chains. The recommendation for 4. Tighten each jam nut without moving the set screw.
adding lubricant is to remove the chains from the lift truck and
soak them in oil. See SIMPLEX or TRIPLEX LIFT
5. Raise and lower the weldments without a load. Check that
CHAINS-REMOVAL AND INSTALLATION to remove the lift
there is minimum clearance, as described in Step 3, with free
chains for lubrication.
movement. If the weldments do not move smoothly, during
lowering, follow the WARNING and adjust the wear plugs
MAST ADJUSTMENTS -equally formore clearance.
NOTE: These procedures are for both the simplex and triplex
WARNING: NEVER loosen the wear plugs if a
mast assemblies. Move the lift truck to an area with a smooth
mast weldment does not move freely during
level floor to make sure the adjustments are accurate.
checks after an adjustment. The weldments or
carriage or reach assembly can suddenly move and cause an
The mast weldments must be aligned so that they are parallel to
injury. Raise the weldment. move the key to the OFF position
each other during operation. Keeping the weldments parallel
and install safety chains as described in SAFETY
will have the result of smoother operation and wear.
PROCEDURES. Loosen the wear plugs to allow movement.
The only adjustments for the load rollers is the adjustment of the
6. If necessary, operate the system so that the lift chains are
wear plugs. These adjustments are made for minimum side
taut. Carefully remove the safety chains. Raise and lower the
clearance and to keep the weldments parallel with equal
weldments with a load. Check that there is minimum clearance,
clearance on each side between all weldments.
as described in Step 3, with free movement. If the weldments do
not move smoothly, during lowering, follow the WARNING and
Wear plugs and wear strips allow adjustment for alignment and
adjust the wear plugs equally for more clearance.
wear. Always adjust the wear plugs and wear strips for one
weldment before making adjustments on other weldments.
7. Repeat Steps 1 through 6 for each weldment.
Chains are adjusted for the following reasons:
4
• So each lift chain of a pair has an equal load, to
prevent too much loadand wear on one chain of a pair.
• So mast weldments move in the correct sequence.

• So chains move over chain sheaves correctly.
Adjustments must be made to both the free lift (triplex only) and
main lift chain sets. Each lift chain is adjusted at the chain
anchor.
Adjust Wear Plugs

Adjust the wear plugs as follows:
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
4. Check that the mast operates correctly as described in

CHECK THE OPERATION OF THE MAST at the beginning of
this CHECKS AND ADJUSTMENTS section.
Adjust Free Lift Chain (Triplex Only)

(See Figure 8-44)
NOTE: Make sure the forks of the reach assembly are
parallel to the floor (no forward or backward tilt).
1. Fully lower the carriage or reach assembly. Measure the

distance from the floor to the top of the forks at the heel. The
correct distance is 57 mm (2.25 in).
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:
• For minimum clearance to prevent too much side

movement of the weldments.
• To keep the weldments parallel.
NOTE: Wear strips and shims on the triplex inner weldment

can be used on either side. There are right and left wear strips
and shims on simplex inner and the triplex intermediate
weldments. See Figure 8-43.
Check and adjust the wear strips as follows:
1. Remove the mast guard. Raise the carriage or reach

assembly for access to the wear strips. Install safety chains as
described in SAFETY PROCEDURES. WEAR STRIPS AND SHIMS ON THE
TRIPLEX INNER .WELDMENT CAN BE USED ON
2. Remove the capscrews, washers, wear strips and shims. EITHER SIDE. THERE ARE RIGHT AND LEFT WEAR
Replace all worn or damaged parts. One wear strip and one STRIPS AND SHIMS ON SIMPLEX INNER AND THE
shim on each side are usually the correct adjustment. There TRIPLEX INTERMEDIATE WELDMENTS.
must be the same number of shims under the wear strip on both 1. CAPSCREW 3. WEAR STRIP
sides of the weldment. Equal shims will keep the weldment 4. SHIM
parallel with equal clearance. _ 2. WASHER
5. WELDMENT CHANNEL _
3. Use a prybar to move the weldment to install shims for Figure 8-43 - Typical Wear Strip Assembly
minimum clearance. Install the shims and new wear strips as
shown in Figure 8-43. Remove the safety chains.
8-57
Yale
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.
6. Check the mast operation as described at the beginning of Triplex:

1. Adjust the main lift chains for equal tension.
7. Install the mast guard if removed.
2. Check chain tension by pushing on both main lift chains at
the same time. If the tension is not the same, remove the mast
Adjust Main Lift Chains
guard. See Figure 8-19. Loosen both locknuts at the chain
NOTE: On triplex masts, the free lift chains must be adjusted anchors to make any adjustments.
before adjusting the main lift chains.
3. Adjust the nuts on the chain anchors until the tension is the
NOTE: The adjustment nuts, to adjust the main lift chains, are same. Tighten the locknuts.
at the chain anchors near the top of the outer weldment.
4. Check the mast operation as described at the beginning of
Read and follow the instructions in MAST ADJUSTMENTS in this CHECKS AND ADJUSTMENTS section.
5. Install the mast guard.
Simplex:
1. Fully lower the carriage or reach assembly. Measure the CARRIAGE OR REACH ASSEMBLY ADJUSTMENTS
distance from the floor to the top of the forks at the heel. The
Adjust Wear Plug
correct distance is 57 mm (2.25 in).
2. If the distance is correct, the chains are adjusted for the Adjust the wear plugs as follows:
correct height. Do Step 5 next. If the distance is NOT correct, do
all of the steps. 1. Fully lower the carriage or reach assembly and make sure
the lift chains are the support for the carriage or reach
3. Remove the mast guard. See Figure 8-19. Loosen both assembly. If the lift chains are loose, operate the system to raise
locknuts at the chain anchors to make any adjustments. the carriage or reach assembly until the lift chains are the
support.
4. Adjust the nuts of the chain anchors equal amounts for the
correct distance (Step 1). /\ WARNING: NEVER loosen the wear plugs if the
J|\ carriage or reach assembly does not move freely
5. Check chain tension by pushing on both chains at the during checks after an adjustment. The carriage or
same time. If the tension is not the same, adjust the nuts on the reach assembly can suddenly move and cause an injury. Raise
chain anchors until the tension is the same and the distance the carriage or reach assembly, move the key to the OFF
(Step 1) is also correct. Tighten the locknuts. position and install safety chains as described in SAFETY
PROCEDURES.
8-58
Yale
TRIPLEX MAIN LIFT
SIMPLEX 1. INNER WELDMENT

