Yale ERP15VT, ERP16VT, ERP18VT, ERP20VT Parts Manual

PARTS MANUAL

ERP15VT, 16VT, 18VT, 20VT

(G807)

Yale Europe Materials Handling Limited

Centennial House, Building 4.5 Frimley Business Park Frimley, Surry GU16 7SG, United Kingdom

524308696

©Yale Corp.

04/2015

SECTIONS

1 GENERAL TRUCK

2 ELECTRICAL SYSTEM

3 DRIVE UNIT

4 STEERING SYSTEM

5 BRAKE SYSTEM

6 HYDRAULIC SYSTEM

7 MAST-TWO STAGE LIMITED FREE-LIFT

8 MAST-THREE STAGE FULL FREE-LIFT

9 MAST-TWO STAGE FULL FREE-LIFT

10 OPTIONS

11 FIELD SERVICE KITS

12 NUMERICAL INDEX

13 USER SUPPORT INFORMATION

This Parts Manual is divided into 13 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

GENERAL INFORMATION

TABLE OF CONTENTS

DESCRIPTION PAGE

ACCELERATOR PEDAL

FOOT DIRECTIONAL CONTROL ............................................................................................................... 5-12

STANDARD ................................................................................................................................................. 5-10

ADD ON OPTIONS

ADD ON TELEMETRY KITS ........................................................................................................................... 11-16

ARMREST SLIDER ASSEMBLY

→ 9/2010 .................................................................................................................................................... 1-60

9/2010 → .................................................................................................................................................... 1-62

AUDIBLE ALARM ............................................................................................................................................ 10-2

AUXILIARY COUNTERWEIGHT

DROP-IN BATTERY REMOVAL (2/2015 →) ............................................................................................. 1-103

OPTIONAL - J2.0XNT (1/2015 →) ............................................................................................................. 1-104

SIDE BATTERY REMOVAL (2/2015 →) .................................................................................................... 1-102

AUXILIARY TUBE EXTENSION KITS ............................................................................................................ 11-3

AUXILIARY TUBE EXTENSIONS

TWO AND THREE STAGE FULL FREE-LIFT ............................................................................................ 10-46

TWO-STAGE LIMITED FREE-LIFT ............................................................................................................ 10-44

BATTERY COMPARTMENT DOOR

SIDE REMOVAL (2/2015 →) ..................................................................................................................... 1-92

BATTERY CONNECTOR AND CABLE

WITH E-STEERING .................................................................................................................................... 2-44

WITH RAPID CHARGE OPTION (→ 2/2015) ............................................................................................ 2-42

WITHOUT RAPID CHARGE OPTION - SIDE BATTERY EXTRACTION (S/N G807B05405L →) ............ 2-36

WITHOUT RAPID CHARGE OPTION - STANDARD AND SIDE BATTERY

EXTRACTION (→ S/N G807B05404L) ...................................................................................................... 2-38

WITHOUT RAPID CHARGE OPTION - STANDARD BATTERY EXTRACTION (S/N G807B05405L →)

.................................................................................................................................................................... 2-40

BATTERY RETENTION

→ S/N G807B02919J ................................................................................................................................. 1-98

S/N G807B02920J → ................................................................................................................................. 1-100

BATTERY TRAY OPTIONS

DROP-IN (→ 2/2015) ................................................................................................................................. 1-80

DROP-IN (2/2015 →) ................................................................................................................................. 1-82

SIDE REMOVAL (S/N G807B02920J ↔ 2/2015) ...................................................................................... 1-86

SIDE REMOVAL (2/2015 →) ..................................................................................................................... 1-88

SIDE REMOVAL - WITH REMOVABLE BATTERY TRAY (2/2015 →) ..................................................... 1-90

SIDE-REMOVAL (→ S/N G807B02919J) .................................................................................................. 1-84

BRAKE PEDAL LINKAGE ............................................................................................................................... 5-2

CAB

FRONT PANEL ASSEMBLY ....................................................................................................................... 1-38

FRONT WIPER ASSEMBLY ....................................................................................................................... 1-40

HEADLINER ASSEMBLY ........................................................................................................................... 1-26

HEATER ...................................................................................................................................................... 1-42

HEATER ASSEMBLY (→ 9/2011) ............................................................................................................. 1-44

