ERP030-040TH (F807)

SERVICE MANUAL CONTENTS

PART YRM REV
SECTION NUMBER NUMBER DATE
FRAME............................................................................................................................ 524204497 0100 YRM 1073 06/04
DC MOTOR MAINTENANCE.......................................................................................... 524158039 0620 YRM 0294 03/08
AC MOTOR REPAIR...................................................................................................... 524214915 0620 YRM 1115 06/06
TRANSAXLE................................................................................................................... 524204498 1300 YRM 1074 07/09
STEERING SYSTEM...................................................................................................... 524204499 1600 YRM 1075 02/08
BRAKE SYSTEM............................................................................................................ 524204500 1800 YRM 1076 03/07
HYDRAULIC SYSTEM.................................................................................................... 524204501 1900 YRM 1077 09/13
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MANUAL CONTROL VALVE......................................................................................... 524204502 2000 YRM 1085 10/06
ELECTRO-HYDRAULIC CONTROL VALVE................................................................. 524204503 2000 YRM 1086 06/04
TILT CYLINDERS........................................................................................................... 524150790 2100 YRM 0103 03/07
CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507,
B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515,
C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND
E564).......................................................................................................................... 524223768 2100 YRM 1139 02/14
TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS
PROGRAM................................................................................................................. 524183085 2200 YRM 1058 04/11
ELECTRICAL SYSTEM.................................................................................................. 524204505 2200 YRM 1078 07/05
AC MOTOR CONTROLLERS/DISPLAY PANEL........................................................... 524204504 2200 YRM 1087 09/13
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
MAST - DESCRIPTION................................................................................................... 524158890 4000 YRM 0521 03/06
MAST - REPAIR.............................................................................................................. 524158891 4000 YRM 0522 07/10
MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508,
B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551,
C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ 524223776 4000 YRM 1148 02/14
FOUR STAGE (QUAD) MAST........................................................................................ 580061048 4000 YRM 1176 09/13
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
PERIODIC MAINTENANCE............................................................................................ 524204506 8000 YRM 1079 06/09
CAPACITIES AND SPECIFICATIONS........................................................................... 524204507 8000 YRM 1080 03/09
DIAGRAMS..................................................................................................................... 524204508 8000 YRM 1081 04/07

PART NO. 524204496 (12/14)

100 YRM 1073 Introduction

Introduction
GENERAL DESCRIPTION OF OPERATION
This section contains a description and the service pro- The frame is a single weldment with mounts for the
cedures for the parts of the frame. These parts include counterweight, overhead guard, mast, steering system,
the frame, counterweight assembly, overhead guard, hydraulic system and transaxles. See Figure 2. The
hood and seat assembly, access panels, and labels. battery cover opens on hinges to give access to the bat-
Throughout this section, forward will refer to travel in tery compartment. The weight of the battery is a major
the direction of the forks and left and right will be deter- part of the counterweight system on an electric lift truck.
mined by an operator sitting in the seat facing forward. A slot in the overhead guard permits removal of the
See Figure 1. battery without removing the overhead guard. Spacers
may be added under the battery as required on some
models.

Each model of lift truck has a cast-iron counterweight

with a weight necessary for the indicated capacity. An
access panel on the top/rear of the counterweight gives
access to the electronic controllers.

The hydraulic pump and motor, steering pump and mo-

tor, drive motors and transaxles, and hydraulic tank are
under the floor plates in the operator compartment. The
floor plates are held in position by tabs and can be re-
moved to give access to components underneath.

The hydraulic control valve is fastened to the front of the

battery compartment. Three covers protect the control
valve and control linkage. The covers are fastened in
A. LEFT SIDE
B. RIGHT SIDE position by machine screws. The top covers are locked
C. FORWARD TRAVEL in place and must be released and swung open before
attempting to open the battery cover.
Figure 1. Truck Orientation

Figure 2. Frame

1
Introduction 100 YRM 1073

DISCHARGING THE CAPACITORS

CAUTION
WARNING To avoid controller damage, always disconnect the
battery, discharge the capacitor(s), and never put
Do not make repairs or adjustments unless you
power to the controller while any power wires are
have both authorization and training. Repairs
disconnected. Never short any controller terminal
and adjustments that are not correct can create
or motor terminal to the battery. Make sure to use
dangerous operating conditions. Do not operate
proper procedure when servicing the controller.
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair 1. Turn key switch to OFF position and disconnect the
is necessary, attach a DO NOT OPERATE tag on battery. Block load wheels to prevent lift truck from
the steering wheel. Remove the key from the key moving.
switch.
2. Open the electrical compartment at the rear of the
WARNING truck.
Disconnect the battery before opening the drive a. Remove the two screws securing the electrical
unit compartment cover or inspecting or repairing compartment door closed.
the electrical system. If a tool causes a short
circuit, the high current flow from the battery can b. Tilt the door back on its hinges to open the
cause personal injury or property damage. compartment.

