Yale MPE060 Service Manual

MAINTENANCE MANUAL
For Models
MPW 060/080
MLW 040/060
MPE 060/080
MPC 060/080 LC/LD
MTR-700
For Service & Parts Contact
Authorized Dealer
Yale Materials Handling Corp

1400 Sullivan Drive
Caller No. 12011
Greenville, NC 27834-2011 1606 © February 1998
Yale
Industrial Trucks user information
EXPLANATION OF MODEL CODE
- MODEL
M-Motorized Hand
-TYPE
P-Pallet
T-Tractor
L-Platform
- OPERATOR POSITION
W-Walk Control
E-End Control
C-Center Control
R-Ride Control
-RATED CAPACITY
700 lbs. Draw Bar Pull
060-6,000 lbs.
080-8,000 lbs.
- BATTERY COMPARTMENT
S-Small
L-Large
M P E 080 L C N 24 T 27 48
OVERALL PALLET FORK LENGTH

Measured in Inches
OVERALL PALLET FORK WIDTH

Measured in Inches
CONTROL TYPE
T-Transistor
VOLTAGE
12-12 Volt
24-24 Volt
- MANUFACTURING SOURCE
N-North America
DESIGN SERIES
A-B-C etc.
To verify that this manual is correct for this truck compare the model code, as explained above, with the nameplate on the truck. Refer to
Table of Contents for nameplate location and information. If the model code in this manual does not agree with the information on the
nameplate contact your Yale industrial truck dealer.
B
Yale
Industrial Trucks
This Maintenance Manual is divided into major sections which are listed on this
page. Quick reference to these sections can be made by placing the right thumb on
the tab of the desired section, bending the book back and thumbing the pages to the
corresponding tab.
SECTIONS
1 OPERATING INSTRUCTIONS
2 GENERAL TRUCK AND LUBRICATION SCHEDULE
3 ELECTRICAL SYSTEM
4 DRIVE UNIT
5 BRAKE SYSTEM
6 CONTROL HANDLE
7 LIFT LINKAGE AND LOAD WHEEL
8 HYDRAULIC SYSTEM
9 BATTERY AND CHARGING SYSTEM
10 USER SUPPORT INFORMATION
11 ALPHABETICAL INDEX
0!
Yale
IndustrialTrucks
SECTION 1
OPERATING INSTRUCTIONS
i
Yale
IndustrialTrucks
SECTION 1 - CONTENTS
DESCRIPTION PAGE NUMBER
OPERATING INSTRUCTIONS-GENERAL 1-1

SERIAL NUMBER 1-1
MODEL CODE 1-1
TRUCK WEIGHT 1-1
CAPACITY RATING 1-1
SAFETY AND INFORMATIONAL LABELS 1-3
OPERATOR PRE-CHECKS AND INSPECTION 1-3
OPERATING PROCEDURE-GENERAL 1-3
SHUT DOWN PROCEDURE 1-4
SAFETY AND OPERATIONAL CHECK LIST 1-4
OPERATING CONTROLS-CONTROL HANDLE 1-7
REVERSING BUTTON 1-7
HORN BUTTON 1-7
DIRECTION AND SPEED CONTROL 1-7
LIFT BUTTON 1-8
LOWER BUTTON 1-8
BRAKES 1-8
BRAKING 1-8
PARKING BRAKE 1-8
STEERING 1-9
BATTERY CONNECTOR 1-9
BATTERY INDICATOR AND HOURMETER (OPTIONAL) 1-10
HANDRAIL CONTROL-MPE 1-10
FAST SPEED CONTROL-MPC AND MTR 1-10
PICKASSIST-MPE (OPTIONAL) 1-11
COAST CONTROL-MPE (OPTIONAL) 1-11
TILT CONTROL 1-11
DESIGNATED OPERATOR POSITION 1-11
OPERATING PROCEDURES 1-13
SAFE MAINTENANCE PROCEDURES 1-13
MOVING A DISABLED LIFT TRUCK 1-14
HOW TO PUT A LIFT TRUCK ON BLOCKS 1-15
HOW TO RAISE DRIVE TIRE 1-16
HOW TO RAISE LOAD WHEELS 1-16
PRECAUTIONS FOR TRUCKS IN STORAGE 1-16
PRECAUTIONS FOR BATTERIES IN STORAGE 1-17
i
ÿ
ÿi
iS,
ÿ
'
ÿ
Yale
IndustrialTrucks OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS-GENERAL be considered when operating on elevated floors, elevators,

etc.
Before attempting to operate this truck, carefully read and
understand these operating procedures.
Capacity Rating
Make sure the truck is in proper operating condition. Visually This rating shows the maximum load capacity of this truck.
inspect the entire truck for any damage that may have occurred Personal injury and damage to the truck can occur if the
during shipment. capacity is exceeded.
NOTE: Throughout this manualthe terms right, left, front and This truck meets all applicable mandatory requirements of
rear relate to the viewpoint of an operator walking with or riding ANSI B56.1-Safety Standard for Powered Industrial Trucks at
on the truck with the forks trailing. the time of manufacture. In addition, these trucks are classified
by Underwriters' Laboratories, Inc. and/or approved by Factory
Familiarize yourself with the information contained on the Mutual Engineering Corporation for the type designation
nameplate which is located on the drive unit top plate. shown on the nameplate. Consult UL Index of Classified
Information on this nameplate is as follows: Products and FM Approval Guide.
Serial Number No additions, omissions or modifications should be made that

will affect compliance to the previously stated requirements or
This is an identification number assigned to this particular truck
in any way minimize the effectiveness of the safety devices.
and should be used when ordering service parts or when
requesting any information from your Yale industrial truck
Safety and informational labels are located in conspicuous
dealer. The serial number is a six digit number preceded by a
locations on this truck and should be strictly followed. Check
letter and is stamped on the truck frame and on the nameplate.
the nameplate of eachtruck before operation. These safety and
informational labels must be replaced immediately if missing or
Model Code
defaced. Labels will vary with type of truck and equipment
The model number andthe serial number should be used when installed. Refer to the Parts Manual for part number and
requesting information. An explanation of the model code is location for all labels.
located on Page B of this manual.
Truck Weight
This isthe approximate weight of the truck without a load on the
forks. This weight plus the weight of the load to be moved must
1. LABEL, DIRECTION ARROW

2. LABEL, OPERATOR WARNING
3. SERIAL NUMBER, FRAME
4. SERIAL NUMBER, NAMEPLATE
MPW SHOWN
MLW AND MPE
SIMILAR
TOP VIEW
-
Figure 1-1 Serial Number, Nameplate, and Warning Label Locations-MPW, MLW and MPE
1-1
Yale
Industrial Trucks
1-2
/
\
f
y-
\
O
o
0
-
'
/ _J MCMÿ11
//O-
1
'
fc5 1
-Effl
ÿ
I
HI
|i
1
o: q ]
Yale
Maximum Capacity
Truck Model No.
Volts Use a Type
Truck Weiqht With
Volts Use a Type

Truck Weiqht Less Batterv
Truck Weiqht With
"1_
lb
Battery Only
nge
Truck Type
Max. A. H.
lb
Batterv
Figure 1-2 - Serial Number, Nameplate, and Warning Label Locations-MPC
Maximum Capacity
Truck Model No.
lb
Battery Only
1.
2.
3.
4.
Figure 1-3 - Serial Number, Nameplate, and Warning Label Locations-MTR

1.
2.
3.
4.
Serial Number
Truck Type
LABEL, DIRECTION ARROW
LABEL, OPERATOR WARNING
SERIAL NUMBER, FRAME
SERIAL NUMBER, NAMEPLATE
Serial Number
Max. A. H.
lb
Batterv
lb To
E
(6 Hour Rate)
E
lb
(6 Hour Rate)
LABEL, DIRECTION ARROW

LABEL, OPERATOR WARNING
SERIAL NUMBER, FRAME
SERIAL NUMBER, NAMEPLATE
lb
lb
ÿWARNING
DONOTOPERATETHISTRUCKUNTIL YOU HAVE...
•
••
••
BeanlralnedandquaHlled
ReadtheOperallngManualattachedtotruck
Readallcaution ruli»attachedtotruck
Checkedthenameplatelorcapaclty
Checked thetruck daky lor proper operation and hadak delects corrected
FAILURE TO COMPLY WITHTHESE REQUIREMENTS
ÿWARNING
3)
Yale
Industrial Trucks OPERATING INSTRUCTIONS
A WARNING
A WARNING
A WARNING APPLY HANDBRAKE
WHEN LEAVING TRUCK.
$$
BRAKK IS NOT AUTOMATICALLY
APPLIED WHEN CONTROL
HANDLE IS RELEASED.
TO APPLY BRAKE: PUSH HANDLE
TO VERTICAL AND HOLD.
I
COAST
L
FOR PARKING OR AUTOMATIC
Yale FAST
BRAKING: SET SELECTOR TO
"BRAKE" POSITION.
Classified by
Underwriters Laboratories Inc.O
As to Fire and
Electric Shock Hazard Only THIS TRUCK IS TO BE EQUIPPED WITH
Type! I Industrial Truck.L A BATTERY MEASURING
No. i . i +1/2 in +1/2 in
BRAKE 0 in
Yalo Materials Handling Corporation
' 15 Junction Rd. Flemington, NJ 08822
f 1.
2.
3.
4.
LABEL-DIRECTIONAL ARROW
PLATE-BATTERY SIZE
PLATE-U.L. APPROVAL
LABEL-PARKING BRAKE
Figure 1-4 - Safety and Informational Labels
5. LABEL-COAST CONTROL
6. LABEL-FAST SPEED
7. LABEL-NO RIDERS
OPERATOR PRE-CHECKS AND INSPECTION 4. Check hydraulic hoses for leaking, chafing, cuts or
reinforcement showing through the outside of the hose.
Before each shift, every 8 hours, it is the operator's
responsibility to carry out the following checks and inspections
5. Operate brakes, all hydraulic controls, reversing switch,
before beginning truck operation. Do not operate truck if it is in
direction and speed control and steering. Make sure they
need of repair, if it is in an unsafe condition, or might contribute
operate freely and return to their proper positions (if equipped).
to an unsafe condition. Remove the key and report the
condition to the proper authority. If the truck becomes unsafe in
6. Inspect condition of wheels and tires.
any way while you are operating it, STOP operating the truck
and report the matter immediately to the proper authority.
7. Inspect forks for any damage (if equipped).
Basic maintenance information and the Recommended
8. Test horn and any other accessories. Make sure they are
Schedule of Maintenance are in the Operational Maintenance
properly mounted and in good working order.
Manual, Part Number 5192938-04, located in the document
holder on the compartment cover. Also refer to Section 2 of this
9. Operate truck and make sure all gauges and meters are
manual.
functioning properly.
1. Make sure all capacity, safety and informational plates or
10. Make sure any unusual noises are investigated
labels are attached. This truck is not considered safe to use
immediately.
without a legible, properly filled out nameplate. Contact Yale
Materials Handling Corporation or your local dealer for Yale
Industrial Trucks if the nameplate is not present and legible. OPERATING PROCEDURE-GENERAL
See the Operating Manual for label and plate locations.
Practice with an empty truck until you (the operator) have
achieved satisfactory smoothness in all operations, traveling,
2. Inspect truck for any damage that might have occurred
lifting, etc.
during the previous shift.
ÿ Never ride a truck that is designed for walk operation.
3. Inspect truck before and after operating, for any signs of
external leaking of the battery, hydraulic system, etc.
1-3
YaloIndustrial Trucks OPERATING INSTRUCTIONS
ÿ Watch clearances, especially around forks. Watch tail ÿ Observe all traffic regulations, including authorized plant
swing. The driver must be aware that the forks can sometimes speed limits. Under normal traffic conditions, keep to the right.
extend beyond the load. This may cause the operator to hit an Maintain a safe distance from the truck ahead (approximately
object or lift another load. three truck lengths), and keep the truck under control at all
times.
ÿ Do not permit passengers to ride on the truck.
ÿ Report all accidents involving personnel, building
ÿ Look in the direction of travel and keep a clear view of the structures and equipment to the proper authority.
path of travel.
ÿ Avoid any abrupt moves. Be a professional. "HANDLE
ÿ If visibility is impaired by the load, operate truck with the WITH CARE."
forks trailing and face in the direction of travel or use extreme
caution. ÿ Do not remove load backrest extension, if so equipped,
unless specifically authorized.
ÿ The high speed control should only be used when riding on
the truck. ÿ Make sure that fork length is at least 2/3 of load length.
ÿ Stop, start, travel, steer and brake smoothly. Slow down for ÿ Carry the load flush against the battery or load backrest.
turns and on uneven or slippery surfaces that could cause truck
to overturn or slide. ÿ Allow no one under or near load or lifting mechanism.
ÿ Before entering trucks or trailers, be certain the brakes on ÿ Watch that your load does not exceed the capacity rating of
the truck ortrailer are applied and wheel chock(s) are in place. If the truck. The truck capacity is posted on the nameplate which
trailers are not coupled to a tractor, supports may be needed to is attached to the truck at the factory.
prevent upending or corner dipping. Check the flooring of
trucks, trailers and railroad cars for breaks and weakness ÿ Do not handle unstable or loosely stacked loads.
before driving onto them.
ÿ Center the forks under the skid or bin to be handled.
ÿ Before driving over a dockboard or bridge plate, be certain
that it is properly secured. Drive carefully and slowly across the ÿ Do not start or operate this truck or any of its functions or
dockboard or bridge plate and never exceed its rated capacity. attachments if you are not in the designated operator's position.
ÿ Maintain a safe distance from the edge of ramps or ÿ Never allow anyone to ride on your truck and never allow
platforms. Do not use this truck for opening or closing freight anyone other than a qualified professional to operate your
doors. truck.
ÿ Do not run over objects on the roadway surface as truck

SHUT DOWN PROCEDURE
stability and steering could be adversely affected.
When leaving truck unattended, fully lower forks, shut off
ÿ Do not push extra loads with the truck. power, set brake, set coast control to off (when equipped),
neutralize controls and remove key. If you park the truck on an
ÿ When approaching cross-aisles, slow down, sound horn incline, chock the wheels.
and keep to the right side of aisle. Operate truck under all
conditions at a speed that will permit it to be brought to a stop in
SAFETY AND OPERATIONAL CHECK LIST
a safe manner.
A "Daily Check List" similar to the one shown on the next page
ÿ On inclines, travel with the load or forks downhill. If the should be used every day before operating the truck. The check
operator should lose footing or control of the lift truck, the lists are available in tablet form with 50 sheets per tablet and
operator will not be in the path of travel. Do not turn on an can be obtained from your local Yale industrial truck dealerfor a
incline. For stability reasons, a lift truck must not be driven nominal fee.
across an incline. Motorized Hand lift trucks are not intended for
operation on grades greater than 10% (a grade that changes 1 Both this manual and the Operating Manual contain the
foot in elevation for every 10 feet of horizontal travel). Recommended Schedules of Maintenance which should be
used as a guide along with the Lubrication Instructions.
ÿ Operate truck on all grades with the forks downhill.
A professional operator should also be familiar with the
ÿ Yield the right of way to pedestrians. information contained in the American National Safety
Standard for Powered Trucks-ANSI B56.1.
1-4
Yale
NOTE: This Daily Check List is available for the Operator. Some items on this list may not be applicable to your truck. This
convenient check list is in tablet form and can be ordered through your Yale Industrial Truck Dealer. Form Number 944-6418-A.
Yale
Industrial Trucks
Daily pre-shift inspection is an OSHA requirement.
We recommend that you document that these
inspections have been made
OPERATOR'S DAILY CHECK LIST
Electric Truck
Record of Fluid Added

Date Operator Battery Water
Truck Number Model Number Hydraulic Oil
Department Serial Number
Shift Drive HourMeter Reading Lift HourMeter Reading
SAFETY AND OPERATIONAL CHECKS (Prior to each shift)
Have a qualified mechanic correct all problems. (O.K.jÿ) Need Maintenance
Leaks-Hydraulic Oil, Battery
Tires-Condition and Pressure
Forks, Top Clip Retaining Pin and Heel-Check Condition
Load Backrest/Extension-Securely Attached
Hydraulic Hoses, Mast Chains and Stops-Check Visually
Finger Guards-Attached
Overhead Guard-Attached
Safety Warnings-Attached (Refer to Parts Manual for Location)
Internal Checks:
Battery-Check Water/Electrolyte Level and Charge
Hydraulic Fluid Level-Check Level
Drive Unit Fluid Level-Check Level
Operator's Compartment:
Operating Manual-in Container
Nameplate-Attached and Information Matches Model, Serial Number and Attachments
Battery Restraint System-Adjusted and Securely Fastened
Seat Belt, Buckle and Retractors-Functioning Smoothly
Brake Fluid-Check Level
Controls (Turn Truck On) Unusual Noises Must Be Investigated Immediately:
Accelerator Linkage-Functioning Smoothly
Service Brake-Functioning Smoothly
Parking Brake-Functioning
Steering Operation-Functioning Smoothly
Drive Control-Forward/Reverse-Functioning Smoothly
Tilt Control-Forward and Back-Functioning Smoothly
Lift and Lowering Control-Functioning Smoothly
Attachment Control-Operation
Horn and Lights-Functioning
Gauges: Hourmeter/Battery Discharge Indicator-Functioning
Instrument Monitors-Functioning
Form 944-6418-A (5/93)
to Copyright 1993 Yale Materials Handling Corporation
Yale
IndustrialTrucks operating instructions
Figure 1-5 - Motorized Hand Trucks and Tractor
1-6
Yale
OPERATING CONTROLS-CONTROL HANDLE

The controls and configuration of the handle will vary by model.
The control handle has the following functions. Direction and
speed of travel are controlled by a butterfly switch on the MPW
models and by the handle grips on all other models. Buttons
control lift, lower and horn. A reversing button is on the end of
the control handle on the MPW, MLW and MPE models. The
brakes are applied by fully raising or fully lowering the control
handle on the MPW, MLW and MPE models. The brakes are
applied by hand pressure on MPC and MTR units.
n=
The MPC and MTR units also have a parking brake which is
mounted at the base of the control handle. These units also
have a three position tilt control to adjust the height of the 3 6 6 3
control handle to the operator's preference.
Figure 1-8 - Control Handle-MPC and MTR
The MLW platform truck is available with a 6 inch or 9 inch high
platform and a variety of lengths to accommodate a wide range Reversing Button
of bins and skids. 1. The reversing button is designed to help protect the
operator from being pinned between the control handle and
The callouts listed in Figure 1-6 through Figure 1-8 are another object. If the button contacts the operator and is
described in the following paragraphs. pushed, when the control handle is in the operating position, the
truck will move away from the operator as long as the button is
pressed. Once the button is released, the truck cannot be
driven toward the operator until the switch is "reset", by moving
the control handle to a "brake on" position. There is no reversing
button on the MPC or MTR models.
WARNING: The reversing button will cause rapid

acceleration of the truck away from the operator.
Horn Button
2. Press the horn button to operate the horn when the key
switch is on. Alert pedestrians or other operators of your
presence. Use Wisely!
3
Figure 1-6 - Control Handle-MPW
Direction and Speed Control

3. The butterfly switch on the MPW models or the handle
grips on all other models control the direction and speed of the
truck. Lower the control handle to the "brake off" position. Press
the butterfly switch or turn the handle grips in the desired
direction of travel. The degree of movement or rotation will
determine the speed at which you travel.
The operator can change the direction of travel while the lift
truck is moving, by moving the direction control in the opposite
direction. The lift truck will come to a stop and then accelerate in
Figure 1-7 - Control Handle-MPE the opposite direction. This action is called "PLUGGING".
1-7
Yalo
Lift Button
BRAKE ON
4. Press the button to raise the forks.
MPW SHOWN
MLW AND
J MPE SIMILAR
Lower Button BRAKE OFF

5. Press the button to lower the forks.
BRAKE ON
J
V
Brakes
6. Used on MPC and MTR models only. Apply brakes by
Figure 1-10 - Braking Application-MPW, MPE and MLW
hand pressure on the brake levers located on either side of the
control handle.
A third method of stopping the lift truck is to use normal friction
(coast) by moving the speed control to OFF.
The brakes on the MPC and MTR are mounted on the control
handle and are applied by pressure to the hand brake levers.
The brakes can be operated with either hand. See Figure 1-9.
PARKING BRAKE
A parking brake is mounted at the base of the control handle
column on the MPC and MTR units.
Figure 1-9 - Hand Brake Levers-MPC and MTR
BRAKING
Several methods of stopping are available. One method of
stopping and direction changing is plugging. Plugging means
reversing the direction control while traveling, causing the unit
to slow to a stop. Return the control to the OFF position to
remain stopped. If the control is not returned to OFF, the lift
truck will accelerate in the opposite direction.
If the battery is low or if power to the motor has been interrupted Figure 1-11 - Parking Brake-MPC and MTR
plugging will not be effective.
The parking brake is not automatically applied. Set the parking
On the MPW, MLW and MPE trucks a second method of brake whenever you leave the truck. Lift up on parking brake
stopping is by fully raising or lowering the control handle. This knob to engage the parking brake. The parking brake when
will operate the mechanical brake. The brake drum is mounted properly adjusted, will hold the truck on a 10% grade. See the
on the bevel gear shaft of the drive unit. Applying the brake Maintenance Manual for adjusting procedures.
shuts off the drive motor.
1-8
Yale
STEERING To steer the MTR unit move the control handle away from the
intended direction of travel.
On the MPW, MLW and MPE models, turn the lift truck to the
right or left by moving the control handle in the desired direction
of travel.
Make sure there is adequate turning clearance. When traveling

in reverse (forks first) the lift truck will move to the side when
turning. This movement is called "tailswing". The operator must
be aware of tailswing and always check to make sure the tail
swing area is clear before turning.
MPW SHOWN
MPE AND MLW
SIMILAR TRAVEL
Figure 1-14 - Steering Directions-MTR
BATTERY CONNECTOR
The battery connector is located on top of the truck. One half of
the connector is attached to the battery cables. The other half of
the connector is attached to the truck's electrical system. Be
TRAVEL sure both halves of the connector are pushed completely
together for proper contact. This is important, as loose
connectors will produce heat and burn the contacts. To
Figure 1-12 - Steering Directions-MPW, MLW and MPE disconnect, pull up on the connector.
To steer the MPC units move the control handle away from the
intended direction of travel. CAUTION: Do not disconnect the connector by
pulling on the cable.
/
/ £
f 1 °\
C B la is rJ
1 1 1 °\
fi ÿ " ))
C G °a 1 il1 l\\
f °/
"J \
1
TRAVEL -
Figure 1-13 - Steering Directions-MPC

/
Figure 1-15 - Battery Connector
1-9
Yale
BATTERY INDICATOR AND HOURMETER

(OPTIONAL)
A combination battery indicator/hourmeter or separate battery
indicators and hourmeters are available for this truck as
optional equipment.
LOWER
_—LIFT
HORN
CURTIS
Figure 1-17 - Handrail Controls-MPE

1. BATTERY INDICATOR METER
Fast Speed Button-This button only needs to be pushed once
and it locks into a higher speed range. To discontinue use of the
HOBBS
1 CURTIS Fast Speed Button, return the direction/speed control to

BATTERY
INDICATOR neutral. Use this control only when the operator is riding on the
truck.
2. BATTERY INDICATOR 3. HOURMETER
Figure 1-16 - Battery Indicator/Hourmeter
The battery indicator features a 10 LED (Light Emitting Diode)

display of state-of-charge. As the battery's state-of-charge FAST SPEED CONTROL-MPC AND MTR
decreases, successive LED's light up. Only the LED indicating High speed is controlled by a foot switch for long distance
the state-of-charge is illuminated. At 70% of discharge an LED travel. The switch is on the floor of the rider compartment. The
will flash, indicating "energy reserve". At 80% of discharge both truck will operate in the higher speed range as long as the
bottom LED's will alternately flash, indicating "empty". The operator's foot is on the switch.
battery should now be recharged.
The hourmeter continually displays total operation hours. The

primary function of the hourmeter is to determine maintenance
intervals as outlined in the Recommended Schedules of
Maintenance located in the Operational Maintenance Manual.
HANDRAIL CONTROL-MPE
The handrail controls are available for the operator when riding
on the platform. The controls are similar to those on the control
handle, lift lower and horn. The handrail control has one
additional button, the fast speed button.
Figure 1-18 - Fast Speed Control-MPC and MTR
1-10
Yale
PICK ASSIST-MPE (OPTIONAL)

The pick assist option is designed to be used with the coast A WARNING I
control option. The operator must walk alongside and stay clear
of the truck. With coast control set to the "coast" position,
depress the inside handle grip and press the button with thumb
\
W COAT
to travel in the forward direction (forks trailing). Release the

button and the truck will coast to a stop. Be sure the path of
travel is clear before operation.
it
Figure 1-20 - Coast Control-MPE
TILT CONTROL
The control handle column is equipped with a three position tilt
control. To adjust the tilt angle, loosen both knobs and move the
control handle to the desired position. After the desired
position has been selected tighten both knobs before
operating truck.
Figure 1-19 - Pick Assist-MPE
COAST CONTROL-MPE (OPTIONAL)

/\ WARNING: When coast control is set the brake is
/ I\ not automatically applied when control handle is
released.
A coast control feature is available forthe MPE truck as optional

equipment. To coast, set the coast control selector to the
COAST position When set, the coast control holds the steer
handle in the BRAKE OFF position. When the control handle is
released the brake is not automatically applied and the truck
will coast. To apply the brake, when using the coast control,
push the handle to the vertical position and hold. To discontinue
use of the coast control, set the coast selector to the BRAKE
position. The control handle will return to the brake on position Figure 1-21 - Tilt Control-MPC and MTR
when released for parking or automatic braking. The coast
control should only be used when the operator is using the truck DESIGNATED OPERATOR POSITION
as a walkie model.
The proper operator position for Walkie motorized hand trucks
is shown in Figure 1-22 through Figure 1-26.
Travel with forks trailing when possible. Steering the truck is

easier with the forks trailing. Walk ahead of the truck and to one
side. Lead the truck with either side of the control handle.
Operate the speed/direction control with one hand. Always look
in the direction of travel.
ÿ1-11
Yale
MPW SHOWN
MPE AND MLW
SIMILAR
TRAVEL
TRAVEL
Figure 1-22 - Forks Trailing Position
Operate forks first when entering a confined area or elevator.

Operate with the forks downhill when traveling on an incline. Figure 1-24 - Rider Position-MPE
Keep both hands on the control handle and within the handle
guards. Always look in the direction of travel.. On the MPE models, the operator should stand to one side of
the steering handle, place one hand on the steering handle and
one hand on the handrail. The handrail control for high speed
should only be used when traveling from the riding position.
The operator should always face in the direction of travel.
MPW SHOWN
MPE AND MLW When traveling on the MPC and MTR units the operator should
SIMILAR stand in the operator's compartment and face in the direction of
travel.
TRAVEL
Figure 1-23 - Forks First Position
When traveling facing the forks on the MPW and MPE units; CD
place both hands on the steering handle. When traveling with TRAVEL
the forks to the rear of the operator, use one hand and walk to
one side of the truck. Should the truck fail to stop for any reason,
you (the operator) will not be in the path of the truck.
Keep your arm straight. If the truck moves away from you, your
stiff arm will force the handle down into a braking position. If the Figure 1-25 - Rider Position-MPC
truck moves toward you, a stiff arm forces the handle up into the
braking position. Operate forks first when entering a confined area or elevator.
Operate with the forks downhill when traveling on an incline.
1-12
Yale
A
Keep both hands on the control handle and within the handle
guards. Always look in the direction of travel. WARNING: Always come to a complete stop
before leaving the truck. Set the parking brake.
SAFE MAINTENANCE PROCEDURES