2. CHAIN SHEAVE
3. LIFT CHAIN
4. COTTER PIN
5. ANCHOR PIN
6. CHAIN ANCHOR
7. LOCKNUT
8. OUTER WELDMENT
9. ADJUSTMENT NUT
10. REACH ASSEMBLY
11. TYPICAL FIXED ANCHOR
12. INTERMEDIATE WELDMENT
TRIPLEX FREE LIFT
13. FREE LIFT CYLINDER
Figure 8-44 - Lift lins - Adjustment

2. Loosen the jam nut on the wear plug using the special tool mast weldments equal on both sides. Keep the carriage or
available from your Yale lift truck dealer. See Figure 8-41 and reach assembly parallel to the mast weldment.
Figure 8-42.
5. Tighten each jam nut without moving the set screw.
3. Adjust the wear plugs to attain zero clearance between the
wear plug and the weldment channel. 6. If necessary, carefully remove the safety chains. Raise
-and lower the carriage without a load. Check that there is
4. Adjust the clearance to approximately 0.5 mm (0.02 in) by minimum clearance with free movement. If the carriage does
turning the adjustment handle 1/8 turn counter clockwise. Keep not move smoothly, during lowering, follow the WARNING and
the clearance between the carriage or reach assembly and adjust the wear plugs equally for more clearance.
8-59
Yale
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.
Adjust Side Rollers o:

1. If necessary, remove the carriage or reach assembly from
the mast. See CARRIAGE or REACH ASSEMBLY-REMOVAL
AND INSTALLATION.
2. Measure the width of the inside face of the inner weldment

in several places. See Figure 8-45. Make a note of the location
and the value of the minimum measurement.
3. Measure and recordthe distance across the side rollers of

the carriage assembly. See "A" of Figure 8-46.
4. Add or remove shims under the side rollers so that the

distance across the rollers is 1/2 mm (0.02 in) less than the
measurement of Step 2.
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.
5. Install the carriage or reach assembly. See CARRIAGE or

REACH ASSEMBLY-REMOVAL AND INSTALLATION or
INSTALLATION OF THE INNER FRAME ASSEMBLY.
Adjust Thrust Rollers

1. Measure the width between the outside edges of the inner
weldment in several places. See Figure 8-45. Make a note of
the location and the value of the maximum measurement.
2. Measure and record the distance between the inside faces

of the thrust rollers of the carriage or reach assembly. See "B" of
Figure 8-46.
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
3. If the distance is not within specifications on both sides,

loosen the capscrews at the rod ends of the reach cylinders.
Use a wrench to rotate the cylinder rods for the correct
distance. Temporarily tighten the capscrews without moving
the rods.
D 0 4. Operate the reach mechanism through several cycles and

fully extend the forks. Move the key to the OFF position and
disconnect the battery. Measure the distance on each side
again. Both measurements must be within specifications AND
the measurements must be within 3 mm (0.12 in) of each other.
If the measurements are not within specifications, do Steps 3
and 4 until all measurements are correct. Temporarily tighten
the capscrews without moving the rods after all measurements
are correct.
5. Fully retract the forks, check each stop on the inner frame.
0 The outer frame or sideshift apron must be just touching the

stop pads.
6. Extend the reach mechanism, move the key to the OFF

position and disconnect the battery. Add or remove shims
under each stop pad as necessary. Do NOT use more than two
shims. Do Steps 5 and 6 until the outer frame just touches on
-
Figure 8-46 Carriage and Reach Assembly Side and both sides.
Thrust Roller Widths
7. Fully extend the forks, move the key to the OFF position
Adjustment for the Reach Cylinders and disconnect the battery. Loosen the capscrews at the rod
NOTE: The reach cylinders must be adjusted if either reach ends of the reach cylinders. Use a wrench to rotate the cylinder
cylinder has been replaced or the rod ends have been rods 1/4 turn clockwise into the cylinder. This adjustment allows
removed. Adjustment is also necessary if major parts of the the stop pads to absorb the shock instead of the reach cylinders
reach mechanism have been replaced. as the mechanism retracts. Tighten the rod end capscrews to
48 to 54 N«m (35 to 40 Ibf ft) torque.
The reach mechanism must be adjusted so that the outer frame
or sideshift apron just touches the stops on the inner frame with Adjustment for the Tilt Cylinder
the cylinders fully retracted. The mechanism must also extend
the correct distance.
/\ WARNING: The points between the scissor arms
Mf\ and the innerframe, outerframe or apron are pinch
ChJ points and can cause an injury. Do NOT put any
/\ WARNING: The points between the scissor arms part of your body between these assemblies if they can move.
II\ andtheinnerframe, outer frame or apron are pinch Always move the key to the OFF position and disconnect the
CmLhJ points and can cause an injury. Do NOT put any battery.
part of your body between these assemblies if they can move.
Always move the key to the OFF position and disconnect the Remove the air from the tilt system as described in REMOVE
battery. AIR FROM THE HYDRAULIC SYSTEM. Operate the tilt
mechanism to move the fork tips to the full up and full down
1. Remove the air from the reach system as described in positions for several cycles.
REMOVE AIR FROM THE HYDRAULIC SYSTEM. Operate
the reach mechanism to fully extend and retract the forks for CAUTION: Makesure Ihefiit pivotsdD not go over
several cycles. the center point. The fork tips will start to move
down instead of continuing to move up during
2. Fully extend the forks, move the key to the OFF position adjustment if the pivots are past center. Higher stress,
and disconnect the battery. Measure the distance between the increased wear and poor operation will also occur during
contact surface of the outer frame or apron andthe stops on the operation.
inner frame. Measure the distance on both sides. The correct
distance for a single reach unit is 610 +3 -6 mm (24 +0.12 Fully extend the forks and operate the tilt function for a full UP tilt'
- 0.25 in). The correct distance for a double reach unit is 1067 of the forks (tilt cylinder fully extended). Move the key to the
+ 3 -6 mm (42 +0.12 -0.25 in). OFF position and disconnect the battery. Loosen the locknut at
the rod end of the tilt cylinder. Rotate the cylinder rod for
8-61
Yale
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
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
TROUBLESHOOTING-MAST
No operation of lift cylinders Lift control linkage disconnected
No oil or not enough oil to supply cylinders
Bad hydraulic leaks, bad pump or pump drive, relief valve set too low,
bad check valve
Slow operation of lift cylinders Not enough oil supply to cylinder(s)
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.
Relief valve pressure is wrong
The spring for the relief valve is weak or damaged
Rough movement of the mast assembly Air in the hydraulic system
Bent rods, cylinders with distortion or damage
Mast assembly damaged or not in alignment
Wear plugs or wear strips adjusted too tight
TROUBLESHOOTING-REACH AND CARRIAGE
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
SPECIFICATIONS
LOAD BACKREST CAPSCREWS, TORQUE 203 N«m (150 Ibf ft)