G807

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

HEATER ASSEMBLY (9/2011 →) ............................................................................................................. 1-46

PVC DOORS ............................................................................................................................................... 1-14

REAR PANEL AND WIPER ATTACHMENT ............................................................................................... 1-18

REAR PANEL ASSEMBLY ......................................................................................................................... 1-20

ROOF FLAP ................................................................................................................................................ 1-24

STEEL DOOR ASSEMBLY - RIGHT HAND ............................................................................................... 1-30

STEEL DOOR ASSEMBLY - LEFT HAND .................................................................................................. 1-32

STEEL DOORS ........................................................................................................................................... 1-28

TOP PANEL ASSEMBLY ............................................................................................................................ 1-22

WINDOW - STEEL DOOR, RIGHT HAND .................................................................................................. 1-34

WINDOW - STEEL DOOR, LEFT HAND .................................................................................................... 1-36

CAB ASSEMBLY

FULL STEEL CAB ....................................................................................................................................... 1-16

WITH PVC DOORS ..................................................................................................................................... 1-12

CAB KITS CARRIAGE ASSEMBLY

THREE STAGE FULL FREE LIFT - A271 - STANDARD ............................................................................ 8-22

THREE STAGE FULL FREE LIFT - A271 - INTEGRAL SIDE-SHIFT ........................................................ 10-26

THREE STAGE FULL FREE LIFT - C662 - STANDARD ........................................................................... 8-48

THREE STAGE FULL FREE LIFT - C662 - INTEGRAL SIDE-SHIFT ........................................................ 10-28

TWO STAGE FULL FREE- LIFT - C663 - INTEGRAL SIDE-SHIFT ........................................................... 10-32

TWO STAGE FULL FREE- LIFT-A272 - INTEGRAL SIDE-SHIFT ............................................................. 10-30

TWO STAGE FULL FREE- LIFT-STANDARD - A272 ................................................................................ 9-36

TWO STAGE LIMITED FREE LIFT - A270 - STANDARD .......................................................................... 7-12

TWO STAGE LIMITED FREE LIFT - A270 - INTEGRAL SIDE-SHIFT ....................................................... 10-22

TWO STAGE LIMITED FREE LIFT - C661 - STANDARD .......................................................................... 7-30

TWO STAGE LIMITED FREE LIFT - C661 - INTEGRAL SIDE-SHIFT ....................................................... 10-24

TWO-STAGE FULL FREE-LIFT - STANDARD (C663) ............................................................................... 9-16

CONTACTOR

WITH E-STEERING (2/2015 →) ................................................................................................................ 2-52

WITHOUT E-STEERING (→ 2/2015) ......................................................................................................... 2-50

CONTROL VALVE

ELECTRO-HYDRAULIC - 3 AND 4 FUNCTION ......................................................................................... 6-66

CONTROLLER

HOIST AND FAN ASSEMBLY (→ S/N G807B05963L) ............................................................................. 2-26

HOIST AND FAN ASSEMBLY - WITHOUT E-STEERING (S/N G807B05964L →) .................................. 2-28

TRACTION AND FAN ASSEMBLY (→ S/N G807B05963L) ...................................................................... 2-32

TRACTION AND FAN ASSEMBLY (S/N G807B05964L →) ...................................................................... 2-34

CONTROLLER 48/36 VDC

HOIST 450A WITH E-STEERING (2/2015 →) ........................................................................................... 2-30

CONTROLLERS

WITH E-STEERING (2/2015 →) ................................................................................................................ 2-22

WITHOUT E-STEERING (→ 2/2015) ......................................................................................................... 2-18

CONVERSION KIT .......................................................................................................................................... 11-2

CONVERSION KITS COUNTERWEIGHT

→ 2/2015 .................................................................................................................................................... 1-4

2/2015 → .................................................................................................................................................... 1-6

G807

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

COWL MOUNT

→ S/N G807B02919J ................................................................................................................................. 1-105

S/N G807B02920J → ................................................................................................................................. 1-106

DASH AND STEERING COLUMN COVERS

FIXED COLUMN ......................................................................................................................................... 1-110

TELESCOPIC COLUMN ............................................................................................................................. 1-112