Your Yale Industrial Truck, as manufactured, meets all the
applicable mandatory requirements of ANSI B56.1-Safety
Standard for Powered Industrial Trucks. In addition, all
standard trucks conform to the Underwriters' Laboratories
requirements for the Type Designation shown on the
nameplate. The truck is also equipped with certain safety
devices as standard equipment. For example, all high lift trucks
are equipped with a load backrest extension and high lift rider
trucks with an operator's overhead guard. When remote
TRAVEL elevating control is specified, an operator's work platform is
supplied.
No additions, omissions or modifications should be made that

will affect compliance to the above requirements or in any way
minimize the effectiveness of the safety devices.
Figure 1-26 - Rider Position-MTR
The following instructions have been prepared for your safety
and the safety of your fellow workers during maintenance
OPERATING PROCEDURES
operations and should be strictly followed. Carefully read and
1. Apply power to the truck by connecting both halves of the understand the maintenance procedures before attempting to
battery connector. Turn the key switch to the ON position. repair the truck. When in doubt of any maintenance procedure,
contact your local Yale industrial truck dealer.
2. On the MPW, MLW and MPE trucks move the control
handle downward away from the upright position. This will 1. Powered industrial trucks may become hazardous if
energize the electrical system and release the brakes. The maintenance is neglected. Therefore, adequate maintenance
brakes are automatically applied when the steering handle is in facilities, personnel and procedures should be provided,
the extreme upper or lower position.
2. The Recommended Schedules of Maintenance should be
Release the parking brake on the MPC and MTR trucks. used as a guide for inspection of the truck.
3. Depress the butterfly switch or turn the handle grip in the 3. Only qualified and authorized personnel should be
desired direction of travel and rotate until the desired speed is permitted to maintain, repair, adjust and inspect the truck.
reached. The operator can change the direction of travel while
the lift truck is moving, by moving the direction control in the 4. The work area should be properly ventilated. Keep shop
opposite direction. The lift truck will come to a stop and then clean and floor dry.
accelerate in the opposite direction. This action is called
"PLUGGING". 5. Avoid fire hazards and have fire protection equipment
present. Do not use an open flame to check level of electrolyte.
4. The speed/direction control and the brakes can be Do not use open pans of fuel or flammable cleaning fluids for
operated with either hand on the MPC and MTR models. Travel cleaning parts.
with forks or coupler trailing whenever possible. Steering the lift
truck is easier with the forks or coupler trailing. 6. Raise the lift truck only if it is on a solid level floor. Use solid
one piece blocks or other positive truck positioning devices to
5. When the coast control on the MPE truck set to the coast support the truck. Chock the wheels to prevent movement of
position, the steer handle in the BRAKE OFF position. When the truck.
the control handle is released the brake is not automatically
applied and the truck will coast. To apply the brake, when using 7. Disconnect the battery. Attach a DO NOT OPERATE tag to
the coast control, push the handle to the vertical position and the control handle.
hold. To discontinue use of the coast control, set the coast
selector to the BRAKE position. The control handle will return to 8. Before removing any component from the truck, make
the brake on position when released for parking or automatic sure that the lifting mechanism (hoist) and slings are of the
braking. proper capacity and in good condition.
1-13
Yale
9. When working on the hydraulic system, be sure the power 2. ANSI/NFPA 505-Type Designations, Area of Use,
isturned off andthe hydraulic pressure is relieved in hoses and Maintenance and Operation of Powered Industrial Trucks
tubes.
This booklet can be obtained from:
10. Brakes, steering mechanisms, control mechanisms,
National Fire Protection Assoc.
warning devices, guards and safety devices should be
Batterymarch Park
inspected regularly and maintained in a safe operating
Quincy, MA 02269
condition.
3. Code of Federal Regulations Title 29, Chapter XVII,
11. All parts of lifting mechanisms should be carefully and
Section 1910.178 (OSHA) Powered Industrial Trucks
regularly inspected and maintained in a safe operating
condition.
12. All hydraulic systems should be regularly inspected and Superintendent of Documents
maintained in conformance with the maintenance schedules. U.S. Government Printing Office
Lift cylinders, valves and other similar parts should be checked Washington, D.C.
to assure that "drift" has not developed to the extent that it would
create a hazard.
MOVING A DISABLED LIFT TRUCK
13. Special trucks or devices designed and approved for Motorized hand trucks are not normally towed. If the drive
hazardous area operation should receive special attention to motor or drive unit will not operate, make repairs at the location
ensure that maintenance preserves the original; approved safe if possible. If the lift truck must be towed, tow the lift truck in the
operating features. direction of the control handle, forks trailing.
14. Modifications and additions which affect capacity and safe Never attempt to tow the lift truck by fastening any towing
truck operation should not be performed by the customer or device to the control handle. Carefully attach the tow chain
user without the manufacturers prior written approval. completely around the motor compartment and battery
Capacity, operation and maintenance instruction plates, tags or compartment. Make sure the tow chain is installed on the lift
labels should be changed accordingly. truck so that the chain will not cause damage. Make sure the
control handle is in the operating position to release the brake
15. Capacity, operation and maintenance instruction plates, during towing (MPW, MLW and MPE trucks). Make sure the
tags and labels should be maintained in legible condition. hand brake is released (MPC, MTR trucks). Steer the lift truck
with the control handle while it is being towed. On the MPW,
16. The truck should be kept in clean condition to minimize fire MLW and MPE lift trucks use one hand and walk to one side of
hazards and facilitate detection of loose or damaged parts. the truck. Do not get between the towing vehicle and the lift
truck.
17. Checking the performance of the truck or attachments
should be conducted in an authorized safe area. WARNING: Be sure to stay clear of the tow chain,
towing vehicle and the lift truck during the towing
18. Always use Yale replacement parts to be sure they are operation to prevent injury.
interchangeable with the original parts and are of a quality
equal to that provided in the original equipment. WARNING: Travel slowly and do not tow on
grades. NEVER tow the lift truck faster than a
You should also be familiar with additional maintenance safety normal walking speed. Always tow smoothly
instructions contained in the following publications: without sudden starts or stops.
1. ANSI B56.1-Safety Standard for Powered Industrial /\ WARNING: Until repairs are complete keep a tag
Trucks / 1\ on the control handle stating-DO NOT OPERATE.
Remove the key.
Society of Mechanical Engineers
345 E. 47th Street
New York, NY 10017
1-14
Yale
HOW TO PUT A LIFT TRUCK ON BLOCKS WARNING: Do not raise the lift truck by attaching
WARNING: Do not put the lift truck on blocks if the
/ 1\ an overhead crane to areas that will be damaged.
/ 1\ surface is not solid, even and level. Make sure that
CmImJ Some of these points are not designed to support
the weight of the lift truck. The lift truck can be damaged or it can
CJLJ any blocks used to support the lift truck are solid,
fall on someone causing serious injury. Attach the chain or sling
one-piece units. Put a block in front and back of the tires
to a support structure of the lift truck frame.
touching the ground to prevent movement of the lift truck.
MPW SHOWN
MPE AND MLW
SIMILAR
A
h
c
1 0
. J I °
I vA*mr .— i - - -LJ
Figure 1-27 - Blocking \ MLW and MPE Models
HOW TO RAISE DRIVE TIRE WARNING: Never raise the forks any higher than
necessary to change the load wheels. Always
1. Put blocks on both sides (front and back) of the load
raise both forks at the same time. Raising the forks
wheels to prevent movement of the lift truck.
too high or uneven can make the lift truck tip over and cause
damage or possible injury.
2. Use a special low clearance hydraulic jack, crane or
another lift truck to raise the drive tire. Make sure that the jack,
2. Use a hydraulic jack, crane or another lift truck to lift the
crane or other lift truck has the correct capacity rating. The
forks. Make sure that the jack, crane or other lift truck has a
capacity must equal at least 2/3 the weight of the lift truck
capacity equal to at least half the weight of the lift truck including
including the battery. See the nameplate.
the battery. See the nameplate.
3. Raise the lift truck only enough to suspend the drive tire.
3. Put blocks under the forks at the rear of the load wheel to
Install additional blocks on each side of the truck under the
support the lift truck. See Figure 1-27 through Figure 1-29.
drive unit frame. See Figure 1-27 through Figure 1-29.
HOW TO RAISE LOAD WHEELS

1. Put blocks on both sides (front and back) of the drive tire to
prevent movement of the lift truck.
1-15
Yale
Industrial Trucks operating instructions
Figure 1-28 - Blocking MPC Models
Figure 1-29 - Blocking MTR Models

PRECAUTIONS FOR TRUCKS IN STORAGE trucks can best be protected by being operated for a short
. . , .. .. ..
Experience has taught that complications can arise as a result
..iU period of time each month.
of improper
. K
, ,
a of trucks during
handling
,
, . .
main areas of concern are electric motors, hydraulic
, , ,, . ' '
, .
periods of storage. The
.
„ , .
.. . . ,
.
,
,.
,, , '
which is clean, dry and free from airborne
,
.
,
Before placing any truck in storage, you must choose an area
.
contaminants.
components and electric truck batteries. Electric powered
1-16
Yale
Electric drive motors must be exercised to keep them free of PRECAUTIONS FOR BATTERIES IN STORAGE
rust and contamination caused by condensation built up over
Batteries should be placed on a wooden pallet and stored in a
periods of inactivity. Operate the truck with the motor at its
dry, moderately cool area. Lead acid batteries will slowly "self
normal temperature for at least five minutes. This exercise
discharge" over a period of time due to their chemical make-up.
period will also allow the transistor control to expel any moisture
This "self discharge" is due to a chemical reaction; therefore,
accumulation.
that chemical reaction can be accelerated by heat resulting in a
more rapid "self discharge". The rate of discharge can amount
Prior to operating a truck each month, make a visual inspection
to an average of about 0.001 point drop in specific gravity per
for leaks or signs of deterioration. Take corrective action
day. If the self discharge is left uncontrolled, excessive sulfating
immediately. Also, check the fluid level in the hydraulic system.
can occur which is difficult to reduce and may damage the
plates. A discharged battery with a specific gravity of 1.100 will
Electric trucks should be stored without batteries, therefore you
freeze at + 18° F. A fully charged battery with a specific gravity of
will have to provide a fully charged battery for the exercise
1.280 will freeze at -87 °F.
period.
The following procedure should be followed when placing a
When a truck is returned to service, it should be given the 200
battery in storage or when not in operation for more than 30
hour inspection shown in the Recommended Schedule of
days.
Maintenance found in Section 2.
a. Give equalizing charge prior to placing new batteries
/\ CAUTION: Do not use a battery charger as a in storage. Used batteries are to be fully charged and
/ 1\ power source for any reason. Damage to the allowed to balance for approximately three more hours.
transistorized controller could result from this
b. If a greasy film forms on the top of a battery, it is acid
practice.
and must be neutralized. Neutralize and clean with a
solution of 16 ounces of baking soda in one (1) gallon of
All hydraulic cylinders should be cycled several times each
water.
month to keep the seals active and to coat the interior walls with
oil. Actuate each cylinder, in both directions, until the stops are c. Store in a cool, dry location on a wooden pallet.
reached. With the power off, actuate each control button to
d. Check each cell in the battery at least once every 30
relieve hydraulic pressure. Forks are to be stored fully
days and boost charge when specific gravity falls below
lowered. Coat any exposed portion of all cylinder rods with
1.240.
fresh high grade SAE 30 or 40 weight engine oil.
e. Protect batteries from ambient contamination.
Battery chargers should be disconnected from the AC power

source when not in use.
1-17
Yale
Industrial Trucks
NOTES
1-18
Yale
Industrial Trucks
SECTION 2
GENERAL TRUCK AND LUBRICATION SCHEDULE

Yale
Industrial Trucks
GENERAL TRUCK AND LUBRICATION
GENERAL 2-1
DRIVE UNIT COMPARTMENT COVER-
REMOVAL AND INSTALLATION 2-1
BATTERY-REMOVAL AND INSTALLATION 2-1
FRAME SEPARATION 2-2
FRAME ASSEMBLY 2-2
TIRES AND WHEELS 2-2
SOLID TIRES 2-3
REMOVE TIRE FROM WHEEL 2-3
INSTALL THE TIRE ON WHEEL 2-3
LOAD WHEELS 2-4
CASTER WHEELS 2-4
YALE WARRANTY INFORMATION 2-4
LUBRICATION INSTRUCTIONS-GENERAL 2-4
LUBRICATION INSTRUCTIONS-MPW AND MLW 2-5
EVERY 350 HOURS 2-5
EVERY 2000 HOURS 2-5
LUBRICATION INSTRUCTIONS MPE 2-6
EVERY 350 HOURS 2-6
LUBRICATION INSTRUCTIONS MPC 2-8
EVERY 350 HOURS 2-8
LUBRICATION INSTRUCTIONS- MTR 2-10
RECOMMENDED SCHEDULE OF MAINTENANCE 2-11
FASTENERS-INTRODUCTION 2-18
THREADS, NOMENCLATURE 2-18
STRENGTH IDENTIFICATION 2-18
YaleIndustrial Trucks GENERAL TRUCK AND LUBRICATION
GENERAL BATTERY-REMOVAL AND INSTALLATION

This manual covers the repair and maintenance of the MPE, /\ WARNING: Batteries are heavy and can cause
MPW and MPC model lift trucks, the MLW pallet lift trucks and / 1\ injury. Use care to avoid injury. Do NOT put hands,
the MTR tractor. arms, feet and or legs between the battery and a
solid object. Make sure the capacity of the crane and spreader
The manual has been sub-divided into various sections which bar is greater than the weight of the battery. The weight of the
contain instructions for removal, disassembly, inspection, battery is normally shown on the battery case. The maximum
assembly, installation and adjustment of the major battery weight is shown on the lift truck nameplate. The
components. Additionally this manual includes, within this spreader bar must NOT be made of metal or it must have
section, the recommended schedules of maintenance and insulated straps.
lubrication schedule. Troubleshooting charts and
recommended specifications are also included within the 1. Move the key to the OFF position. Disconnect the battery.
sections. Use a spreader bar and lifting device to remove the battery.
Various components that are not covered in specific sections 2. Loosen and remove the nuts, lockwashers, and
are covered in this section. Some of these components have to capscrews retaining the brackets on either side of the battery.
be removed to complete maintenance or repairs covered in
other sections. 3. Lift the battery out of the truck. Do not let the battery move
from side to side. Make sure the battery cables have clearance.
DRIVE UNIT COMPARTMENT COVER-
REMOVAL AND INSTALLATION
/\ WARNING: Do not make repairs or adjustments

/ I\ unless you have both authorization and training.
Repairs and adjustments that are not correct can
CRANE
SPREADER BAR
create a dangerous operating condition. Do not operate a lift INSULATOR STRAPS
truck that needs repairs. Report the need for repairs to your BATTERY
supervisor immediately. If repair is necessary, put a "DO NOT
OPERATE" tag on the control handle. Remove the key from the
key switch.
The drive unit compartment cover must be removed for access

to the electrical system, hydraulic system, drive unit and for
servicing the motorized lift truck.
1. Move the key to the OFF position. Disconnect the battery.
2. To remove the cover, loosen and remove the four button

head screws retaining the cover to the frame.
/\ WARNING: The capacitor in the motor controller

/ 1\ can hold an electrical charge after the battery is
CmJ disconnected. To prevent electrical shock and 9267
injury, discharge the capacitor before inspecting or repairing
any component in the drive unit compartment. Wear safety Figure 2-1 - Changing the Battery
glasses. Make certain the battery has been disconnected.
Use a screwdriver or jumper wire to make a short-circuit across /\ CAUTION: The replacement battery must fit the
the B+ and B- terminals of the motor controller. 11\ battery compartment. Make sure the battery
cables have clearance to move during lifting and
3. Before attempting to do any work in the drive unit lowering of the forks. Make sure that the replacement battery is
compartment, discharge the capacitor in the motor controller. the correct voltage and weight as shown on the nameplate.
4. To install the cover, align the cover with the frame and 4. Before installing a new battery, make sure the battery is the
install the four button head capscrews. correct size and weight for the lift truck. Make sure the battery
has clearance for installation. Check that the battery connector
5. Connect the battery cable. can be attached to the lift truck connector without pulling during
lifting and lowering operations. Do not damage the battery
cables during installation. Install the battery.
2-1
Yale
Industrial Trucks GENERAL TRUCK AND LUBRICATION
/\ WARNING: If the lift truck was operated using a CYLINDER-REMOVAL. On the MPC models disconnect the
11\ low battery, inspect for welded contacts BEFORE high speed pedal wire harness before separating the
connecting a charged battery. The circuit will not weldments.
reset and lift truck operation cannot be controlled if the contacts
are welded. Refer to Section 3, this manual. Prevent 6. Remove both pivot pins retaining the upper link to the drive
side-to-side movement of the battery by adjusting the brackets unit frame. Refer to Section 7-UPPER LINK-REMOVAL.
on each side of the battery and tighten the capscrews,
lockwashers and nuts to retain the batteries. 7. Remove both drive unit frame pivot pins retaining the
rocker arm to the drive unit frame. Refer to Section 7-ROCKER
5. Locate the retaining brackets on each side of the battery. ARM-REMOVAL.
Install and tighten the capscrews, lockwashers, and nuts to
keep the battery from moving from side to side. 8. Carefully move one of the frames away from the other.
6. Remove the blocks from under the truck.

FRAME ASSEMBLY
7. Connect the battery. Test operate the motorizedhandtruck 1. Align both frames so the pins may be installed to assemble
before returning the truck to service. the frames to each other.
2. Install both drive unit frame pivot pins to attach the rocker
FRAME SEPARATION
arms to the drive unit frame. Refer to Section 7-ROCKER
NOTE: These instructions do NOT apply to the MTR or the ARM-INSTALLATION.
MLW models. Only the platform can be removed from the frame
on the MLW models. See Section 7-LOAD PLATFORM 3. Install both pivot pins to attach the upper link to the drive
ASSEMBLY LINKAGE. unit frame. Refer to Section 7-UPPER LINK-INSTALLATION.
Connect the high speed pedal wire harness on the MPC
In some cases a fork frame or a drive unit frame may be models.
damaged while the rest of the truck is still useable. The two
frames may be separated from each other by using the steps 4. Install the pivot pin to attach the hydraulic cylinder to the
outlined. fork frame. Refer to Section 8-HYDRAULIC CYLINDER-
INSTALLATION.
I|\ unless you have both authorization and training. 5. Install the battery. Refer to BATTERY-REMOVAL AND
LbJ Repairs and adjustments that are not correct can INSTALLATION.
create a dangerous operating condition. Do not operate a lift
truck that needs repairs. Report the need for repairs to your 6. Install the drive unit compartment cover. Refer to DRIVE
supervisor immediately. If repair is necessary, put a "DO NOT UNIT COMPARTMENT COVER-REMOVAL AND INSTALLA¬
OPERATE" tag on the control handle. Removethe key from the TION.
key switch.
7. Remove the blocks and lower the motorized lift truck to the
1. Raise the motorized lift truck to its maximum height. Move floor. Check the pull rod adjustment, see Section 7-PULL ROD
the key to the OFF position. Disconnect the battery. ADJUSTMENT.
2. Removethe drive unit compartment cover. RefertoDRIVE 8. Test operate the truck before returning the truck to service.
UNIT COMPARTMENT COVER-REMOVAL AND INSTALLA¬
TION.
TIRES AND WHEELS
3. Position blocks under both sides of the truck in the area of 1. Check the tires for damage. Inspect the tread and remove
the battery compartment and under both forks. See Section any objects that will cause damage.
1-HOW TO PUT A LIFT TRUCK ON BLOCKS.
2. Smooth any cuts or tears to prevent further damage. Check
4. Remove the battery. Refer to BATTERY-REMOVAL AND for bent or damaged rims. Check for loose or missing parts.
INSTALLATION. Remove any wire, straps or other material that may have
wrapped around the axle.
5. Remove the top clevis pin retaining the hydraulic cylinder
to the frame. Refer to Section 8-HYDRAULIC
2-2
Yale
WARNING: The lifting and carrying of solid tires is

not recommended because their weight could be
in excess of 45 kg (100 lb). Where applicable use a
wheel or tire dolly to assist in the removal and installation of the
wheel.
2. Removethe wheel lug nuts and remove the wheel from the
lift truck.
3. To press the tire off of the wheel hub, follow the instructions
in INSTALL THE TIRE ON THE ONE PIECE WHEEL.
Install the Tire on Wheel

1. Make sure the new tire is the correct size for the lift truck.
Do not mix types of tires, types of tire treads, or wheels of
Figure 2-2 - Inspecting Tires different manufactures on any one lift truck.
Standard tire sizes are listed in Table 2-1 for both drive/steer 2. Tire sizes listed in Table 2-1 are for drive/steer tires.
and load wheels. For lift trucks equipped with special tires
consult your nearest authorized Yale industrial truck dealer. 3. Position the new tire in the press. See Figure 2-3. Align the
wheel and tire assembly removed from the truck on top of the
MODEL SIZE TIRE new tire. Make certain the wheels are aligned. Make certain the
tires are level. Position a press ring on top of the wheel hub.
MPW 060 10x5 RUBBER
MPW 080 10x5 POLY
MPE 060/080 10x5 POLY
t
MPC 060/080 10x5 POLY 4
MTR 10x5 RUBBER
MTR 10x5 POLY
MLW (Small 10x5 RUBBER

battery box)
MLW (Large 10x5 POLY

battery box)
Table 2-1 - Tire Size and Composition
1. PRESS RING
SOLID TIRES 2. OLD TIRE
Remove Tire from Wheel 3. NEW TIRE
4. WHEEL HUB
NOTE: To change cushion tires, the wheel must be pressed
out of the rim. The proper tools, equipment and press ring must Figure 2-3 - Press Solid Tire on Wheel
be used. Do not attempt to change tires (rims) or wheels unless
you have the proper tools, equipment and experience. 4. Carefully apply hydraulic pressure until the wheel hub is
forced from the old tire into the into the new tire. The new solid
1. Loosen the wheel lug nuts. Put the lift truck on blocks as tire when properly seated will be flush to the outer edge of the
described in Section 1-HOW TO PUT THE LIFT TRUCK ON wheel hub. See Figure 2-4.
BLOCKS.
2-3
Yale
IndustrialTrucks GENERAL TRUCK AND LUBRICATION
Truck Dealer. Additional Standard Manuals, Special Parts

Manuals and Maintenance Manuals are also available from
SOLID your Yale industrial truck dealer for a nominal charge. For the
TIRE optimum in professional repair and maintenance, we
recommend your Yale industrial truck dealer's factory trained
mechanics for Yale service and a Yale Maintenance
OUTER EDGE Agreement.
WHEEL HUB PRESS TIRE
FLUSH TO
THIS SIDE LUBRICATION INSTRUCTIONS-GENERAL
The following Lubrication Instructions are for standard models.
0.25 REFt Trucks used for special applications may be equipped with
extra lubrication fittings, covers, special oils, etc. Consult your
nearest authorized Yale industrial truck dealer when servicing
these models.
WARNING: Yale industrial trucks are equipped

with certain safety devices as standard equipment,
for example: load backrest extensions, finger
guards, etc. If for any reason these safety devices are removed
Figure 2-4 - Solid Tire Pressed onto Drive Wheel when the truck is being serviced, adjusted, repaired or
overhauled, these safety devices must be properly reinstalled
before any testing or operation of the truck is to be done. Failure
LOAD WHEELS
to comply with this warning could result in serious injury to the
Refer to Section 7 for removal and assembly procedures for the mechanic and/or the operator.
load wheels.
Refer to both the Recommended Schedule of Maintenance
Charts and these Lubrication Instructions when inspecting,
CASTER WHEELS
lubricating and servicing these models. Also, readand observe
Refer to Section 7 for removaland assembly procedures for the all safety and operational precautions outlined in this manual
caster wheels. before performing any work on this truck.
NOTE: The interval of time referred to in this schedule of

YALE WARRANTY INFORMATION
lubrication is based on normal operating conditions. If the
A Yale Warranty Statement is provided with each new Yale
vehicle is operated in areas of high contamination such as dust,
Industrial Truck. To maintain your Yale Warranty in good
corrosive vapors, etc., the interval of time should be adjusted
standing you must follow the Recommended Schedule of
accordingly.
Maintenance and perform the daily operational and safety
checks in this section and in Section 1. The Lubrication Refer to the appropriate charts in this section for the oils and
Instructions in this section must also be followed. grease that are recommended for use on these models.
If you require a warranty repair you must contact your Yale

industrial truck dealer for warranty service during the periods EVERY 8 HOURS
outlined in the Warranty Statement. Your Yale industrial truck
Perform all safety and operational checks as outlined in the
dealer has complete details on which components are covered
Recommended Schedules of Maintenance found in this
and the types of repairs that are warrantable. When in doubt
section.
about your warranty coverage, be sure to contact your Yale
industrial truck dealer. If you have a warranty problem that
Check battery level and add water if necessary to maintain the
cannot be resolved with your Yale industrial truck dealer, you
level that is recommended by the manufacturer. A certain
may request a review of your problem by contacting the Yale
amount of water loss in battery cells is normal. Always replace
Regional Service Representative.
water at the end of a charge. Use approved tap water or distilled
water.
All new Yale trucks are shipped with an Operating Manual. The
Standard Parts Manual is available through your Yale Industrial
2-4
Yale
THE OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) REQUIRES THAT THE USER EXAMINETHE TRUCK BEFORE EACH
SHIFT TO BE SURE IT IS IN SAFE WORKING ORDER.
LUBRICATION INSTRUCTIONS-MPW AND MLW To Check Hydraulic Oil Level:
EVERY 350 HOURS Remove drive unit cover. Remove breather cap from hydraulic
pump and reservoir. Add hydraulic oil, if necessary, through the
Apply lithium base, multi-purpose No. 2 grease with a high
breather filler pipe until oil begins to run out. Installbreather cap
pressure gun to the following fittings. Clean lube fittings
and tighten. DO NOT OVERFILL.
before and after lubricating.
11. Hydraulic Reservoir Breather-Remove drive unit cover.
LOCATION OF LUBE FITTINGS NO. OF FITTINGS Remove breather and clean with a suitable cleaning solution,
blow dry with compressed air and install. Replace breather if it
1. Control Handle-Pivot Shaft 1
cannot be cleaned or is damaged.
2. Drive Unit Bearing-Access Holes in Drive Unit
12. Drive Unit-Check gear oil level. Elevate truck to access
Compartment 2
drive unit. Keep truck level. Remove cover. Remove drive unit
oil level and fill plug. Oil should run out slightly. Add oil, if
3. Load Wheel Axle-Raise Forks
necessary, until oil runs out oil level and fill hole. Replace oil
MPW (Corrosion Only) 2
level and fill plug. DO NOT OVERFILL.
4. Brake Shoe Pivot Pins-Remove Drive Unit Cover .... 2 EVERY 2000 HOURS
13. LoadWheel Bearings-Disassemble, clean and inspect for
wear or damage. Prelubricate the bearings with grease and
WARNING: Care must be taken when assemble.
/!\ greasing brake shoe pivot pins. Do not
allow grease to get on brake linings which 14. Drive Unit Gear Oil-Refer to Step 12. Remove drive unit
can cause brake failure. Make sure lube fittings are cover. Remove both drain and oil level plugs to drain gear oil.
thoroughly wiped clean of all grease when lubricating Replace drain plug. Remove breather in housing top cover and
these pivot pins. DO NOT OVER LUBRICATE. add flushing oil through breather port. Remove drain plug to
drain flushing oil. Replace drain plug. Add gear oil through
breather port until oil begins to run out oil level hole. Replace oil
5. Brake Cam-Remove Drive Unit Cover 1 level plug. Drive unit capacity 1.4 litre (1.5 quart). DO NOT
OVERFILL.
6. Lift Linkage,MPW 22
MLW 8 15. Hydraulic System-Remove drive unit cover. Remove
reservoir. Empty hydraulic oil into a suitable container and
Apply engine oil (SAE 20 or 30) to all friction points of the discard in accordance with local regulations. Clean hydraulic
following with an oil can or spray. tank using a suitable cleaning solution and dry with
compressed air. Clean and inspect strainer. Replace strainer if
7. Brake Roller-Linkage clogged or damaged. Installtank. Make sure tank is cleanand
dry.
Apply grease to the following friction surfaces.
8. Brake Cam and Roller Assembly To Fill Hydraulic Tank:
Remove breather filler cap. Add hydraulic oil thru breather filler
9. Control Handle Torsion Spring pipe until oil begins to run out. Capacity approximately 1.4 litre
(1.5 quart). Install breather cap and tighten. Raise and lower
10. Hydraulic Oil Level-Check the hydraulic oil level when the forks, while bringing oil to normal operating temperature. Then
oil is at normal operating temperature and forks are in the recheck hydraulic oil level by performing the operations
lowered position. outlined in Step 10. DO NOT OVERFILL.
2-5
Yale Industrial Trucks GENERAL TRUCK AND LUBRICATION
Figure 2-5 - Lubrication Points ÿMPW 060-080 and MLW 040-060

LUBRICATION INSTRUCTIONS-MPE Apply engine oil (SAE 20 or 30) to all friction points of the
following with an oil can or spray.
EVERY 350 HOURS
8. Coast Control Pivot Pins
Apply lithium base, multi-purpose No. 2 grease with a high
9. Brake Roller-Linkage
before and after lubricating.
LOCATION OF LUBE FITTINGS NO. OF FITTINGS
1. Control Handle-Pivot Shaft 2 10. Brake Cam and Roller Assembly
2 Drive Unit Bearing-Access Holes in Drive Unit 11. Control Handle Torsion Spring
Compartment 2
12. Hydraulic Oil Level-Check the hydraulic oil level when the
3. Load Wheel Axle-Raise Forks (Corrosion Only) 2 oil is at normal operating temperature and forks are in the
lowered position.
4. Brake Shoe Pivot Pins-Remove Drive Unit Cover .... 2
To Check Hydraulic Oil Level:
5. Brake Cam-Remove Drive Unit Cover 1
Remove drive unit cover. Remove breather cap from hydraulic
pump and reservoir. Add hydraulic oil, if necessary, through the
breather filler pipe until oil begins to run out. Install breathercap
WARNING: Care must be taken when and tighten. DOt NOT OVERFILL.
greasing brake shoe pivot pins. Do not
allow grease to get on brake linings which 13. Load Wheel Bearings-Disassemble, clean and inspect for
can cause brake failure. Make sure lube fittings are wear or damage. Prelubricate the bearings with grease and
thoroughly wiped clean of all grease when lubricating assemble.
these pivot pins. DO NOT OVER LUBRICATE.
14. Hydraulic Reservoir Breather-Remove drive unit cover.
Remove breather and clean with a suitable cleaning solution,
6. Caster Wheels-Raise and Block Truck 2 blow dry with compressed air and install. Replace breather if it
7. Lift Linkage 22
2-6
Yale
15. Drive Unit-Check gear oil level. Elevate truck to access level plug. Drive unit capacity 1.4 litre (1.5 quart). DO NOT
drive unit. Keep truck level. Remove cover. Remove drive unit OVERFILL.
necessary, until oil runs out oil level and fill hole. Replace oil 18. Hydraulic System-Remove drive unit cover. Remove
level and fill plug. DO NOT OVERFILL. reservoir. Empty hydraulic oil into a suitable container and
discard in accordance with local regulations. Clean hydraulic
16. LoadWheel Bearings-Disassemble, clean and inspect for tank using a suitable cleaning solution and dry with
wear or damage. Prelubricate the bearings with grease and compressed air. Clean and inspect strainer. Replace strainer if
assemble. clogged or damaged. Installtank. Make sure tank is clean and
dry.
EVERY 2000 HOURS
To Fill Hydraulic Tank:
17. Drive Unit Gear Oil-Refer to Step 14. Remove drive unit
cover. Remove both drain and oil level plugs to drain gear oil.
pipe until oil begins to run out. Capacity approximately 1.4 litre
Replace drain plug. Remove breather in housing top cover and
add flushing oil through breather port. Remove drain plug to
forks, while bringing oil to normal operating temperature. Then
recheck hydraulic oil level by performing the operations
outlined in Step 12. DO NOT OVERFILL.
COAST CONTROL OPTION
Figure 2-6 - Lubrication Points-MPE 060-080
2-7
Yale
LUBRICATION INSTRUCTIONS-MPC 5. Lift Linkage 22

EVERY 350 HOURS
Apply engine oil (SAE 20 or 30) to all friction points of the
Apply lithium base, multi-purpose No. 2 grease with a high following with an oil can or spray.
before and after lubricating. 6. Brake Linkage

1. Drive Unit Bearing-Access Holes in Drive Unit 7. Brake Cam and Roller Assembly
Compartment 2
8. Hydraulic Oil Level-Check the hydraulic oil level when the
2. Load Wheel Axle-Raise Forks (Corrosion Only) 2 oil is at normal operating temperature and forks are in the
lowered position.
3. Brake Shoe Pivot Pins-Remove Drive Unit Cover 2
To Check Hydraulic Oil Level:
Remove drive unit cover. Remove breather cap from hydraulic
WARNING: Care must be taken when pump and reservoir. Add hydraulic oil, if necessary, through the
greasing brake shoe pivot pins. Do not breatherfillerpipe until oil begins to run out. Installbreather cap
allow grease to get on brake linings which and tighten. DO NOT OVERFILL.
can cause brake failure. Make sure lube fittings are
thoroughly wiped clean of all grease when lubricating 9. Hydraulic Reservoir Breather-Remove drive unit cover.
these pivot pins. DO NOT OVER LUBRICATE. Remove breather and clean with a suitable cleaning solution,
blow dry with compressed air and install. Replace breather if it
4. Caster Wheels-Raise and Block Truck 2
1
3
6
7
10, 12
Figure 2-7 - Lubrication Points-MPC 060-080
2-8
Yale
10. Drive Unit-Check gear oil level. Elevate truck to access 13. Hydraulic System-Remove drive unit cover. Remove
drive unit. Keep truck level. Remove cover. Remove drive unit reservoir. Empty hydraulic oil into a suitable container and
oil level and fill plug. Oil should run out slightly. Add oil, if discard in accordance with local regulations. Clean hydraulic
necessary, until oil runs out oil level and fill hole. Replace oil tank using a suitable cleaning solution and dry with
level and fill plug. DO NOT OVERFILL. compressed air. Clean and inspect strainer. Replace strainer if
clogged or damaged. Install tank. Make sure tank is clean and
11. LoadWheel Bearings-Disassemble, clean and inspect for dry.
wear or damage. Prelubricate the bearings with grease and
assemble. To Fill Hydraulic Tank:
EVERY 2000 HOURS pipe until oil begins to run out. Capacity approximately 1.4 litre
12. Drive Unit Gear Oil-Refer to Step 10. Remove drive unit
forks, while bringing oil to normal operating temperature. Then
cover. Remove both drain and oil level plugs to drain gear oil.
recheck hydraulic oil level by performing the operations
Replace drain plug. Remove breather in housing top cover and
outlined in Step 9. DO NOT OVERFILL.
add flushing oil through breather port. Remove drain plug to
level plug. Drive unit capacity 1.4 litre (1.5 quart). DO NOT
OVERFILL.
2-9
Yale
LUBRICATION INSTRUCTIONS-MTR 3. Brake Linkage