SCISSOR ARMS, TORQUES
Center Pivot Capscrews 41 N«m (30 Ibf ft)
End Pivot Capscrews (Double Reach Only) 39 N«m (29 Ibf ft)
REACH CYLINDER, TORQUES

Piston Nut 95 N«m (70 Ibf ft)
Retainer 129-142 N*m (95-105 Ibf ft)
Rod End Capscrews 48-54 N«m (35-40 Ibf ft)
TILT CYLINDER, TORQUES
Retainer 167-176 N«m (123-130 Ibf ft)
Rod End Locknut 81-156 N«m (60-115 Ibf ft)
SIDESHIFT CYLINDER, TORQUES
Retainer 129-142 N«m (95-105 Ibf ft)
TILT PIVOT LOCKNUTS, TORQUE 136 N«m (100 Ibf ft)

REACH MECHANISM
Stroke ( + 6.4/- 9.6 mm) 610 mm 914 mm 1067 mm
( + 0.25/ -0.38 in) (24 in) (36 in) (42 in)
Reach Time, Maximum 5.5 sec 5.5 sec 5.5 sec
Retract Time, Maximum 4.5 sec 4.5 sec 4.5 sec
Fork Tilt Angle (Truck Level ± 1 °)
Down 3°±1°
0
Up 4° ± 1
Fork Height, Fully Lowered (no tilt) 64 mm (2.50 in)
OPERATING PRESSURES & AMPERES

(Measured at pump, ±10% acceptable) kPa (psi) Amps
Relief 24V 13,790 (2000) 89
36V 13,790 (2000) 49
Reach
No Load 24V 6895(1000) 50
Capacity Load 24V 8964(1300) 55
No Load 36V 6206 (900) 30
Retract
No Load 24V 7584(1100) 60
Capacity Load 24V 11,722(1700) 70
No Load 36V 8274(1200) 35
Capacity Load 36V 11,032(1600) 45
Tilt Forward
No Load 24V 12,066(1750) 85
Capacity Load 24V 11,722(1700) 80
No Load 36V 8964(1300) 35
Tilt Backward
No Load 24V 9998(1450) 70
Capacity Load 24V 12,066(1750) 80
No Load 36V 6895(1000) 30
Capacity Load 36V 12,411 (1800) 50
8-64
Yale
Industrial Trucks
SECTION 9
BATTERY AND CHARGING SYSTEM

Yale
Industrial Trucks
BATTERY AND CHARGING SYSTEM
BATTERY AND CHARGING SYSTEM-GENERAL 9-1

SAFETY TIPS FOR HANDLING INDUSTRIAL TRUCK BATTERIES 9-1
BATTERY TROUBLESHOOTING 9-3
BATTERY TROUBLESHOOTING .. 9-4
LEAD-ACID BATTERIES 9-5
SPECIFIC GRAVITY 9-5
CHEMICAL REACTION 9-5
HOW TO SELECT THE BATTERY 9-6
VOLTAGE OF A BATTERY 9-6
BATTERY RATINGS 9-6
KILOWATT HOURS 9-7
THE BATTERY AS A COUNTERWEIGHT 9-7
THE NEW BATTERY 9-7
BATTERY MAINTENANCE 9-7
MAINTENANCE RECORDS 9-8
CLEANING THE BATTERY 9-9
ADDING WATER . 9-9
HYDROMETER 9-9
BATTERY TEMPERATURE 9-10
CHARGING THE BATTERY 9-10
TYPES OF BATTERY CHARGES 9-11
METHODS OF CHARGING 9-11
TROUBLESHOOTING THE CHARGER 9-11
HOW TO KNOW WHEN THE BATTERY IS FULLY CHARGED 9-11
BATTERY CHARGING AREA 9-12
EQUIPMENT NEEDED 9-12
Yale
IndustrialTrucks BATTERY-AND CHARGING SYSTEM
BATTERY AND CHARGING SYSTEM-GENERAL 4. WARNING: Be sure water is readily available in

This section describes selection and maintenance of large
/ I\ case electrolyte accidentally splashes on your skin
or clothing. Extreme care should be taken in
batteries used in electric lift trucks. This information pertains to
flushing electrolyte from the eye. Use plain water only and
the service personnel that maintain industrial truck batteries.
obtain medical attention immediately.
SAFETY TIPS FOR HANDLING -