DC/DC CONVERTER

→ S/N G807B06434M ................................................................................................................................ 10-4

S/N G807B06435M → ................................................................................................................................ 10-6

DISPLAY ......................................................................................................................................................... 2-53

DOME LIGHT .................................................................................................................................................. 10-14

DRIVE TIRE AND WHEEL ASSEMBLY .......................................................................................................... 3-10

DRIVE UNIT ASSEMBLY ................................................................................................................................ 3-2

ELECTRICAL ARRANGEMENT

→ S/N G807B02104H ................................................................................................................................ 2-4

S/N G807B02105H ↔ 10/2013 .................................................................................................................. 2-8

WITH E-STEERING (2/2015 →) ................................................................................................................ 2-14

WITHOUT E-STEERING (10/2013 ↔ 2/2015) ........................................................................................... 2-10

FLOOR PLATES ............................................................................................................................................. 1-108

FORK POSITIONER ASSEMBLY ................................................................................................................... 10-42

FORKS

OPTIONAL .................................................................................................................................................. 1-119

STANDARD ................................................................................................................................................. 1-118

FRAME HINGE

2/2015 → .................................................................................................................................................... 1-96

FREE LIFT ASSEMBLY

THREE STAGE FULL FREE LIFT - A271 (→ S/N A271B02146H) ........................................................... 8-10

THREE STAGE FULL FREE LIFT - A271 (S/N A271B02147H →) ........................................................... 8-14

THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-40

TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-8

FREE LIFT CYLINDER ASSEMBLY

THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-20

THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-46

TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-14

FREE-LIFT ASSEMBLY

TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-34

FRONT WORK AND MARKER LIGHTS ......................................................................................................... 10-8

FUSE PANEL ASSEMBLY

WITH E-STEERING (2/2015 →) ................................................................................................................ 2-48

WITHOUT E-STEERING (→ 2/2015) ......................................................................................................... 2-46

HEADER HOSE ASSEMBLY

THREE STAGE FULL FREE LIFT - A271 (S/N G807B02139H →) ........................................................... 8-28

G807

iii

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

THREE STAGE FULL FREE LIFT - A271 - 3 RD FUNCTION HOSES (→ S/N G807B02138H) .............. 8-24

THREE STAGE FULL FREE LIFT - A271 - 4 TH FUNCTION HOSES (→ S/N G807B02138H) ............... 8-26

THREE STAGE FULL FREE LIFT - C662 - 3 RD FUNCTION HOSES (→ S/N G807B02138H) .............. 8-50

THREE STAGE FULL FREE LIFT - C662 - 4 TH FUNCTION HOSES (→ S/N G807B02138H) .............. 8-52

THREE STAGE FULL FREE-LIFT - C662 (S/N G807B02139H →) (→ 12/2012) .................................... 8-56

THREE STAGE FULL FREE-LIFT - C662 (12/2012 →) ............................................................................ 8-60

TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-38

TWO STAGE FULL FREE LIFT - C663 - 3 FUNCTION (→ S/N G807B02138H) ...................................... 9-18

TWO STAGE FULL FREE LIFT - C663 - 4TH FUNCTION (→ S/N G807B02138H) ................................. 9-20

TWO STAGE LIMITED FREE LIFT - A270 (→ S/N A270B01595H) .......................................................... 7-14

TWO STAGE LIMITED FREE LIFT - A270 (S/N A270B01596H →) .......................................................... 7-16

TWO STAGE LMITED FREE-LIFT - C661 .................................................................................................. 7-32

TWO-STAGE FULL FREE-LIFT - C663 (S/N G807B02139H →) .............................................................. 9-22

HEADER HOSE CONVERSION KITS HOOD AND COUNTERWEIGHT COVER

2/2015 → .................................................................................................................................................... 1-72

LATE PRODUCTION (→ 2/2015) .............................................................................................................. 1-68

WITH RAPID CHARGE OPTION (→ 2/2015) ............................................................................................ 1-74

HOOD AND COVERS

EARLY PRODUCTION ............................................................................................................................... 1-64

HYDRAULIC CONTROL VALVE

MANUAL - 3 AND 4 FUNCTION (→ S/N G807B03975K) ......................................................................... 6-44