NOTE: Hydraulic Maintenance not necessary on MTR
4. Coupler Linkage
(Tractor).
EVERY 350 HOURS
Apply lithium base, multi-purpose No. 2 grease with a high 5. Brake Cam and Roller Assembly
before and after lubricating. 6. Drive Unit-Check gear oil level. Elevate truck to access
drive unit. Keep truck level. Remove cover. Remove drive unit
necessary, until oil runs out oil level and fill hole. Replace oil
1. Drive Unit Bearing-Access Holes in Drive Unit level and fill plug. DO NOT OVERFILL.
Compartment 2
7. LoadWheel Bearings-Disassemble, clean and inspect for
2. Brake Shoe Pivot Pins-Remove Drive Unit Cover .... 2 wear or damage. Pre-lubricate the bearings with grease and
assemble.
WARNING: Care must be taken when EVERY 2000 HOURS

greasing brake shoe pivot pins. Do not 8. Drive Unit Gear Oil-Refer to Step 6. Remove drive unit
allow grease to get on brake linings which cover. Remove both drain and oil level plugs to drain gear oil.
can cause brake failure. Make sure lube fittings are Replace drain plug. Remove breather in housing top cover and
thoroughly wiped clean of all grease when lubricating add flushing oil through breather port. Remove drain plug to
these pivot pins. DO NOT OVER LUBRICATE. drain flushing oil. Replace drain plug. Add gear oil through
level plug. Drive unit capacity 1.4 litre (1 .5 quart). DO NOT
Apply engine oil (SAE 20 or 30) to all friction points of the OVERFILL.
following with an oil can or spray.
Figure 2-8 - Lubrication Points-MTR 700
2-10
Yale
RECOMMENDED SCHEDULE OF MAINTENANCE

Although this Recommended Schedule of Maintenance is are followed. If in doubt of any procedure or component to be
intended for use with all motorized hand lift truck models, not all inspected, adjusted and lubricated, or if the truck is specially
models are equipped with all the items listed in this schedule. equipped and used for special applications, consult your
Be certain this schedule is read thoroughly and all operations nearest authorized Yale industrial truck dealer for assistance.
NOTE: Some items on these charts not be applicable to your truck.
LEGEND
A -Every 8 Hours X-lndicates Visual Inspection, Test and Adjust as Required
B - Every 350 Hours O-lndicates Drain and Refill
C - Every 2000 Hours R-lndicates Replacement
IR— Initial Replacement
CO-Complete Overhaul MH-1094
SAFETY AND OPERATIONAL CHECKS (Prior to each shift)

Only the 8 hour CHECKS are to be performed by the operator. Have a qualified mechanic correct all prob¬ A B c
lems in accordance with appropriate YALE maintenance instructions.
Leaks-Hydraulic Fluid X
Tires-Condition X
Forks, Top Clip Retaining Pin and Heel-Condition X
Load Backrest-Attached X
Hydraulic Hoses, Mast Chains and Stops-Check Visually X
Finger Guards-Attached X
Safety Warnings-Attached (Refer to Parts Manual for Location) X
Internal Checks:
Battery-Water/Electrolyte Level and Charge X
Hydraulic Tank Fluid Level-Check Level X o
Operating Manual in Container X
Nameplate Attached-Information Matches Model, Serial Number and Attachments X
Battery Restraint in Place X
Controls (Turn Truck On) Unusual Noises Must Be Investigated Immediately:
Accelerator Linkage-Functioning Smoothly X
Attachment Control-Operation X
Battery Indicator-Functioning X
Brake System-Functioning Smoothly X
Drive Control-Forward/Reverse-Functioning Smoothly X
Lift and Lowering Control-Functioning Smoothly X
Horn-Functioning X
Hourmeter-Functioning X
Instrument Monitors-Functioning X
Lights-Functioning X
Reach Control-Functioning Smoothly X
Steering Operation-Functioning Smoothly X
Tilt Control-Functioning Smoothly X
2-11
Yalo
Industrial Trucks general truck and lubrication
NOTE: The following inspections and necessary corrections are the responsibility of the user.
LUBRICATION CHECK: A B c
Blow off, Clean When Necessary and Inspect for Damage.
Lubricate-Chassis (All Fittings) X
All Linkage X
Friction Surfaces on Mast X
Friction Surfaces on Attachment X
Clean and Lube Lift Chains X
Clean and Repack Wheel Bearings X
Differential Gear Oil Level X 0
Hydraulic Tank Breather X R
Drive Unit Oil Level X O
HYDRAULIC SYSTEM CHECK: A B c

Lift and Tilt Cylinders for Leaks and Proper Operation X CO
Tilt Cylinder Rod End Adjustment X
Hydraulic Pump for Noise and Operation X
Hydraulic Control Valve for Leaks and Operation X
Relief Valve Settings X
All Hoses, Tubing and Fittings for Wear and Leaks X
Attachment Operation X
Attachment Cylinder for Leaks X
For General Leaks X
MAST-CARRIAGE-ATTACHMENT CHECK A B c
Mast and Carriage Safety Stops X
Mast Flange Wear X
Mast Rollers and Wear Plugs X
Carriage Rollers and Wear Plugs X
Chain Anchors X
Chain for Wear or Cracks (Use Indicator (5180968-69) X
Pallet/Forks/Platform (Visual) X
Forks (See Note 2) X
Attachment-Sliding Surface Wear X
Attachment-Rotating Parts and Torque Bolts X
2-12
Yale
DRIVE UNIT CHECK: A B c

Brake Adjustment X
Brake Drums and Linings-Wear X
Electric Motor and Drive Unit Mounting Bolts X

Wheel Bolts-Torque to Specifications X
Trunnion Bolts, Mast and Frame (Retorque to Specifications) X
ELECTRICAL SYSTEM CHECK: A B c

NOTE: DO NOT use Steam to Clean Electrical Parts
Clean all Controls X
Interlock Switches-Functioning X
Accelerator Switch and Potentiometer-Functioning X
Electronic Card-Functioning X
Time Delay-Functioning X
Direction Switch-Functioning X
Pedal Switches-Functioning X
Valve Lift and Tilt Switches-Functioning X
All Motors-Clean with Compressed Air-Functioning X
All Motors-Check Brushes and Springs-Functioning X
All Motors-Clean Power Wire Terminals-Functioning X
Battery Box and Connectors-Neutralize and Clean X
Battery Condition-Physical and Electrical X
All Wire Connections-Tightness and Corrosion X
Contactors-Tips and Wire Connections-Tightness and Corrosion X
GENERAL CHECK: A B c
All Bolts, Nuts, Cotter Pins, Etc. X
Load Backrest-Cracks, Mounting, Etc. X
2-13
Yale
ROAD AND LOAD TEST TRUCK-The following items must be tested at initial installation of the truck and after every
maintenance inspection or repair.
Test the rated load in a clear area (See Notes 3 and 4). Report any questionable functions or unusual noises.
Steering
Brake System
Horn, Lights
Emergency Disconnect
Mast-Verify all stops are installed and limit switches are functioning properly
Lift-Full Lift and Lower (Do not tilt forward) (See Note 3)
Tilt-With Load lowered operate full forward and backward (See Note 4)
Attachment-Operate all Functions
NOTES: 4. With the mast vertical and with a rated load at 24 in.
(609.6 mm) load center, check tilt cylinder, if equipped, for drift.
1. Tires-Condition affects stability, safety and load capacity Tilt drift must not exceed 1;0 in. (25.4 mm ) in 2 minutes, oil at
that can be handled safely. 79° F (44°C). Refer to Service Bulletin SE-1077 for Procedure
to Measure Hydraulic Drift.
2. Use Magnaglo or equivalent Fatigue Crack Detector to test
forks. Refer to Service News Bulletin SE-643 for Procedure on 5. The presence of hydraulic fluid on cylinder rods and fittings
Field Testing Load Forks. The Bulletin also defines minimum does not necessarily indicate a leak.
acceptable fork tine thickness due to wear.
3. With the mast vertical and with a rated load at 24 in. (609.6 Recycle all waste oils.
mm) load center, check lift cylinder drift. Lift drift must not
exceed 1.0 in. (25.4 mm) in 2 minutes, oilat79°F(44°C). Refer
to Service Bulletin SE-1077 for Procedure to Measure
Hydraulic Drift.
To obtain more information on the above referenced Service Bulletins, contact your nearest authorized YALE industrial truck dealer.
2-14
Yale
HYDRAULIC OILS
YALE PART NUMBER 5143618-00 0034142-00 0032570-00
Type FOR ALL HYDRAULICALLY ACTUATED EQUIPMENT

Ambient Air Temperature Normal Cold Storage Arctic
Anticipated Ambient Air + 32° to +110° F + 32° to -25° F 0° to -60° F
Temperature Range 0° to +44° C 0° to -32° C -18° to -52° C
Actual Useable Operation Oil + 18° to +148° F -12° to +113° F -55° to +65° F
Temperature Range -8° to +65° C -25° to +45° C -49° to +18° C
ASTM Viscosity Grade
S-215/92 Minimum S-105/110 Minimum S-75/200 Minimum
Number/Index (Ret.)
Pour ° F Maximum -20° F (-29° C) -50° F (-46° C) -75° F (-60° C)
MIL-Specifications MIL - H-5606
APPROVED SOURCES
American (Amoco) Rykon Number 21 Rykon Number 11 No Product
Atlantic Richfield (Arco) Duro AW-46 No Product No Product
Burmah-Castrol Hyspin AWH-46 No Product No Product
Chevron Oil Company Chevron AW Hyd. Oil 46 Chevron AW Hyd. Oil MV Aviation Hyd. Fluid A
Cities Service (Citco) Pacemaker XD-20 No Product No Product
Exxon Nuto H 46 No Product Univis J-43
Fiske Brothers Lubriplate HO-1 No Product No Product
Gulf Harmony 48AW No Product No Product
Houghton & Company Hydro Drive HP 200 Cosmolubric 1702 No Product
Keystone (Pennwalt) KLC Number 5 No Product No Product
Mobil Oil Co. (Mobil) DTE 25 DTE 15 AERO-HFA
Pennzoil Oil Co. Pennzoil AW 46 Pennzoil AW 22 No Product
Phillips Petroleum Magnus A-215 No Product No Product
Shell Tellus 46 No Product Aeroshell Fluid 4

Solene Ind. Lubricant H-205-B No Product No Product
Sun Oil Co. (Sunoco) Sunvis 821 WR No Product No Product
Texaco Rando HD-46 Rando HD-AZ Aircraft Hyd "BB"
Valvoline Oil Co. Anti-Wear No. 20 Anti-Wear No. 10 No Product
Field Personnel Note: The hydraulic oils, as listed herein, are approved YALE Materials Handling Corporation sources that meet
or exceed the specifications annotated. The use of hydraulic oils other than the suppliers and products listed is unauthorized.
2-15
Yalo
GEAR OILS
YALE PART NUMBER 3101530-34 3101530-36 3101530-38
Application Special Application Standard Application Special Application

SAE Grade 80W-90 85W-140* 75W-90
Type Multi-Purpose EP Multi-Purpose EP Multi-Purpose EP
Base Oil Conventional Petroleum Conventional Petroleum Synthetic
MIL-Specification No. MIL-L-2105C MIL-L-2105C MIL-L-2105C
API Service Classification GL-5 GL-5 GL-5
Anticipated Ambient -15° to +100° F Used where the ambient As low as -60°F (-51C°)
Temperature (-26° to +38° C) temperature is continuously Primarily intended for cold
Most Yale lift truck operations above +90° F ( + 32° C). This storage and/or Arctic
will fall within this temperature oil must not be used below conditions; can be used as
range. + 20° F (-7°C). high as +90°F ( + 32°C).
Note: This oil is a synthetic
formulation.
APPROVED SOURCES
Burmah-Castrol HYPOY C80W/90 HYPOY C85W/140 No Product

Century Hulburt Inc. No Product Century Hulburt GL-5 No Product
85W/140
Chevron Chevron Universal Chevron Universal No Product
Gear Lube 80W/90 Gear Lube 85W/140
Exxon Exxon Gear Oil Exxon Gear Oil No Product
GX 80W/90 GX 85W/140
Mobil Mobilube HD 80W/90 Mobilube HD 85W/140 Mobilube SHC 75W/90
Pennzoil Pennzoil MP 4092 No Product No Product
Phillips 66 Philube SMP Gear Oil Philube SMP Gear Oil No Product
80W/90 80W/90
Solene Lub. Inc Solene Gear Oil #905 Solene Gear Oil #2500 No Product
Sun Sunfleet GL-5 Sunfleet GL-5 No Product
Gear Lube 80W/90 Gear Lube 85W/140
Union 76 Unocal MP Gear Lube LS 85W- 140 No Product
LS 80W/90
* Not an all season oil. Viscosity is essentially the same as old single grade 140.
Field Personnel Note: The gear oils, as listed herein, are approved YALE Materials Handling Corporation sources that meet
or exceed the specifications annotated. The use of gear oils other than the suppliers and products listed is unauthorized.
2-16
Yale
GREASE
STANDARD FOR HIGH PRESSURE FITTINGS, PLAIN AND

ANTI-FRICTION BEARINGS AND WHEEL BEARINGS
YALE PART NUMBER 3101560-36 3101562-46
Ambient Air Temp. Normal Freezer
Type Quality Automotive Quality Automotive

Soap Type Lithium Complex Lithium Complex
NLGI Grade 2
Dropping Point Approximately + 500° F ( + 262°C) + 398°F ( + 205°C)
237 @ + 100°F ( + 38°C)
Base Oil Viscosity (SUS) 67/75 @ +210°F ( + 100°C)
51 @ +210°F (+ 100°C)
-30 to +350°F -40 to +250°F

Nominal Operating Temperature Range
(-35 to + 178°C) (-40 to +122X)
Container must be plainly marked with Container must be plainly marked with
Identification
supplier's product identification supplier's product identification
APPROVED SOURCES
Exxon Corporation Ronex MP

Texaco Regal AFB 2
Mobil Oil Corporation Mobil Grease 532
Solene Lubricants Incorporated Solene S-1065
Union 76 Unocal UNOBA EP Grease 2
Field Personnel Note: The greases as listed herein are approved YALE Material Handling Corporation sources that meet or
exceed the specifications annotated. The use of greases other than the suppliers and products listed is unauthorized.
2-17
Yale
FASTENERS-INTRODUCTION The number of threads per inch for inch fasteners may either be
shown as UNC (Unified National Coarse) or UNF (Unified
Threaded fasteners like bolts, nuts, capscrews, and studs are
National Fine). Metric fasteners show the thread pitch.
made to specifications that describe the mechanical strength
and hardness of the fastener. A fastener used in a design
A capscrew will have the following description:
application is selected according to its specifications. Yale
Materials Handling Corporation buys parts from many
countries. Parts that are purchased must be to Yale standards. INCH METRIC
There are several standards used by these countries in the
manufacture of threaded fasteners. Many of these fasteners 1/2x13 UNC x 1-1/2 M12x 1.75x50
are similar, but cannot be used as a direct replacement. To
make sure that you have the correct fastener, order fasteners
A x B C x D < X m X O
|
and parts through the Yale Parts Distribution Center, A = Shank Diameter A = Thread Size
Danville, IL.
B = Number of Threads B = Pitch
Service persons must use replacement fasteners that have the
Per Unit of Length C = Length
same specifications. Fasteners made to each specification
have identification marks for that specification. This C = Type of Thread
specification is commonly called "Grade" for SAE standards
and "property class" for metric standards. This section D = Shank Length
describes the identification of some common fasteners.
Table 2-2 - Capscrew Description
The metric system used by Yale Materials Handling
Strength Identification
Corporation is described as SI (Le Systeme d'Unites or the
International System of Units, also called SI in all languages). The most common property classes for metric fasteners are 8.8
The SI system of measurement is described in ISO Standard and 10.9. The property class is marked with a number on the
1000, 1973. A conversion table of common measurements is head of the capscrew or on a nut. Property classes lessthan 8.8
shown in Figure 2-9. are often not marked. Grades for inch bolts go from 2 to 8.
Grade 2 fasteners normally do not have any marks. The
Threads, Nomenclature following tables show the marks that identify the grades and
property classes for different fasteners.
The thread design is specified by a series of numbers and
letters for inch and metric fasteners. See Figure 2-9. The
CAUTION: When fasteners must be replaced,
diameter of the shank of the fastener is shown first in the series the new fasteners must be of the same strength or
[M12 = 12 mm, M20 = 20 mm (1/2 = 1/2 inch, 3/4 = 3/4 inch)].
greater than the original fasteners. The new
fasteners must also be the correct size.
The length of the shank is often indicated as part of the
description of a fastener. This length is shown in inches for inch
NOTE: Identification marks are according to bolt strength.
fasteners and in millimetres for metric fasteners.
The higher the number or the increase in the number of marks
indicates increased bolt strength.
1.0 in.
1
13 THREADS 1/2x13 UNC-THREAD
(DIA. x NO. OF THREADS PER INCH)
"VWWWWWW
U.S.
DIA.
METRIC
M12x1.75 mm-THREAD
(mm DIA. x THREAD PITCH mm)
Figure 2-9 - Thread Design
2-18
Yale
INCH FASTENERS METRIC FASTENERS

STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
TYPE OF FASTENER 'MARKINGS NOT REQUIRED 'MARKINGS NOT REQUIRED
5.2 8 4.6* 4.8* 5.8* 8.8
1
. \/
.4.1 ÿ4. 5.8 8.8y
HEX. HEAD CAPSCREWS AND 9.8 10.9 12.9

CAPSCREWS
9.8> 10. >J2.
MARKINGS FOR
SIZE M5 AND
LARGER
(0 SAME AS ABOVE
HEX. HEAD FLANGE SCREWS
5
SAME AS ABOVE
12-POINT FLANGE SCREWS

10.9 12.9
ÿV
MARKINGS NOT REQUIRED 10.9 12.9
HEX. SOCKET HEAD

CAPSCREWS
4.8* 9.8
u
SEMS
5.1
Table 2-3 - Capscrews and Screws
2-19
Yale

STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
TYPE OF FASTENERS * MARKINGS NOT REQUIRED * MARKINGS NOT REQUIRED
4.6* 4.8* 5.8* 8.8
5* 5.2*
9.8 10.9 12.9

MARKINGS
FOR SIZE
M5 AND
LARGER
STUDS
OR
OPTIONAL GEOMETRIC SYMBOLS

FOR SIZES M5 THRU M11 ONLY.
mm rriD rnm
OR
HEX. NUTS o o o
mn dm
(ED MARKINGS NOT REQUIRED

5
ITsTI
8
fTsT)
9
IToTI PTioTl
10
NW)
12
HEX. SLOTTED NUTS
10 12
MARKINGS NOT REQUIRED
HEX. FLANGE NUTS 1QV VI
Table 2-4 - Studs and Nuts
2-20
Yale

TYPE OF FASTENER STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
DEDQSn
s X
OR 10
ÿ X
ID 10
ALL METAL PREVAILING

TORQUE NUTS
10
OR
jcn.
ALL METAL PREVAILING OR
TORQUE FLANGE NUTS
J3L JUL
Table 2-5 - Torque Nuts
2-21
Yale

TYPE OF FASTENER STRENGTH LEVELS: SAE GRADES STRENGTH LEVELS: PROPERTY CLASS
OR
E MARKINGS NOT REQUIRED

NYLON INSERT
PREVAILING
OR
TORQUE NUTS
10
ÿ
MARKINGS NOT REQUIRED
NYLON INSERT OR
PREVAILING
TORQUE NUTS
10
Table 2-6 - Torque Nuts with Nylon Inserts
2-22
Yale
Marking No Mark 3 Marks 6 Marks Socket Head 12 Pt.-Flanged
SAE Grade 1960 Series 1936 & 60 Series
Size (in) Thread Dry Lub. Dry Lub. Dry Lub. Dry Lub. Dry Lub.
1/4 20 8 12 9 13 10 16 12
1/4 28 10 14 10 15 11 18 14
5/16 18 11 17 13 25 18 28 20 33 25
5/16 24 12 19 14 25 20 30 22 36 27
3/8 16 20 15 30 23 45 35 48 36 58 44
3/8 24 23 17 35 25 50 35 55 41 65 49
7/16 14 30 24 50 35 70 55 77 58 93 70
7/16 20 35 25 55 40 80 60 86 65 104 78
1/2 13 50 35 75 55 110 80 118 89 142 106
1/2 20 55 40 90 65 120 90 132 99 160 120
9/16 12 70 55 110 80 150 110 170 127 205 153
9/16 18 80 60 120 90 170 130 189 141 228 171
5/8 11 100 75 150 110 220 170 235 176 283 212
5/8 110 85 170 130 240 180 267 200 320 240
3/4 10 175 130 260 200 380 280 417 313 501 376
3/4 16 195 145 300 220 420 320 467 350 559 420
7/8 9 165 125 430 320 600 460 672 504 707 530
7/8 14 185 140 470 350 660 500 741 562 778 584
8 250 190 640 480 900 680 1006 756 1060 795
12 270 200 700 530 1000 740 1125 833
14 340 260 750 580 1030 785 1230 883 1190 892
1-1/8 7 350 270 800 600 1280 960 1283 966 1702 1276
1-1/8 12 400 300 880 660 1440 1080 1425 1066 1908 1431
1-1/4 7 500 380 1120 840 1820 1360 1600 1200 2162 1621
1-1/4 12 550 420 1240 920 2000 1500 1800 1350 2660 1995
1-3/8 6 660 490 1460 1100 2380 1780 2382 1782
1-3/8 12 740 560 1680 1260 2720 2040 2708 2033
1-1/2 6 870 650 1940 1460 3160 2360 2800 2100 4177 3133
1-1/2 12 980 730 2200 1640 3560 2660 3000 2260 4700 3525
NOTES:
1. The term lub. includes the application of high stress lubrication to the fastener, and fasteners that have a cadmium plating.
2. Dry values include screws that only have a thin film of oil to prevent rust.
3. The torque values are minimum. Values to 20% higher are permitted.
4. Fasteners with zinc plating must have a 10% higher torque than dry value.
Table 2-7 - General Guide to Torque Values
2-23
Yale
Industrial Trucks general truck and lubrication
Grade JIS F4T ISO 8.8 or JIS F8T ISO 10.9 or JIS F11T ISO 12.9
Marking
o oNone 8.8 or F8T or 8T
Q
10.9 or F11T or 11T
O 12.9
Size Pitch N»m (Ibf ft) N»m (Ibf ft) N«m (Ibf ft) N»m (Ibf ft)
M4 0.7 — — 2.9 2 4.1 3 4.9 3.5
M5 0.8 — — 6 4 8.5 6 10 7
M6 1.0 4.3 3 10 7 14 10 17 12
M8 1.25 10 7 25 18 35 25 41 30
M8 1.0 10 7 27 20 38 28 45 33
M10 1.5 20 15 49 35 69 50 83 60
M10 1.25 20 15 52 38 73 53 88 64
M12 1.75 35 25 86 62 120 87 145 105

M12 1.25 35 25 95 69 135 98 160 116
M14 2.0 57 41 135 98 190 137 230 166

M14 1.5 57 41 150 108 210 152 250 181
M16 2.0 88 64 210 152 295 213 355 257

M16 1.5 88 64 225 163 315 228 380 275
M18 2.5 — — — 405 300 — —

M20 2.5 172 124 •M0 297 580 420 690 499
M20 1.5 172 124 460 333 640 463 770 557
M24 3.0 297 215 710 514 1000 723 1200 868
M24 2.0 297 215 780 564 1100 796 1300 940
M30 3.5 591 427 1450 1049 2000 1447 2400 1736
M30 2.0 591 427 1600 1157 2250 1627 2700 1953
NOTES:
1. Reduce the torque values approximately 20% when high stress lubrication is applied to the fastener, or fasteners that have a
cadmium plating.
2. Dry values include screws that only have a thin film of oil to prevent rust.
3. The torque values are minimum. Values to 20% higher are permitted.
4. Fasteners with zinc plating must have a 10% higher torque than dry value.
5. Marking not required on M5 and smaller fasteners.
Table 2-8 - General Guide to Torque Values
2-24
Yale
JIC FLARED TYPE AND SAE

SWIVEL ADAPTER UNIONS
STRAIGHT THREAD O-RING FITTINGS
DASH THREAD MAXIMUM TORQUE Nÿm (Ibf ft) DASH MAXIMUM TORQUE N«m (Ibf ft)
PIPE SIZE
SIZE SIZE SWIVEL NUT LOCKNUT SIZE FEMALE PIPE MALE PIPE
-2 5/16"-24 8(6) 8(6) -2 1/8"-27 18(13) 16(12)
-3 3/8"-24 8(6) 8(6) - - - -
-4 7/16"-20 14 (10) 11 (8) -4 1/4"-18 27 (20) 34 (25)

-5 1/2"-20 20 (15) 14(10) - - - -
-6 9/16"- 18 27 (20) 18 (13) -6 3/8"- 18 34 (25) 54 (40)

-8 3/4"- 16 41 (30) 28 (21) -8 1/2"-14 64 (47) 73 (54)
-10 7/8"- 14 54 (40) 456 (33) - - - -
-12 1-1/16"-12 95 (70) 65 (48) -12 3/4"- 14 114(84) 106 (78)

-14 1-3/16"- 12 108 (80) 76 (56) - - - -
-16 1-5/16"- 12 122 (90) 85 (63) -16 1"—11-1/2 175(129) 152 (112)
-20 1-5/8"-12 163 (120) - -20 1-1/4"-11-1/2 206 (152) 209 (154)
-24 1-7/8"-12 178(131) - -24 1-1/2"- 11-1/2 206 (152) 286 (211)
-32 2- 1/2"-12 407 (300) - -32 2"-11-1/2 407 (300) 407 (300)
NOTE: Values shown are for zinc plated fittings. Values for cadmium plated fittings may vary slightly, but not enough to be of
any appreciable difference.
*Torque Values furnished by Air-Way Manufacturing Co., Olivet, Michigan
Table 2-9 - Recommended Maximum Torque Values for Hydraulic Fittings*
2-25
Yale
MULTIPLY BY TO GET MULTIPLY BY TO GET

AREA
inches2 (in2) X 6.452 = centimeters2 (cm2) centimetres2 (cm2) X 0.155 = inches2 (in2)
feet2 (ft2) X 0.093 = meters2 (m2) metres2 (m2) X 10.764 = feet2 (ft2)
LINEAR
inches (in) X 25.4 = millimeters (mm) millimetre (mm) X 0.039 = inches (in)
feet (ft) X 0.305 = meters (m) metre (m) X 3.281 = feet (ft)
yards (yd) X 0.914 = meters (m) metre (m) X 1.094 = yards (yd)
miles (mi) X 1.609 = kilometers (km) kilometre (km) X 0.621 = miles (mi)
MASS
ounces (oz) X 28.35 = grams (g) grams (g) X 0.035 = ounces (oz)
pounds (lb) X 0.454 = kilograms (kg) kilograms (kg) X 2.205 = pounds (lb)
tons (2,000 lb) X 907.18 = kilograms (kg) kilograms (kg) X 0.001 = tons (2,000 lb)
tons (2,000 lb) X 0.907 = metric ton (t) metric ton (t) X 1.102 = tons (2,000 lb)
POWER
horsepower (hp) X 0.746 = kilowatts (kW) kilowatts (kW) X 1.34 = horsepower (hp)
PRESSURE
pounds/in2 (psi) X 6.895 = kilopascal (kPa) kilopascal (kPa) X 0.145 = pounds/in2 (psi)
pounds/in2 (psi) X 0.007 = megapascal (MPa) megapascal (MPa) X 145.04 = pounds/in2 (psi)
TEMPERATURE
(°Fahrenheit-32) X 0.56 = "Celsius (C) ("Celsius x 1.8) + 32 = "Fahrenheit
TORQUE
pound inches (Ibf in) X 0.113 = Newton meter (N»m) Newton metre (N»m) X 8.851 = pound inches (Ibf in)
pound feet (Ibf ft) X 1.356 = Newton meter (N«m) Newton metre (N«m) X 0.738 = pound feet (Ibf ft)
VELOCITY
miles/hour (mph) X 1.609 = kilometer/hour (km/h) kilometre/hr (km/h) X 0.621 = miles/hour (mph) '
VOLUME
inches3 (in3) X 16.387 = centimeters3 (cm3) centimetres3 (cm3) X 0.061 = inches3 (in3)
inches3 (in3) X 0.016 = litres (I) litres (I) X 61.024 = inches3 (in3)
quarts, U.S. (qt) X 0.946 = iitres (I) litres (I) X 1.057 = quarts, U.S. (qt)
quarts, U.S. (qt) X 0.83 = quarts, Imp. (qt) quarts, Imp. (qt) X 1.205 = quarts, U.S. (qt)
gallons, U.S. (gal) X 3.785 = litres (I) litres (I) X 0.264 = gallons, U.S. (gal)
gallons, U.S. (gal) X 0.83 = gallons, Imp. (gal) gallons, Imp. (gal) X 1.205 = gallons, U.S. (gal)
ounces (oz) X 29.57 = milliliter (ml) millilitre (mi) X 0.034 = ounces (oz)
Table 2-10 - Conversion Table for Metric and English Units
2-26
Yale
IndustrialTrucks
SECTION 3
ELECTRICAL SYSTEM
1
Yale
IndustrialTrucks
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM-GENERAL 3-1

ELECTRICAL SYSTEM-CHECKS 3-1
TRANSISTOR MOTOR CONTROLLER 3-15
GENERAL 3-15
CONTROL 3-15
PLUGGING 3-15
STATIC-RETURN-TO-OFF (SRO) FUNCTION 3-15
THERMAL PROTECTION FUNCTION 3-16
LOW VOLTAGE PROTECTION FUNCTION 3-16
CURRENT LIMIT 3-16
MOTOR CONTROLLER REPLACEMENT 3-16
SEQUENCE OF OPERATION-TRACTION CIRCUIT 3-16
TROUBLESHOOTING 3-17
FAULT PROCEDURES 3-17
ADJUSTMENTS 3-21
PLUGGING ADJUSTMENT 3-21
ACCELERATION ADJUSTMENT 3-21
CURRENT LIMIT ADJUSTMENT 3-21
ACCELERATOR POTENTIOMETER ADJUSTMENT 3-22
ELECTRONIC LOGIC MODULE (ELM) 3-22
GENERAL 3-22
OPERATION 3-23
TESTING 3-23
CONTACTORS 3-24
TESTING CONTACTORS 3-25
CONTACTOR REPLACEMENT 3-25
CONTACTOR COMPONENT REPLACEMENT 3-26
FUSES 3-26
BRAKE SWITCH 3-26
REMOVAL AND INSTALLATION 3-26
RELAYS 3-27
HEIGHT LIMIT SWITCH 3-27
STEERING HANDLE SWITCHES 3-28
REMOVAL 3-28
INSTALLATION 3-28
PICK ASSIST SWITCHES-MPE (OPTIONAL) 3-30
REMOVAL 3-30
INSTALLATION 3-30
MOTOR MAINTENANCE-GENERAL 3-31
BRUSH AND COMMUTATOR INSPECTION 3-31
NORMAL COMMUTATOR SERVICE 3-32
COMMUTATOR PROBLEMS 3-33
(Continued on following page)