WARNING WARNING
Some checks and adjustments are done with the DO NOT short across the motor controller terminals
battery connected. Do not connect the battery until with a screwdriver or jumper wire.
the procedure tells you to do so. Never have any
metal on your fingers, arms, or neck. Metal items NOTE: Some lift trucks are equipped with a premium
can accidentally make an electrical connection and controller, which controls the hydraulic motor as well as
cause injury. the traction motors.

3. Discharge the capacitor in the controller by con-

WARNING necting a 200-ohm, 2-watt resistor across the con-
Before performing any tests or adjustments, block troller’s BT+ and B terminals for 10 seconds using
the lift truck to prevent unexpected movement. insulated jumper wires. See Figure 3.

4. On the premium controller, also connect the 200-

WARNING ohm, 2-watt resistor across the controller’s P+ and
The capacitor in the transistor controller(s) can B terminals for 10 seconds using insulated jumper
hold an electrical charge after the battery is dis- wires. See Figure 4.
connected. To prevent an electrical shock and
personal injury, discharge the capacitor(s) before 5. Remove the 200-ohm, 2-watt resistor before recon-
inspecting or repairing any component in the drive necting the battery.
unit compartment. Wear safety glasses. Make
certain that the battery has been disconnected.

2
100 YRM 1073 Covers and Floor Plates

1. POSITIVE CONNECTION (BT+) 1. POSITIVE CONNECTION (BT+)

2. NEGATIVE CONNECTION (B ) 2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR 4. 200-OHM, 2-WATT RESISTOR
5. POSITIVE CONNECTION (P+)
Figure 3. Discharging the Capacitors (Standard)
Figure 4. Discharging the Capacitors (Premium)

Covers and Floor Plates

Many system components, such as hydraulic hoses, Various covers and floor plates provide access to these
pump and motor, and wiring harnesses, are located in components during service and securely cover these
the area around and under the operator compartment. areas during normal operation. See Figure 5.

3
Covers and Floor Plates 100 YRM 1073

1. CAPSCREW 7. ANTI-SLIP PAD

2. ATTACHING HARDWARE 8. ANTI-SLIP PAD
3. CLIP NUT 9. RIGHT FLOOR PLATE
4. HARNESS COVER (ELECTRIC VALVE) 10. CENTER FLOOR PLATE
5. HARNESS COVER (MANUAL VALVE) 11. LEFT FLOOR PLATE
6. CAPSCREW 12. HOSE COVER

Figure 5. Covers and Floor Plates

4
100 YRM 1073 Overhead Guard Repair

Overhead Guard Repair

INSTALL
WARNING
The overhead guard is part of the operator protec- 1. Position overhead guard just above mounts on the
tion system. Do not operate the lift truck without the counterweight and cowl using an overhead lifting
overhead guard correctly fastened to the lift truck. device and sling.

The overhead guard is designed to provide protection 2. Route the wires through each overhead guard post
to the operator from falling objects and in the event of and install to lights as removed.
a tip over. A high visibility design allows for an unob-
structed view while maintaining structural integrity. Re- 3. Lower overhead guard supports onto the mounts.
moval of the battery is simplified by the slot in the over-
4. Install and tighten six capscrews, washers, and
head guard. This provides access to the battery with an
nuts securing overhead guard to the lift truck.
overhead lifting device without removing the overhead
Tighten capscrews to 134 N•m (99 lbf ft).
guard.
5. Remove sling and overhead guard.
REMOVE

WARNING
The overhead guard is heavy. Make sure the sling,
chain, eyebolts, and crane or lifting device have the
capacity to lift the overhead guard.

1. Remove the six capscrews, washers, and nuts that

secure the supports of the overhead guard to the
counterweight and cowl. See Figure 6.

2. Use an overhead lifting device and sling to lift the

overhead guard until it is just higher than the coun-
terweight mounts.