MANUAL - 3 AND 4 FUNCTION (S/N G807B03976K ↔ 2/2015) ............................................................. 6-48

MANUAL - 3 AND 4 FUNCTION (2/2015 →) ............................................................................................. 6-52

HYDRAULIC CONTROLS

ELECTRO-HYDRAULIC ............................................................................................................................. 6-64

MANUAL ..................................................................................................................................................... 6-36

HYDRAULIC CONVERSION KITS .................................................................................................................. 11-2

HYDRAULIC FILTER HOUSING ..................................................................................................................... 6-20

HYDRAULIC HOSE

MAST .......................................................................................................................................................... 6-34

HYDRAULIC HOSES AND FITTINGS

AUXILIARY HOSES .................................................................................................................................... 6-32

STEERING (→ PENDING PER ECN 15533404) (→ 2/2015) ................................................................... 6-26

STEERING - WITH SYNCRONOUS STEERING (PENDING PER ECN 15533404 →) ............................ 6-28

STEERING - WITHOUT SYNCRONOUS STEERING (PENDING PER ECN 15533404 →) .................... 6-30

HYDRAULIC LEVERS - LINKAGE ASSEMBLY (MANUAL) ........................................................................... 6-40

HYDRAULIC MOTOR ..................................................................................................................................... 6-12

HYDRAULIC POWER UNIT INSTALLATION

→ 2/2015 .................................................................................................................................................... 6-4

ELECTRIC STEERING ............................................................................................................................... 6-6

HYDRAULIC PUMP ........................................................................................................................................ 6-14

HYDRAULIC PUMP AND MOTOR

ELECTRIC STEERING (2/2015 →) ........................................................................................................... 6-10

HYDRAULIC PUMP AND MOTOR ASSEMBLY

→ 2/2015 .................................................................................................................................................... 6-8

HYDRAULIC SUPPLY AND RETURN

→ 2/2015 .................................................................................................................................................... 6-22

WITH ELECTRIC STEERING (2/2015 →) ................................................................................................. 6-24

G807

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

HYDRAULIC TANK AND ATTACHING PARTS

ELECTRIC STEERING (2/2015 →) ........................................................................................................... 6-18

HYDRAULIC TANK ASSEMBLY

→ 2/2015 .................................................................................................................................................... 6-16

IMPACT SENSOR

→ 2/2015 .................................................................................................................................................... 10-48

2/2015 → .................................................................................................................................................... 10-50

INLET SECTION

ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-68

MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-56

INTEGRAL SIDE-SHIFT

FORK POSITIONER - TWO STAGE LIMITED FREE-LIFT ........................................................................ 10-34

FORK POSITIONER (907 MM) - 2 AND 3 FFL ........................................................................................... 10-36

FORK POSITIONER (977 MM) - 2 AND 3 FFL ........................................................................................... 10-38

INTEGRAL SIDE-SHIFT CYLINDER .............................................................................................................. 10-40

LABELS

EXTERIOR .................................................................................................................................................. 1-120

HYDRAULIC CONTROL FUNCTIONS ....................................................................................................... 1-124

INTERIOR ................................................................................................................................................... 1-122

LIFT CYLINDER ASSEMBLY

TWO STAGE LIMITED FREE LIFT - A270 ................................................................................................. 7-10

TWO STAGE LIMITED FREE LIFT - C661 ................................................................................................. 7-26

LIFT/TILT SECTION

ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-70

LIFT/TILT/AUXILIARY SECTION

MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-58

LIGHT/ALARM ADD-ON OPTIONS KITS ....................................................................................................... 11-4

LIGHTS

WITH STANDARD OVERHEAD GUARD ................................................................................................... 2-62

LOAD BACKREST EXTENSION ..................................................................................................................... 1-116

MAIN LIFT ASSEMBLY

THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-6

THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-36

TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-28

TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-6

MAIN LIFT CYLINDER ASSEMBLY

THREE STAGE FULL FREE LIFT - A271 ................................................................................................... 8-18

THREE STAGE FULL FREE LIFT - C662 .................................................................................................. 8-42

MAIN LIFT CYLINDER LH

TWO STAGE FULL FREE LIFT - A272 ...................................................................................................... 9-30

TWO STAGE FULL FREE LIFT - C663 ...................................................................................................... 9-10