Yale
Industrial Trucks
REMOVAL
SECTION 3
HYDRAULIC MOTORS
INSTALLATION
- CONTENTS (Continued)
ELECTRICAL SYSTEM
BRUSH REPLACEMENT, DRIVE AND
DRIVE MOTOR-BRUSH REPLACEMENT

HYDRAULIC PUMP MOTOR-BRUSH REPLACEMENT
DRIVE MOTOR
REMOVAL
INSTALLATION
HYDRAULIC PUMP MOTOR
DRIVE AND HYDRAULIC MOTORS

DISASSEMBLY
ASSEMBLY
COMMUTATOR REPAIRS
TESTS
DAMAGED FIELD AND ARMATURE
SHORT-CIRCUIT IN AN ARMATURE WINDING
SHORT-CIRCUIT IN THE ARMATURE
OPEN CIRCUIT IN A FIELD COIL
SHORT-CIRCUIT INA FIELD COIL
SHORT-CIRCUIT BETWEEN FIELD AND MOTOR CASE
BRUSH HOLDER
SCHEMATIC 5045797-00-TYPE "E"-MPE-UP TO S/N 576760
.
WIRING DIAGRAM 5045797-00-TYPE E'-MPE-UP TO S/N 576760 . . .
OPTIONS DIAGRAM 5045797-00-TYPE "E"-MPE-UP TO S/N 576760 .
SCHEMATIC 5047437-00-TYPE "EE"-MPE-UP TO S/N 576760
WIRING DIAGRAM 5047437-00-TYPE "EE"-MPE-UP TO S/N 576760 .
OPTIONS DIAGRAM 5047437-00-TYPE "EE"-MPE-UP TO S/N 576760
SCHEMATIC 5048687-00-TYPE E'-MPE-
FROM S/N 576761 TO A803N08540U
WIRING DIAGRAM 5048687-00-TYPE E'-MPE-
FROM S/N 576761 TO A803N08540U
OPTIONS DIAGRAM 5048687-00-TYPE "E"-MPE-
FROM S/N 576761 TO A803N08540U
SCHEMATIC 5052537-00-TYPE "E" AND "EE"-MPE-
S/N A803N0854 WAND UP
WIRING DIAGRAM 5052537-00-TYPE "E"AND "EE"-MPE¬
OPTIONS DIAGRAM 5052537-00-TYPE "E"AND "EE"-MPE-
S/N A803N0854 1U AND UP
SCHEMATIC 5046247-OO-TYPE E'-MPC-UP TO S/N 576760
WIRING DIAGRAM 5046247-00-TYPE E'-MPC-UP TO S/N 576760 . . .
OPTIONS DIAGRAM 5046247-00-TYPE E'-MPC-UP TO S/N 576760 .
3-36
3-37
3-37
3-38
3-38
3-38
3-38
3-38
3-39
3-39
3-39
3-40
3-40
3-41
3-41
3-41
3-41
3-42
3-42
3-42
3-42
3-44
3-46
3-48
3-50
3-52
3-54
3-56
3-58
3-60
3-62
3-64
3-66
3-68
3-70
3-72

Yale
IndustrialTrucks
DESCRIPTION
SECTION 3 - CONTENTS (Continued)
ELECTRICAL SYSTEM
SCHEMATIC 5048037-00-TYPE "EE"-MPC

WIRING DIAGRAM 5048037-00-TYPE "EE"-MPC
OPTIONS DIAGRAM 5048037-00-TYPE "EE"-MPC
SCHEMATIC 5048737-00-TYPE "E"-MPC-
FROM S/N 576761 TO A803N08599U
WIRING DIAGRAM 5048737-00-TYPE "E"-MPC-
FROM S/N 576761 TO A803N08599U
OPTIONS DIAGRAM 5048737-00-TYPE "E'-MPC-
FROM S/N 576761 TO A803N08599U
SCHEMATIC 5052547-00-TYPE "E"AND "EE"-MPC-
S/N A803N08600U AND UP
WIRING DIAGRAM 5052547-00-TYPE "E"AND "EE'-MPC-
OPTIONS DIAGRAM 5052547-00-TYPE "E"AND "EE"-MPC-
SCHEMATIC 505 1147-00-TYPE "E" AND "EE'-MPC-
S/N A899N0 1501U AND UP
WIRING DIAGRAM 5051147-00-TYPE "E" AND "EE"-MPC-
OPTIONS DIAGRAM 5051147-00-TYPE "E" AND "EE"-MPC-
SCHEMATIC 5045807-00-TYPE "E"-MPW-UP TO S/N 576819
FROM S/N 576820 TO A838N06613U

SCHEMATIC 5052557-00-TYPE "E"AND "EE"-MPW-
WIRING DIAGRAM 5052557-00-TYPE "E" AND "EE"-MPW-
OPTIONS DIAGRAM 5052557-00-TYPE "E" AND "EE'-MPW-
SCHEMATIC 5046677-00-TYPE "E'-MTR-UP TO S/N 576845 .
PAGE NUMBER
......
WIRING DIAGRAM 5045807-00-TYPE "E"-MPW-UP TO S/N 576819 . .
OPTIONS DIAGRAM 5045807-00-TYPE "E'-MPW-UP TO S/N 576819 .
SCHEMATIC 504 744 7-00— TYPE "EE'-MPW-UP TO S/N 576819
WIRING DIAGRAM 5047447-OO-TYPE "EE"-MPW-UP TO S/N 576819 .
OPTIONS DIAGRAM 5047447-00-TYPE "EE'-MPW-UP TO S/N 576819
SCHEMATIC 5048727-00-TYPE "E"-MPW-
FROM S/N 576820 TO A838N06613U
WIRING DIAGRAM 5048727-00-TYPE "E"-MPW-
FROM S/N 576820 TO A838N06613U
OPTIONS DIAGRAM 5048727-00-TYPE "E"-MPW-
WIRING DIAGRAM 5046677-00-TYPE "E"-MTR-UP TO S/N 576845 ...

OPTIONS DIAGRAM 5046677-00-TYPE "E'-MTR-UP TO S/N 576845 .
SCHEMATIC 5048747-00-TYPE "E'-MTR-
FROM S/N 576846 TO A817N05790U
3-74
3-76
3-78
3-80
3-82
3-84
3-86
3-88
3-90
3-92
3-94
3-96
3-98
3-100
3-102
3-104
3-106
3-108
3-110
3-112
3-114
3-116
3-118
3-120
3-122
3- 124
3- 126
3-128

Yale
IndustrialTrucks
SECTION 3 - CONTENTS (Continued)

ELECTRICAL SYSTEM
WIRING DIAGRAM 5048747-00-TYPE "E"-MTR-

FROMS/N 576846 TO A817N05790U 3-130
OPTIONS DIAGRAM 5048747-00-TYPE "E"-MTR-
FROM S/N 576846 TO A817N05790U 3-132
SCHEMATIC 5052567-00-TYPE "E" AND "EE"-MTR-
S/N A817N0579 1U AND UP 3-134
WIRING DIAGRAM 5052567-00-TYPE "E"AND "EE"-MTR-
S/NA817N0579 WAND UP 3-136
OPTIONS DIAGRAM 5052567-00-TYPE "E"AND "EE'-MTR-
S/N A817N05791U AND UP 3-138
SCHEMATIC 7524767-00-TYPE "E"-MLW-S/N B828N01501S AND UP 3-140
WIRING DIAGRAM 7524767-00-TYPE "E"-MLW-
S/N B828N01501S AND UP 3-142
OPTIONS DIAGRAM 7524767-00-TYPE "E"-MLW-
S/N B828N01501S AND UP 3-144
Yale
Industrial Trucks ELECTRICAL SYSTEM
ELECTRICAL SYSTEM-GENERAL 2. The Yale electric lift truck has a two-wire system. The
frame must not be a common electrical path. Check for 50,000
The electrical system of the Yale motorized hand trucks has
ohms or more between each terminal of the lift truck half of the
undergone continuous improvement and modernization. This
battery connector and a clean connection on the frame.
section contains maintenance information for electrical
Remove any circuit paths between the connector and the frame
systems ranging from early production models to current
of the lift truck. Carbon dust in a motor or other parts can cause
production models. Check the truck model code and serial
a circuit path. Check for additional equipment that is causing a
number before performing any work to determine which
circuit path to the frame.
procedures and maintenance information are applicable to the
truck to be repaired.
3. Check for voltage between each terminal of the battery half
of the battery connector and a clean connection on the frame.
Normally there is some small voltage (less than 30% of the
/ 1\ unless you have both authorization and training.
battery voltage) between the battery and the frame, even if the
Repairs and adjustments that are not correct can
resistance is very high. A higher voltage can indicate a dirty
battery or a battery with damage. Clean the battery and battery
truck that needs repairs. Report the need for repairs to your
compartment as necessary.
OPERATE" tag on the control handle. Removethe key from the
4. Visually check for parts or wires that are loose or
key switch.
damaged.
//\
WARNING: Disconnect the battery and separate
NOTE: Make an identification for any wires before you
?\ the connector before opening the compartment
disconnect them. The wires must be connected correctly after
cover or inspecting or repairing the electrical
checks or repairs.
system. If a tool causes a short-circuit, the high current flow
from the battery can cause an injury or parts damage.
The following pages contain illustrations of the drive end of the
motorized hand trucks covered in this section. This section
covers trucks from early production to the present. Therefore,
/ I\ can hold an electrical charge after the battery is
several views of certain trucks are shown, depending on the
disconnected. To prevent electrical shock and
serial number of the truck. Refer to the truck serial number to be
sure to view the correct drive end illustration.
any component in the drive unit compartment. Wear safety
Use a screwdriver or jumper wire to make a short-circuit across
the B+ and B- terminals of the motor controller. 111 POSITIVE
</. NEGATIVE
/\ WARNING: Some checks require the battery
/ 1\ connected. Do not connect the battery until the
procedure tells you to connect the battery. Make
sure the drive wheel is raised to prevent truck movement and
possible injury. Raise the drive wheel. See Section 1-HOWTO
PUT A LIFT TRUCK ON BLOCKS. The blocks must prevent
the lift truck from falling and causing injury or damage.
NOTE: All checks, adjustments and repairs in the drive unit

compartment are done with the compartment cover removed.
Remove the drive unit compartment cover to access the
/
electrical components. Refer to Section 2-DRIVE UNIT
COMPARTMENT COVER-REMOVAL AND INSTALLATION.
NOTE: Refer to the wiring diagrams and schematics at the

end of this section for additional information. 1. BATTERY
2. TRACTION MOTOR ARMATURE
CHECKS 3. TRACTION MOTOR FIELD
4. REVERSE CONTACTOR CONTACTS
1 . Check the specific gravity of the battery. If the specific 5. FORWARD CONTACTOR CONTACTS
gravity is less than 1.260, the battery is not fully charged or is 6. FET'S SWITCH
damaged. A fully charged battery has a specific gravity of
1.270-1.290. A discharged battery has a specific gravity of Figure 3-1 - Basic Traction Motor Circuit
approximately 1.130.
3-1
Yale
IndustrialTrucks ELECTRICAL SYSTEM
1 2 3 4 5 6
14 13 12 11 10 9
1. CONTACTOR PANEL 6. DRIVE MOTOR 11. LIFT CYLINDER 16. TERMINAL BLOCK (TB-2)
2. KEY SWITCH 7. HORN 12. DRIVE UNIT 17. FUSE, CONT. 15A., FU-3
3. CONNECTOR 8. LIFT LIMIT SWITCH 13. CONTROLLER 18. RELAY (CR-2)
4. FUSE, HYD. 200A., FU 1 9. HYDRAULIC UNIT 14. LIFT LINKAGE 19. RELAY (CR-1)
5. CONTACTORS 10. BRAKE LINKAGE 15. FUSE TRACT. 200A., FU-2 20. TERMINAL BLOCK (TB-1)
Figure 3-2 - Drive Unit Compartment-MPE (Early Production)
3-2
Yale
1318 21 2 6 579 8
13 12 14 15
1. IGNITION SWITCH 8. HORN 15. BRAKE SWITCH

2. BRAKE SYSTEM 9. SUPPRESSOR 16. RELAY CR1
3. BATTERY CONNECTOR 10. MOUNTING BRACKET 17. RELAY CR2
4. VARISTOR-LIFT CONTACTOR 11. LIFT LIMIT SWITCH 18. FUSE F1
5. VARISTOR—SOLENOID VALVE 12. CONTROLLER 19. FUSE F2
6. WIRE HARNESS 13. CONTACTOR PANEL 20. FUSE F3
7. HYDRAULIC SYSTEM 14. DRIVE UNIT 21. FWD/REV CONTACTORS
-
Figure 3-3 Drive Unit Compartment-MPE (From S/N 57661 to A803N08540)
3-3
Yale
2 18 7 21 13 20 12 21 20
19 8 9
1. CONTACTOR PANEL 8. LIFT CYLINDER 15. HORN

2. ELECTRONIC LOGIC MODULE 9. HYDRAULIC HOSE 16. SUPPRESSOR
3. CABLE (A5-1) 10. HYDRAULIC HOSE 17. LIFT LIMIT SWITCH
4. CABLE (A6-1) 11. HYDRAULIC POWER UNIT 18. IGNITION SWITCH
5. PMC SPEED CONTROLLER 12. CABLE (-) 19. MAIN DRIVE UNIT
6. CABLE (M-) 13. CABLE (A5) 20. CABLE (PM1)
7. BATTERY CONNECTOR 14. CABLE (A6) 21. CABLE (PM2)
Figure 3-4 - Drive Unit Compartment-MPE (S/N A803N08541 and up)
3-4
Yak)
9
1. CONTACTOR PANEL 6. DRIVE MOTOR 11. LIFT CYLINDER 16. FUSE, CONT. 15A., FU-3
2. KEY SWITCH 7. HORN 12. DRIVE UNIT 17. RELAY (CR-2)
3. CONNECTOR 8. LIFT LIMIT SWITCH 13. CONTROLLER 18. TERMINAL BLOCK (TB-1)
4. FUSE, HYD. 200A., FU 1 9. HYDRAULIC UNIT 14. LIFT LINKAGE
5. CONTACTORS 10. BRAKE LINKAGE 15. FUSE TRACT. 200A., FU-2
Figure 3-5 - Drive Unit Compartment-MPW (Early Production)
3-5
Yale
1 2 18 3 4 5 6 7
17
19
20
J
16
Zat
rz
15 14 13 12
1. IGNITION SWITCH 9. VARISTOR-LIFT CONTROL 17. RELAY CR1

2. BATTERY CONNECTOR 10. MOUNTING BRACKET 18. FUSE FU1
3. FWD/REV CONTACTOR 11. LIFT LIMIT SWITCH 19. FUSE FU2
4. WIRE HARNESS 12. BRAKE SYSTEM 20. FUSE F3
5. VARISTOR-SOLENOID VALVE 13. BRAKE SWITCH
6. HYDRAULIC SYSTEM 14. DRIVE UNIT
7. SUPPRESSOR 15. CONTROLLER
8. HORN 16. LIFT LINKAGE
Figure 3-6 - Drive Unit Compartment-MPW (From S/N 576820 to A838N06511U)
3-6
Yale

Figure 3-7 - Drive Unit Compartment-MPW (S/N A838N06512U and up)
3-7
Yale
1 2 3 4 5 6 7
14 13 12 11 10 9 8
1. CONTACTOR PANEL 6. DRIVE MOTOR 11. LIFT CYLINDER 16. FUSE, CONT. 15A., FU-3
2. KEY SWITCH 7. HORN 12. DRIVE UNIT 17. TERMINAL BLOCK (TB-1)
3. CONNECTOR 8. LIFT LIMIT SWITCH 13. CONTROLLER
4. FUSE, HYD. 200A., FU 1 9. HYDRAULIC UNIT 14. LIFT LINKAGE
5. CONTACTORS 10. BRAKE LINKAGE 15. FUSE TRACT. 200A., FU-2
Figure 3-8 - Drive Unit Compartment-MPC (Early Production)
3-8
Yale
ifcrrfa.
1. IGNITION SWITCH 7. SUPPRESSOR 13. DRIVE UNIT

2. BATTERY CONNECTOR 8. HORN 14. CONTROLLER
3. FWD/REV CONTACTOR 9. VARISTOR-LIFT CONTACTOR 15. LIFT LINKAGE
4. BRAKE SYSTEM 10. MOUNTING BRACKET 16. FUSE FU1
5. VARISTOR SOLENOID VALVE 11. LIFT LIMIT SWITCH 17. FUSE FU2
6. HYDRAULIC SYSTEM 12. BRAKE SWITCH 18. FUSE F3
Figure 3-9 - Drive Unit Compartment-MPC (From S/N 576761 to A803N08599U)
3-9
Yale
2 18 7 21 13 20 12 21 20
19 8 9

Figure 3-10 - Drive Unit Compartment-MPC (S/N A803N08600U and up)
3-10
IndustrialTrucks electrical system
1. CONTACTOR PANEL 5. DRIVE MOTOR 9. DRIVE UNIT 13. FUSE, TRACT. 200A., FU-2
2. KEY SWITCH 6. HORN 10. CONTROLLER 14. TERMINAL BLOCK (TB-1)
3. CONNECTOR 7. BRAKE LINKAGE 11. TERMINAL BLOCK
4. CONTACTORS 8. SUPPORT 12. FUSE.CONT. 15A., FU-3
Figure 3-11 - Drive Unit Compartment-MTR (Early Production)
3-11
Yale
1 2 3 4 5 6
10 9 8
1. IGNITION SWITCH 7. HORN

2. BATTERY CONNECTOR 8. DRIVE UNIT
3. FWD/REV CONTACTOR 9. CONTROLLER
4. WIRE HARNESS 10. CONTACTOR PANEL
5. BRAKE LINKAGE 11. FUSE FU1
6. SUPPRESSOR 12. FUSE FU3
Figure 3-12 - Drive Unit Compartment-MTR (From S/N 991606 to A817N05790U)
3-12
Yale
2 8 7 9 10 11
14
1. CONTACTOR PANEL 8. IGNITION SWITCH

2. ELECTRONIC LOGIC MODULE 9. CABLE (A5)
3. CABLE (A5-1) 10. CABLE (A6)
4. CABLE (A6-1) 11. CABLE (-)
5. PMC SPEED CONTROLLER 12. HORN
6. CABLE (M-) 13. SUPPRESSOR
7. BATTERY CONNECTOR 14. MAIN DRIVE UNIT
Figure 3-13 - Drive Unit Compartment-MTR (S/N A817N05791U and up)
3-13
Yale
1. IGNITION SWITCH 8. HYDRAULIC SYSTEM 15. BUSS BAR (M-)

2. FWD/REV CONTACTORS 9. HORN 16. BUSS BAR (B + )
3. BRAKE SYSTEM 10. SUPPRESSOR, HORN 17. BUSS BAR (A2)
4. RELAY 11. CONTROLLER 18. FUSE (FU1)
5. VARISTOR-LIFT CONTACTOR 12. CONTACTOR PANEL 19. FUSE (FU2)
6. VARISTOR-SOLENOID VALVE 13. DRIVE UNIT 20. FUSE (FU3)
7. WIRE HARNESS 14. BUSS BAR (B-)
Figure 3-14 - Drive Unit Compartment-MLW
3-14
Yale
1. M- POWER TERMINAL
2. TERMINAL 2
3. TERMINAL 1
4. B- POWER TERMINAL
5. B+ POWER TERMINAL
6. KEY SWITCH INPUT
7. F/R CONTACTOR OUTPUT
8. STATIC-RETURN-TO-OFF OR 1A
9. BRAKE OR EMERGENCY REVERSE
10. FORWARD INPUT
11. REVERSE INPUT
12. A2 POWER TERMINAL
Figure 3-15 - Transistor Motor Controller

TRANSISTOR MOTOR CONTROLLER Refer to the Wiring Diagrams and Schematics at the rear of this
section for connection information.
General
The traction motor is controlled by a Curtis Transistor Motor Control
Controller, also known as a MOSFET or PMC controller. The
The control circuit receives operator inputs from the key switch,
controllers used in trucks covered by this manual will vary
the brake switch and the accelerator potentiometer. The circuit
depending on truck model and truck voltage. Refer to the
receives internal inputs from the power circuit for thermal
appropriate parts manual to identify the specific motor
protection, plugging sensing, low voltage protection and motor
controller used on the truck to be serviced.
current (current limit). The control circuit regulates speed
control, current limit and plugging strength.
The motorcontroller is used to regulate the speed of the traction
motor. The motorcontroller applies battery voltage in short, fast
Plugging
pulses to the DC motor to control the speed. The direction of
rotation of the traction motor is controlled by forward and The plugging circuit provides smooth electrical braking and
reverse contactors. saves wear and tear on the drive tires and the drive unit gears.
Plugging occurs when the truck is traveling in one direction and
The motorcontroller is sealed in an aluminum case and cannot the operator switches the directional control to the opposite
be repaired. The complete unit must be replaced if correct direction. Avoid plugging the drive motor when the drive wheel
troubleshooting methods indicate that the unit is damaged. is jacked off the ground.
In addition to controlling the movement of the truck, the motor The plugging function is designed to allow the truck to travel 1 to
controller performs the following functions: 2 times the length of the lift truck before the truck reverses
direction after the directional control isswitched to the opposite
a. Monitors temperature to provide high and low
direction. The plugging distance is adjustable. Refer to
temperature protection to the motor controller.
ADJUSTMENTS, this section.
b. Checks that an operator follows the correct starting
sequence to help prevent unexpected operation. This Static-Return-To-Off (SRO)
function is called "Static-Return-To-Off" (SRO).
The SRO function prevents the operation of the lift truck when
c. Checks the traction circuit for malfunctions and the starting sequence is not performed in the correct order. The
prevents lift truck operation if a failure is sensed. starting sequence is as follows:
d. Checks the current in the motor circuit and a. Turn the key switch to the ON position.
automatically decreases the motor voltage to reduce the
b. Lower the steering handle to release the brake and
current and prevent damage. The plugging circuit is also
close the brake switch. Battery voltage is now supplied to
controlled for smoother operation.
the control circuit.
3-15
Yale
c. Rotate the Direction/Speed control in the desired Low Voltage Protection

direction of travel to select travel direction and speed.
The motor controller and the battery are protected from a low
voltage condition. A 12 volt motor controller requires at least 9
If Step (c.) is done before steps (a.) and (b.) are done, the truck
volts to function properly. A 24 volt motor controller requires at
will not move in either direction. The control circuit must get
least 16 volts to function properly. The battery current drain
battery voltage through the key and brake switches before it
increases as the battery voltage decreases. If the battery
gets a speed signal from the accelerator potentiometer.
voltage is low, the control circuit decreases the current drain.
The battery can still operate the lift truck to move it for battery
The S RO function prevents the lift truck from going to full speed
charging or replacement.
operation if a malfunction occurs in the accelerator circuit. An
open circuit in the accelerator circuit is normally sensed as a full
Current Limit
speed signal by the control card. If this malfunction exists, the
SRO function will prevent operation. If the malfunction occurs The control circuit limits the traction motor current to a
during normal operation, the control circuit senses an maximum value to protect the motor controller, motor and
accelerator potentiometer input of more than 7000 ohms (open battery. The maximum value is set by the manufacturer.
circuit) and stops operating. The circuit will return to normal
operation after the malfunction is repaired. Motor Controller Replacement
Make an identification and disconnect the wires and cables
Thermal Protection
from the motor controller. Remove the mounting screws and
There is a sensor to sense the heat within the motor controller remove the controller. Apply a thin coating of silicone grease
housing. If the motor controller gets too hot or too cold for (Yale Part Number 5042232-39) on the bottom of the
correct operation, the control circuit will decrease the current to replacement motor controller. Installthe replacement controller
protect the controller. The lift truck will operate at a slower on the lift truck. Connect the wires and cables to the same
speed to permit it to be moved to a location out of the work area. terminals as identified during the removal procedure.
Key switch to the ON

position.
Brake switch closes as Gate Driver turns OFF signal

steer handle is lowered. Gate Driver of Control Circuit to FETs gate. OFF TIME
sends ON pulse to FETs gate. (pulse width) set by rest of
ON TIME (pulse width) set by time remaining in one cycle at
accelerator potentiometer 15 kHz.
Control Circuit has battery signal.
positive. Circuit checks for
proper signal from accelerator
_ potentiometer._ Power pulse to traction
FETs ON for time of gate ON motor circuit ends.
Direction/Speed Control
_ pulse._
rotated for slow forward travel.
Induction current flows

through Flyback Diode and
FWD/REV switch forward Power Pulse to traction traction motor.
contacts close. Accelerator motor circuit.
potentiometer signal to
Control Circuit.
Control Circuit repeats

cycle.
Forward contactor energized
or ELM sets direction corre¬
sponding to input received.
Figure 3-16 - Sequence of Operation

3-16
Yale
TROUBLESHOOTING
This section describes the most common faults that can occur in trucks with the CURTIS TRANSISTOR CONTROLLER. Follow the
General Procedures to make sure that maintenance problems give the correct troubleshooting results. Follow the fault procedure that
best describes the problem.
FAULT PROCEDURES
The following pages have some common faults of these lift trucks and the procedures for finding the cause.
FAULT NUMBER 1 . ONE DIRECTIONAL CONTACTOR WILL NOT CLOSE
Possible Causes: • Damaged (open) wire(s) in control circuit

• Direction switch is damaged
• Contactor coil is damaged
• Motor controller is damaged at FWD or REV terminal.
1.0 Check that the direction switch closes. 1.0.1 Contacts of direction switch do not close in
one direction. Repair or replace the switch.
1.0.2 The direction switch closes. Check FWD or

REV contactor coil and wire 27 at contactors.
1.1 Only REV contactor will close. Check for bat¬ 1.1.1 Voltage at wire 6. Traction reverse switch or
hL
tery voltage at wire 6 terminal of traction re¬ wiring is damaged.
verse or direction switch with both switches in
neutral position.
1.1.2 No voltage at wire 6. Directional switch, wir¬
ing, FWD contactor coil or motor controller is
damaged.
1.1 Only FWD contactor will close. Check for bat¬ 1.1.1 Voltage at wire 8. Traction reverse switch or
tery voltage at wire 8 terminal of traction re¬ wiring is damaged.
verse or direction switch with both switches in
neutral position.
1.1.2 No voltage at wire 8. Directional switch, wir¬
ing, REV contactor coil or motor controller is
damaged.
3-17
Yale
FAULT NUMBER 2. DIRECTIONAL CONTACTORS WILL NOT CLOSE FOR

OPERATION IN EITHER DIRECTION
Possible Causes:
• Battery not connected Key switch or brake switch is damaged
• Control fuse is damaged Traction reverse switch is damaged
• F/R switch is damaged Battery voltage is low
• Motor controller Is damaged Wires in circuit are open
• Static Return to Off (SRO) invoked
2.0 Check for battery voltage on the battery side 2.0.1 Battery voltage at control fuse. Check for an open
of control fuse. control fuse.
2.0.2 No battery voltage at control fuse. Connect bat¬

tery or check wiring between battery and fuse.
2.1 Check for battery voltage at control fuse ter¬ 2.1.1 Battery voltage at key switch. Check for dam¬
minal of key switch. aged key switch.
2.1.2 No voltage at key switch. Wire to key switch or

connections are damaged.
2.2.1 Battery voltage at brake switch. Check for dam¬

2.2 Key switch closed. Check for battery voltage aged brake switch.
at key switch terminal of brake switch.
2.2.2 No voltage at brake switch. Check for damaged
wire to brake switch or damaged key switch.
2.3.1 Battery voltage at B+ terminal. Possible dam¬

2.3 Key switch closed. Check for battery voltage
aged motor controller.
at B+ terminal of motor controller.
2.3.2 No voltage at B+ terminal. Check for damaged

wire A5.
2.4 Brake switch closed. Check for battery volt¬ 2.4.1 Battery voltage at traction reverse switch. Check
age at brake switch terminal of traction re¬ for damaged traction reverse switch.
verse switch.
2.4.2 No voltage at traction reverse switch. Check for
damaged wire to switch or damaged brake
switch.
2.5 Check for battery voltage at traction reverse 2.5.1 Voltage at F/R switch. Check for damaged F/R
switch terminal of F/R switch. switch or damaged wire to switch.
2.5.2 No battery voltage at F/R switch. Check for dam¬

aged traction reverse switch or damaged wire to
F/R switch.
2.6 Check for damaged wire(s) to FWD/REV 2.6.1 Wires not damaged. Check for damaged contac¬
contactors. tor coils.
3-18
Yale
FAULT NUMBER 3. LIFT TRUCK WILL NOT MOVE IN EITHER DIRECTION. THE
DIRECTIONAL CONTACTORS CLOSE NORMALLY. NO POWER
WHEN DIRECTION/SPEED CONTROL IS MOVED.
Possible Causes:
Traction fuse is damaged • Accelerator potentiometer damaged or needs adjustment
Open circuit between motor and contactors • Damaged (open) traction motor cables
Power contacts of direction contactor are damaged • Motor controller is damaged
Traction motor is damaged
Hi-Pedal Disable (HPO) invoked
• Damaged ELM
3.0 Check traction fuse. * 3.0.1 If fuse is damaged, replace fuse with one of the
correct value.
<\ 3.0.2 If fuse is not damaged, go to 3.1. |

3.1 Check for battery voltage between B+and B-
terminals of motor controller.
. 3.1.1 No battery voltage. Check cables between bat¬
tery and terminals. Check input to and output
from ELM.
>| 3.1.2 Battery voltage. Go to 3.2.
3.2 Check for battery voltage at A2 terminal on 3.2.1 No battery voltage at A2.Buss bar from motor
motor controller. controller to contactor, cables to armature of
traction motor, motor brushes or motor armature
are damaged. Motor brushes or cables are
damaged. Replace or repair. Motor brushes and
cables are not damaged. Armature is open, re¬
place motor.
3.2.2 Battery voltage. Go to 3.3.
3.3 Check voltage at both field coil terminals of 3.3.1 No battery voltage at field coils. Check power
traction motor with direction contactor ener¬ contact of direction contactor, cable F4 and trac¬
gized. tion motorfield. Repair or replace damaged con¬
tact, cable or motor.
3.3.2 Battery voltage. Go to 3.4.
3.4 Checkforvoltagesweep between B+and M- 3.4.1 No battery voltage at M-. Check power contact
terminals of motor controller from neutral to of direction contactor and BUSS BAR. Repair or
full speed. replace damaged contact or BUSS BAR. Trou-
bleshoot motor controller. See fault number 5.
3.4.2 0 V to Battery voltage. PMC OK, check motor

and associated wires.
3-19
Yale
FAULT NUMBER 4. DIRECTIONAL CONTACTORS CLOSE, LIFT TRUCK

ACCELERATES TO FULL SPEED IMMEDIATELY.
Possible Causes:
• Accelerator potentiometer damaged or needs adjustment • Motor controller is damaged
4.0 Check that accelerator potentiometer is wired 4.0.1 Potentiometer is wired correctly. Check that wire
correctly. See the WIRING DIAGRAMS. 29 to 18 voltage varies as speed control is
moved.
4.0.2 Voltage does not change. Adjust or replace po¬

tentiometer.
4.1 Voltage varies. Check for short-circuit of 4.1.1 Wires are not damaged. Check motor controller
wires 29 and 18. on bench check. Replace if damaged.
FAULT NUMBER 5. TROUBLESHOOTING MOTOR CONTROLLER

Possible Causes:
• Static Return to Off (SRO) invoked • B- to M- short in wiring
• PMC inputs not correct • Bad connection in 6 pin connector to PMC
TEST POINTS EXPECTED VALUE
Disconnect six pin input to PMC and check the following at the wiring connector.
| 5.0 B+ TO B- -*
5.0.1 Battery volts. If not, check wires and connec¬
tions.
5.1.1 Battery volts w/key and brake switches

| I m
m closed. If less than battery voltage, check wir¬
5.1 KSItoB- I ing through key switch and brake switch.
5.2 F/R toB- 5.2.1. Battery voltage w/brake switch an$l either
directional switch closed. If not, check wiring.
5.3.1. Battery volts w/brake switch and forward

5.3 Fwd to B - directional switch closed. If less than battery
switch check FWD switch and related wiring.
5.4.1. Battery volts w/brake switch and reverse

5.4 Rev to B - directional switch closed. If less than battery
switch check REV switch and related wiring.
Connect six pin connector and check the following.
5.5 Terminal 2 to 3 with wires 18 and 29 discon¬ 5.5.1. 6+ volts. If less than 6 volts replace PMC.
nected. (Across terminals.) *
5.6 Resistance between wire 18 and 29 while dis¬ 5.6.1. Minimum of 3300 ohms. If less than 3300
connected and accelerator in neutral. ohms, adjust potentiometer in accelerator.
5.7.1. 0 volts to battery volts as accelerator is ro¬

5.7 Check for voltage sweep between B+ and tated. If no voltage as handle is rotatedandall
M - terminals of motor controller from neu¬ other inputs are correct, replace PMC.
tral to full speed.
3-20
Yale
ADJUSTMENTS If it is necessary to make any adjustments to the PMC, perform

the following steps:
/ I\ unless you have both authorization and training. a. Turn the key switch to the OFF position and
Repairs and adjustments that are not correct can disconnect the battery cable.
b. Remove the compartment cover and discharge the
truck that needs repairs. Report the need for repairs to your
capacitor.
OPERATE" tag on the control handle. Remove the key from the c. Remove the 3 mm (0.12 in) socket head screws to
key switch. access the adjustment screws.
d. Adjust the motor controller as required using a small
/\ WARNING: Disconnect the battery and separate
insulated screwdriver.
11\ the connector before opening the drive unit
compartment cover or inspecting or repairing the e. Install the socket head screws after the proper
electrical system. If a tool causes a short-circuit, the high adjustments have been made. Install the compartment
current flow from the battery can cause an injury or parts cover and connect the battery cable. Test the truck for
damage. proper operation before returning the truck to service.