Why Volumes of water applied quickly and continuously will
INDUSTRIAL TRUCK BATTERIES prevent serious injury to the skin. Quick medical attention is
necessary to assure proper care and treatment.
WARNING: Disconnect the battery from the lift
truck when doing maintenance and repair work.
5. /\ WARNING: Apply strong neutralizer such as
I? \ baking soda when acid is spilled on the floor and
clean up promptly.
Why - The live current may cause arcing or a short circuit with
attendant damage to equipment or injury.
Why - Baking soda will neutralize the acid and make it safe to
clean or flush from the floor.
2. /\
WARNING: Wear rubber apron, gloves, boots
/f\
and goggles, when handling, checking, filling,
6. /\ WARNING: Take proper care in melting the
Lijcharging or repairing batteries.
I
f\ sealing compound when preparing to seal a
battery. Avoid puncturing the hard surface of
Why - To protect yourself against burns resulting from
partially melted compound with a screwdriver or other sharp
accidental spillage of electrolyte - a mixture of sulfuric acid
tool. Compound may ignite if it is heated too rapidly.
and water.
Why - The hot liquid may squirt up and burn your hand, face or
3./\ WARNING: Keep open flames away from
body. If it should catch fire it creates the hazard of an open
11\ batteries - do not check electrolyte level with a
flame. Burning consumes oil in the compound and impairs its
_
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.
LEAD BUSHING VENT AND FILLER CAP

ÿ TERMINAL POST
CELL COVER
POSITIVE NEGATIVE
PLATE ' PLATE
SEPARATOR
CONTAINER
Figure 9-1 - Lead-Acid Industrial Truck Battery

9-1
Yale
IndustrialTrucks BATTERY AND CHARGINGSYSTEM
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.
& WARNING: When mixing acid to prepare

electrolyte, ALWAYS POUR ACID SLOWLY INTO
WATER and never water into acid. Always store
acid in plastic or glass container.
17. When batteries are disposed of as scrap at the end of
useful life, they should be sent to a authorized recycling center
or salvage dealer.
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
m WARNING: Always lift batteries with mechanical

equipment such as a hoist, crane or lift truck. Move
batteries horizontally with power tracks, conveyors
or rollers. Make sure that hoist hooks, spreader bars and other
tools are of ample strength and properly installed. Cover top of
batteries and the proper rules for their charging, handling and
maintenance.
-
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
PROBLEM POSSIBLE CAUSE CORRECTION

Battery Overheats On Discharge Over discharge Limit discharge to 1.110 specific gravity.
Put more batteries into -sen/ice. Set up
more frequent charging schedule.
Excessive load Determine cause of overload and correct.
Rutmore batteriesinto service if
equipment requirements exceed battery
capacity.
Not fully charged prior to work Needs more frequent and complete
assignment, resulting in over discharge charging.
Electrolyte levels low Add water as required. Do not assign
battery to work if levels are below top of
plates.
When overheating is confined to few Install heat insulating material between
cells, nearby operating equipment may equipment cells with air circulating space
be source between.
Operating in high ambient temperatures Provide cool location for charging and
good ventilation.
Low Electrolyte Level Broken or cracked jar Replace jar.
Water additions neglected or cell missed Better maintenance supervision. Add
in previous water addition. water as required to all ceils.
Overcharging Adjust charging equipment.
a. Voltage relay set for many cells a. Connect relay for proper number of
cells.
b. Timer set for too many hours b. Reduce time.
c. Voltage change rate relay operating c. Reduce voltage value at which voltage
relay operates.
Specific Gravity Between Cells Not Overfilled with water Do not fill above high level - give
Uniform equalizing charge and adjust acid.
Operating cell with cracked jar Replace jar and adjust acid.
Acid not adjusted properly after jar Adjust acid specific gravity.
change
Vent caps removed during operation Keep vent caps securely in place. Give
equalizing charge and adjust acid.
Electrolyte leaking through sealing Reseal and adjust acid.
compound
Operating battery with broken coil cover Replace cover and adjust acid.
Neutralrzrng agentin eel1 Keep-vent caps in place at all times
except when adding water. Keep battery
clean.
Unequal cell voltages Refer to Unequal Cell Voltages
Unequal Cell Voltages Over discharge. Also more than .020 Give an equalizing charge and do not
points spread in specific gravity from discharge below 1.110.
average
Lack of equalizing charges Give an equalizing charge periodically.
Internalshunt Make internal inspection of low voltage
cell and correct cause. Check for split
separator and moss short.
9-3
Yale
BATTERY TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE CORRECTION

Unequal Cell Voltages (Continued) Dirty battery top Neutralize and clean top of battery.
Cells operated with low electrolyte level Add water as required. Give equalizing
charge.
Low specific gravity of fully charged cell Adjust acidjafter equalizing charge.
Sediment space filled Replace battery.

Half tap on cells for lower voltage circuit Remove tap and connect load to battery
terminals through resistance.
External source heating certain cells Install heat insulating material between
heat source and battery.
Impurities in cell Add only distilled or approved water to
electrolyte.
Variation in charge rate Take readings when charge rate is
constant.
Battery Will Not Work Full Shift Uneven cell voltages Give an equalizing charge.
Low electrolyte levels Refer to Low Electrolyte Level.
Battery not charged before work cycle Check charging schedules. Do not assign
discharged battery to work.
One or more jars leaking electrolyte Replace broken jars.
Incorrect battery (number of cells) Install battery with correct voltage and
assigned to equipment capacity to equipment.
Fully charged specific gravity below Adjust specific gravity to normal.
normal
Impurities in electrolyte Add only distilled or approved water to
electrolyte.
Operator "riding the brake" Discourage practice.
Using reverse in place of braking Discourage practice.
Inexperienced operator Instruct him on power conservation.
Load excessive Use larger battery or reduce load.
Wheels, axles and bearings need grease Plan lubrication schedule.
Tires under inflated or wrong type Plan periodic check of air pressure.
Brakes dragging Adjust brakes properly.
Series field in motor shorted or grounded Replace field and remove ground.
Armature needs repair Replace or repair armature.
Ground on equipment Find ground and insulate.
Excessive grades Use larger battery or revise battery
charge schedule.
Capacity or equipment assigned to job Reassign equipment.