MAIN LIFT CYLINDER RH

TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-32

TWO STAGE FULL FREE- LIFT - C663 ..................................................................................................... 9-12

G807

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

MAST ASSEMBLY

THREE STAGE FULL FREE LIFT - A271 - INNER, INTERMEDIATE AND OUTER (→ S/N A271B02146H)

.................................................................................................................................................................... 8-2

THREE STAGE FULL FREE LIFT - A271 - INNER, INTERMEDIATE AND OUTER (S/N A271B02147H →)

.................................................................................................................................................................... 8-4

THREE STAGE FULL FREE LIFT - C662 - INNER, INTERMEDIATE AND OUTER (→ S/N C662B02349H)

.................................................................................................................................................................... 8-32

THREE STAGE FULL FREE LIFT - C662 - INNER, INTERMEDIATE AND OUTER (S/N C662B02350H →)

.................................................................................................................................................................... 8-34

TWO STAGE FULL FREE LIFT - C663 (→ S/N C663B01671H) ............................................................... 9-2

TWO STAGE FULL FREE LIFT - C663 (S/N C663B01672H →) ............................................................... 9-4

TWO STAGE FULL FREE- LIFT - A272 ..................................................................................................... 9-26

TWO STAGE LIMITED FREE LIFT - A270 (→ S/N A270B01595H) .......................................................... 7-2

TWO STAGE LIMITED FREE LIFT - A270 (S/N A270B01596H →) .......................................................... 7-6

TWO STAGE LIMITED FREE LIFT - C661 (→ S/N C661B01677H) ......................................................... 7-18

TWO STAGE LIMITED FREE LIFT - C661 (S/N C661B01678H →) ......................................................... 7-22

MASTER CYLINDER ...................................................................................................................................... 5-4

MINI-LEVER CONTROLS

3 FUNCTION ............................................................................................................................................... 2-54

4 FUNCTION ............................................................................................................................................... 2-58

MIRROR

CONVEX REAR VIEW ................................................................................................................................ 10-16

DUAL REAR VIEW ...................................................................................................................................... 10-18

MISCELLANEOUS ADD-ON OPTION KITS ................................................................................................... 11-4

OUTLET SECTION

MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-60

OVERHEAD GUARD

→ S/N G807B02919J ................................................................................................................................. 1-8

S/N G807B02920J → ................................................................................................................................. 1-10

PARKING BRAKE RELEASE

→ 2/2008 .................................................................................................................................................... 5-6

2/2008 → .................................................................................................................................................... 5-8

POSITIONER SENSOR

MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-62

REAR REFLECTORS AND TAIL LIGHTS ...................................................................................................... 10-10

REVERSE HANDLE ........................................................................................................................................ 10-20

SEAT

FULL SUSPENSION - SHEET 1 0F 2 ......................................................................................................... 1-48

FULL SUSPENSION - SHEET 2 OF 2 ........................................................................................................ 1-52

FULL SUSPENSION, HIGH BACK - SHEET 1 0F 2 ................................................................................... 1-54

FULL SUSPENSION, HIGH BACK - SHEET 2 OF 2 .................................................................................. 1-58

G807

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

SERVICE KITS

SIDE PANELS ................................................................................................................................................. 1-78

STATIC STRAP ............................................................................................................................................... 1-114

STEER AXLE ASSEMBLY

→ 2/2015 .................................................................................................................................................... 4-4

STEER AXLE MOUNTING

→ 2/2015 .................................................................................................................................................... 4-2

STEER TIRE AND WHEEL ASSEMBLY ......................................................................................................... 4-15

STEERING ACCUMULATOR

→ PENDING PER ECN 15533404 ............................................................................................................ 4-34

STEERING AXLE

ELECTRIC STEERING - PAGE 1 OF 4 ...................................................................................................... 4-8

ELECTRIC STEERING - PAGE 2 OF 4 ...................................................................................................... 4-10

ELECTRIC STEERING - PAGE 3 OF 4 ...................................................................................................... 4-12

ELECTRIC STEERING - PAGE 4 OF 4 ...................................................................................................... 4-14

STEERING COLUMN ASSEMBLY

FIXED (→ 10/2013) .................................................................................................................................... 4-20

FIXED (10/2013 →) .................................................................................................................................... 4-22