/ |\ can hold an electrical charge after the battery is
—
any component in the drive unit compartment. Wear safety """"
glasses. Make certain the battery has been disconnected. . foXol-fol-
the B+ and B- terminals of the motor controller.
*\ \
O
\ \
Plugging Adjustment
Turn the plugging (braking) adjustment screw clockwise to
increase the plugging effect and stop the lift truck in a shorter
1
/
\ V
distance. Turn the adjustment screw counterclockwise to
decrease the plugging effect. The traction motor generates 1. MOTOR CONTROLLER
more heat and the motor brushes wear at a faster rate when the 2. BRAKING (PLUGGING) ADJUSTMENT
motor controller is adjusted for a shorter stopping distance SCREW (CW = HARDER BRAKING)
(increased plugging). The default or factory setting is obtained 3. CURRENT LIMIT ADJUSTMENT SCREW
when the adjustment screw is set in the one o'clock position. (CW = HIGHER CURRENT)
4. CONTROLLED ACCELERATION ADJUSTMENT
Acceleration Adjustment SCREW (CW = FASTER ACCELERATION)
Turn the adjustment screw counterclockwise to decrease the

rate of acceleration. Turn the acceleration adjustment screw
clockwise to increase the acceleration rate. The traction motor
generates more heat and the motor brushes wear at a faster
rate when the motor controller is adjusted for an increased MIDPOINT
acceleration rate. The default or factory setting is obtained 12 O'CLOCK POSITION.
when the adjustment screw is set in the twelve o'clock position.
Current Limit Adjustment

The current limit adjustment is factory-set at the maximum 400
amps. Increasing the current limit can cause damage to the
motor controller or the traction motor and can cause the truck to
MINIMUM MAXIMUM
run at a higher than normal speed, especially when driven
POSITION POSITION
unloaded. Decreasing the current limit can affect the starting
torque and can cause the truck to run at less than top speed ENLARGED VIEW OF
when fully loaded. The current limit setting should remain at the ADJUSTING SCREWS
factory setting. If necessary, turn the current limit adjustment (2, 3 AND 4 AS SHOWN ABOVE)
screw clockwise to increase the current limit or
counterclockwise to decrease the current limit. Figure 3-17 - Motor Controller Adjustment Locations
3-21
Yale
Accelerator Potentiometer Adjustment ELECTRONIC LOGIC MODULE (ELM)

1. Move the key to the OFF position. Disconnect the battery. General
2. Remove the four corner screws and washers retaining the The electronic logic module (ELM) is used on late modeltrucks.
top cover assembly to the base of the control handle. See The ELM improves the reliability of the electrical system by
Figure 3-21. The two center screws retain the mounting consolidating the truck logic components into an
bracket assembly to the base. environmentally protected, solid-state circuit board. The ELM
3. Secure the reversing button so that it does not fall. Lift the eliminates the need for mechanical relays, terminal boards,
top cover assembly carefully off the base and remove the auto external diodes, and the wiring and connections associated
reverse actuator, springs and plunger. with these components. The ELM has the following inputs and
4. Mark the wires for identification before disconnecting the outputs:
wires from the switches. Remove the connector to the
1. Battery Positive - positive battery level signal when the
potentiometer and the connector to the lift, lowering, horn and
auto reversing switches. key switch is in the ON position.
5. Test the potentiometer using an ohmmeter (R x 100 2. Battery Negative - connected to battery negative.
scale). Connect the ohmmeter to the potentiometer connector. 3. Traction Reversing Switch - Digital input at battery level
The ohmmeter should read greater than 3300 ohms when the connected to traction reversing switch responsible for evoking
control lever is in neutral. Move the control lever to the forward, the emergency reverse feature.
and then to the reverse direction. The meter should indicate
less than 100 ohms at maximum travel in either direction. 4. High Speed Switch (Rabbit) - Digital input at battery level
connected to the high speed switch to provide the signal to
6. Center the potentiometer, using the ohmmeter, as follows: enter "rabbit" mode. This option is available only on walk/ride
a. Position the control in neutral. and ride models.
b. Loosen the setscrews retaining the gear on the
5. Brake Switch - Digital input at battery levelconnected from
potentiometer.
the brake switch.
c. Rotatethe potentiometer shaft slowly clockwise, then
slowly counterclockwise with a screwdriver until the 6. Aux. Forward Switch - Digital input at battery level
midpoint of the potentiometer is located. connected to the two switches connected in series form the
d. Tighten the setscrews when the midpoint is obtained. handle of the truck. Note that these two switches are
If the correct readings cannot be obtained, the independent from the forward/reverse switches. When both
potentiometer must be replaced. switches are closed, the truck travels in the forward direction at
the maximum walk speed. This option is available only on
7. Install the two connectors. walk/ride and ride models.
8. Align the plunger, springs and reversing switch actuator 7. Forward Switch - Digital signal at battery level connected
and both the top cover and base. Install the four screws and from the forward switch to provide a directional input to the
washers to retain the cover to the base. ELM. This signal is also connected to the traction controller.
9. Connect the battery, turn the key to the ON position and 8. Reverse Switch - Digital signal at battery level connected
test the lift truck for proper operation before returning the truck from the reverse switch to provide a directional input to the
to service. ELM. This signal is also connected to the traction controller.
9. Forward Contactor - Output connected to the negative
1 POTENTIOMETER GEAR
side of the forward contactor coil.
2. SETSCREW
3, ADJUSTMENT SLOT 10. Reverse Contactor - Output connected to the negative
4. ROLL PIN side of the reverse contactor coil.
5. SPUR GEAR 4
11. Traction Control PMT Input - Connected to the PMT driver
output of the traction controller.
12. Accelerator Potentiometer - Analog signal connected
from the accelerator potentiometer.
13. Traction Controller Reversing Switch Input -Digital output

at battery level to provide reversing switch input to the traction
controller.
14. Traction Controller Accelerator Potentiometer -
Accelerator potentiometer signal to the traction controller.
Figure 3-18 - Potentiometer Gear Installation
3-22
Yale
ELM Operation Testing the ELM

• The ELM receives power when the key switch is in the The most effective way to test the ELM is to replace it with a
ON position. spare ELM and check for proper operation. Proceed as follows:
• All inputs remain battery negative unless driven to battery WARNING: Parts of this procedure requires
voltage.
working on the lift truck with full electric current
• Activation of the traction reversing switch has the present. Do not wear any rings, watches or other
following affect: jewelry while working around the contactor panel. Use a
When the traction reversing switch is pressed, the truck properly insulated tool when manually closing a contactor with
travels in the reverse direction at maximum speed. power connected.
Upon release of the traction reversing switch, the
1. Block the lift truck so that the drive wheels are off the floor.
command for the reverse direction is removed.
See Section 1-HOW TO PUT THE LIFT TRUCK ON BLOCKS.
The truck will not operate in the forward direction again
2. Remove the drive unit compartment cover. See Section
until the accelerator switch mechanism is returned to
2-DRIVE UNIT COMPARTMENT COVER-REMOVAL AND
neutral, the brake is applied, or the key switch cycled from
INSTALLATION.
the ON to the OFF position and back to the ON position.
WARNING: Never operate the traction motor at
NOTE: The traction reversing switch overrides all other
full speed for more than a few seconds when the
operations, with one exception. If the truck is in the "rabbit"
drive wheels are off the floor. A series wound DC
mode, the reversing switch is deactivated.
motor will continue to accelerate indefinitely until it exceeds the
designed maximum rpm, then self-destruct. Personal injury or
• Activation of the high speed switch has the following damage to the lift truck can occur.
affect:
The high speed switch requires a specific sequence of
3. Check the condition of the battery. If it is not fully charged,
events to beactivated. This prevents the switch from being
replace it with a fully charged battery.
held closed mechanically (anti-tie down). To enter the
"rabbit" mode, the operator must select and remain in a
4. Unplug the ELM connector and plug the harness
direction and then press the high speed switch.
connector into a spare ELM. Check the truck for proper
The "rabbit" mode allows the truck to be operated at operation. If the spare ELM corrects the problem, replace the
maximum speed. original ELM.
The "rabbit" mode is cancelled with the removal of the
If a spare ELM is not available, it will be necessary to test the
directional signal (forward or reverse), the application of
input signals to the ELM. Use a multimeter and a Break Out Box
the brake, or the switching of the key switch to the OFF Kit (P/N 580002086) to test the input signals.
position.
• The auxiliary forward switch allows the truck to travel in CAUTION: Do not insert the probes of the
the forward direction at the maximum walk speed while multimeter directly into the ELM connector. The
the switch is pressed. Break Out Box Kit is designed to allow access to
the terminals for testing.
• The forward and reverse switches provide the command
for the forward or reverse contactor, respectively, to be 1. Make sure the battery isconnected and the key switch is in
energized, provided that the traction controller PMT driver the ON position. Set the multimeter to read voltage. Test the
is on. inputs according to Table 3-11 .
Figure 3-19 - Break Out Box Kit
3-23
Yale
Industrial Trucks electrical system
Connect Multime¬ Connect Multime¬

To Test Input ter red lead to ter black lead to
Check or Verify
Signal for Break Out Box Break Out Box
Terminal Terminal
Battery voltage 7 20 Multimeter should indicate battery voltage. If not, check fuse F3, key
switch, wiring, and the battery.
Brake switch 18 20 With the brake switch open (brake applied), the meter should read
zero volts. With the brake switch closed (brake off), the meter should
read battery voltage. If not, check the brake switch and wiring.
Reverse direc¬ 12 20 With the brake switch closed and the rotary grip in neutral, the meter
tion switch should read zero volts. Turn the rotary grip for reverse direction. The
meter should now read battery voltage. If not, check the reverse
switch and wiring.
Forward direc¬ 11 20 With the brake switch closed and the rotary grip in neutral, the meter
tion switch should read zero volts. Turn the rotary grip for forward direction. The
meter should now read battery voltage. If not, check the forward
switch and wiring.
Reverse con¬ 23 20 With the brake switch closed, the meter should read battery voltage.
tactor coil If not, check the reverse contactor, suppressor, and wiring.
Forward con¬ 16 20 With the brake switch closed, the meter should read battery voltage.
tactor coil If not, check the forward contactor, suppressor, and wiring.
High Speed 13 20 With the brake switch closed, the meter should read zero volts. Acti¬
(Rabbit) switch vate the rabbit switch. The meter should now read battery voltage. If
not, check the rabbit switch and wiring.
Traction re¬ 21 20 With the brake switch closed, the meter should read zero volts. Acti¬
verse switch vate the traction reverse switch. The meter should now read battery
voltage. If not, check the traction reverse switch and wiring.
Table 3-11 - ELM Voltage Checks
2. Disconnect the battery. Check the accelerator 3. If all of the inputs to the ELM check out OK, The problem
potentiometer input as follows: could be the ELM. Replace the ELM and check the truck for
proper operation.
a. Disconnect potentiometer leads 25 and 26 from the
terminals at the traction controller.
CONTACTORS
b. Set the multimeter to read resistance.
A contactor is a switch, controlled by an electromagnetic coil,
c. Connect the red lead of the meter to the Break Out
used to close or open a power circuit. Electronic drivers in the
Box terminal 8 and the black lead to terminal 2.
motor controller send electric current to the electromagnetic
d. With the rotary grip in the neutral position, the meter coil in the contactor. The electromagnetic field produced by the
should read approximately 3300 ohms. current flow to the coil causes the power circuit contacts to
move against spring pressure to open or close the power circuit
e. Rotate the grip for the reverse direction to the stop.
of the contactor. When the electromagnetic coil is deenergized,
The meter should read a resistance value less than 100
the spring pressure moves the power circuit back to the original
ohms.
or normal position. Power circuit contacts of a contactor are
f. Return the rotary grip to the neutral position. The called Normally Open (NO) or Normally Closed (NC), referring
meter should read approximately 3300 ohms. to the position of the contacts when the electromagnetic coil of
the contactor is not energized. When spring pressure holds the
g. Rotate the grip for the forward direction to the stop.
power circuit contacts in the open position, the circuit is called
The meter should read a resistance value less than 100
Normally Open. When spring pressure holds the power circuit
ohms.
contacts in the closed position, the circuit is called Normally
h. If the readings above are incorrect, check the wiring Closed (NC). When the contactor coil is energized, the spring
from the potentiometer to the ELM. If OK, replace the pressure is overcome by the electromagnetic field to switch the
potentiometer. contacts from their normal position to the opposite position. A
single contactor may contain both normally open and normally
closed power circuit contacts.
3-24
Yale
The power circuit contacts are made of special silver alloy. The 8. Disconnect the battery. Disconnect the contactor coil
contacts normally look black and rough. This condition does not wires. Measure the resistance of the coil with an ohmmeter. A
indicate problems with the contactor, nor does it affect the suppressor diode with a resistor in series is part of the coil. The
operation of the lift truck. Cleaning is not necessary. DO NOT diode will cause the ohmmeter to indicate a difference in
USE A FILE ON THE CONTACTS. DO NOT LUBRICATE THE resistance when measured in one direction compared with the
CONTACTS. Replace the contacts when the silver alloy is worn other direction. Measure the resistance in each direction. Use
away to the base support metal. the highest resistance indication. When testing the coils for the
forward and reverse contactors, the ohmmeter should read 18
The direction of rotation of the traction motor is controlled by the
ohms±10%. When testing the coils for the lift and lower
"FORWARD" and "REVERSE" contactors. Each contactor has
contactors the ohmmeter should read 50 ohms ± 10%.
two sets of normally open (NO) contacts, two sets of normally
Replace the coil if the resistance readings indicate a
closed (NC) contacts and an electromagnetic coil. Current
short-circuit or an open circuit in both directions.
flows through the traction motor field in one direction when the
"FORWARD" contactor is energized and in the other direction
9. If the contactor closes but the truck does not work properly,
when the "REVERSE" contactor is energized. This action gives
check the electrical function of the high current section of the
direction control to the traction motor.
contactor (the tips and buss bars). With the lift truck battery
connected and all switches closed, connect a volt ohmmeter
Testing Contactors
across the high current terminals of the contactor.
/\ WARNING: Parts of this procedure requires
Set the high voltage scale of the meter to the lowest range
/f \ working on the lift truck with full electric current
higher than battery voltage (50 volts for a 36 volt battery, etc.).
present. Do not wear any rings, watches or other
On forward and reverse contactors, with the contactor open, a
jewelry while working around the contactor panel. Use a
reading of zero volts should be obtained. As the contactor
properly insulated tool when manually closing a contactor with
closes, the meter should jump then immediately drop to zero or
power connected.
close to zero. This is the voltage drop across the contactor. On
pump contactors, readthe voltage across the contactor with the
1. Block the lift truck so that the drive wheels are off the floor.
tips open. Battery voltage should drop to zero or near zero as
See Section 1-HOWTO PUT THE LIFT TRUCK ON BLOCKS.
the tips close.
Make certain that the hydraulic controls are in the neutral
position. A high voltage drop (2 volts or more) across the tips indicates a
poor contact or high resistance. Check for burned or worn tips,
2. Remove the drive unit compartment cover. See Section incorrect size or mismatched tips and for an incorrect gap
2-DRIVE UNIT COMPARTMENT COVER-REMOVAL AND setting on contactors with adjustable point gaps.
INSTALLATION.
Contactor Replacement
/\ WARNING: Never operate the traction motor at
/\ WARNING: Disconnect the battery and separate
11\ full speed for more than a few seconds when the
11\ the connector before opening the compartment
drive wheels are off the floor. A series wound DC
cover or inspecting or repairing the electrical
motor will continue to accelerate indefinitely until it exceeds the
system. If a tool causes a short-circuit, the high current flow
designed maximum rpm, at which point it will self-destruct. from the battery can cause an injury or parts damage.
Personal injury or damage to the lift truck can occur.
/|\ WARNING: The capacitor in the motor controller
3. Check the condition of the battery. If it is not fully charged, / I\ can hold an electrical charge after the battery is
replace the battery with a fully charged battery before disconnected. To prevent electrical shock and
continuing. injury, discharge the capacitor before inspecting or repairing
4. Visually check to see if the contactor closes when the glasses. Make certain the battery has been disconnected.
circuit is energized. If the contactor closes, skip to Step 9. If the Connect a load such as a horn across the B+ and B- terminals
contactor does not close, proceed to Step 5. of the motor controller to discharge the capacitors.
NOTE: Make an identification of wires before disconnecting
5. Check the contactor for loose, broken or corroded
to ensure the wires are connected properly after checks or
connections at the contactor. repairs are performed.
6. Check the mechanical function of the contactor. Use an 1. If the lift truck has an EE rating, remove the cover of the
insulated tool, such as an electricians screwdriver, to manually contactor box for access to the contactor terminals.
close the contactor tips. Check for looseness or binding of the
moving parts of the contactor. The parts should move freely, but 2. Make an identification of the wires and cables and
should not be loose. disconnect them from the contactor assembly.
7. Visually check the tips for pitting, burning or wear. 3. Remove the mounting screws. Replace the contactor.
3-25
Yalo
6. If the coil will be replaced, remove the cover base. Remove

the screws that fasten the coil frame to the mount bracket.
Remove the coil and frame. Remove the bushing part of the
plunger and the armature cap from the coil. Install these parts
on the replacement coil.
7. Install the coil and frame on the mount bracket.
8. Install the cover base, fixed contact bars and plungers on
1. CAPSCREW the coil frame. Make sure both springs are on both plungers.
2. BUSS BAR
9. Install the contactor cover and install the contactor.
3. COVER
4. SPRING 10. Install the contact carrier, the lower fixed contact bars and
5. FIXED CONTACTS the lower clamps.
6. PLUNGERS
& MOVABLE FUSES
CONTACTS
WARNING: The capacitor in the motor controller
7. COVER BASE
can hold an electrical charge after the battery is
8. COIL AND
FRAME
9. MOUNT BRACKET
10. ARMATURE CAP
Motorized hand trucks use a single 15 amp fuse for the control
circuit, and 200 amp fuses for both the hydraulic pump motor
11379 and the drive motor. The fuses are located on the contactor
10 panel. Remove and replace as required. If it cannot be
NOTE: THE POWER CONNECTIONS FOR THE FIXED determined visually that a fuse has failed, check for continuity
CONTACTS MAY BE DIFFERENT THAN SHOWN. using an ohmmeter. To replace either FU-1 or FU-2, loosen the
capscrews retaining them. Install a new fuse and tighten the
Figure 3-20 - Forward and Reverse Contactor Assembly capscrews. FU-3 is retained by a fuse holder. Make certain that
replacement fuses are of the correct size and amperage rating
4. Install the wires and cables as removed. Install the cover of before installation.
the contactor box on EE units.
MODEL 200 AMPS 200 AMPS 15 AMPS
Contactor Component Replacement
MPE.MLW, HYDRAULIC TRACTION CONTROL
NOTE: If both the contacts and the coil of a contactor need MPW,MPC PUMP (FU-1) (FU-2) (FU-3)
to be replaced, replace the complete contactor as described
above. Replace all of the contacts for any contactor if any TRACTION CONTROL
contact needs replacing. MTR N. A. (FU-1) (FU-2)
1. Remove the contactor as described in CONTACTOR Table 3-12 - Fuses

REPLACEMENT. BRAKE SWITCH
2. Make an identification of the buss bars for correct Removal and Installation
installation. Remove the buss bars and nuts that fasten to the Refer to Section 5-BRAKE SYSTEM for access to the brake
fixed contacts. switch. Check the brake switch for continuity. If the brake switch
must be removed, identify and remove the leads from the
3. Remove the two screws that fasten the cover to the switch. Remove the nut retaining the switch to the bracket.
contactor. Remove the cover of the contactor. Do NOT lose the Remove the switch. To install, attach the switch with the nut and
plunger springs. install the wires.
4. Replace the four fixed contacts in the contactor cover. Connect the battery. Move the brake handle to check that the
brake switch closes when the brake is released and opens
5. Remove the two plunger assemblies and movable when the brake is engaged. The brake switch is normally open
contacts and replace the three fixed contact bars. Replace the untilthe control handle is moved to the operating position. Refer
contacts of the plungers. to Section 5-BRAKE ADJUSTMENT to properly adjust the
brake switch
3-26
Yale
RELAYS
VALUE-RELAY
NOTE: No relays are used on the MPC or MTR models, or on RELAY DEENERGIZED
trucks equipped with the electronic logic module (ELM). TERMINALS FUNCTION
12 VOLTS 24 VOLTS
WARNING: The capacitor in the motor controller 10 and 11 RELAY COIL 107 OHMS 410 OHMS
disconnected. To prevent electrical shock and Table 3-3 - Auto Reverse Relay Coil CR-1 MPE, MLW and
injury, discharge the capacitor before inspecting or repairing MPW Only
any component in the drive unit compartment. Wear safety VALUE VALUE
glasses. Make certain the battery has been disconnected. RELAY RELAY RELAY
Use a screwdriver or jumper wire to make a short-circuit across TERMINALS FUNCTION DEENERGIZED ENERGIZED
1 and 7 N/C Continuity Open
Contacts
The M PW60-80 uses one relay. The relay is used for automatic
traction reversing. The automatic reversing relay is used to lock 6 and 9 N/O Open Continuity
out the ability of the lift truck to travel toward the operator after Contacts
the traction reverse button is depressed. The relay is reset by
5 and 8 N/O Open Continuity
moving the control handle to the full up or down position. Contacts
Two relays are used on MPE060-080 motorized lift trucks. The Table 3-4 - Auto Reverse Relay Contacts CR-1 MPE,
relays are used for automatic traction reversing and for fast MLW and MPW Only
speed. The automatic traction reversing relay is used to lock
out the ability of the lift truck to travel toward the operator after VALUE-RELAY
the traction reverse button is depressed. The relay is reset by RELAY DEENERGIZED
TERMINALS FUNCTION
moving the handle to the full up or down position. The fast 12 VOLTS 24 VOLTS
speed relay increases the truck speed when the fast speed
button on the handrail is pressed. To discontinue use of the fast 7 and 8 RELAY COIL 160 OHMS 650 OHMS
speed feature, return the directional/speed control to neutral. A Table 3-5 - Fast Speed Relay Coil CR-2 MPE Only
third relay is used when the optional pick handle is furnished.
VALUE VALUE
Test the relay coil using an ohmmeter and the applicable chart RELAY RELAY RELAY
TERMINALS FUNCTION DEENERGIZED ENERGIZED
below. Perform the test with the wires disconnected from the
relay contact terminals. If an incorrect reading is obtained, 6 and 4 N/O Open Continuity
replace the relay. Check the relay contacts by energizing the Contacts
relay coil. Continuity
5 and 3 N/O Open
Contacts
HEIGHT LIMIT SWITCH
Table 3-6 - Fast Speed Relay Contacts CR-2 MPE Only
The function of the height limit switch is to prevent the hydraulic
pump from running against relief by cutting off power to the VALUE-RELAY
solenoid after the hydraulic cylinder has reached the maximum RELAY DEENERGIZED
extend position. The height limit switch is located in the drive TERMINALS FUNCTION
unit compartment on the right side of the lift truck on all models 12 VOLTS 24 VOLTS
except the MTR. The MTR does not require a height limit 10 and 11 RELAY COIL 107 OHMS 410 OHMS
switch.
Table 3-7 - Pick Handle Relay Coil CR-3 MPE Only
Check the height limit switch for continuity. If there is no
continuity, the switch must be replaced. Make certain the leads VALUE VALUE
RELAY RELAY RELAY
are properly identified before they are removed. Disconnect the
TERMINALS FUNCTION DEENERGIZED ENERGIZED
leads to the switch. Remove the two capscrews, lockwashers
and nuts retaining the switch to the frame. Align a new switch 4 and 7 N/O Open Continuity
with the holes in the frame and install the capscrews, Contacts
lockwashers and nuts. Connect the leads to the switch. N/O Open Continuity
6 and 9
Connect the battery and test operate the lifting mechanism to Contacts
determine if the switch is operating properly. The switch is
normally closed until the forks reach the maximum height which 2 and 8 N/C Continuity Open
is 235 mm (9.25 in). Contacts
Table 3-8 - Pick Handle Relay Contacts CR-3 MPE Only
3-27
Yale
STEERING HANDLE SWITCHES 10. To remove the shaft from the control head arms.
Disassemble the capscrews, washers, lockwashers and
Removal
handle grips from the shaft. Refer to Section 6-CONTROL
WARNING: Do not make repairs or adjustments HANDLE HEAD-REMOVAL.
unless you have both authorization and training.
Repairs and adjustments that are not correct can 11. Disassemble the top cover assembly by removing the
create a dangerous operating condition. Do not operate a lift retaining screws and lockwashers. Be careful not to lose the
truck that needs repairs. Report the need for repairs to your springs, covers or actuators when removing the switch
supervisor immediately. If repair is necessary, put a "DO NOT assembly from the cover assembly. Remove the switch
OPERATE" tag on the control handle. Remove the key from the retainer. The switch retainer is held in position with four spring
key switch. loaded arms that are part of the switch support.
12. Remove the switches. Remove the actuators or covers
Remove the key from the key switch.
and springs from the steering handle cover.
2. Remove the four corner screws and lockwashers retaining
Installation
the top cover assembly to the base of the control handle.
1. Install the horn and traction reversing switches in the
NOTE: The two center screws and lockwashers retain the switch support. Connect the wires to the proper switches.
travel switch assembly to the base.
2. Assemble the switch retainer to the switch support. Install
3. Hold the traction reversing switch actuator so that it does the actuators, covers and springs in the steering control cover.
not fall. Carefully lift the top cover assembly off the base and Align the switch assembly and cover and install the four screws
remove the reversing switch actuator, springs and plunger. to retain the switch assembly and cover assembly. Make
certain that the reversing switch is located properly in the switch
4. Disconnect both the connector to the potentiometer and support before mating the two assemblies.
the connector to the horn, auto reversing, lift and lower
switches. Make certain all wires are identified before 3. Install the handle grips onto the shaft. Align the shaft
disconnecting them from the switches. assembly with the control handle arms and install the
capscrews, washers and lockwashers to retain the shaft
NOTE: The horn, auto reversing lift and lower switches,
assembly.
located in the top cover assembly may be tested for continuity
without disassembly of the top cover assembly. Make certain
4. Install the control levers on the shaft and install the
that the harness is disconnected when testing for continuity.
setscrews to retain the levers to the shaft.
5. Test the switches for continuity. Visually inspect the travel
5. Install the potentiometer in the mounting bracket. Install
switches for broken roller or broken springs. Replace any
the lockwasher and nut on the opposite side. Install the gear on
switch found to be damaged.
the potentiometer shaft using the two setscrews. Make certain
that the potentiometer gear and the sector gear on the
NOTE: The travel switches may be replaced individually. It is
mounting bracket are properly engaged. The gears must be
not necessary to disassemble the mounting bracket from the
free to rotate through full travel and return to neutral when the
base to replace the travel switches. The potentiometer, travel
control lever is released. Adjust the potentiometer, see
switches and control levers are the only serviceable items.
ACCELERATOR POTENTIOMETER ADJUSTMENT.
6. Remove the screws, nut plate, standoff, spacer and
6. Align the reverse and forward switches, insulators,
insulators to disassemble the forward and reverse switches
standoff, spacer and nut plates with the mounting bracket.
from the mounting bracket.
Apply adhesive sealant HCE-66 to the capscrews. Install the
capscrews and tighten to 0.34-0.45 N«m (3-4 Ibf in) torque.
7. To remove the control levers, remove the setscrews
retaining the levers to the shaft.
7. Attach the mounting bracket to the base using the two
screws and lockwashers. Attach the two connectors.
8. Disassemble the mounting bracket from the base by
removing the two screws and lockwashers. 8. Align the plunger, springs and auto reverse actuator and
both the top cover assembly and base. Install the four screws
NOTE: If the accelerator potentiometer is removed, the
and washers to retain the cover to the base.
potentiometer MUST be adjusted during assembly. See
ACCELERATOR POTENTIOMETER ADJUSTMENT 9. Connect the battery, install the key, turn the key to the ON
position and test the truck for proper operation.
9. Remove the setscrews retaining the potentiometer spur
gear and remove the gear. Remove the nut and lockwasher,
then remove the potentiometer from the mounting bracket.
3-28
Yale
1. ACTUATOR
2. SPRING
3. RUBBER STOPPER
4. TOP COVER
5. ACTUATOR 19. INSULATOR HEAD ASSEMBLY WITHOUT ELECTRIC
6. ACTUATOR 20. SWITCH LIFT AND LOWER SWITCHES
7. ACTUATOR 21. SPACER
8. SPRING 22. SETSCREW
9. SWITCH RETAINER 23. SPUR GEAR 33. SHAFT
10. SWITCH 24. CAPSCREW 34. SPUR GEAR
11. SWITCH SUPPORT 25. MOUNTING BRACKET 35. ROLL PIN
12. CAPSCREW 26. CAPSCREW 36. LOCKWASHER
13. LOCKWASHER 27. CONTROL LEVER 37. CAPSCREW 43. COVER
14. CAPSCREW 28. SETSCREW 38. LOCKWASHER 44. BRACKET (OPTIONAL)
15. SWITCH ASSEMBLY 29. BUSHING 39. CAPSCREW 45. CAPSCREW (OPTIONAL)
16. POTENTIOMETER 30. TORSION SPRING 40. CAPSCREW 46. RESISTOR (OPTIONAL)
17. STANDOFF 31. CAM 41. BASE 47. LOCKWASHER (OPTIONAL)
18. NUT PLATE 32. ROLL PIN 42. COVER 48. NUT (OPTIONAL)
Figure 3-20 - Control Head Switches
3-29
Yale
PICK ASSIST SWITCHES-MPE (OPTIONAL) 6. Remove the two capscrews and lockwashers retaining the
switch and bracket to the pick handle arm. Remove the switch
Removal
from the bracket by removing the hex. nut and lockwasher.
WARNING: Do not make repairs or adjustments
unless you have both authorization and training. 7. Remove the two capscrews and lockwashers retaining the
Repairs and adjustments that are not correct can end guard, button, spring and switch.
truck that needs repairs. Report the need for repairs to your Installation
1. Connect the lead wires furnished with the new switches to
OPERATE" tag on the control handle.
the existing splice in the control handle. Carefully run the wires
NOTE: There are two switches located under the grip handle from the control handle to the pick handle arm.
on each side of the pick handle. The two switches are wired in
series and both switches must be replaced if one switch fails. 2. Install the bottom switch in the bracket using a lockwasher
Test the switches for continuity. If there is no continuity, replace and hex. nut. Install the bracket and switch on the pick handle
the switches. arm using the two capscrews and lockwashers.
3. Align the upper switch, spring, button and end guard in the
Remove the key from the key switch.
pick handle. Install the two capscrews and lockwashers to
retain the components to the pick handle arm.
2. Remove the two capscrews and lockwashers that retain
the grip cover to the pick handle arm. Remove the grip cover.
4. Align the plunger, springs and auto reverse actuator and
the top cover assembly and base. Install the four screws and
3. Remove the four corner screws and lockwashers retaining
washers to retain the cover to the base of the control handle.
the top cover assembly to the base of the control handle. The
two center screws and lockwashers retain the travel switch
5. Align the grip cover with the pick handle arm. Make certain
assembly to the base.
that the wiring to the switches will not interfere with the
movement of the grip cover. Install the two capscrews and
4. Secure the auto reversing switch actuator so that it does
lockwashers to retain the grip cover to the pick handle arm.
not fall. Carefully lift the top cover assembly off the base and
remove the reversing switch actuator, springs and plunger.
6. Connect the battery, install the key, turn the key to the ON
position and test the truck for proper operation.
5. Locate where the pick handle switches are spliced in the
control handle. Tag the wires for identification. Disconnect the
wires to the switches that are to be removed.
1. PICK HANDLE ARM