NOTE: Tie a cord around the wires from each post of

the overhead guard before removal. Remove the wires
from the post. Untie the cord from the wires and tape
each end of the cord to the overhead guard where it en-
ters the post. Use the cord to pull the wires up through
the post when installing the overhead guard.
1. OVERHEAD GUARD
3. Tag and disconnect the wiring from each post of 2. COUNTERWEIGHT
the overhead guard. Carefully remove the wiring 3. FRAME
4. CAPSCREWS (4) FRONT
if necessary. 5. CAPSCREWS (2) REAR
6. CAPSCREWS (2) UPPER
4. Completely remove the overhead guard from the lift 7. CAPSCREWS (2) LOWER
truck.
Figure 6. Overhead Guard Mounting

5
Hood and Seat Assembly 100 YRM 1073

Hood and Seat Assembly

The hood is the platform for the seat assembly and is emergency battery disconnect that allows the operator
located above the battery. It functions as a battery re- to quickly disconnect the battery while seated on the lift
straint that completely covers the battery compartment. truck in case of an emergency.
See Figure 7. Its function as the battery restraint, when
correctly locked to the frame, is to hold the battery in the The seat assembly slides on seat rails that are fas-
battery compartment if an accident causes the lift truck tened to the hood by four capscrews. A lever at the
to tip over. The hood is composed of a plastic cover left front side of the base controls the adjustment of the
attached to a metal frame. Two hinges at the back of seat to the forward and backward positions. Optional
the hood attach it to the frame. A sliding latch mech- seats are available in cloth or vinyl with features such
anism on the front of the hood locks the hood closed as semi-suspension, full suspension, and limited swivel.
during operation. A double-dampened, gas-controlled All seats have a seat switch installed in the bottom cush-
strut holds the hood in the open position. ion that senses operator presence. When the operator
is not on the seat, the seat switch opens and interrupts
Opening the sliding latch unlocks the hood from the the controller stopping operation of the lift truck.
frame so the hood can be raised to access the battery.
See Figure 8. The latch can only be accessed after The hood, seat belt, hip restraint brackets, seat, and
releasing and raising the hydraulic levers and linkage seat mount are all parts of the operator restraint sys-
assembly up and out of the way. A button on each side tem. Checks and adjustments for the operator restraint
of the assembly can be pressed to release the assem- system are described in the Operating Manual and the
bly so it can be moved clear of the hood on its hinged section Periodic Maintenance 8000 YRM 1079.
bracket. The latch must be in good condition and prop-
To raise the hood and seat assembly, move the seat to
erly secured before the lift truck can be operated. If the
the rear of the hood if necessary. Move the steering
latch does not lock the hood in the closed position, the
column to the most forward position. Release and raise
hydraulic levers and linkage assembly will not lock into
the hydraulic levers and linkage. Open the latch mech-
position and the lift truck will not operate.
anism and raise the hood.
A large, red button switch is mounted on the hood at
the right side of the seat assembly. This switch is an

1. SEAT 2. HOOD 3. SEAT SWITCH CONNECTOR

Figure 7. Hood and Seat Assembly

6
100 YRM 1073 Hood and Seat Assembly

6. Remove capscrews securing hood mounting brack-

ets to hood and lift hood from truck.

7. Slide hood mounting brackets from studs on coun-

terweight brackets. Replace bushings if necessary.

8. Remove the capscrews, washers, and nuts retain-

ing the hood cover to its metal frame if necessary.

INSTALL
1. Install the capscrews, washers, and nuts to secure
the hood cover to its metal frame.

2. Install new bushings to mounting brackets if neces-

sary. Slide hood mounting brackets onto counter-
weight bracket studs as removed.