FIXED - ELECTRIC STEERING ................................................................................................................. 4-24

TELESCOPIC (→ 10/2013) ........................................................................................................................ 4-26

TELESCOPIC (10/2013 →) ........................................................................................................................ 4-27

TELESCOPIC WITH TILT MEMORY - ELECTRIC STEERING ................................................................. 4-28

STEERING HAND PUMP ASSEMBLY

→ PENDING PER ECN 15533404 ............................................................................................................ 4-30

PENDING PER ECN 15533404 → ............................................................................................................ 4-32

STEERING WHEEL AND COLUMN

FIXED .......................................................................................................................................................... 4-16

TELESCOPIC .............................................................................................................................................. 4-18

STROBE LIGHT ASSEMBLY AND REAR WORK LIGHT .............................................................................. 10-12

TIE RODS

ELECTRO-HYDRAULIC CONTROL VALVE .............................................................................................. 6-72

MANUAL HYDRAULIC CONTROL VALVE ................................................................................................ 6-61

TILT CYLINDER AND MAST INSTALLATION ................................................................................................ 6-74

TILT CYLINDER ASSEMBLY .......................................................................................................................... 6-76

TILT SENSOR GROUP ................................................................................................................................... 2-56

TRACTION MOTOR ASSEMBLY ................................................................................................................... 3-4

TRACTION SPEED LIMITER

STANDARD AND INTEGRAL SIDE-SHIFT CARRIAGES .......................................................................... 10-52

TRANSMISSION

COVER AND BRAKE DISCS ...................................................................................................................... 3-6

HOUSING .................................................................................................................................................... 3-8

WIRE HARNESS

AUXILIARY PLUG ....................................................................................................................................... 2-165

CAB ACCESSORY ..................................................................................................................................... 2-152

CAB ACCESSORY - ALTERNATE PART .................................................................................................. 2-153

G807

vii

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

DC CONVERTER - 12V OUTLET (→ 9/2013) ........................................................................................... 2-158

DC CONVERTER - 12V OUTLET (9/2013 →) ........................................................................................... 2-162

DC/DC CONVERTER ................................................................................................................................. 2-164

DC/DC CONVERTER - W/ E-STEERING ................................................................................................... 2-166

HEATER ...................................................................................................................................................... 2-144

HYDRAULIC FLUID LEVEL AND PRESSURE ........................................................................................... 2-155

LIGHTS WITH OVERHEAD GUARD (→ 10/2013) .................................................................................... 2-156

LIGHTS WITH OVERHEAD GUARD (10/2013 →) .................................................................................... 2-160

MAIN WITH ELECTRO-HYDRAULICS - SHEET 1 OF 2 (→ S/N G807B02113H) .................................... 2-70

MAIN WITH ELECTRO-HYDRAULICS - SHEET 2 OF 2 (→ S/N G807B02113H) .................................... 2-74

MAIN WITH ELECTRO-HYDRAULICS - SHEET 1 OF 2 (S/N G807B02114H →) .................................... 2-78

MAIN WITH ELECTRO-HYDRAULICS - SHEET 2 OF 2 (S/N G807B02114H →) .................................... 2-82

MAIN WITH ELECTRO-HYDRAULICS AND E-STEERING - SHEET 1 0F 2 (2/2015 →) ......................... 2-94

MAIN WITH ELECTRO-HYDRAULICS AND E-STEERING - SHEET 2 OF 2 (2/2015 →) ........................ 2-98

MAIN WITH ELECTRO-HYDRAULICS, WITHOUT E-STEER - SHEET 1 OF 2 (S/N G807B06004L →)

.................................................................................................................................................................... 2-86

MAIN WITH ELECTRO-HYDRAULICS, WITHOUT E-STEER - SHEET 2 OF 2 (S/N G807B06004L →)

.................................................................................................................................................................... 2-90