is inadequate
9-4
Yale
Industrial Trucks BATTERY AND CHARGING SYSTEM
LEAD-ACID BATTERIES Chemical Reaction

A lead-acid battery converts chemical energy into electrical The cell generates a voltage (potential difference) when two
energy. The battery is discharged when the chemical reaction different types of metal are in the electrolyte. The two metals in
has occurred and the battery will not supply its rated voltage a lead-acidcell are lead peroxide (Pb03) for positive plates, and
and current. A reverse chemical action must occur so that the sponge1lead (Pb) -for negative plates. A potential difference of
battery can be used again. The batteries can be charged by an approximately two volts per cell is generated. The potential
electric voltage and current from an outside source to provide difference does not vary according to the size of the cell.
the reverse chemical action. The lead-acid.chemicals store the
electrical energy until needed. During the discharging of the cell, lead peroxide and sponge
lead mix with sulfuric acid to make lead sulfate (PbS04) on both
A lead-acid battery is made from several lead-acid batteries plates. This action decreases the voltage in the cell. When the
called cells. Each cell has positive and negative plates with sulfuric acid is removed from the electrolyte, the specific gravity
dielectric spacers between each plate. All of the plates are in a of the electrolyte decreases. The potential difference of a
solution of electrolyte. discharged cell is approximately 1.75 volts.
Specific Gravity
The strength of the electrolyte is measured in points of specific
gravity. For example, a solution of sulfuric acid has a specific 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
INCREASED LEAD SULFATE

ELECTROLYTE
Figure 9-3 - Cell Discharging
When a direct current is applied to a discharged cell, the lead

sulfate is changed into lead and sulfuric acid. The lead goes to
the positive plate and stays as lead and to the negative plate
NEGATIVE POSITIVE and stays as lead peroxide. The concentration of sulfuric acid in
PLATE PLATE the electrolyte increases. The specific gravity of the electrolyte
increases 3S the concentration of sulfuric acid increases. In a
SPONGE LEAD fully charged cell, the positive plate again contains the lead
LEAD PEROXIDE peroxide and the negative plate contains the sponge lead.
In a fully charged cell, the electrolyte has a specific gravity of

1.270 to 1.130. NEVER discharge a battery below a specific
Figure 9-2 - Fully Charged Cell gravity of 1.130. The battery can have permanent damage if
discharged below 1.130.
9-5
Yale
per day is normally equal to the number of batteries needed.

1.75
The capacity of the battery you need is found as follows:
VOLTS
• The size of the lift truck and the attachments.
• The type of work. Heavy duty operation or normal
operation for one eight hour-work period.
2\] MINIMUM OF \
>.
SULFURIC S The battery voltage you need is found as follows:
ACID
¥i. • Will your lift truck operateun more than one vottageT
t
\. i\
MAXIMUM \ • If you have more than one lift truck in operation, do the
WATER battery voltages need to be the same?
£2 Lift trucks are available in various voltage ranges. The small

MINIMUM MINIMUM "Motorized Hand" trucks are normally 12 to 24 volts. Larger
SPONGE LEAD "Sit-down Rider" lift trucks are normally 24 to 48 volts.
LEAD PEROXIDE
Voltage of a Battery
MAXIMUM LEAD SULFATE
To reach the necessary battery voltage, the cells are connected
in series. For example:
Figure 9-4 - Discharged Cell • 24 volts 12 cell battery

• 36 volts 18 cell battery
BATTERY • 48 volts 24 cell battery
CHARGER
2.33
VOLTS
INCREASED
SULFURIC
ACID
DECREASED
S
N
WATER .' s
INCREASED INCREASED
SPONGE LEAD
LEAD PEROXIDE
DECREASED LEAD SULFATE
Figure 9-5 - Cell Charging

HOW TO SELECT THE BATTERY Figure 9-6 - Cell Voltage
The battery needed to operate a period of eight hours depends
Battery Ratings
on many conditions. Operations that require the lift truck to go
up ramps or require the use of additional "attachments The ratings of batteries are measured in ampere-hours (AH)
increases the use of power from the battery. Some work and kilowatt-hours (KWH) at a constant rate of discharge. The
conditions require that more than one battery must be used number and size of plates increases the amp-hour rating. A
during a work period. The number of eight hour work periods rating of six hours is the standard. Ampere-hours is the
9-6
Yale
measurement of battery capacity. To calculate ampere-hours, THE NEW BATTERY

multiply amperes by hours. For example, 5 amperes times 5
Inspect every new battery for damage. Make sure the
hours is 25 ampere-hours. You cannot change the potential
electrolyte in each of the cells is at the correct levei. Charge the
difference of a cell. You can increase the ampere-hour rating by
battery for six hours or until the specific gravity is correct. Some
increasing the number of plates in a cell, or by installation of
new batteries may require -cycling 7 to: AO- times before the;
larger plates. The constant rate of discharging can be
battery accepts a full charge. (Cycling is charging and then
compared to a measurement of the battery capacity and
discharging the battery at a prescribed rate. Refer to the
ampere-hours. For example, a battery with a rating of 600
instructions shipped with the battery.) Make sure the battery is
ampere-hours during a work period of six hours will generate
correctly installed in the lift truck. Use a correct spreader bar
100 amperes per hour for six hours. (The same battery cannot
with slings to lift and move the battery.
generate 300 amperes for two hours. The heat generated with
the battery will damage the battery.)
CAUTION: Always use a spreader bar and slings
that lift vertically on the lifting eyes of the battery.
Kilowatt Hours
DO NOT use a chain or sling without a spreader
A kilowatt is 1000 watts. A watt is a measure of electric power. bar or you will damage the battery.
The capacity in kilowatt-hours is the total power generated by
the battery. Watt-hours are measured by multiplying the voltage Use the correct blocks or spacers to hold the battery in
by ampere-hours. To measure the kilowatt-hours, divide the position in the lift truck. Make sure that the battery
watt-hours by 1000. compartment is clean and dry. All of the vents caps must be in
position when the battery is in service. If the vent caps are
__
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.
To calculate the kilowatt-hours for a battery that has a rating of

