Maintenance

DIAGRAMS
ERP1.6,1.8,2.0ATF (ERP030-040TH) [F807]

PART NO. 524204508 8000 YRM 1081

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Diagrams Table of Contents

TABLE OF CONTENTS

Diagrams, Schematics, or Arrangements ............................................................................................................ 1

Figure 1. Schematic Diagram - AC Controller ............................................................................................ 1
Figure 2. Schematic Diagram - AC Controller ............................................................................................ 2
Figure 3. Schematic Diagram - AC Controller ............................................................................................ 3
Figure 4. Schematic Diagram - AC Controller ............................................................................................ 4
Figure 5. Schematic Diagram - CAN Dash ................................................................................................. 5
Figure 6. Schematic Diagram - CAN Dash ................................................................................................. 6
Figure 7. Schematic Diagram - CAN Dash ................................................................................................. 7
Figure 8. Schematic Diagram - Hydraulic Lever ......................................................................................... 8
Figure 9. Schematic Diagram - Valve Module ............................................................................................ 9
Figure 10. Schematic Diagram - Options - Converter ................................................................................ 10
Figure 11. Schematic Diagram - Options - Lights, Fan............................................................................... 11
Figure 12. Wiring Diagram - Cowl .............................................................................................................. 12
Figure 13. Wiring Diagram - Cowl .............................................................................................................. 13
Figure 14. Wiring Diagram - Hydraulic Control Valves ............................................................................... 14
Figure 15. Wiring Diagram - Hydraulic Control Valves ............................................................................... 15
Figure 16. Wiring Diagram - Electric Control Valves .................................................................................. 16
Figure 17. Wiring Diagram - Hood and Seat .............................................................................................. 17
Figure 18. Wiring Diagram - Contactor Panel............................................................................................. 18
Figure 19. Wiring Diagram - Controller....................................................................................................... 19
Figure 20. Wiring Diagram - Options - Lights ............................................................................................. 20
Figure 21. Wiring Schematic - Options - Lights .......................................................................................... 21
Figure 22. Wiring Diagram - Options - Lights ............................................................................................. 22
Figure 23. Wiring Diagram - Options - Lights ............................................................................................. 23
Figure 24. Schematic and Diagram Notes.................................................................................................. 24
Figure 25. Wiring Diagram - Cooling Fan ................................................................................................... 25
Figure 26. Hydraulic Schematic.................................................................................................................. 26
Figure 27. Hydraulic Schematic.................................................................................................................. 27

This section is for the following models:

ERP1.6,1.8,2.0ATF (ERP030-040TH) [F807]

©2007 Yale Materials Handling Corp. i

8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 1. Schematic Diagram - AC Controller

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 2. Schematic Diagram - AC Controller

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 3. Schematic Diagram - AC Controller

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 4. Schematic Diagram - AC Controller

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 5. Schematic Diagram - CAN Dash

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 6. Schematic Diagram - CAN Dash

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 7. Schematic Diagram - CAN Dash

7
Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 8. Schematic Diagram - Hydraulic Lever

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 9. Schematic Diagram - Valve Module

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 10. Schematic Diagram - Options - Converter

10
8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 11. Schematic Diagram - Options - Lights, Fan

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 12. Wiring Diagram - Cowl

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 13. Wiring Diagram - Cowl

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 14. Wiring Diagram - Hydraulic Control Valves

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 15. Wiring Diagram - Hydraulic Control Valves

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 16. Wiring Diagram - Electric Control Valves

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 17. Wiring Diagram - Hood and Seat

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 18. Wiring Diagram - Contactor Panel

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 19. Wiring Diagram - Controller

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 20. Wiring Diagram - Options - Lights

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 21. Wiring Schematic - Options - Lights

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 22. Wiring Diagram - Options - Lights

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 23. Wiring Diagram - Options - Lights

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 24. Schematic and Diagram Notes

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 25. Wiring Diagram - Cooling Fan

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Diagrams, Schematics, or Arrangements 8000 YRM 1081

Figure 26. Hydraulic Schematic

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8000 YRM 1081 Diagrams, Schematics, or Arrangements

Figure 27. Hydraulic Schematic

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 NOTES

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 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

8000 YRM 1081 4/07 (2/07)(6/05)(11/04)(10/04)(6/04) Printed in U.S.A.