2. COVER GRIP
3. CAPSCREW
4. LOCKWASHER
5. CAPSCREW
6. BRACKET
7. SWITCH
8. CAPSCREW
9. SWITCH
10. SPRING
11. BUTTON
12. END GUARD
HANDLE GRIP
(REF.)
Figure 3-21 - Pick Handle Switch Installation
3-30
Yalo
MOTOR MAINTENANCE-GENERAL BRUSH AND COMMUTATOR INSPECTION

This portion of the electrical section describes disassembly and WARNING: Put blocks under each side of the
assembly, brush replacement, inspection and checks for truck under the drive unit frame. Position blocks on
malfunction of DC motors. Inspect the commutator and both sides of the load wheels. The blocks must
brushes every 200 hours of operation. The commutator is the prevent the lift truck from falling and causing injury or damage.
rotating electric connection between the armature and the
electric power supplied by the battery. Brushes made of carbon 1. Raise the drive wheel off the floor. Block the lift truck. See
compounds slide on the rotating commutator and are the path Section 1-HOW TO PUT A LIFT TRUCK ON BLOCKS.
for electricity from the battery to the commutator and the Disconnect the battery.
armature. The maintenance of the commutator and the
brushes is important to the good operation of a DC motor. 2. Remove the drive unit compartment cover. Refer to
Section 2-DRIVE UNIT COMPARTMENT COVER-RE¬
Drive motors and hydraulic pump motors are similar in design. MOVAL AND INSTALLATION.
The hydraulic pump motors are smaller than the drive motors,
but the disassembly and maintenance of these motors are WARNING: The capacitor in the motor controller
similar. can hold an electrical charge after the battery is
3. Discharge the capacitor in the motor controller.

Y\
4. If used, remove the brush covers to the motor. Wear eye
protection. Use a vacuum cleaner or compressed air to remove
dirt and "brush dust" from the commutator area.
NOTE: Vacuum cleaning, when possible, is the

recommendation of manufacturers of electric motors. The use
of compressed air can send dirt particles into the bearings and
other areas of the motor that can cause possible damage.
5. Visually inspect the commutator surface. Refer to Figures

3-20 through 3-28. The commutator wears slowly in normal
service. The mica must be cut below the surface of the
commutator bars after a long service period or after a
commutator has been turned in a lathe. Carefully rotate the
armature. DO NOT damage the commutator if you use a tool to
rotate the armature.
6. Inspect the white or gray insulation (mica) between the

commutator bars. The mica must not touch the brushes or the
brushes will wear very rapidly.
mr
7. Install the brush covers, when used and the drive unit
compartment cover. Refer to Section 2-DRIVE UNIT
COMPARTMENT-REMOVAL AND INSTALLATION.
8. Connect the battery. Lower the truck to the floor. Test

operate the motorized hand truck before returning the truck to
service.
Figure 3-22 - Drive Motor
3-31
Yale
Normal Commutator Service surface condition is the lubrication between the commutator
and the brushes. The brushes will wear rapidly if this surface
A commutator that has been in service will have a smooth and
condition does not develop during the first six to ten hours of
polished surface with a darker brown color where it rotates
operation after a commutator with a new surface is installed.
under the brushes. A variation of color on the commutator
surface between light brown and darker brown is normal. This
A dark color on the surface of the commutator where it Variations between light brown and dark brown colors are
rotates on the brushes is a normal condition. also normal. The surface of the commutator must be
smooth.
6939
A condition called "slot bar marking" is also normal if the A very dark surface is also a normal and acceptable
commutator surface is smooth. The variable color occurs condition if the commutator surface is smooth.
in a pattern according to the number of conductors per
slot.
Figure 3-23 - Normal Commutator Surfaces
3-32
Yale
Commutator Problems
Commutator problems and motor problems are shown in
Figure 3-24 through Figure 3-32. Refer to COMMUTATOR
REPAIRS.
Heavy streaks and fine grooves indicate the beginning of

damage to the commutator.
Possible Causes:
• Operation of the motor in dirty and abrasive conditions
• Continuous operation of a motor with a light load
• Brush pressure is too low
• Worn brushes
6939
Figure 3-24 - Commutator Problems
Grooves and lines that have followed the heavy streaks and fine
grooves shown in Figure 3-25. The armature must be removed
from the motor so that the commutator can be repaired. A
commutator with this condition will cause the brushes to wear
rapidly.
Possible Causes:
• Continuous operation of a motor with a light load
• Brush pressure is too low
• Worn brushes
6939
3-33
Yale
Grooves that are the width of the brushes.

Possible Causes:
• Wrong type of brushes for this motor and operation
• Brush pressure is too high
A condition called "copper drag" occurs when copper from the

commutator bar is pulled into the slot between the commutator
bars. This condition will cause a short-circuit between the
commutator bars if it is not corrected. The brushes will wear
rapidly.
Possible Causes:
• Wrong type of brushes for this motor and operation
• Brush pressure is wrong (too high or too low)

6946
Electrical burns on commutator bars on opposite sides of the

commutator.
Possible Causes:
• Open armature winding
• Motor has been stalled
3-34
Yale
Copper wears rapidly at the edge of the commutator bars.
Possible Causes:
Operation of the motor in dirty and abrasive conditions
Wrong type of brushes for this motor and operation
1. Flashover causes burning of ends of commutator bar.
2. Open circuit in winding causes deep burning of adjacent

commutator bars.
3. Overheating causes damage to varnish insulation.
f . V;r.i Possible Causes:

%;•" tl > *5
V.' aJ? "
• Motor has been too hot. Wrong lift truck for the application
U/Aif • Open armature winding
• Open field coil
Check for loose or high commutator bars.
Possible Causes:
6942
• Motor has been too hot
High commutator bars Rapid brush wear from
at each brush position high commutator bars
can occur if the motor
is stalled
3-35
Yale
BRUSH REPLACEMENT, DRIVE AND Newtons per each cm2 (1.5 to 3.0 Ibf per each in2) when
HYDRAULIC MOTORS measured with a spring scale.
Worn motor brushes must be replaced before they damage the
surface of the commutator. Move the brush spring and remove
a brush from the brush holder. Measure the length of the brush
as shown in Figure 3-33. Replace all of the brushes if the length
of one brush is less than the minimum length. Brushes are
made to different specifications for motors used in different
applications. Use only replacement brushes approved by YALE
MATERIALS HANDLING CORPORATION.
1. Move key to OFF position. Disconnect the battery.
2. Remove the drive unit compartment cover. Refer to

MOVAL AND INSTALLATION.

3. Remove the drive unit compartment cover to access the

motors. Remove the brush covers to the motor. Wear eye
protection. Use a vacuum cleaner or compressed air to remove
dirt and "brush dust" from the commutator area.
4. Make a note of the arrangement and connections of the

brush assembly. The replacement brushes must be installed in orv
20 mm Minimum
the same positions as they were removed. Bmsh
(0.8 in) Dimension
5. Loosen the screw that fastens the brush wire to its
terminal. Remove the brush springs and brushes.
1. BRUSH HOLDER (4)
6. Inspect the brush holders for burns and damage. Make 2. BRUSH YOKE
sure the brush holder is fastened tightly to the mounts at the end 3. BRUSH SPRING (4)
of the motor. Make sure the new brushes will move freely and 4. BRUSH SET
smoothly in the brush holders. 5. SPRING SURFACE OF BRUSH
6. COMMUTATOR SURFACE OF BRUSH
7. Connect the new brush wire to its terminal mount.
Figure 3-33 - Brush Assembly
NOTE: When the brushes must be replaced, a recommenda¬
tion is to also replace the brush springs. A brush for a drive motor has an area of approximately 2. 1 x 0.5
in = 1.05 in2 (5.33 x 1.27 cm = 6.8 cm2). Brush springs for the
8. Check the brush springs for damage from heat and drive motor normally have a spring force of approximately 2 Ibf
corrosion. Replace damaged brush springs. Check that the and8ozf ±4ozf (10.2 ±1.1 Newtons) when measured with a
brush springs for approximately equal pressure. Brush springs spring scale as shown in Figure 3-35.
normally have a spring pressure of approximately 1.0 to 2.0
3-36
Yale
SPRING SCALE
BRUSH IN BRUSH HOLDER
COMMUTATOR
BRUSH SPRING
1. BRUSH
2. BRUSH SPRING
Figure 3-35 - Check Brush Spring Pressure

Figure 3-34 - Brush Removal and Inspection
A brush for a hydraulic pump motor has an area of Section 2-DRIVE UNIT COMPARTMENT COVER-RE¬
approximately 1.74x0.375 in = 0.653 in2 (4.42x0.95 cm = MOVAL AND INSTALLATION.
4.21 cm2). Brush springs for the hydraulic pump motor normally
have a spring force of approximately 1 Ibf and 8 ozf ±4 ozf WARNING: The capacitor in the motor controller
(6.3 ±1.1 Newtons) when measured with a spring scale as can hold an electrical charge after the battery is
shown in Figure 3-35. disconnected. To prevent electrical shock and
NOTE: The brush springs used in motors made by Yale have any component in the drive unit compartment. Wear safety
a constant force design. The force of the brush spring against glasses. Make certain the battery has been disconnected.
the brush stays almost constant as the brush wears and Use a screwdriver or jumper wire to make a short-circuit across
becomes shorter in its brush holder. the B+ and B- terminals of the motor controller.
9. New brushes must be made to fit the surface of the 3. Disconnect the spring and brush holder from the motor.
commutator by an abrasive procedure called "stoning the Remove the brushes. Turn the steering handle for easier
commutator". Use a Brush Seater and Commutator Stone access to the brushes on the opposite side of the motor. Install
(No. 23-007M from the Ideal Company or an equivalent brush new brushes.
seater stone). Refer to STONING THE COMMUTATOR.
4. Install the brush holders and springs in the drive motor.
If new brushes are not fitted to the commutator by stoning, the
contact surface can be small until the brushes wear to fit the 5. Install the drive unit compartment cover. Refer to Section
commutator. This small surface can cause burns and a rough 2-DRIVE UNIT COMPARTMENT COVER-REMOVAL AND
surface on the commutator. "Stoning the commutator" is most INSTALLATION.
easily done when the motor rotates slowly. When the motor
rotates at higher speeds, the centrifugal force removes the 6. Connect the battery, turn the key to the ON position and
abrasive particles from the commutator more quickly. See test operate the lift truck before returning the truck to service.
Figure 3-38.
Hydraulic Pump Motor-Brush Replacement
Drive Motor-Brush Replacement
3-37
Yale
2. Remove the drive unit compartment cover. Refer to 6. Lift the motor off of the drive unit housing.
MOVAL AND INSTALLATION. 7. Remove the locknut, pinion gear and shims from the
armature shaft.
can hold an electrical charge after the battery is 8. Inspect components for damage and replace as
disconnected. To prevent electrical shock and necessary. If the bevel gear is damaged, the bevel pinion must
injury, discharge the capacitor before inspecting or repairing also be replaced. The pinion and gear can only be replaced as a
any component in the drive unit compartment. Wear safety matched set. Refer to Section 4-UPPER HOUSING-RE¬
glasses. Make certain the battery has been disconnected. MOVAL.
the B+ and B- terminals of the motor controller. 9. Remove old sealant from the housing.
3. It is necessary to loosen the two capscrews retaining the Installation

hydraulic unit to the frame and tip the hydraulic unit toward the
1. Install shims, bevel gear and lock nut on the armature
front of the lift truck. Remove the two capscrews retaining the
shaft. Tighten the nut to 53 N«m (39 Ibf ft) torque.
cover to the motor. Remove the cover.
2. Apply sealing compound, Yale part number 5020589-05 or
4. Remove the springs and brushes. Inspect the brushes.
equivalent on the drive unit housing.
The brushes should be a minimum of 7 mm (0.275 in) in length
at the smallest point. Replace the brushes as a set. Inspect the
3. Position the motor on the housing.
springs for damage from heat (color changes) and corrosion.
Replace any damaged springs.
4. Installthe capscrews and lockwashers to attach the motor
to the housing. Tighten the capscrews to 49 N*m (36 Ibf ft)
5. Installthe cover and the two capscrews to retain the cover.
torque.
6. Tighten the two capscrews that retain the pump to the
5. Install the motor wires and harness clamps.
frame to 49 N«m (36 Ibf ft) torque.
6. Install the control handle. Refer to Section 6 of this manual
7. Connect the battery, turn the key to the ON position and
for the correct installation procedures.
test operate the lift truck before returning the truck to service.
7. Install the drive unit compartment cover. Refer to Section
DRIVE MOTOR 2-DRIVE UNIT COMPARTMENT-REMOVAL AND INSTAL¬
LATION.
Removal
WARNING: Put blocks under each side of the 8. Connect the battery. Lower the truck to the floor. Test
truck under the drive unit frame. Position blocks on operate the motorized hand truck before returning the truck to
both sides of the load wheels. The blocks must service.
prevent the lift truck from falling and causing injury or damage.
HYDRAULIC PUMP MOTOR
1. Raise the drive wheel off the floor. Block the lift truck. See
Section 1-HOW TO PUT A LIFT TRUCK ON BLOCKS. Removal
Disconnect the battery.
drive unit. Refer to Section 2-DRIVE UNIT COMPARTMENT-
REMOVAL AND INSTALLATION.
3. Remove the control handle. Refer to Section 6 of this
3. To remove the hydraulic pump motor the complete
manual for the correct removal procedures for the type of
hydraulic unit must be removed. See Section 8-HYDRAULIC
motorized hand truck being worked on.
UNIT-REMOVAL.
4. Tag and disconnect the motor wires and the harness
4. Remove the two capscrews retaining the motor to the
clamps on the motor.
hydraulic pump. Separate the motor from the pump.
5. Remove the four capscrews that retain the motor to the
5. Remove the pinion end cover from the armature.
drive unit housing.
3-38
Yale
6. Removethe screws that fasten the brush holder assembly the motor field ring so that the parts will be assembled again in
to the commutator end cover. the same positions.
7. Disassemblethe components of the motor as necessary to 2. Remove the brush cover, if used. Remove the brushes and
make repairs. spring assemblies.
Installation 3. Remove the capscrews from the commutator end of the

motor. Carefully slide the end cover from the the motor and
1. Align the locating pin in the pump and install the hydraulic
armature shaft. Do not damage the parts. A puller is often
motor on the pump using the two capscrews to retain the pump
necessary to separate the end cover from the motor field ring.
and cover.
CAUTION: The pinion end cover and the
2. Install the hydraulic unit to the frame. Refer to Section
armature are heavy components. Work carefully
8-HYDRAULIC UNIT-INSTALLATION.
so that the field coils, pole pieces, andthe armature
are not damaged during disassembly and assembly.
2-DRIVE UNIT COMPARTMENT-REMOVAL AND INSTAL¬
4. Remove the screws that fasten the pinion end cover to the
LATION.
motor field ring. Remove the end cover and armature. Use a
plastic or rubber hammer as necessary to loosen the end cover.
5. Remove the pinion end cover from the armature.
service.
6. Remove the screws that fasten the brush holder assembly
DRIVE AND HYDRAULIC MOTORS to the commutator end cover.
Disassembly
7. Disassemblethe components of the motor as necessary to
1. Clean the outside surfaces of the motor before make repairs.
disassembly. Make index marks on the ends of the motor and
14 15
1. BRUSH HOLDER ASSEMBLY 8. ARMATURE ASSEMBLY 15. DRIVE END HEAD

2. CAPSCREW 9. BRUSH SET 16. BEARING
3. TERMINAL SCREW 10. CAPSCREW 17. NUT
4. BRUSH SPRING SET 11. FIELD COIL SET 18. CAPSCREW
5. TERMINAL SCREW 12. CAPSCREW 19. BEARING RETAINER
6. COMMUTATOR END 13. POLE PIECE 20. CAPSCREW
7. BEARING 14. INSULATOR 21. FIELD RING
Figure 3-36 - Typical Drive Motor
3-39
Yale
Assembly 5. Carefully install the armature and pinion end cover in the
motor field ring. Make sure the index marks are aligned. Install
1. Make sure all of the components are clean. If the bearings
and tighten the screws.
were worn, install new bearings in the end covers.
6. Carefully install the commutator end cover on the armature
2. Make sure the field coils and pole pieces are installed
and fasten it to the motor field ring. Install and tighten the
correctly in the motor field ring.
capscrews.
3. Install the brush holder assembly in the commutator end
7. Install the brushes and spring assemblies. Replace the
cover.
brush cover, if used. See HYDRAULIC PUMP MOTOR-
BRUSH REPLACEMENT and DRIVE MOTOR-BRUSH
4. Install the pinion end cover on the armature.
REPLACEMENT.
1. COVER BAND
2. COVER BAND END HEAD
3. WAVE WASHER
4. BEARING
5. BRUSH HOLDER
6. SPRING 11. MOUNTING BRACKET
7. BRUSH SET 12. ARMATURE
8. FIELD COIL 13. FAN
9. TERMINAL KIT 14. BEARING
10. CAPSCREW 15. END HEAD
Figure 3-37 - 1 ic Pump Motor

COMMUTATOR REPAIRS drive unit compartment cover must be removed for access to
the motor. Raise the drive wheel. See Section 2-HOW TO PUT
WARNING: Wear eye protection. Raise the drive
A LIFT TRUCK ON BLOCKS.
wheel. Operate the motor at low speed. Protect
your fingers, Do not use a brush seater stone less
CAUTION: Do not permit the brush seater stone
than 60 mm (2.5 in) in length.
to stay in contact with the commutator too long and
cause more wear than necessary.
1. If the commutator has grooves or other damage, the
armature must be removed so that the commutator can be
2. Operate the motor so that the commutator rotates in the
repaired. Motors are normally repaired by service personnel
same direction as the long tips of the brushes. Apply the brush
that have the special equipment required for the repair.
seater stone to the moving commutator with light pressure.
Connect the battery so that the motor can be operated. The
Move the brush seater stone backward and forward across the
3-40
Yale
surface of the commutator until the marks on the commutator 4. When the brushes have the correct contact surface with
are removed. Apply the brush seater stone to the commutator the commutator, use compressed air to remove the abrasive
before each set of brushes so that the brush seater particles dust from the commutator area and the motor.
have an even distribution.
5. When the installation and checks are complete, install the
3. Turn the key switch to the OFF position and disconnect the brush cover. Make sure that the wires to the brushes do not
battery. Check all brush contact surfaces. The brushes fit touch any part of the motor case and cause a short-circuit.
correctly when 85% of the brush contact surface touches the
commutator. This procedure normally requires approximately
15 to 45 minutes.
1. BRUSH SEATER STONE
NOTE: A brush seater stone can also be fastened to a wood stick with glue as shown in the
illustration. This arrangement makes it easier to apply a brush seater stone in small places.
Figure 3-38 - Stoning the Commutator

TESTS as the damaged commutator bars rotate under each brush.
See Figure 3-39.
Damaged Field and Armature
The tests described in the following paragraphs are to help a Short-Circuit in an Armature Winding
service person check a motor for damage and determine if it
A short-circuit in a motor winding is difficult to test because of
must be sent to a repair service for rebuilt motors. The
the normal low resistance (less than one ohm) of a good
resistance checks will not normally indicate a short-circuit in a
armature. Use a Meggar to check for a short-circuit in a motor
motor winding. A resistance greater than 1 to 2 ohms can
winding. A motor with a short-circuit in an armature winding will
indicate a damaged winding. The motor must be removed from
have a different sound when it begins to operate, but a service
the lift truck and disassembled as shown in the illustrations
person must have experience to hear and understand the
before the tests can be done.
difference in sound. A winding with a short-circuit will also run
hotter than a good winding and can have indications of heat
The armature windings in large electric motors normally have
damage. A winding that shows heat damage when the other
less than one ohm of resistance. The two commutator bars for a
windings are normal can have a short-circuit.
winding are found 180 degrees apart on the commutator. If a
volt-ohmmeter (R x 1 scale) is used to check the resistance
Another indication of a short-circuit will be a higher than normal
between the two commutator bars of the winding, a resistance
current draw by the motor. A higher than normal current draw
of more than one ohm indicates a problem in that winding. A
can also indicate other problems or needed adjustments and
resistance of infinity («>) indicates an open (damaged) winding.
does not always indicate a short-circuit in a motor winding.
If the armature has an open circuit, there will normally be two
Short-Circuit in the Armature
burned commutator bars on opposite sides of the commutator.
These burned areas will cause the brushes to wear rapidly. A volt-ohmmeter (R x 10,000 scale) can be used to test for a
When the motor operates, large electric sparks and arcs occur short-circuit between an armature winding and the armature
3-41
Yale
shaft. Put one probe on the armature shaft and the other probe
on a commutator bar. See Figure 3-39. A resistance of less
than one megohm indicates a problem between a winding and
the armature shaft.
NOTE: Clean the dirt and "brush dust" from the commutator
area before making a test for a short-circuit.
11415
1. FIELD COIL TERMINAL

2. OHMMETER
Figure 3-40 - Test for an Open Field Circuit
Another indication of a short-circuit will be a higher than normal

1. ARMATURE SHAFT current draw by the motor. A higher than normal current draw
2. COMMUTATOR can also indicate other problems or needed adjustments and
3. PROBES TO OHMMETER does not always indicate a short-circuit in a motor winding.
Figure 3-39 - Test for an Armature Short-Circuit Short-Circuit Between Field and Motor Case
Open Circuit in a Field Coil A volt-ohmmeter (R x 10,000 scale) can be used to test for a
short-circuit between the field and the motor case. Put one
The field windings in large electric motors normally have less probe on the motor case and the other probe on a field terminal.
than one ohm of resistance. If a volt-ohmmeter (R x 1 scale) is Check the resistance between the field terminal and the motor
used to check the resistance between the two terminals of the case. A resistance of less than one megohm indicates a
winding, a resistance greaterthan one ohm indicates a problem problem between the field terminal and the motor case. Make
in that winding or corrosion in the terminal connection. See sure that carbon dust has been cleaned from the motor before
Figure 3-40. making this test.
Short-Circuit in a Field Coil Brush Holder
A short-circuit in a motor field winding is difficult to test because Make sure the carbon dust has been removed from the brush
of the normal low resistance (less than one ohm) of a good field. holders. Use a volt-ohmmeter (R x 10,000 scale) to measure
A Meggar can be used to check for a short-circuit in a motor the resistance between the brush holder and the motor case.
winding. A motor with a short-circuit in a field winding will have a The correct resistance should be infinity (°°).
different sound when it begins to operate, but a service person
must have experience to hear and understand the difference in
sound. A winding with a short-circuit will also run hotter than a
good winding and can have indications of heat damage.
3-42
Yale
NOTES
3-43
Yale
15 AMP
FUSE 3
! I I I I I
200 AMP 200 AMP
FWD REV
FIELD
HEIGHT
LIMIT
28 smitch 23
LOWER
OONT CONT 50LEN0ID
OPTIONAL
EQUIPMENT
SEE SHEET
USE WIRE »48C ON THIS MODEL (MPE). 2 OF 5
DO NOT USE WIRE «40D ON THIS TRUCK MODEL.
HE ALL UNUSED WIRES 10 MAIN WIRE HARNESS.
ALL OE VICES ARE SHOWN IN THE NORMAL POSITION
WHEN THE UNIT IS STOPPED WITH NO OPERATOR.
FOR PROPER OPERATION OF B.D.I. WITH HOUR METER

'REVERSE* IS IRAVEL IN IHfc OIRtCIION OF IHE FORKS.
CONNECT WIRE »12A AS FOLLOWS.

12 VOLT TRUCK CONNECT TO TERMINAL »l ANO
24 VOLT TRUCK CONNECT TO TERMINAL #S.
5045797-00
Sheet 1 of 5
Figure 3-42 - Schematic 5045797-00-Type "E"-MPE-Up to S/N 576760 Revision 6
3-44
ELECTRICAL SYSTEM
FOR ALL OTHER NOTES SEE SHEET 1 OF 5
i—i—r 12A 48C 26 12A
40 40
\y \v
T™ I
I CRIP
SWITCH
I CRIP
[g SWITCH
4BC 2G 12A
H
HANOLE
Ft! ,1
| HANDLE
I
Q 6
HEATER HEATER HEATER HEATER HOUR BATTERY BATTERY
CONTROL CONTROL BRAKE HEIGHT METER DISCHARGE DISCHARGE
COVER HANDRAIL SWITCH LIMIT OPTIONAL INDICATOR INDICATOR
SWITCH SWITCH OPTIONAL SWITCH OPT IONAL W/HOUR METER
OPTIONAL OPTIONAL OPTIONAL OPTIONAL
J_ I_ 1_ L
13 13E 1 3J 13H
—
FROM
- 1 3F
SHEET 1 OF S
5045797-00
Sheet 2 of 5
Figure 3-42 - Schematic 5045797-00-Type "E"-MPE-Up to S/N 576760 (Continued) Revision 6
3-45
Yale
BATTERY
HOUR METER AND/OR
BATTERY INDICATOR
CONNECTIONS
SEE SHEET 5 OF 5
CONTROL PANEL
©CR2
FWD
CONTROL PANEL
PMC
REV
TRANSISTOR CONTROLLER
5045797-00
Sheet 3 of 5
Figure 3-43 - Wiring Diagram 5045797-00-Type "E"-MPE-Up to S/N 576760 Revision 6
3-46
ELECTRICAL SYSTEM
* CONTROL HANDRAIL —
i
VIEW OF CONTROL HANDLE AND COVER

ARE FACING CONTACTS. WIRING IS SHOWN
WITH COVER REMOVED.
2L 2F
28 13D 24A
HOIST MOTOR
24A 130
TRACT ON MOTOR
E5i
HFATFR-COI D STORAGE
OPTIONAL
CONTROL HANDLE - CONTROL COVER
ACCELERATOR
BRAKE SWITCH
TRACT ION REVERSE SWITCH ||

REVER5E FORWARD r
SWITCH SWITCH 4r_
HEATER-COLO STORAGE
(?A)(?7J|3S](40) ||40)|3S||22
5045797-00
Sheet 4 of 5
Figure 3-43 - Wiring Diagram 5045797-00-Type "E"-MPE-Up to S/N 576760 (Continued) Revision 6
3-47
Yale
FROM
MAIN HARNESS SEE NOTE #2
HOUR METER
AND B.O.I. FROM
CONNECTION MAIN HARNESS
SEE SHEET 3 OF 5 SEE NOTE HOUR METER
ANO B.D.I.
CONNECTION
SEE SHEET 3 OF S
I FROM
MAIN HARNESS
HOUR METER
AND B.D.I.
CONNECTION
BATTERY DISCHARGE INDICATOR
SEE SHEET 3 OF 5
WITH HOUR METER BATTERY 015CHARGE INDICATOR
KEY SWITCH
TB1
TO
MAIN HARNESS
HOUR METER
AND B.D.I.
CONNECTION
SEE SHEET 3 OF 5
STROBE LIGHT
REMOVE AND INSULATE
EXISTING 13 WIRE (S) AT
CURTIS 933/30 LIFT CONTACTOR AND
BATTERY DISCHARGE INDICATOR RtPLACt WITH WIRE 113.
X REMOVE EXISTING WIRING (29A, SI ANO 44) HANOI F WIRING

FROM CR1 , CR2 AND REPLACE WITH
CORRESPONDING WIRING FROM PICK GRIP
WIRE HARNESS. RECONNECT EXISTING WIRING
SPLICE ,q s"-"*
J1 JUMPER
(29A, 61 AND 44) WITH CORRESPONDING
WIRING FROM PICK GRIP WIRE HARNESS AS SHOWN. J ...
'Zpo|
SPLICE
.cxt!
SPLICE
r ,—
TO
MAIN HARNESS
HOUR METER
ANO B.O.I.
existing
CONNECTION
SEE SHEET 3 OF S ypg 48c
I'ÿl36!35!8 h°lyl16i WIRE HARNESS HANDLE - PICK GRIP
-€-29C- "
_ 1_ LL
T TT nn ji][ ca h
1, 1
- < _
REMOVE ANO INSULATE EXISTING
13 WIRE (5) AT LIFT CONTACTOR
ANO REPLACE WITH WIRE 113.
/ 44 4 ÿ
J.... i|4 4 o CR1

EXISTING
<M>@@
CONTACTOR PANEL HIRING
s|
&
4-
14 s|
T txlbl 1NG
PICK GRIP OPTION
CURTIS 933/1 OR 933/4 B.D. 1.