3. With the aid of an assistant or overhead lifting de-

vice and sling, position the hood on the hinges and
install the four capscrews. Tighten snugly but do
not torque at this time. Place the hood in the closed
position.
1. SLIDING LATCH 2. HOOD
MECHANISM 3. FRAME 4. Open and close the hood to check for proper clear-
ance. The minimum clearance between the hood
Figure 8. Latch Mechanism and the front plate of the frame is 3.5 mm (0.14 in.).
Check to ensure the proper clearance.
REMOVE
5. Tighten the capscrews to 86 N•m (63 lbf ft).
1. Disconnect the battery connector.
6. Raise the hood. Align and install the gas-filled
2. Tag and disconnect the electrical connectors to the struts and install the locking clips to retain the
emergency battery disconnect, the seat switch, and struts to the hood and install capscrews to secure
the hood and latch position switches. Remove hood the lower ends to frame.
and latch switches if necessary.
7. If the seat assembly has been removed, install the
3. Remove the emergency battery disconnect switch mounting bracket to the hood using capscrews,
and hood and latch position switches, if necessary. washers, and nuts. Hold the slide function lever in
the open position and slide the seat into mounting
NOTE: The seat assembly does not have to be removed bracket tracks. Release the lever and install the
from the hood to remove the hood from the lift truck. To stop screws.
remove the seat, remove the four capscrews that fasten
the seat base to the hood. Lift the seat assembly from 8. Install hood and latch switches and emergency bat-
the hood. If the seat is not being removed, raise the tery disconnect switch, if removed, and adjust as
hood. necessary.

4. Remove the stop screws from the seat assembly, 9. Connect the wiring harnesses to the seat switch,
hold the slide function lever in the open position, emergency battery disconnect, and the hood and
and slide the seat from the mounting bracket. Re- latch position switches.
move mounting bracket from hood if necessary.
10. Close the hood. Make certain that the locking
5. Disconnect the double-dampened, gas-controlled mechanism to retain the hood is properly engaged.
struts by removing the locking clips retaining the Close the hydraulic linkage and covers.
struts to the hood and the capscrews securing the
lower ends to frame. Move the hood to the closed 11. Connect the battery connector.
position.

7
Counterweight 100 YRM 1073

Counterweight
REMOVE
WARNING
Do not operate the lift truck if the capscrews for 1. Remove battery. See the section Periodic Mainte-
the counterweight are not installed. When the nance 8000 YRM 1079 for instructions on removing
capscrews are removed, the counterweight can fall the battery.
from the lift truck.
NOTE: It may not be necessary to remove the battery
A one-piece, cast iron counterweight is used to offset platform. Perform only the steps necessary to complete
the weight of the load. See Figure 9. The counterweight the required service.
is mounted to the rear of the truck using four mount-
ing bolts and is supported by a protruding flange of the 2. Remove battery platform if necessary:
frame. See Figure 9. A compartment space, accessed
a. Remove the battery spacer and the acid tray
by a hinged door, has been designed into the center of
positioned on top of the battery platform.
the counterweight to house the electrical connections.
b. Remove the two capscrews, washers, and nuts
A battery platform is used to support the battery on the
retaining the platform to the frame.
lift truck frame. The battery platform also serves as part
of the counterweight system and requires the use of an c. Use a lifting device to lift the platform out of the
overhead lifting device for removal or installation. Be lift truck.
sure to replace the same battery platform, or one of
equal weight, if the platform must be removed. 3. Remove overhead guard. See Overhead Guard
Repair.

4. Remove the two large screws securing the electri-

cal compartment access door in the closed position
and pull open the door.

5. Discharge the capacitor(s). See Discharging the

Capacitors.

NOTE: Make note of wires and cable routing for proper

reassembly.

6. Remove socket head screws and detach the con-

troller panel from the electrical compartment ac-
cess door. Remove wire ties securing wires and
cables to the door hinge mechanism.

7. Remove the electrical compartment access door

and hinges if necessary.

WARNING
The counterweight is very heavy. Make sure the
chains, eyebolts, and overhead lifting device have
the capacity to lift the counterweight.

8. Install a clevis on each of the overhead guard

mounts. See Figure 10. Install tempered, grade 8
bolts and nuts or the proper pins for each clevis.
Attach a chain to each clevis. Use an overhead
lifting device to hold the weight of the counter-
weight. Make sure the sling, chain, eyebolts, and
overhead lifting device have the capacity to lift the
Figure 9. Counterweight counterweight.

8
100 YRM 1073 Counterweight

10. Use the overhead lifting device to lift the counter-

weight off the mounting flange and away from the
frame. See Figure 9.

INSTALL

WARNING
The counterweight is very heavy. Make sure the
chains, eyebolts, and overhead lifting device have
the capacity to lift the counterweight.

1. Use an overhead lifting device to lift the counter-

weight into position. See Remove, Step 8. Some
assistance will be required to align the mounting
holes in the counterweight with those in the frame.

2. Install the four capscrews and hardened flat wash-

ers that hold the counterweight to the frame.
Tighten the capscrews to 435 N•m (321 lbf ft).

3. Disconnect the chain. Remove the clevis from each

overhead guard mount.