600 ampere-hours and a 48 volt system, use this formula. NON-METALLIC
--
STRAPS
48 x 600 I Power available from a fullv l

T000
28 8 KWH
I charged battery. j
All the electrical operations figure a specific watt-hours in
electric energy. These operations include distances, loads,
ramps, lifting heights, attachments, etc. The watt-hours can be
converted to kilowatt-hours to indicate the battery needed for
the operation. Always select the correct type of battery.
Remember, a battery that has a rating of 300 ampere-hours will
not do the same job as a battery that has a rating of 600
ampere-hours. Do not permit the specific gravity to go below
the limits shown in the manual.
THE BATTERY AS A COUNTERWEIGHT

On electric lift trucks that use the battery as part of the
counterweight, the battery is part of the capacity of the lift truck
to lift loads. The minimum weight of the battery is shown on the
nameplate. If the battery is not the minimum weight, the
capacity of the lift truck is reduced. If the battery used in the lift
truck is less than the size of the battery compartment, blocks Figure 9-7 - Lifting the Battery
and spacers must be installed to hold the battery in position.
The maximum allowable movement of a battery is 12.7 mm
(0.5 in) from side to side and 12.7 mm (0.5 in) fore and aft. BATTERY MAINTENANCE
(Reference ANSI B-56.1.) Battery maintenance must include a good battery charger, a
clean battery, keeping the electrolyte at the correct level, and
keeping a record of the battery.
9-7
Yale
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.
Rattpry Inappntinn Rppnrt a—

*— ÿ «ÿ
- lut. HM la .
fcrttf ftr
WiidM
1
—
--.
Ommm
CILL
vocrt
posmvi
CAttMUM
MOPIC
(MUVtTY
TINT. CILL
na
21
o— mm
Ow *»
CILk
VOkTB
-
POSIT!V«
CADMIUM
mopic
OAAVtTY
TIMS.
2 22
3 23
4 24
S 23
•7
20
27
• 20
9
10
11
13
_ 20
X
31
32 _ . --
-- .
Figure 9-8 - Battery Inspection Report
9-8
Yale
Daily Battery Record
o* am
MT(
Figure 9-9 - Dail Battery Record

Cleaning the Battery 9-10 shows a general rule for the incorrect electrolyte ievel. See
the instructions from the manufacturer of your battery for the
Keep the battery compartment clean and dry. Use a clean cloth
operating level of the electrolyte.
to wash the battery with water. Dry with compressed air.
CELL HEIGHT DIMENSION "A"

CAUTION: Do not clean the battery with steam or
hot water. Do not use a high pressure hose. Less than 38 cm (15 in) 3 mm (1/8 in)
38-61 cm (15 -24 in) 6 mm (1/4 in)
Remove any electrolyte from the battery compartment to
prevent corrosion. If there is electrolyte on the top of the battery, Greater than 61 cm (24 in) 12 mm (1/2 in)
apply a solution of bicarbonate of soda. Mix a solution Table 9-1 - Electrolyte Level
containing 1.1 lb (0.5 kg) of soda for every 4.22 qts (4 litres) of
water. Apply the solution, then flush the solution from the
battery with clean water. Wash the battery and battery
BOTTOM OF FILL TUBE
compartment as needed. Six months between cleaning is the
maximum recommended interval. COVER FILL HOLE
HIGH LEVEL
NOTE: If the top of the battery is wet from electrolyte, check
to see if the electrolyte level is too high or the battery charger
is not operating correctly. LOW LEVEL
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
percent of sulfuric acid in the electrolyte increases. When the

electrolyte level decreases by 3 mm (0.12 in) the specific
gravity measurement can increase by 3 to 5 points.
When using the hydrometer, make sure there is enough liquid

in the barrel to let the float move freely. The float must-nottouch
the side, top, or bottom of the barrel for the correct method of
reading the hydrometer.
LIQUID
SPECIFIC GRAVITY LEVEL
SCALE-
FLOAT
Figure 9-12 - Battery Thermometer

Never charge or discharge a battery at a rate that will raise the
Figure 9-11 - Hydrometer temperature of the electrolyte above 50° C (120° F). A
temperature above this amount will damage the battery. The
Battery Temperature cells in the center of the battery are normally at the highest
temperature, if the battery temperature is too hot, make sure
The temperature of the electrolyte will change the reading of the
the ventilation of the battery is increasedand make sure that the
specific gravity. When the temperature increases
charge or discharge rate is not too high. A recommendation for
approximately 6° C (10° F), the specific gravity will decrease by
a battery in service is 8 hours of use (discharge), followed by 8
0.003 points. Refer to Figure 9-12 for making specific gravity
hours of cooling, followed by 8 hours of charging.
corrections.
The normal electrolyte temperature is 25° C (77° F). At this
SPECIFIC temperature the electrolyte has a specific gravity of
GRAVITY ELECTROLYTE CORRECTION CORRECT 1.285-1.295 with no correction for temperature. If the
READING TEMP. POINTS VALUE hydrometer you are using does not have a temperature
correction, you will have to use a thermometer. Special battery
1.210 31° C (87° F) +0.003 1.213
thermometers are available that will indicate the correction
1.210 27° C (80° F) +0.001 1.211 factor directly and add or subtract the correct number of points.
1.210 25° C (77° F) +0.000 1.210