WfTH HOUR METER (S) - 1 2 AND 24 VOLTS
5045797-00
Sheet 5 of 5
Figure 3-44 - Options Diagram 5045797-00-Type "E"-MPE-Up to S/N 576760 Revision 6
3-48
Yale
NOTES
3-49
Yale
15 AMP
FUSE 3 OPTIONAL
EQUIPMENT
SEE SHEET
FUSE 1 FUSE 2
2 OF S
200 AMP
— 40B
REVEASE
SWITCH
Q-/\ -35
O-
SWITCH 2
HANDRAIL
4?
1
22 M
I Ono
23 M
Iono
24 h- |I
48 48 SWITCH
HAWJRAIL
L.
FWD REV
FIELO
HLIGHI
LIMIT
20 SWITCH 23
'TBI
LOWER
SOLENOID
EQUIPMENT
SEE SHEET
USE WIRE »4BC ON THIS MOOFI (MPE) .

DO NOT USE WIRE «400 ON THIS TRUCK MODEI .
TIE ALL UNUSED WIRES TO MAIN WIRE HARNESS.
ALL OEVICES ARE SHOWN IN THE NORMAL POSITION

CONNECT WIRE »12A AS FOLLOWS. 'REVERSE* IS TRAVEL IN THE DIRECTION OF THE FORKS.
12 VOLT TRUCK CONNECT TO TERMINAL #1 AND
24 VOLT TRUCK CONNECT TO TERMINAL #5.
5047437-00
Sheet 1 of 5
Figure 3-45 - Schematic 5047437-00-Type "EE"-MPE-Up to S/N 576760 Revision 1
3-50
ELECTRICAL SYSTEM
FOR ALL OTHER NOTES SEE SHEET 1 OF S
i—i—r 40D 48C 48C 26 12A
Ul Ubt
v v i
480 2G 12A

CONTROL CONTROL BRAKE HEIGHT I METER DISCHARGE 0 15CHARGE
COVER HANDRAIL SWITCH LIMIT I OPTIONAL INDICATOR INDICATOR
SWITCH SWITCH OPTIONAL SWITCH OPTIONAL W/HOUR METER
J_ 1_ I
1 3E 13J 13H
5047437-00
Sheet 2 of 5
Figure 3-45 - Schematic 5047437-00-Type "EE"-MPE-Up to S/N 576760 (Continued) Revision 1
3-51
Yale
BATTERY
HOUR METER AND/OR
BATTERY INDICATOR
SEE SHEET 5 OF 5
CONTROL PANEL
CRT
©CR2
FWD
TB2
REV
—
Jl . I ec
FWD
CONTROL PANEL
PMC
5047437-00
Sheet 3 of 5
Figure 3-46 - Wiring Diagram 5047437-00-Type "EE"-MPE-Up to S/N 576760 Revision 1
3-52
ELECTRICAL SYSTEM
r—
* CONTROL HANDRAIL
i
> '
HOIST 1
: contactor
J
HOIST MOTOR
TRACTION MOTOR
r— CONTROL HANDLE CONTROL COVER

* -i
I3E —crQ j
— 13-
•reÿ23J LOWER SW
ENLARGED VIEW
OF CONNECTOR X2 AND X3
5047437-00
Sheet 4 of 5
Figure 3-46 - Wiring Diagram 5047437-00-Type "EE"-MPE-Up to S/N 576760 (Continued) Revision 1
3-53
Yale
FROM
5EE NOTE »2
MAIN HARNESS
HOUR METER
ANO B.O.I. FROM
SEE SHEET 3 OF S HOUR METER FROM
AND B.O. I. MAIN HARNESS SEE NOTE
CONNECTION HOUR METER
SEE SHEET 3 OF 5 AND B.O. I.
CONNECTION
BATTERY DISCHARGE INOICATOR SEE SHEET 3 OF S
WITH HOUR METER BATTERY DISCHARGE INDICATOR HOUR METER
TO
MAIN HARNESS
HOUR METER
AND B.D. I. SEE NOTE
TO
CONNECTION
MAIN HARNESS
SEE SHEET 3 OF 5
HOUR METER
AND B.D. I .
CONNECTION
SEE SHEET 3 OF 5
H) ID ABC RFMOVF ANn INSUI ATF
SEE NOTE #1 EXISTING 13 WIRECS) AT
CURTIS 933/30 LIFT CONTACTOR AND
BATTERY DISCHARGE INDICATOR REPLACE WITH WIRE 113.
REMOVE AND INSULATE EXISTING

13 WIRECS) AT LIFT CONTACTOR
AND REPLACE WITH WIRE 113.
CURTIS 933/1 OR 933/4 B.O.I.

WITH HOUR METER (5) - 12 AND 24 VOLTS

5047437-00
Sheet 5 of 5
Figure 3-47 - Options Diagram 5047437-00-Type "EE"-MPE-Up to S/N 576760 Revision 1
3-54
Yale
NOTES
3-55
Yale
15 AMP
FUSE 3 Ur I1 ONAL
2 EQUIPMENT
SEE SHEET
MORN
SWITCH 2
CR2 I HIGH
SPEED
48 48 SWITCH
FWD MANOR* IL
FIELD
2n SWITCH
< FdM 1 TBI

CR1 HOIST LOWER
CONT SOLENOID
(OP IIONAL)
OPTIONAL
SEE SHEET
USE WIRE #48C ON THIS MODEI (MPE) . 2 OF S
DO NOT USE WIRE #400 ON THIS TRUCK MODEL.
TIE ALL UNUSED WIRES TO MAIN WIRE HARNESS.
ALL DEVICES ARE SHOWN IN THE NORMAL POSITION

'REVERSE* IS TRAVEL IN THE DIRECTION OF THE FORKS.
CONNECT WIRE »12A AS FOLLOWS:
12 VOLT TRUCK CONNECT TO TERMINAL #1 ANO
5048687-00
Sheet 1 of 5
Figure 3-48 - Schematic 5048687-00-Type "E"-MPE-From S/N 576761 to A803N08540U Revision 2
3-56
ELECTRICAL SYSTEM
71—!—T 48C 2G 12A
I
PICK PICK
5
GRIP GRIP
O. SWITCH IO SWITCH
T[ HANDLE T HANDLE
48C 2G 1 2A
1GRIP
®
PICKpICK
CO ID
I PICK
I® GRIP
SWITCH SWITCH
HANDLE HANDLE

CONTROL CONTROL BRAKE HEIGHT METER DISCHARGE DISCHARGE
COVER HANDRAIL SWITCH LIMIT OPTIONAL INDICATOR INDICATOR
SWITCH SWITCH OPTIONAL SWITCH OPTIONAL W/HOUR METER
5048687-00
Sheet 2 of 5
Figure 3-48 - Schematic 5048687-00-Type "E"-MPE-From S/N 576761 to A803N08540U (Continued) Revision 2
3-57
Yale
BATTERY
HOUR METER AND/OR
BATTERY INDICATOR
CONNECTIONS
SEE SHEET 5 OF 5
CONTROL PANEL
TBI [
1
1 9
— —:
CR1
©CR2
TB2
CONTROL PANEL
PMC REV
5048687-00
Sheet 3 of 5
Figure 3-49 - Wiring Diagram 5048687-00-Type "E"-MPE-From S/N 576761 to A803N08540U Revision 2
3-58
ELECTRICAL SYSTEM
— * CONTROL HANDRAIL
WITH COVER REMOVED.
S* \
s
HOIST MOTOR
24A 1 3D
TRACTION MOTOR
HFATFR-COl 0 STORAGF
OPTIONAL
CONTROL HANDLE CONTROL COVER
ACCELERATOR —{xQ J
{n=)tec:"
BRAKE SWITCH
REVERSE FORWARD
SWITCH SWITCH
(2A) [22] ID(jo)

GI]lE)la)@
5048687-00
Sheet 4 of 5
Figure 3-49 - Wiring Diagram 5048687-00-Type "E"-MPE-From S/N 576761 to A803N08540U (Continued) Revision 2
3-59
Yale
FROM
MAIN HARNESS SEE I
HOUR METER
ANO B.D. I. FROM
SEE SHEET 3 OF 5 HOUR METER FROM
AND B.O.I. MAIN HARNESS
SEE SHEET 3 OF 5 AND B.D. I.
CONNECTION
SEE SHEET 3 OF 5
WITH HOUR METER BATTERY DISCHAR6E INDICATOR HOUR METER
TO
MAIN HARNESS
HOUR METER
ANO B.O.I.
CONNECTION
SEE SHEET 3 OF 5
REMOVE AND INSULATE

EXISTING 13 WIRE(S) AT
CURTIS 933/3D LIFT CONTACTOR AND
TO
MAIN HARNESS KEY SWITCH
HOUR METER
AND B.D. I. TB1
CONNECTION
SEE SHEET 3 OF 5
H) IU'" 48C r©T®T®T®T©TQT®l
5EE NOTE #1
STROBE LIGHT
REMOVE AK) INSULATE EXISTING
X REMOVE EXISTING WIRING C29A; 61 AND 44) HANDLE WIRING

FROM CRI, CR2 ANO REPLACE WITH
CORRESPONDING WIRING FROM PICK GRIP
WIRE HARNESS. RECONNECT EXISTING WIRING
'LICE |n n"1 SPLICE
(29A| 61 ANO 44) WITH CORRESPONDING
WIRING FROM PICK GRIP WIRE HARNESS AS SHOWN. 4'o HANDLE SWITCHES L
FRONT VIEW- TERMINAL ANO WIRE LOCATION

(ENLARGED FOR CLARITY) I=PSI
SPLICE
CURTIS 933/1 OR 933/4 B.D.I.

WITH HOUR METER (5) 12 AND 24 VOLTS
jÿ40E
' 1 3|38|351
1 8 |40|l4|l8|
- WIRE HARNESS HANDLE - PICK GRIP

-29A
— 61 —ÿ-61B—
29C—v
'
\
J
K55 If n nil n H
"
L~_i
< - j
44 B( O
EXISTING
ÿ
41
CONTACTOR PANEL WIRING

6
o8
|3| 5| T EXISTING
PICK GRIP OPTION
5048687-00
Sheet 5 of 5
Figure 3-50 - Options Diagram 5048687-00-Type "E"-MPE-From S/N 576761 to A803N08540U Revision 2
3-60
Yale
NOTES
3-61
Yale
OPTIONAL
2 OF 5
-1e LOWER HORN

NOT USEO i SWITCH SWITCH SWITCH
HANDRAIL HANORAIL
TRACTION
MOTOR
LOWER HORN
5WITCH SWITCH SWITCH
s: r WD
'Atrac iA' HI SPD
HANDLE HANDLE HANDLE
FIELD
: : fwd rev : ÿ
HEIGHT
LIMIT
LOWER
SOLENOID
ACCELERATOR
POTENTIOMETER
NOTES EQUIPMENT
5EE SHEET
FOR PROPER OPERATION OF B.D.I. ALL DEVICES ARE SHOWN IN THE NORMAL POSITION 2 OF S
CONNECT WIRE #12A AS FOLLOWSi WHEN THE UNIT IS STOPPED WITH NO OPERATOR.
12 VOLT TRUCK CONNECT TO TERMINAL «1 ANO "REVERSE" IS TRAVEL IN THE DIRECTION OF THE FORKS.
ALL CONNECTORS ARE SHOWN FROM FRONT VIEW
GD USE TY WRAP TO TIE CONNECTOR #4 TO MAIN WIRE HARNESS ANO ARE ENLARCEO FOR CLARITY
5052537-00
Sheet 1 of 5
Figure 3-51 - Schematic 5052537-00-Type "E" and "EE"-MPE-S/N A803N08541 U and up Revision 1
3-62
ELECTRICAL SYSTEM
i—r—t—i 40 2 12
ÿ W ÿ
48 2 12
J, PICK "1I PICK I

gÿ GRIP
?R'P
SWITCH
GRIP
SWITCH
HANDLE I HANDLE I
n
-Sj
PICK PICK I HEATER HEATER IEATER HOUR BATTERY BATTERY
CRIP CRIP CONTROL CONTROL BRAKE METER DISCHARGE DISCHARGE
SWITCH SWITCH COVER HANDRAIL SWITCH CURTIS 701 INDICATOR INDICATOR
HANDLE HANOI. F SWITCH SWITCH OPTIONAL (DIGITAL) OPTIONAL W/HOUR METER
_J OPTIONAL OPTIONAL OPTIONAL OPTIONAL
J_ i_ 1_ I
13 13 13 13
FOR ALL OTHER NOTES SEE SHEET ' OF S
5052537-00
Sheet 2 of 5
Figure 3-52 - Options Schematic 5052537-00-Type "E" and "EE"-MPE-S/N A803N08541U and up Revision 1
3-63
Yale
TO KEY SWITCH
SEE SHEET 4 OF S
HOUR METER AND/OR
HANDRAIL CONTROL BATTERY INDICATOR
SEE SHEET 4 OF S CONNECTIONS
SEE SHEET 5 OF 5
CONTACTOR HARNESS
TO
LIFT PUMP MOTOR, HORN
AND HEIGHT LIMIT SW
3-1 SPLICE
SEE SHEET 4 OF 5
CONTROL PANEL
2 SPLICE
ELECTRONIC NEG STUD

LOGIC MODULE
(ELM)
rTTÿn
TRACTION MOTOR
FRONT VIEW OF CONNECTOR #5 SEE SHEET 4 OF 5
FOR EE MOD POWER

FUSES ARE ENCLOSED.
CONNECTION POINTS ARE
SIMILAR FOR
40 5PLICE
13 SPLICE
CONTROL HANDLE HARNESS

SEE SHEET 4 OF S
SEE VIEW A- 5EE VIEW B-B

F3 B
SEE SHEET 4 OF 5
PMC
IRANSISIOH CON IROLLER
CONTROL PANEL -
FW B-B
5052537-00
Sheet 3 of 5
Figure 3-53 - Wiring Diagram 5052537-00-Type "E" and "EE"-MPE-S/N A803N08541 U and up Revision 1
3-64
ELECTRICAL SYSTEM
CONTROL HANDRAIL
2 - i- 13E
BATTERY
KATER-COLD STORAGE
MAIN HIRE HARNESS

SEE SHEET 3 OF 5
CONTACTOR PANEL
SEE SHEET 3 OF S
MOIST I
•CZ CONTACTOR =»
PANEL
OF S
OF S
OF S LIFT PUMP
TRACTION MOTOR MOTOR
X8
ENLARGED VIEW
FOR ALL OTHER NOTES SEE SHEET I OF S
5052537-00
Sheet 4 of 5
Figure 3-43 - Wiring Diagram 5052537-00-Type "E" and "EE"-MPE-S/N A803N08541U and up (Cont.) Revision 1
3-65
Yale
FROM
MAIN HARNESS TO
HOUR METER MAIN HARNESS ÿ33=2
(CURTIS 701) HOUR METER
CONNECTION AND B.D. I.
SEE SHEET 3 OF S CONNECTION
SEE SHEET 3 OF 5 ÿO -ABC
CUTIS 701 HOUR METER (DIGITAL)

13 WIRE (S) AT LIFT CONTACTOR
CURTIS 933/1 OR 933/4 B.D. i .

WITH HOUR METER (5) - 1 2 AND 24 VOLTS
FROM
MAIN HARNESS SEE NOTE #1
HOUR METER
AND B.O. I.
CONNECTION
SEE SHEET 3 OF S
FROM
MAIN HARNESS
HOUR METER
BATTERY DISCHARGE INDICATOR W/HOUR METER ANO B.O.I,
CONNECTION
SEE SHEET 3 OF 5
SPLICE DETAILS
SPLICE 13-1
5PLICE 13
HANDLE WIRING
SPLICE .TTTTI SPLICE

RIGHT SIDE
LEFT SIDE SPLICE 2
4'0 HANDLE SWITCHES HANDLE SWITCHES
SPLICE 40
5PLICE 40-
PICK GRIP
(OPTIONAL)
SPL ICE 2-
(FOR CLARITY ONLY WIRING IS SHOWN)
5052537-00
Sheet 5 of 5
Figure 3-54 - Options Diagram 5052537-00-Type "E" and "EE"-MPE-S/N A803N08541U and up Revision 1
3-66
Yale
NOTES
3-67
Yale
FUSF 3
15 AMP SWITCH OPTIONAL
FUSE 1 FUSE 2 2 OF 5
200 AMP 200 AMP
FIELD
LD Ct
BUS BAR
HOIST
.
I 2© I Q]
BUS BAR

2. FOR PROPER OPERATION OF B.D.I. WITH HOUR METER WHEN THE UNIT IS STOPPED WITH NO OPERATOR.
CONNECT WIRE «12A AS FOLLOWS: "REVERSE' IS TRAVEl. IN THE DIRECTION OF THE FORKS.
24 VOLT TRUCK CONNECT TO TERMINAL »S.
5046247-00
Sheet 1 of 5
-
Figure 3-55 Schematic 5046247-00-Type "E"-MPC-Up to S/N 576760 Revision 2
3-68
ELECTRICAL SYSTEM
FOR ALL OTHER NOTES SEE SHEET I OF 5
i2A
r
2F 2E 48 12l
ÿ ÿ ÿ
HEATER ÿCATER HEATER HOUR BATTERY BATTERY

CONTROL BRAKE HEIGHT METER DISCHARGE DISCHARGE
COVER SWITCH LIMIT OPTIONAL INDICATOR INDICATOR
SWITCH OPTIONAL SWITCH OPTIONAL W/HOUR METER
OPTIONAL OPTIONAL OPTIONAL
ÿ ÿ ÿ
J_ L
I3E 13H 13G 13A 13A 13A
5046247-00
Sheet 2 of 5
Figure 3-55 - Schematic 5046247-00-Type "E"-MPC-Up to S/N 576760 (Continued) Revision 2
3-69
Yale
KEY SWITCH BATTERY

HOUR METER
AND/OR
BATTERY INDICATOR
CONNECTIONS
SEE SHEET 5 OF 5
CONTROL PANEL
TBI
FWD
REV
View 'B'
5046247-00
Sheet 3 of 5
Figure 3-56 - Wiring Diagram 5046247-00-Type "E"-MPC-Up to S/N 576760 Revision 2
3-70
ELECTRICAL SYSTEM
VIEW OF CONTROL HANOLE ANO COVER

FRONT VIEW
ENLARGED FOR CL
(CONNECTOR XS)
HOIST MOTOR
TRACT ON MOTOR
— —
HEIGHT LIMIT SWITCH
I
13
2
HEATER-COLD STORAGE
OPTIONAL
CONTROL HANDLE i CONTROL COVER

* 3E -dQ
ACCELERATOR
POT
I I—
-*={mS — 24
Sep
40C (
9RAKE SWITCH 408 6
— 13
REVERSE FORWARD
SWITCH SWITCH
SdOO
ÿ©(30
5046247-00
Sheet 4 of 5
Figure 3-56 - Wiring Diagram 5046247-00-Type "E"-MPC-Up to S/N 576760 (Continued) Revision 2
3-71
Yale
FROM
MAIN HARNESS
HOUR METER
AND B.O.I. FROM
SEE SHEET 3 OF 5 HOUR METER FROM
AND B.O. I. MAIN HARNESS
SEE SHEET 3 OF 5 ANO B.D.I.
CONNECTION
SEE SHEET 3 OF 5
WITH HOUR METER BATTERY DISCHARGE INDICATOR

5046247-00
Sheet 5 of 5
Figure 3-57 - Options Diagram 5046247-00-Type "E"-MPC-Up to S/N 576760 Revision 2
3-72
Yale
NOTES
3-73
Yale
KEY
SWITCH
SPEEO FOOT
SWITCH
FIELD
HOIST LOWER
CONT SOLENOID
ACCtLERAlCR
POIfcNT lOMEILR
— 13A
TO
OPTIONAL
EOUIPMENT
SEE SHEET
2 OF 5
2. FOR PROPER OPERATION OF B.D.I. WITH HOUR METER ALL DEVICES ARE SHOWN IN THE NORMAL POSITION
CONNECT WIRE »I2A AS FOLLOWS: WHEN THE UNIT IS STOPPED WITH NO OPERATOR.
12 VOLT TRUCK CONNECT TO TERMINAL #1 AND "REVERSE" IS TRAVEL IN THE DIRECTION OF THE FORKS.
5048037-00
Sheet 1 of 5
Figure 3-58 - Schematic 5048037-00-Type "EE"-MPC Revision 1
3-74
ELECTRICAL SYSTEM
rr
2A 2F 2E
HFATFR HFATFR HOUR BATTFRY BATTERY

CONTROL BRA<E METER DISCHARGE DISCHARGE
COVtR SWI ICH OP 1 1ONAL INOICAIOR INOICAIOR
xK y\<
1 3b 1 3H 13G ISA ISA 13A
J_ I
5048037-00
Sheet 2 of 5
Figure 3-58 - Schematic 5048037-00-Type "EE"-MPC (Continued) Revision 1
3-75
Yale
BATTERY
C-) (ÿ)
CONTROL PANEL
01 02
VIEW C
PARALLEL SPLICE
ENLARGED FOR CLARITY
SEE VIEW B
CONTROL PANEL
5048037-00
Sheet 3 of 5
Figure 3-59 - Wiring Diagram 5048037-00-Type "EE"-MPC Revision 1
3-76
ELECTRICAL SYSTEM

WITH COVER REMOVED.
FRONT VI EN
VIEW ENLARGED FOR CLARITY
(CONNECTOR XS)
SOLENOI
HO ST MOTOR
TRACTION MOTOR
—
HEIGHT LIMIT SWITCH
13
— 2
HEATER-COLO STORAGE
OPTIONAL
- CONIROL HANULt CONIROL COVtR

* —crQj—
ACCELERATOR
3C 13 —
HtiDflBc:
400 6
FRONT VIEW
MEW ENLARGEO FOR CLARITY
(CONNECTOR X2 ANO X3)
5048037-00
Sheet 4 of 5
-
Figure 3-59 Wiring Diagram 5048037-00-Type "EE"-MPC (Continued) Revision 1
3-77
Yale
FROM
MAIN HARNESS
HOUR METER *=12A:
FROM
AND B.O.I.
MAIN HARNESS
CONNECTION
HOUR METER
SEE SHEET 3 OF S FROM
ANO B.D.I.
MAIN HARNESS
CONNECTION
HOUR METER
SEE SHEET 3 OF S
AND B.D.I.
CONNECTION
SEE SHEET 3 OF S

5048037-00
Sheet 5 of 5
Figure 3-60 - Options Diagram 5048037-00-Type "EE"-MPC Revision 1
3-78
Yale
NOTES
3-79
Yale
TO
KEY
SWITCH OPTIONAL
EQUIPMENT
SEE SHEET
2 OF S
EV FWO :
FIELO
HOIST
MOTOR
HOIST LOWER
CONT SOLENOID
OPTIONAL
EQUIPMENT
SEE SHEET
2 OF S

2. FOR PROPER OPERATION OF B.O.I. WITH HOUR METER WHEN THE UNIT IS STOPPED WITH NO OPERATOR.
CONNECT WIRE #12A AS FOLLOWS i 'REVERSE* IS TRAVEL IN THE DIRECTION OF THE FORKS.
12 VOLT TRUCK CONNECT TO TERMINAL »1 AND
5048737-00
Sheet 1 of 5
-
Figure 3-61 Schematic 5048737-00-Type "E"-MPC-From S/N 576761 to A803N08599U Revision 2
3-80
ELECTRICAL SYSTEM
T7 48 12A
ÿ W ÿ
HFATFR HFATFR HOUR BATTFRY BATTFRY

CONTROL BRAKE HETER DISCHARGE DISCHARGE
COVtR SWITCH OPTIONAL INDICATOR INUICAIOR
OPT IONAL OPTIONAL OPTIONAL
& fk X
J_ 1_ I
1 3t 1 3H 13G 1 3A 1 3A T 3A
T3A
FROM
SHEET 1 OF 5
5048737-00
Sheet 2 of 5
Figure 3-61 - Schematic 5048737-00-Type "E"-MPC-From S/N 576761 to A803N08599U (Continued) Revision 2
3-81
Yale
KEY switch BATTERY

HOUR METER /C\ (-) (ÿ)
AND/OR
w
BATTERY INDICATOR FOR ALL OTHER NOTES SEE SHEET I OF 5
CONNECTIONS
SEE SHEET 5 OF 5
(-) (ÿ)
— --- CONTROL Dl 02
PANEL •
TBI I© K pi A loieiiiii
6 8A I 0
1 40A MA 1 BA
r *
j£ £
FUSE 3
5 AMP
5048737-00
Sheet 3 of 5
Figure 3-62 - Wiring Diagram 5048737-00-Type "E"-MPC-From S/N 576761 to A803N08599U Revision 2
3-82
ELECTRICAL SYSTEM

ARE FACING CONTACTS. HIRING IS SHOWN
WITH COVER REMOVED.
:= Sic: FOR ALL OTHER NOTES SEE SHEET 1 OF S
FRONT VIEW
(CONNECTOR X5>
•£% \
Is — 2»2E 13H
13Ej
—
HOIST MOTOR
TRACTION MOTOR
HEIGHT LHT SWITCH
-
* CONTROL HANDLE -| - CONTROL COVER
*13E —aQ J -
ACCELERATOR
- - 13 —
POT
t
L
I
BRAKE SWITCH
4oc r~
c '"1"ÿ ~t~2,
HOIST SW
Jr -VT
giuu
ÿ©d3)@
5048737-00
Sheet 4 of 5
Figure 3-62 - Wiring Diagram 5048737-00-Type "E"-MPC-From S/N 576761 to A803N08599U (Continued) Revision 2
3-83
Yale
FROM
MAIN HARNESS
HOUR METER
AND 8.0.1. FROM
HOUR METER
AND B.D. I. MAIN HARNE5S
SEE SHEET 3 OF 5
AND B.D. I.
CONNECTION
BATTERY DISCHARGE INDICATOR SEE SHEET 3 OF S

__ . __
5048737-00
Sheet 5 of 5
Figure 3-63 - Options Diagram 5048737-00-Type "E"-MPC-From S/N 576761 to A803N08599U Revision 2
3-84
Yale
NOTES
3-85
Yale
FUSE 3
15 AMP OPT ONAL
SFF SHEFT
2 OF 5
HOT U5C0<-16
TRACTION
MOTOR
0j LIFT HORN
SWITCH SWITCH SWITCH
HANDLE HANDLE
HI 5PD
FIELD FOOT 5W
fF4ÿ>my3>.F3ÿ
HOT USED<-44
HOT USE0<-35
LIMIT
SWITCH
50LEN0ID
ACCELERATOR
POTENTIOMETER
EQUIPMENT
FOR PROPER OPERATION OF B.D.I. WITH HOUR METER ALL OE VICES ARE SHOWN IN THE NORMAL POSITION
CONNECT WIRE »12A AS FOLLOWS. WHEN THE UNIT IS STOPPED WITH NO OPERATOR.
12 VOLT TRUCK CONNECT TO TERMINAL «1 ANO "REVERSE" IS TRAVEL IN THE DIRECTION OF THE FORKS.
24 VOLT TRUCK CONNECT TO TERMINAL »5.
ANU ARE ENLARGEO FOR CLARITY
5052547-00
Sheet 1 of 5
-
Figure 3-64 Wiring Schematic 5052547-00-Type "E" and "EE"-MPC-S/N A803N08600U and up Revision 1
3-86
ELECTRICAL SYSTEM
i—r
ÿ ÿ ÿ
HEATER HEATER HEATER HOUR BATTERY BATTERY

COVER SWITCH LIMIT CURTIS 701 INOICATOR INOICATOR
SWITCH OPTIONAL SWITCH (OIGITAL) OPTIONAL W/HOUR METER
OPT IONAl OPTIONAL OPTIONAL OPTIONAL
ÿ
* ** *
_ 1_ 1_ 1
13 1 13
5052547-00
Sheet 2 of 5
Figure 3-65 - Options Schematic 5052547-00-Type "E" and "EE"-MPC-S/N A803N08600U and up Revision 1
3-87
Yale
TO KEY SWITCH
SEE SHEET A OF 5
FOR USE ON HOUR METER AND/OR
TRUCKS HJTH BATTERY INDICATOR
HANDRAIL CONTROL (MPE) CONNECTIONS
'
"N 40F SEE SHEET 5 OF 5
40H 24A CONTACTOR HARNESS
40H
C ,6
2H
13E
22A 23A
JUL LIFT PUMP MOTOR, HORN
AND HEIGHT LfMIT SW
SEE SHEET 4 OF 5
CONTROL PANEL -
ELECTRONIC NEG STUD

LOGIC MODULE
(ELM)
6 9 1
FRONT VIEW OF CONNECTOR #5

TRACTION MOTOR
SEF SHFFT 4 OF S
FOR EE MOD POWER

FUSES ARE ENCL05ED
SIMILAR FOR
13 SPLICE
HIGH SPEEO CONTROI HANOI F HARNFSS

FOOT SWITCH
SFF SHFFT 4 OF 5
SEE VIEW A-A SEE VIEW 0-0

SEC SHEET 4 Or S
© © ©
FWD REV
PMC
VIEW A-A
CONTROL PANEL
TOR ALL OTHER NOTES SEE SIIEE" 1 Of" C
5052547-00
Sheet 3 of 5
Figure 3-66 - Wiring Diagram 5052547-00-Type "E" and "EE"-MPC-S/N A803N08600U and up Revision 1
3-88
ELECTRICAL SYSTEM
BATTERY
(-) CO
26 12
2M 12A C-) CO
MAIN WIRE HARNESS

SEE SHEET 3 OF S
NEG STUD FUSE #2
CONTACTOR HARNESS
CONTACTOR PANEL
SEE SHEET 3 OF 5 PM2 PM1
CABLE ASSY
TO CONTACTOR
SEE SHEET 3
CONTACTOR HARNESS
SEE SHEET 3 OF S
CONTACTOR HARNESS
SEE SHEET 3 OF 5 22 28
LIFT PUMP
TRACTION MOTOR MOTOR
40-1 SPLICE
2-1 SPLICE
40A 26 13H

HEIGHT LIMIT SW TCH
ACCELERATOR
HEATER-COLD STORAGE
COPTIONAL)
9
BRAKE SWITCH 40C (
35A—'
TRACTION REVERSE SWITCH
REVERSE FORWARD
SWITCH SWITCH
(2aJ[22][35](40J (jSKHHHii!
ÿ (24) (23)0 [Kg[23][24]j3SA
ENLARGED VIEW
OF CONNECTOR X2 AND X?
5052547-00
Sheet 4 of 5
Figure 3-66 - Wiring Diagram 5052547-00-Type "E" and "EE"-MPC-S/N A803N08600U and up (Cont.) Revision 1
3-89
Yale
FROM
MAIN HARNESS
HOUR METER
(CURTIS 701)
CONNECTION
SEE SHEET 3 OF S
TO
MAIN HARNESS
HOUR METER
ANO B.O.I.
CONNECTION
SEE SHEET 3 OF S

13 MIRE (S) AT LIFT CONTACTOR
AND REPLACE WITH HIRE 113.
O®0®(2
5)0©@0@©
FROM
MAIN HARNESS
HOUR METER
AND B.O.I.
CONNECTION
SEE SHEET 3 OF 5
CURTIS 933/1 OR 933/4 B.D.I.