4. If removed, install the electrical compartment

hinges and door.

5. Install the controller panel to the inside of the electri-

cal compartment door using the proper socket head
screws. Secure wires and cables inside the electri-
cal compartment as removed.

6. Close the door to the electrical compartment and

secure using two large screws.

1. CHAIN 7. Install the battery platform and the acid tray in the
2. OVERHEAD GUARD MOUNTS battery compartment.
3. CLEVIS
a. Use an overhead lifting device to place the plat-
Figure 10. Lifting the Counterweight form into the lift truck.

9. Remove the four M20 × 2.5 × 60 capscrews and b. Install the two capscrews, washers, and nuts
hardened flat washers that hold the counterweight retaining the platform to the frame.
to the frame. Four capscrews hold the counter-
weight to the frame from the inside and can be ac- c. Install the battery spacer and the acid tray on
cessed from the battery compartment. Two of the top of the battery platform.
capscrews are located at the bottom of the coun-
8. Install the overhead guard. See Overhead Guard
terweight, while the other two are located approxi-
Repair.
mately in the center of the counterweight. The nuts
for the capscrews are cast in the counterweight. 9. Install the battery. See the section Periodic Main-
Refer to Figure 6. tenance 8000 YRM 1079.

9
Safety Labels 100 YRM 1073

Safety Labels
1. Clean the painted surface. Use household clean-
WARNING ing products to clean new paint and clean old paint
Safety labels are installed on the lift truck to give with cleaning solvent. DO NOT use solvent on new
information about operation and possible hazards. paint. Make sure the surface is dry and is clean of
It is important that all safety labels are installed on dirt, oil, and grease.
the lift truck and can be read.
2. Remove the paper from the back of the label and
DO NOT add to or modify the lift truck. Any change hold the label by the edges. Do not touch the ad-
to the lift truck, the tires, or its equipment can hesive surface.
change the lifting capacity. The lift truck must be
rated as equipped and the nameplate must show
the new capacity rating. Contact your Yale lift truck
CAUTION
dealer for a replacement nameplate. The label cannot be moved after it touches the sur-
face.
If a label must be replaced, use the following procedure
to install a new label. See Figure 11, Figure 12, and 3. Carefully hold the label in the correct position above
Figure 13. the surface and carefully apply to the correct loca-
tion. Make sure that all air is removed from under
the label by smoothing any wrinkles or bubbles with
WARNING your fingers working from the center out. Check
Always use solvents and paints in an area with ad- that the corners and edges are tight against the sur-
equate ventilation. Do not use solvents or paints face.
near heat, fire, or electrical equipment that can cre-
ate sparks. Follow the manufacturer’s instructions
and cautions.

10
100 YRM 1073 Safety Labels

A. SIDE VIEW B. REAR VIEW C. FRONT VIEW

1. OVERHEAD GUARD IMPACT RATING PLATE 11. EE CONSTRUCTION
2. MAST WARNING 12. BATTERY SPACER WARNING
3. YALE 13. YALE
4. OPERATOR RESTRAINT 14. PATENTS AND TRADEMARKS
5. TILT COLUMN 15. UL LABEL
6. MAST WARNING 16. AUXILIARY FUNCTION
7. PINCH POINT 17. SIDESHIFT
8. UNIT NUMBER DECAL 18. TILT
9. YALE 19. LIFT
10. CORROSION/FREEZER 20. LABEL (EUROPEAN ONLY)

Figure 11. Label Locations - General

11
Safety Labels 100 YRM 1073

1. LOCK/UNLOCK
2. NAMEPLATE
3. PINCH POINT
4. PINCH POINT
5. OPERATOR WARNING
6. BATTERY DISCONNECT
1. BRAKE SYSTEM FLUID LABEL 7. PINCH POINT
2. HYDRAULIC OIL FILL LABEL 8. NO RIDERS
3. BRAKE SYSTEM FLUID TAG 9. PINCH POINT
Figure 12. Label Locations - Below Floor Plates Figure 13. Label Locations - Battery Compartment
Cover

12
100 YRM 1073 Painting Instructions

Painting Instructions
Seat Assembly and Rails
WARNING Information Case
Always use solvents and paints in an area with Tires
ventilation. Do not use solvents or paints near Mast Chains and Hoses
heat, fire, or electrical equipment that can make Battery Connector
sparks. Follow the manufacturer’s instructions Key Switch
and cautions. Cylinder Rods
All Plastic Covers
1. Remove all dirt from the surface to be painted.
Clean the area to be painted. Use a solvent for
painted surfaces to remove grease and oil before CAUTION
sanding. Do not use solvent on new paint. Make Do not paint the pads, plastic covers or knobs, ca-
sure all oil and grease is removed. bles, labels, information plates, or controls. Paint
can make some assemblies not operate correctly.
2. Use sandpaper to remove the top surface of paint
and rust from the metal. All metal surfaces where 4. Paint the surfaces. Use the correct paint from your
the paint is completely removed, must be primed. dealer for Yale lift trucks. Follow the directions on
Apply primer before applying the paint. the container.