CHARGING THE BATTERY
1,210 18° C (64° F) -0.004 1.206
WARNING: Batteries produce explosive hydro¬
+ 0.001 for each 1.7° C (3° F) from the 25° C (77° F) gen gas when charging. Always open the battery
Base Value Degrees C + 17.8 x 1.8 = Degrees F. cover or hood and provide good ventilation
when charging.
Table 9-2 - Specific Gravity Corrections
To charge the battery, a direct current must pass through the
cells in the opposite direction to the discharging:current. The
ampere-hours must be equal to the discharging ampere-hours
plus the energy lost as heat. This additional amount of charge
will vary according to the battery and the temperature, but the
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
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.
2. Ventilation. Hydrogen gas comes from the batteries during

• Distilled water.
charging. • Air and water supplies for cleaning.
3. Drains for cleaning the batteries. • Maintenance records.
• A work bench.
4. Type and size of the batteries.
• Spare parts and repair equipment.
5. Type of lift truck. • Protective clothing and safety equipment for handling
batteries.
6. Distances that the lift trucks must travel for service.
• Water sources for washing eyes and preventing acid
burns.
7. Safety regulations and instructions.
• Install a NO SMOKING sign in the service area.
• Keep the charger in a clean, dry area with good
ventilation.
9-12
Yale
IndustrialTrucks
SECTION 10
10 USER SUPPORT INFORMATION

Yale
IndustrialTrucks
USER SUPPORT INFORMATION
SERVICE PARTS ORDERING INSTRUCTIONS 10-1

TECHNICAL PUBLICATIONS 10-1
PARTS MANUAL 10-1
OPERATING MANUAL 10-1
OPERATOR TRAINING 10-1
SERVICE TRAINING COURSES 10-1
SERVICE TRAINING MATERIALS 10-1
Yale
IndustrialTrucks USER SUPPORT INFORMATION
Your investment in a Yale® industrial truck is important to you and to your Yale industrial truck dealer. You measure the return on your
investment through the drivers who operate the trucks and the mechanics who service them safely and efficiently.
A "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.
SERVICE PARTS ORDERING INSTRUCTIONS OPERATOR TRAINING

In order to avoid delay, unnecessary correspondence and to Yale "Basic Operator Training" program helps industrial truck
have your orders filled correctly, promptly and at the least users increase materials handling productivity and safety
possible expense, the following is the recommended through proper lift truck operation training and motivation. The
procedure to use when ordering replacement parts. Yale program is based upon real life experience - not
theoretical concepts. We developed a "complete" program that
Contact your authorized Yale Industrial Truck Dealer and give is totally self-contained - incorporating the most modern
him the following information: instructional techniques, including elements of self-study,
audio-visual support (both video and slides) and
1. Your Purchase order number.
classroom study.
2. Complete invoicing and shipping address.
3. Specify the method of shipment, otherwise the least SERVICE TRAINING COURSES
expensive method will be used.
User and Yale Industrial Truck Dealer service technicians can
4. Correct part number(s) and description(s). Use your improve their technical ability for maintaining and repairing Yale
parts manual as a reference. industrial trucks and reduce down-time and cost by
participating in Yaie sponsored Service Training courses. A
5. Model and serial number of the truck.
variety of mechanical, electrical and electronic subjects are
offered at published tuition rates. Courses are available at user
TECHNICAL PUBLICATIONS and dealer facilities in addition to regularly scheduled courses
which are conducted at Yale Corporate Headquarters in
Technical literature, with detailed information, is available at a
Remington, New Jersey.
nominal fee to assist users to effectively maintain Yale
industrial trucks in a safe, useful condition. Parts Manuals with
complete replacement parts identification, Service SERVICE TRAINING MATERIALS
Maintenance Manuals which provide service and overhaul
Your own service training efforts are supported through a
procedures andadditional copies of this Operating Manual, can
complete line of Yale Service Training materials. An index is
be obtained from your Yale industrial truck dealer.
available from your Yale industrial truck dealer which lists
textbooks, audio-visual programs, films and their cost which
PARTS MANUAL - will provide your trainer with everything necessary to conduct
1704 (5203717-04) NR-AD/NDR-AD/NS-AE service training for your organization.
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.
The Operating Manual describes various operating techniques

and safety warnings for the operator. The Operating Manual
also contains a guide to safe maintenance practices and
recommended schedules for maintenance.
If the Operating Manual is missing from any Yale industrial

truck, it should be replaced. Replacement copies are available
for a nominal fee from your Yale industrial truck dealer.
10-1
Yale
IndustrialTrucks user support information
NOTES
10-2
Yale
IndustrialTrucks
SECTION 11
11 ALPHABETICAL INDEX
Yale
IndustrialTrucks ALPHABETICAL INDEX
A Remove Air from Steering System 6-14