MAIN WITH MANUAL HYDRAULICS - SHEET 1 OF 2 (→ S/N G807B02104H) ...................................... 2-102

MAIN WITH MANUAL HYDRAULICS - SHEET 2 OF 2 (→ S/N G807B02104H) ...................................... 2-106

MAIN WITH MANUAL HYDRAULICS - SHEET 1 OF 2 (S/N G807B02105H →) ...................................... 2-110

MAIN WITH MANUAL HYDRAULICS - SHEET 2 OF 2 (S/N G807B02105H →) ...................................... 2-114

MAIN WITH MANUAL HYDRAULICS - SHEET 1 OF 2 (S/N G807B06004L ↔ 11/2014) ......................... 2-118

MAIN WITH MANUAL HYDRAULICS - SHEET 2 OF 2 (S/N G807B06004L ↔ 11/2014) ......................... 2-122

MAIN WITH MANUAL HYDRAULICS AND E-STEERING - SHEET 1 OF 2 (2/2015 →) .......................... 2-134

MAIN WITH MANUAL HYDRAULICS AND E-STEERING - SHEET 2 OF 2 (2/2015 →) .......................... 2-138

MAIN WITH MANUAL HYDRAULICS, WITHOUT E-STEER - SHEET 1 OF 2 (11/2014 ↔ 2/2015) ........ 2-126

MAIN WITH MANUAL HYDRAULICS, WITHOUT E-STEER - SHEET 2 OF 2 (11/2014 ↔ 2/2015) ........ 2-130

MANUAL HYDRAULICS ............................................................................................................................. 2-145

MANUAL INTERLOCK ................................................................................................................................ 2-146

REAR WIPER .............................................................................................................................................. 2-151

RH LIGHT WITH FREEZER DISPLAY - WITH TURN SIGNAL (→ 10/2013) ............................................ 2-66

RH LIGHT WITH FREEZER DISPLAY - WITH TURN SIGNAL (10/2013 →) ............................................ 2-68

RH LIGHT WITH STANDARD DISPLAY - WITHOUT TURN SIGNALS (→ 10/2013) ............................... 2-64

RH LIGHT WITH STANDARD DISPLAY - WITHOUT TURN SIGNALS (10/2013 →) ............................... 2-65

STEER COLUMN ........................................................................................................................................ 2-149

STEER UNIT ............................................................................................................................................... 2-148

STEERING COLUMN WITH ELECTRIC STEERING (2/2015 →) ............................................................. 2-150

SYNCHRONOUS STEERING ..................................................................................................................... 2-147

TURN SIGNAL ............................................................................................................................................ 2-142

viii

G807

GENERAL INFORMATION

ABBREVIATIONS QUICK REFERENCE SHEET

Listed below are abbreviations used in parts manuals to denote the following expressions:

spacer

TERM DEFINITION

Amp Amperes

AR As Required

BDI Battery Discharge Indicators

BWI Brush Wear Indicator

CE Communicator End

CRE Corrosive Environment

D/B Date Break

dbA Decibel "A" Scale

DE Drive End

ECH Empty Container Handler

ECH-3 Empty Container Handler - 3 High

Stacking

ECH-4 Empty Container Handler - 4 High

Stacking

ECH-5 Empty Container Handler - 5 High

Stacking

ECH-6 Empty Container Handler - 6 High

Stacking

ECH-7 Empty Container Handler - 7 High

Stacking

ECM Electronic Control Module

ECN Engineering Change Notice

EEPROM Electrically Erasable Programmable

Read Only Memory

EPA US Environmental Protection Agency

EPROM Electrically Programmable Read Only

Memory

FRE Freezer Environment

in. inches

LPG Liquefied Petroleum Gas

MAP Manifold Absolute Pressure

mm millimeters

MSTS Microprocessor Spark Timing System

NPT National Pipe Threads

O/S Oversize

PTO Power Take Off

RPM Revolutions per Minute

S/N Serial Number

TMM Truck Management Module

UL Type D Diesel-Powered Safety Rating

UL Type DS Diesel-Powered Safety Rating

UL Type E Battery-Powered Safety Rating

UL Type EE Battery-Powered Safety Rating

UL Type ES Battery-Powered Safety Rating

UL Type G Gasoline-Powered Safety Rating

UL Type GS Gasoline-Powered Safety Rating

UL Type LP Gas-Powered Safety Rating

UL Type LPS LP Gas-Powered Safety Rating

U/S Undersize

UL Underwriters Laboratory

V Volts

G807

GENERAL INFORMATION

HOW TO USE THE ILLUSTRATED PARTS MANUAL

This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

G807

HOW TO FIND THE DESIRED PART NUMBER

GENERAL INFORMATION

WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:

1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

2. Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:

3. Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).