CAUTION WARNING
DO NOT put tape on cylinder rods to protect from Make sure all labels are installed after painting is
paint. Use a thick layer of multipurpose grease to complete. Safety labels are installed on the lift truck
protect cylinder rods. Cylinders can be damaged if to give information about possible hazards. It is
operated with tape on the cylinder rod. important that all safety labels are installed on the
lift truck and can be read.
3. Protect all surfaces that will not be painted.
DO NOT paint: 5. Check that all labels are installed in the correct lo-
Pedal Pads cations on the lift truck. See Safety Labels.
Lever Knobs
NOTE: Use colors approved by Yale Material Handling
Instrument Panel
Corporation.
Steering Wheel
Labels and Information Plates

13
1300 YRM 1074 Introduction

Introduction
GENERAL DISCHARGING THE CAPACITORS
This section contains the removal, disassembly, repair,
inspection, assembly, and installation instructions for
WARNING
the transmission and traction motor that make up the DO NOT make repairs or adjustments unless you
transaxle assemblies used on these models. are properly trained and have authorization to do
so. Improper repairs and adjustments correct can
Some components associated with the transaxle are create dangerous operating conditions. Do not op-
not covered in this section because they are more erate a truck in need of repair. Report the need for
closely associated with other systems. repairs to your supervisor immediately. If repair is
See the section Brake System 1800 YRM 1076 for necessary, attach a DO NOT OPERATE tag to the
information on the electric brake and the service steering wheel and disconnect the battery connec-
brake lines and master cylinder. tor.
See the section Periodic Maintenance 8000 YRM
1079 for information on the tire and wheel assem- WARNING
blies. Disconnect the battery before opening the electric
compartment cover or inspecting or repairing the
WARNING electrical system. If a tool causes a short circuit,
DO NOT make repairs or adjustments unless you the high current flow from the battery can cause
are properly trained and have authorization to do personal injury or equipment damage.
so. Improper repairs and adjustments correct can
create dangerous operating conditions. Do not op- WARNING
erate a truck in need of repair. Report the need for
Some checks and adjustments are performed with
repairs to your supervisor immediately. If repair is
the battery connected. DO NOT connect the bat-
necessary, attach a DO NOT OPERATE tag to the
tery until the procedure tells you to do so. Never
steering wheel and disconnect the battery connec-
wear jewelry or other metal items on your fingers,
tor.
arms, or neck when performing service to the lift
Throughout this section, forward will refer to travel in truck. Metal items can accidentally make an electri-
the direction of the forks and left and right will be deter- cal connection and cause injury.
mined by sitting in the seat facing forward. See Figure 1.
WARNING
Block the lift truck drive tires to prevent unexpected
movement before performing any tests or adjust-
ments.

WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is dis-
connected. To prevent an electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component in the elec-
trical compartment. Wear safety glasses. Make
certain that the battery has been disconnected.

A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL

Figure 1. Truck Orientation

1
Introduction 1300 YRM 1074

CAUTION
To avoid controller damage, always disconnect the
battery and discharge the capacitor before perform-
ing service or repairs inside the electrical compart-
ment. NEVER apply power to the controller when
any wires are disconnected. NEVER short any con-
troller terminal or motor terminal to the battery. Al-
ways use proper procedure when servicing the con-
troller.

1. Block load wheels to prevent lift truck from moving.

2. Turn the key switch to the OFF position and discon-

nect the battery.

3. Open the electrical compartment:

a. Remove two screws securing the electrical

compartment door. 1. POSITIVE CONNECTION (BT+)
2. NEGATIVE CONNECTION (B )
b. Pull the compartment door open on its hinges. 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
WARNING Figure 2. Discharging the Capacitors (Standard)
DO NOT short across the motor controller terminals
with a screwdriver or jumper wire.