Access Doors and Covers 2-1 Remove Air from the Brake System 5-8
ANSI Information 1-10 Commutator
Anti-seize Lubricating Compound Repairs 3-91
Approved Sources 2-18 Stoning 3-91
Anti-Seize Lubrication Compound 2-18 Component Repair and Testing 3-2
Articulating Axle Weldment
General 3-2
Installation 4-4
Contactor Panel Assembly 3-2
Removal 4-4
Description/Features 3-2
Articulation Adjustment Procedure 4-2
Axle Assembly 4-2 Installation 3-3
Removal 3-2
B Contactors 3-3
Battery Auxiliary Switch 3-3
Battery Connector 1-8 "EE" Type 3-5
Storage 1-12 Description/Features 3-3
Battery and Charging System 9-1
Installation 3-4
Battery Compartment 2-2
Removal 3-4
Battery Disconnect Switch 3-8
Testing 3-4
Installation 3-9
Removal 3-8 Conversion Table - Metric / English 2-27
Bolts and Screws 2-20
Brake Assembly 5-1 D
Assembly and Installation 5-2 Dash Display Assembly 3-79
Removal and Disassembly 5-1
Adjustment 3-80
Brake Fluid 2-17
Description/Features 3-79
Brake Fluid Capacity 2-10
Brake Pedal 1-8 Installation 3-80
Brake Switch-Replace 5-7 Voltage Selection 3-80
Operation 3-79
C Removal 3-79
Capacity Rating 1-1 Troubleshooting 3-81
Carriage Assembly 8-1 Double Reach Scissor Arms 8-18
Removal and Installation 8-6 Assembly and Installation 8-21
Carriage Load Rollers Cleaning and Inspection 8-21
Removal and Installation 8-8
Removal and Disassembly 8-18
Carriage or Reach Assembly Adjustments 8-58
8-60 Drive Motor
Adjust Side Rollers
Adjust Thrust Rollers 8-60 Tests 3-91
Adjust Wear Plug 8-58 Drive Unit Oil Capacity 2-10
Adjustment for Reach Cylinders 8-61
Adjustment for the Sideshift Cylinder 8-62 E
Adjustment for the Tilt Cylinder 8-61
Electrical System Introduction 3-1
Carriage or Reach Sheaves
General 3-1
Removal and Replacement 8-37
Caster
Installation 2-7 F
Removal 2-7 Fasteners 2-19
Caster and Caster Wheels 2-6 Bolts and Screws 2-20
Caster Wheels Strength Identification 2-19
Installation 2-6
Studs and Nuts 2-21
Removal 2-6
Thread Nomenclature 2-19
Charging the Battery 9-10
Torque Nuts 2-22
Checks and Adjustments
Brake Adjustment 5-7 Torque Nuts with Nylon Inserts 2-23
Check for Leaks in Hydraulic System 8-54 Torque Value Guide 2-24
Check Lift Chains 8-55 Floor Plate Assembly 5-5
Check Mast Operation 8-54 Assembly and Installation 5-5
Remove Air from Hydraulic System 8-54 Removal and Disassembly 5-5
11-1
Yale
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 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
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
M Diagnostics History 3-64

Road and Load Test 2-15 Diagnostics Menu 3-64
Safety and Operational Checks 2-12 Disconnecting the Hand Set from the
Mast Manual Lowering 3-9 Traction Motor Controller 3-62
Mast Adjustments 8-56 More Info Key 3-61
Adjust Free Lift Chain (Triplex Only) 8-57 Operating Modes 3-63
Adjust Main Lift Chains 8-58 . 3-64
Diagnostics History
......
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
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
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
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
Disassembly 6-4 8-33
Triplex Mast Assembly
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
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

Yale SM NR035 040 045AD - NDR030 ADB815 - NS040 050 AEB816

Uploaded by

Copyright:

Available Formats

Yale SM NR035 040 045AD - NDR030 ADB815 - NS040 050 AEB816

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Yale SM NR035 040 045AD - NDR030 ADB815 - NS040 050 AEB816

Uploaded by

Copyright:

Available Formats

MAINTENANCE MANUAL

For Service & Parts Contact

Yale Materials Handling Corp

2 GENERAL TRUCK AND LUBRICATION SCHEDULE

8 MAST AND REACH ASSEMBLY

9 BATTERY AND CHARGING SYSTEM

DESCRIPTION PAGE NUMBER

OPERATING INSTRUCTIONS-GENERAL 1-1

OPERATING INSTRUCTIONS-GENERAL C. Truck Weight

a new plate if this unit is equipped other than as >

If a truck is shipped incomplete from

covered by the label shown above. Do Pt

Capacities and cautions contained on

Figure 1-1 - Nameplate Information

SAFETY LABELS OPERATOR PRE-CHECKS AND INSPECTION

/j\ WARNING Basic maintenance information and the Recommended

A CAUTION screens and all other safety devices are attached.

2. Make sure all capacity, safety and informational plates or

ÿ Do not push loads with the truck.

Figure 1-2 - Typical Narrow Aisle Electric Lift Truck

Daily pre-shift inspection is an OSHA requirement. Operator's Daily Check List

SAFETY AND OPERATIONAL CHECKS (Prior to each shift)

MODEL AND OPERATING INFORMATION

These trucks feature operator comfort, low noise and vibration

No additions, omissions, changes or modifications should be

Before attempting to operate this truck, carefully read and

Figure 1-4 - Operating Controls

1. The Instrument Display is located near the steering tiller

mode data. This internal battery is not serviceable and is

2. Control Handle - The multi-function control handle is

The handle is moved horizontally for forward and reverse

5. Battery Power Disconnect - A red battery power

WARNING: Reverse steering is available for this

Figure 1-9 - Battery Power Disconnect

6. Brake Pedal - The brake is applied when the pedal is

Figure 1-10 - Brake Pedal

7. Before removing any component from the truck, such as

8. When working on the hydraulic system, be sure the truck is

9. When necessary to work with mast in a raised position,

MOVING A DISABLED LIFT TRUCK HOW TO PUT A LIFT TRUCK ON BLOCKS

DRIVE/STEER & CASTER WHEELS LOAD WHEELS

Figure 1-12 - Putting a Lift Truck on Blocks

,2. Neutralize and.clean the battery with a solution of 16

GENERAL TRUCK AND LUBRICATION SCHEDULE

DESCRIPTION PAGE NUMBER

GENERAL MAST SCREEN

Figure 2-2 - NS Lift Truck

A WARNING: Batteries are heavy. Use care to

Figure 2-3 - Changing the Battery Figure 2-4 - Inspecting Tires

MODEL DRIVE/STEER TIRES CASTER WHEELS LOAD WHEELS

3. The correct tools, equipment and a press ring must be

Install the Tire on the One Piece Wheel

SINGLE LOAD WHEELS

1. SWIVEL PLATE 9. LOCKWASHER

Figure 2-9 - Single Load Wheels Figure 2-10 - Caster Wheels

Make sure the blocks are in a location to permit removal of the

InstaHation-Caster Wheels DRIVE 4.8*6.4 mm 1

2. Install the guard washers at each bearing of each wheel.

1. Every 350 hours during routine maintenance. CASTER SIDE ADJUSTMENT