4. Locate the assembly the required part is used on and turn to the page indicated for that assembly. Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN:

5. Use the Numerical Index (Page 12-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL:

The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

6. Parts Supersession Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.

Five periods in the PART NO. column (. . . . .)

indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a page number in the DESCRIPTION column (FPage 3-4)

7. Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc. Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

8. Indented descriptions under the DESCRIPTION column are used to indicate assemblies and

subparts of assemblies. In the example on the previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE.

9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

10. Serial number breaks identify the most current parts information and are shown as follows:

→ S/N A810N2639

Indicates last serial number affected.

S/N A810N2640 →

Indicates the first serial number affected.

S/N A810N1553 ↔ S/N A810N3291

Indicates a range of serial numbers affected.

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows:

→ S/N Pending Per ECN 63243

Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 →

Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows:

→ D/B 3/00

Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 →

Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ↔ D/B 4/00

Indicates a range of production dates of the item affected.

Contact your local dealer for Yale lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS:

When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Yale lift trucks.

G807

GENERAL INFORMATION

IDENTIFICATION OF TRUCK SERIAL NUMBERS

NOTE: Serial Number breakdown is only for trucks built after 1994.

(1) and (2) The first letter and three numbers indicate the truck unit code.

(3) The second letter indicates the plant of manufacture.

(4) The four or five digit number indicates the production sequence number of the truck.

(5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.

The letters "I", "O", and "Q" will not be used.

For pending serial numbers contact your local dealer for Yale lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

xii

G807

GENERAL INFORMATION

IDENTIFICATION OF MAST SERIAL NUMBERS

(1) and (2) The first letter and number indicates the mast unit code.

(3) The second letter indicates the plant of manufacture.

(4) The four or five digit number indicates the production sequence number of the mast.

(5) Carriage travel in millimeters stamped just below the serial number.

Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).

For pending production sequence numbers contact your local dealer for Yale lift trucks.

LIFT EQUIPMENT IDENTIFICATION

1. Fork part number, capacity rating, plant code letter, and date of manufacture are stamped approximately six inches below the top of most forks.

2. The carriage group number is stamped on the right hand side of the top crossmember (pin type) or on the back of the right hand end of the bottom crossmember (hook type). A date code has two letters in line with or below the carriage group number.

3. The mast identification number has a unit code, a letter indicating the plant of manufacture, and a serial number. Underneath the production sequence number is a four digit number that indicates the carriage travel in millimeters.

4. Tilt and lift cylinder group numbers are stamped on the cylinder shell.

Always refer to the group, serial, or part number when ordering service parts.

Modification of masts and carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". contact your dealer for Yale lift trucks for information on these assemblies.

G807

xiii

GENERAL INFORMATION

IDENTIFICATION OF ATTACHMENT AND SIDE-

SHIFT CARRIAGE SERIAL NUMBERS

(1) and (2) The first letter and three numbers indicate the attachment unit code.

(3) The second letter indicates the plant of manufacture.

(4) The four or five digit number indicates the production sequence number.

For pending production sequence numbers contact your local dealer for Yale lift trucks.

Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify the attachment.

Always refer to the group, serial, or part number when ordering service parts.

Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". Contact your dealer for Yale lift trucks for information on these assemblies.

xiv

G807

PUBLICATIONS

GENERAL INFORMATION

Every new lift truck is provided with an OPERATING MANUAL. This manual has information that the operator must know for inspection and operation of the lift truck.

MANUALS with complete replacement part identification, are available at a nominal fee from your Yale dealer to assist users in effectively maintaining Yale lift trucks in a safe, useful condition. See the list below for information on ordering specific publications

SERVICE MAINTENANCE MANUALS, which provide

for this model lift truck.

service and overhaul procedures, and PARTS

PUBLICATION YALE PART NUMBER

Operating Manual.................................................................................................................... 524319284

Service Manual (Complete)..................................................................................................... 524320408

Parts Manual........................................................................................................................... 524308696

G807

GENERAL INFORMATION

NOTES

xvi

G807

SECTION 1

1 GENERAL TRUCK

CONTENTS

SECTION 1

GENERAL TRUCK