NOTE: Some lift trucks are equipped with a premium

controller, which controls the hydraulic motor as well as
the traction motors.

4. Discharge the capacitor in the controller by con-

necting a 200-ohm, 2-watt resistor across the con-
troller’s BT+ and B terminals for 10 seconds using
insulated jumper wires. See Figure 2.

5. On the premium controller, also connect the 200-

ohm, 2-watt resistor across the controller’s P+ and
B terminals for 10 seconds using insulated jumper
wires. See Figure 3.

6. Remove the 200-ohm, 2-watt resistor before recon-

necting the battery.

1. POSITIVE CONNECTION (BT+)

2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. POSITIVE CONNECTION (P+)

Figure 3. Discharging the Capacitors (Premium)

2
1300 YRM 1074 Description

Description
TRANSMISSION Legend for Figure 4

The lift truck uses two transmissions. One transmission 1. LEFT TRANSMISSION
is mounted on each side of the lift truck frame beneath 2. TRACTION MOTORS
3. RIGHT TRANSMISSION
the cowl. The transmission is an in-line gear set that in-
corporates a wet disk brake assembly within the trans-
TRACTION MOTOR
mission housing. The traction motor is mounted on one
side of the transmission, and the drive wheel and tire The traction motor is a three-phase AC induction motor.
assemblies are mounted to the other side of the trans- DC battery current is converted into AC current in the
mission. See Figure 4. The transmission is secured motor controller and then supplied to the traction motor.
to the lift truck frame using a series of five capscrews. The traction controller controls motor speed and direc-
The transmission housing provides the mounts needed tion. Each traction motor contains a speed encoder de-
to attach the mast to the lift truck. vice that provides continuous motor speed and direction
information to the motor controller. Each traction mo-
Power from the traction motor is transmitted to the trans-
tor also contains a temperature sensor that continually
mission through an internal spline in the input gear. The
monitors motor temperature and communicates that in-
input gear drives the first reduction gear. The input and
formation to the motor controller. See Figure 5.
first reduction gear are helical gears. The first reduc-
tion gear acts as the power input to a three-planet, sin-
gle-reduction, planetary gear set. This planetary gear
set drives the output (wheel hub) to rotate the drive tire
and move the lift truck.

Figure 5. Traction Motor

Figure 4. Transmission Mounting

3
Maintenance 1300 YRM 1074

Maintenance
OIL LEVEL CHECK 1. Raise and safety-chain the mast to access the
transaxle assemblies. See Periodic Maintenance
Each transaxle has a separate oil supply which must 8000 YRM 1079.
be maintained. See Figure 6. Make sure the lift truck
is parked in a level area. To check the oil level, remove 2. Turn the key switch to the OFF position and discon-
the oil fill plug. The oil should be level with the bottom nect the battery. Block the wheels to prevent unex-
of the oil fill hole. If necessary, add oil through the oil pected movement.
fill hole until the oil is level with the bottom of the hole.
Replace the oil fill plug and torque to 40 N•m (30 lbf ft). 3. Place a drip pan with at least a 3.8 liter (4 qt) ca-
Check the oil level in both transaxles every 500 hours pacity under each transaxle.
or every three months.
4. Remove the fill plugs on each transaxle. See Fig-
ure 7.

5. Remove the drain plugs on each transaxle.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.

6. After both transaxles have drained completely,

replace the drain plugs and torque to 40 N•m
(30 lbf ft). Remove the drip pans and dispose of
waste oil properly.

7. Fill the transaxles with oil until level with the bottom
of the oil fill holes. See Figure 6.

8. Install the fill plugs and torque to 40 N•m (30 lbf ft).
1. OIL FILL PLUG
2. R.H. TRANSAXLE
3. TRACTION MOTOR
4. PARKING BRAKE

Figure 6. Transaxle Oil Fill Plug

OIL CHANGE

WARNING
The oil is hot at normal operating temperatures. Be
careful when draining the oil.

NOTE: Operate the lift truck for 5 minutes or until the

transaxle is warm to the touch. Oil is thick and will drain 1. BRAKE BLEED VALVE
easier and more thoroughly when it is warm. Each 2. TRANSAXLE HOUSING
transaxle uses separate, self-contained oil supplies. 3. DRAIN PLUG
The oil in the transaxle should be changed after the
first 200 hours of operation and every 1000 hours or Figure 7. Transaxle Drain Plug
every six months thereafter.

4
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