WITH HOUR METER CS) - 12 AND 24 VOLTS
SPLICE DETAILS
SPMCC
SPLICE 13
FROM
MAIN HARNESS
HOUR METER
AND B.D.I.
CONNECTION
SEE SHEET 3 OF 5
-2M -/ -2N -
N
SPLICE 40
BATTERY DISCHARGE INDICATOR W/HOUR METER
5052547-00
Sheet 5 of 5
-
Figure 3-67 Options Diagram 5052547-00-Type "E" And "EE"-MPC-S/N A803N08600U and up Revision 1
3-90
Yale
NOTES
3-91
Yale
15 AMP
FUSE 3 OPTIONAL
SEE SHEET
FIELD ÿ <5 \ NOT USED-*— 44 —

NOT USED— 35 —
SEE SHEE I
U3 rev
LOWER
01
SOLENOID
WHT-»
NOT USED— 63
EQUIPMENT
FOR PROPER OPERATION OF B.D.I. WITH HOUR METER 2 OF 5

CONNECT WIRE #12A TO TERMINAL »S.
FOR ALL SPLICE DETAILS SEE SHEET 5 OF 5
INSULATE ANO SECURE WIRES #40 g #35,35A. ALL DEVICES ARE SHOWN IN THE NORMAL POSITION
'REVERSE' IS TRAVEL IN THE DIRECTION OF THE FORKS.
5051147-00
Sheet 1 of 5
-
Figure 3-68 Schematic 5051147-00-Type "E" and "EE"-MPC-S/N A899N01501U and up Revision 3
3-92
ELECTRICAL SYSTEM
48 2 12
ÿ ÿ ÿ
4B 2 12
HEATER
CONTROL
COVER
HEATER
BRAKE
SWITCH
0
HEATER
HEIGHT
LIMIT
HOUR
J
METER
CURTIS 701
6
BATTERY
DISCHARGE
INDICATOR
BATTERY
OISCHARGE
INDICATOR
SWITCH OPT IONAL SWITCH (DIGITAL) OPTIONAL W/HOUR METER
505114700
Sheet 2 of 5
Figure 3-42 - Schematic 5051147-00-Type "E" and "EE"-MPC-S/N A899N01501U and up (Continued) Revision 3
3-93
Yale
LIFT PUMP MOTOR, HORN
CONTROL PANEL •
ELECTRONIC NEG STUD

LOGIC MODULE
(ELM)
FRONT VIEW OF CONNECTOR *5
FOR 'EE' MOD POWER

FUSES ARE ENCLOSED.—
SIMILAR FOR 'E' i 'EE'
FWD REV
PMC REV
CONTROL PANEL VIEW.
FWD
5051147-00
Sheet 3 of 5
Figure 3-69 - Wiring Diagram 5051147-00-Type "E" and "EE"-MPC-S/N A899N01501U and up Revision 3
3-94
ELECTRICAL SYSTEM

BATTERY
C-> (ÿ)
(-) (ÿ)
2M 12A
MAIN ANO HANDRAIL HARNESS

NEC STUD FUSE *2
CONTACTOR PANEL
SEE SHEET 3 OF S
CONTACTOR HARNESS
CONTACTOR PANEL
SEE SHEET 3 OF 5 PM2 PM1
CABLE ASSY
TO CONTACTOR PANEL
SEE SHEET 3 OF 5
X-1 AND X-6
CONTACTOR HARNESS
SEE SHEFT 3 OF 5
SOLENOID
TRACTION MOTOR LIFT PUMP

MOTOR
40-1 SPLICE
2-t SPLICE
wiÿinn
ÿ©(11)13
HEIGHT LIMIT SWITCH
3- —
HEATER-COLD STORAGE
CONTROL HANDLE CONTROL COVER OPTIONAL
ACCELERATOR — 2 13
BRAKE SWITCH —
40C (
REVERSE FORWARD
SWITCH SWITCH
505114700
Sheet 4 of 5
Figure 3-43 - Wiring Diagram 5051147-00-Type "E" and "EE"-MPC-S/N A899N01501U and up (Cont.) Revision 3
3-95
Yale
FROM FROM
FROM MAIN HARNESS MAIN HARNESS
MAIN HARNESS HOUR METER HOUR METER
HOUR METER ANO 8.0.1. ANO 8.0. I.
(CURTIS 701) CONNECTION CONNECTION
CONNECTION SEE SHEET 3 OF 5 SEE SHEET 3 OF S
SEE SHEET 3 OF S

WITH HOUR METER
SPLICE 13-1 SPLICE 40-1
-I3F-ÿ-,3,
- - X
-13K ' 131
SPLICE 13 TO
MAIN HARNESS C==?=j]
HOUR METER I Q=d 12 y
-6L -20-.
SPLICE 2-1
- 2 - -2A-
ANO B.O.I.
CONNECTION
SEF SHEET 3 OF S
| DE2*!
Qttr abc;
-2F -'
SPLICE 2
_2E

-2M -' -2N-
X 13 WIRE (S) AT LIFT CONTACTOR
OK -' x-40E—
SPLICE DETAILS
CURTIS 933/1 OR 933/4 B.D.I.
WITH HOUR METER (S) -
12 AND 24 VOLTS
L.H. REMOTE BOX R.H. REMOTE BOX
o
LEFT AND RIGHT HAND REMOTE BOX
FOR ALL 01HER NOIfcS Stfc SHEEI 1 OF 5

5051147-00
Sheet 5 of 5
Figure 3-70 -Options Diagram 5051147-00-Type "E" and "EE"-MPC-S/N A899N01501U and up Revision 3
3-96
Yale
NOTES
3-97
Yalo
12A
12 -H
STUO FUSE 3
FUSE 1 FUSE 2
200 AMP 200 AMP
-40B-
TBI
TRANSISTOR
CONTROLLER
AS
40B-
35A
ÿ6A-
FWD REV
FIELD 35A
LIFT
BATTERY I CONT
•FA F3
TBI TB 1
t
FWD REV
L,FT/"S
PUMP (mTRI 35A 2? 35A
MOTOR Vf
29
--
1
CR1
ÿÿ»TB1
TBI
FWD
CONT
REV
CONT
TB1
ÿ35 A
13A- 13A
STUD
13F 13F- 13F-
NOTE:
ON 12 VOLT TRUCK CONNECT WIRE #12A TO TERMINAL '1 ALL DEVICES ARE SHOWN IN THE NORMAL POSITION
AND ON 24 VOLT TRUCK CONNECT TO TERMINAL #5 ON WHEN THE UNIT IS STOPPED WITH NO OPERATOR.
BATTERY DISCHARGE INDICATOR WITH HOUR METER "REVERSE" IS TRAVEL IN THE DIRECTION OF THE FORKS.
5045807-00
Sheet 1 of 3
Figure 3-71 - Schematic 5045807-00-Type "E"-MPW-Up to S/N 576819 Revision 4
3-98
ELECTRICAL SYSTEM
1 ?A
I I
40D
D2
38 40C 12A 40D 2G 12A
LOWER HORN SEE

SWITCH 5W ITCH NOTE #1
I
'jt J\
oI <->l
'
f 3 6 5
335
4 2 1
L J
'
HEATER HEATER I HOUR I BATTERY BATTERY
| CONTROL ' BRAKE
1 METER DISCHARGE DISCHARGE
COVER 5W ITCH | OPTIONAL | INDICATOR INDICATOR
SWITCH
OPTIONAL SWITCH I I OPTIONAL W/HOUR METER
I
13 13F 13
I I
I I
I I
LOWER HORN
SOLENOID I I
I I
I I
I I
504580700
Sheet 1 of 3
Figure 3-42 - Schematic 5045807-00-Type "E"-MPW-Up to S/N 576819 (Continued) Revision 4
3-99
Yale
BATTERY
HOUR METER AND/OR
BATTERY INDICATOR
CONNECTIONS
SEE SHEET 3/3
CONTROL PANEl
TBI
CRl g)
FWD
— CONTROL PANEL
5045807-00
Sheet 2 of 3
Figure 3-72 - Wiring Diagram 5045807-00-Type "E"-MPW-Up to S/N 576819 Revision 4
3-100
ELECTRICAL SYSTEM
VIEW OF CONTROL HANDLE ANO COVER

* ARE FACING CONTACTS. WIRING IS SHOWN
WITH COVER REMOVED.
PUMP MOTOR
- *CONTROL HANDLE -i kCONTROL cover -

ACCELERATOR
POT
4J
FWD REV
VIEW V VIEW '8' OF CONNECTOR X2 ANO X3
504580700
Sheet 2 of 3
Figure 3-43 - Wiring Diagram 5045807-00-Type "E"-MPW-Up to S/N 576819 (Continued) Revision 4
3-101
Yale
HE5ET
FROM
MAIN HARNESS
HOUR METER
AND B.D.I.
CONNECTION TO
SEE SHEET 1/3 AND 2/3
HOUR METER MAIN HARNESS
HOUR METER D
AND B.D. I.
CONNECTION
SEE SHEET 1/3 AND 2/3 O
REMOVE AND INSULATE

EXISTING 13 WIRE (S) AT
CURTIS 933/3D LIFT CONTACTOR AND
FROM
SEE NOTE #1
MAIN HARNESS FOR PIN LOCATION SEE
ENLARGED FRONT VIEW BELOW'
HOUR METER £=12A
AND B.D.I.
CONNECTION
J1 JUMPER

WITH HOUR METER
TO
MAIN HARNESS
HOUR METER
AND B.D. I.
ÿPF13A=13
CONNECTION
SEE SHEET 1/3 AND 2/3 Qn 4QD
CONNECT WIRE «12A AS FOLLOWS i
12 VOLT TRUCK CONNECT TO TERMINAL #1 AND ©CO
ATTACH WITH EXISTING 28 WIRE
24 VOLT TRUCK CONNECT TO TERMINAL «5. AT LIFT CONTACTOR.
©CO
13 HIRE <S> AT LIFT CONTACTOR
AND REPLACE WITH HIRE 113.
(T: "Vj? (Z) ©
FROM
MAIN HARNE5S
HOUR METER
\ (sT)r?)©®®©(i
O \© 3@@(n)(r5) Io
AND B.D. I.
CONNECTION
FRONT VIEW-TERMINAL AND WIRE LOCATION
(ENLARGED FOR CLARITY)

CURTIS 933/1 OR 933/-1 B.D.I.
WITH HOUR METER (5) - 12 AND 24 VOLTS
5045807-00
Sheet 3 of 3
Figure 3-73 - Options Diagram 5045807-00-Type "E"-MPW-Up to S/N 576819 Revision 4
3-102
Yale
NOTES
3-103
Yale
STUD
15 AMP
n OPTIONAL
EQUIPMENT
SEE SHEET
2 OF 5
TRACTION TBI 02
REVERSE
SWITCH
35A 38 40C <; 2

*
! t-, L
C H
,1. ,1
•c
FWD
FIELO
REV
| 3 •A
27
' r
D3
ÿ | HOIST
CONT 6A
HO, ST
MOTOR
I I TBI
D,gI if )i
REV CRT HOIST LOWER HORN
CONT CONT SOLENOID
1 3 3
.
1
OPTIONAL
EQUIPMENT
SEE SHEET
2 OF 5
FOR PROPFR OPFRATION OF B.D.I. WITH HOUR MFTFR

CONNFCT WIRE »1?A AS FOllOWS. ALL DEVICES ARE SHOWN IN THE NORMAL POSITION
12 VOLT TRUC< CONNECT TO TERMINAL #1 AND WHEN THE UNIT IS STOPPED WITH NO OPERATOR.
24 VOLT TRUC< CONNECT TO TERMINAL »S.
'REVERSE' IS TRAVEL IN THE DIRECTION OF THE FORKS.
5047447-00
Sheet 1 of 5
Figure 3-74 - Schematic 5047447-00-Type "EE"-MPW-Up to S/N 576819 Revision 1
3-104
ELECTRICAL SYSTEM
2
I
2F
I
2E 12A
ÿ ÿ ÿ
BATTERY
DISCHARGE
INDICATOR
W/HOUR METER
OPTIONAL
13E 13H 130 13F 13F 13F
5047447-00
Sheet 2 of 5
Figure 3-74 - Schematic 5047447-00-Type "EE"-MPW-Up to S/N 576819 (Continued) Revision 1
3-105
Yale
BATTERY
HOUR METER AND/OR
BATTERY INDICATOR
CONNECTIONS
SEE SHEET 5 OF 5
CONTROL PANEL
TB1
CR1 @
REV
u-
CONTROI PANFI
PMC
RFV
-RANSISTOR CONTROI I FR
5047447-00
Sheet 3 of 5
Figure 3-75 - Wiring Diagram 5047447-00-Type "EE"-MPW-Up to S/N 576819 Revision 1
3-106
ELECTRICAL SYSTEM
X VIEW OF CONTROL HANDLE AND COVER

WITH COVER REMOVED.
FOR ALL OTHER NOTES SEE SHEET 1 OF s'
HOIST MOTOR
(CONTROL HANDLE "CONTROL COVER

— 136 -crÿl- -13-
ENLARGED VIEW
5047447-00
Sheet 4 of 5
Figure 3-75 - Wiring Diagram 5047447-00-Type "EE"-MPW-Up to S/N 576819 (Continued) Revision 1
3-107
Yale
FROM
SEE NOTE
MAIN HARNESS
HOUR METER
AND B.O.I. FROM
SEE SHEET 3 OF S HOUR METER FROM
ANO B.O.I. MAIN HARNESS
SEE SHEET 3 OF 5 AND 8.D. I.
CONNECTION
SEE SHEET 3 OF S
J1 JUMPER
TO
MAIN HARNESS
HOUR METER
TO AND B.D. I.
MAIN HARNESS
CONNECTION
HOUR METER SEE SHEET 3 OF 5
ANO B.O.I.
CONNECTION
SEE SHEET 3 OF S REMOVE AND INSULATE
EXISTING 13 WIRE(S) AT
CURTIS 933/30 LIFT CONTACTOR ANO

ANO REPLACC WITH WIRE 113.
CURTIS 933/1 OR 933/4 B.D. 1.

WITH HOUR METER (S) - 12 AND 24 VOLTS
run ALL UiriCK NUIC3 JLL jnCL I I Ur D

__
5047447-00
Sheet 5 of 5
Figure 3-76 - Options Diagram 5047447-00-Type "EE"-MPW-Up to S/N 576819 Revision 1
3-108
Yale
NOTES
3-109
Yale
>-
en
LU
C
CO
TO
OPTIONAL
EQUIPMENT
SEE SHEET
2 OF 5
ON 12 VOLT TRUCK CONNECT WIRE #12A TO TERMINAL #1 ALL DEVICES ARE SHOWN IN THE NORMAL POSITION
AND ON 24 VOLT TRUCK CONNECT TO TERMINAL »5 ON WHEN THE UNIT IS STOPPED WITH NO OPERATOR.
BATTERY DISCHARGE INDICATOR WITH HOUR METER "REVERSE* IS TRAVEL IN THE DIRECTION OF THE FORKS.
5048727-00
Sheet 1 of 5
Figure 3-77 - Schematic 5048727-00-Type "E"-MPW-From S/N 576820 to A838N06613U Revision 2
3-110
ELECTRICAL SYSTEM
2A
I
2F
I
2E 12A
ÿ ÿ W
HFATFR HFATFR HFATFR HOUR BATTFRY BATTFRY

COVER SWITCH LIMIT OPTIONAL INDICATOR INDICATOR
yk yk
J_ I
1 3t 1 3H 13G 1 3F 1 3F 1 3F
—
FROM
— 13F
SHEET 1 OF 5
5048727-00
Sheet 2 of 5
Figure 3-77 - Schematic 5048727-00-Type "E"-MPW-From S/N 576820 to A838N06613U (Continued) Revision 2
3-111
Yale
KEY SWITCH BATTERY

HOUR METER AND/OR
BATTERY INDICATOR
CONNECTIONS
SEE SHEET 5 OF S
CONTROL PANEL
2.2E-
s— PM2 1
CONTROL PANEL - FWD
W=
PMC
REV
VIFW '31
5048727-00
Sheet 3 of 5
Figure 3-78 - Wiring Diagram 5048727-00-Type "E"-MPW-From S/N 576820 to A838N06613U Revision 2
'3-112
ELECTRICAL SYSTEM

WITH COVER REMOVED.
HOIST MOTOR
*CONTROl HANDLE kCONTROL COVER

-13E —CEÿI- -13-
X2
ENLARGED
5048727-00
Sheet 4 of 5
Figure 3-78 - Wiring Diagram 5048727-00-Type "E"-MPW-From S/N 576820 to A838N06613U (Continued) Revision 2
3-113
Yale
FROM
MAIN HARNESS
HOUR METER
FROM
AND B.D.I.
MAIN HARNESS
CONNECTION
HOUR METER
ANO B.D.I.
MAIN HARNESS
CONNECTION
HOUR METER
SEE SHEET 3 OF S
ANO 8.0.1.
CONNECTION
BATTERY OISCHARGE INDICATOR
SEE SHEET 3 OF 5
TO
MAIN HARNESS
HOUR METER
ANO 8.0.1.
CONNECTION
SEE SHEET 3 OF S
TO
MAIN HARNESS
HOUR METER
REMOVE AND INSULATE
AND B.O.I. EXISTING 13 WIRE(S) AT
CONNECTION CURTIS 933/30 LIFT CONTACTOR ANO
SEE SHEET 3 OF 5 BATTERY D 1 5CHARGE INDICATOR REPLACE WITH WIRE 113.

»)0®©©®(£
5)©©©©@©
CURTIS 933/1 OR 933/4 B.D.I.

W I IH HOUR METER (S) -
12 ANO 24 VOLTS

5048727-00
Sheet 5 of 5
Figure 3-79 - Options Diagram 5048727-00-Type "E"-MPW-From S/N 576820 to A838N06613U Revision 2
3-114
Yale
NOTES
3-115
Yale
FUSE 3
15 AMP
SEE SHEET
MOTOR
I-T--T-1
FIELD
F4ÿyrrv(3).F3-
|
LIMIT
SWITCH
ACCELERATOR
POTENTIOMETER
OPTIONAL
EQUIPMENT
SEE SHEET
FOR PROPER OPERATION OF B.D.I. WITH HOUR METER ALL DEVICES ARE SHOWN IN THE NORMAL POSITION 2 OF S
CONNECT WIRE #12A AS FOLLOWS s WHEN THE UNIT IS STOPPED WITH NO OPERATOR.
17 VOLT TRUCK CONNECT TO TERMINAL #1 AND 'REVERSE* IS TRAVEL IN THE DIRECTION OF THE FORKS.
A: I CONNFCTORR ARF SHOWN FROM FRONT VIFW
CZ> USE TY WRAP TO TIE CONNECTOR #4 AND #8 TO MAIN WIRE HARNESS. AND ARF FNI ARGFD FOR CI ARITY
CD JUMPER ASSEMBLY (CONNECTOR 3A) MUST BF
CONNECTED TO CONNECTOR 3 (MAIN HARNESS),
FOR PROPER TRUCK OPERATION.
5052557-00
Sheet 1 of 5
Figure 3-80 - Wiring Schematic 5052557-00-Type "E" and "EE"-MPW-S/N A838N06614U and up Revision 1
3-116
ELECTRICAL SYSTEM
7—r
ÿ ÿ ÿ
HEATER HEATER HEATER HOUR BATTERY BATTERY

CONTROL BRAKE HEIGHT METER OISCHARGE DISCHARGE
COVER SWITCH LIMIT CURTIS 701 INOICATOR INOICATOR
SWITCH (OPTIONAL) SWITCH (OJGITAL) (OPTIONAL) W/HOUR METER
(OPTIONAL) (OPTIONAL) OPTIONAL (OPTIONAL)
13 13
J_J-
FOR ALL OTHER NOTES SEE SHEET T OF S
5052557-00
Sheet 2 of 5
Figure 3-81 - Options Schematic 5052557-00-Type "E" and "EE"-MPW-S/N A838N06614U and up Revision 1
3-117
Yale
#3A
CONTROL PANEL
ELECTRONIC NEG STUD

LOGIC MODULE
(ELM)
FRONT VIEW OF CONNECTOR »5
FOR 'EE' MOD POWER
SIMILAR FOR *E* 8 *EE'
FWD REV
FWD
CONTROL PANEL
REV
#4
5052557-00
Sheet 3 of 5
Figure 3-82 - Wiring Diagram 5052557-00-Type "E" and "EE"-MPW-S/N A838N06614U and up Revision 1
3-118
ELECTRICAL SYSTEM
BATTERY
KEY SWITCH
(-) (O
/ 5
(-) CO
HA IN WIRE HARNESS
SEE SHEET 3 OF 5
NEG STUD FUSE #2
CONTACTOR HARNESS
CONTACTOR PANEL
SEE SHEET 3 OF 5 JUMPER
CABLE ASSY
TO CONTACTOR PANEL
SEE SHEET 3 OF S m21
ÿ
-
-13D —
k
13C —
CONTACTOR HARNESS
SEE SHEET 3 OF S
CONTACTOR HARNESS
SEE SHEET 3 OF 5
TRACTION MOTOR
~ÿ5
40-1 SPLICE
l—A6
—
2-1 SPLICF -ÿ)3 ÿ4
63~l
- x ,-
NOT USED ON
THIS TRUCK MODEL
- CONTROL HANDLE - CONTROL COVER HEIGHT LIMIT SWITCH

ACCELERATOR 13E -C>&
?=f
40c r
40B B
REVERSE FORWARD
SWITCH SWITCH
H
sinmi® 35 22
ÿ®(D@ 23 24
5052557-00
Sheet 4 of 5
Figure 3-82 - Wiring Diagram 5052557-00-Type "E" and "EE"-MPW-S/N A838N06614U and up (Cont.) Revision 1
3-119
Yale
FROM
MAIN HARNESS
HOUR METER
(CURTIS 701)
CONNECTION
SEE SHEET 3 OF S
*= 48
TO
MAIN HARNESS
HOUR METER
ANO B.O.I.
CONNECTION
nnn=i3A
SEE SHEET 3 OF 5

!U©©©©®(2
jy©@@©(i°)©
FROM
MAIN HARNESS
HOUR METER
ANO B.O.I.
CONNECTION
SEE SHEET 3 OF 5
BATTERY DISCHARGE INDICATOR CURTIS 933/1 OR 933/4 B.D. 1 .

WITH HOUR METER (5) - 1 2 AND 2 A VOLTS
SPLICE DETAILS
FROM
MAIN HARNESS 5PLICE 2
HOUR METER
ANO B.O. I.
CONNECTION
SEE SHEET 3 Of 5
SPLICE 40
BATTERY DISCHARGE INDICATOR W/HOUR METER SPLICE 40-1
SPLICE 2
5052557-00
Sheet 5 of 5
-
Figure 3-83 Options Diagram 5052557-00-Type "E" and "EE"-MPW-S/N A838N06614U and up Revision 1
3-120
Yale
NOTES
3-121
Yale
1 2A
2G ÿ
1 2A
ÿ(+)ÿ
FUSE *2 KEY
STUD 15 AMP SW ITCH
FUSE #1
200 AMP
BUS
BAR
CONTROLLER
TBI
L$J 21
REV FW
FIELD
BATTERY I i
REV FW:
BUS BAR
29 -
REV
CONT CONT
BUS BAR
29 -
ÿ(-)• 13A 13A
STUD
13F
ALL DEVICES ARE SHOWN IN IHE NORMAL POSH ION

"REVERSE" IS TRAVEL IN THE DIRECTION OF THE FORKS.
5046677-00
Sheet 1 of 3
Figure 3-84 - Schematic 5046677-00-Type "E"-MTR-Up to S/N 576845 Revision 2
3-122
ELECTRICAL SYSTEM
I
12A
\ O"0 IOC
\HIGH Ho-
QUO
HORN
SPEED SWITCH
FOOT
SW1 ICH
3 6 5
1.2,
| HOUR I BATTERY BATTERY

MFTFR DISCHARGE DISCHARGE
I INDICATOR INDICATOR
W/HOUR METER
OPTIONAL
oi
I I
13F 13F
I
- 1 3F
_ i
504667700
Sheet 1 of 3
Figure 3-42 - Schematic 5046677-00-Type "E"-MTR-Up to S/N 576845 (Continued) Revision 2
3-123
Yale
BATTERY
HOUR METER
AND/OR
BATTERY INDICATOR
CONNECTIONS
CONTROL PANEL
TBI
FWD
REV
TRANSISTOR CONTROL I FR
5046677-00
Sheet 2 of 3
Figure 3-85 - Wiring Diagram 5046677-00-Type "E"-MTR-Up to S/N 576845 Revision 2
3-124
ELECTRICAL SYSTEM
VIEW OF CONTROL HANDLE ANO COVER

TRACTION MOTOR
i—
* CONTROL HANDLE —
i CONTROL COVER -
VIEW "A" VIEW
504667700
Sheet 2 of 3
Figure 3-43 - Wiring Diagram 5046677-00-Type "E"-MTR-Up to S/N 576845 (Continued) Revision 2
3-125
Yale
FROM
MAIN HARNESS
HOUR METER
AND B.D.I.
CONNECTION
SEE PAGE 2 OF 3
HOUR METER
FROM
MAIN HARNESS
HOUR METER
.
AND B.D. I
CONNECTION
SEE PAGE 2 OF 3
FROM
MAIN HARNESS
HOUR METER
.
ANO B.D. I
CONNECTION
5FF PAGE 2 OF 3

WITH HOUR METER
5046677-00
Sheet 3 of 3
Figure 3-86 - Options Diagram 5046677-00-Type "E"-MTR-Up to S/N 576845 Revision 2
3-126
Yale
NOTES
3-127
Yale
TO
OPTIONAL
EQUIPMENT
SEE SHEET
2 OF S
HIGH HORN
SPEEO SWITCH
FOOT
REV FWO SWITCH
FIELD
BATTERY
OPTIONAL
EQUIPMENT
SEE SHEET
2 OF 5

"REVERSE" IS TRAVEL IN THE DIRECTION OF THE FORKS.
5048747-00
Sheet 1 of 5
Figure 3-87 - Schematic 5048747-00-Type "E"-MTR-From S/N 576846 to A817N05790U Revision 2
3-128
ELECTRICAL SYSTEM
HOUR BATTERY BATTERY

METER DISCHARGE DISCHARGE
OPTIONAL INDICATOR INDICATOR
OPTIONAL W/HOUR METER
OPTIONAL
O048747-00
Sheet 2 of 5
Figure 3-87 - Schematic 5048747-00-Type "E"-MTR-From S/N 576846 to A817N05790U (Continued) Revision 2
3-129
Yale
BATTERY
HOUR METER
AND/OR
BATTERY INDICATOR
CONNECTIONS
SEE SHEET 5 OF 5
CONTROL PANEL
TBI
FWD
PMC
i=
REV
VI FW *B'
5048747-00
Sheet 3 of 5
Figure 3-88 - Wiring Diagram 5048747-00-Type "E"-MTR-From S/N 576846 to A817N05790U Revision 2
3-130
ELECTRICAL SYSTEM

WITH COVER REMOVED.
FRONT VIEW
CCONNECTOR XS>
sfe
Ss
TRACTION MOTOR
f-m CONTROL HANDLE CONTROL COVER -

ÿS36
ACCELERATOR
POT
J~]-WHT/29 -
_
\ |-BLK/14 -
B 408
BRAKE SWITCH
5048747-00
Sheet 4 of 5
Figure 3-88 - Wiring Diagram 5048747-00-Type "E"-MTR-From S/N 576846 to A817N05790U (Continued) Revision 2
3-131
Yale
FROM
MAIN HARNESS
HOUR METER
ANO B.D.I. FROM
SEE SHEET 3 OF S HOUR METER
FROM
ANO B.O. I. MAIN HARNESS

SEE SHEET 3 OF 5 AND B.O. I.
CONNECTION
SEE SHEET 3 OF S

5048747-00
Sheet 5 of 5
-
Figure 3-89 Options Diagram 5048747-00-Type "E"-MTR-From S/N 576846 to A817N05790U Revision 2
3-132
Yale
NOTES
3-133
Yale
FUSE 3
OPTIONAL
EQUIPMENT
SEE SHEET
2 OF 5
I" NOT USED ÿ

—
MOTOR
\ T T I
HORN
SWITCH
HANDLE
r HU Rev HI 5PU
FIELD FOOT 5W
-A
: ; fhd REV ::
NOT USED \— 44
NOT USED — 35
i
ACCELERATOR
POTENTIOMETER
NOT USED
OP I IONAL
FOUIPMFNT
SEE SHEE1
CONNECT WIRE #12A AS FOLLOWS .


'REVERSE" IS TRAVEL IN THE DIRECTION OF THE FORKS.
2 OF 5
24 VOLT TRUCK CONNECT TO TERMINAL »5.

ANO ARE ENLARGED FOR CLARITY
5052567-00
Sheet 1 of 5
-
Figure 3-90 Wiring Schematic 5052567-00-Type "E" and "EE"-MTR-S/N A817N05791U and up Revision 1
3-134
ELECTRICAL SYSTEM
12
I
HEATER HEATER HOUR BATTERY BATTERY
CONTROL BRAKE METER DISCHARGE DISCHARGE
COVER SWITCH CURTIS 701 INDICATOR INDICATOR
SWITCH (OPTIONAL) (DIGITAL) OPTIONAL W/HOUR METER
(OPTIONAL) OPTIONAL OPTIONAL
5052567-00
Sheet 2 of 5
Figure 3-91 - Options Schematic 5052567-00-Type "E" and "EE"-MTR-S/N A817N05791U and up Revision 1
3-135
Yale
CONTROL PANEL
X3
ELECTRONIC NEC STUD

LOGIC MODULE
(ELM)
FRONT VIEW OF CONNECTOR X5
X6
FWD REV
PMC
ISTOR CONTRO FWD
B- B+
CONTROL PANEL
V:
REV
X4
(ROTATED 90')
FOR ALL OTHER NOTES SEE SHEET I OF 5
5052567-00
Sheet 3 of 5
-
Figure 3-92 Wiring Diagram 5052567-00-Type "E" and "EE"-MTR-S/N A817N05791U and up Revision 1
3-136
ELECTRICAL SYSTEM
BATTERY
(-) (ÿ)
MAIN AND HANDRAIL HARNESS
CONTACTOR PANEL
SEE SHEET 3 OF S NEG STUD FUSE »2
CONTACTOR HARNESS
CONTACTOR PANEL
SEE SHEET 3 OF 5
CABLE ASSY
TO CONTACTOR PANEL
SEE SHEET 3 OF S
CONTACTOR HARNESS
SEE SHEET 3 OF S
M 3R
RING TERMINALS INSULATED
--
WITH
SHRINK TUBING
CONTACTOR HARNESS TRACTION MOTOR

SEE SHEET 3 OF 5
-AS
0S
40-1 SPLICE
2-1 SPLICE
40A 2G 13H
USED FOR OPTIONAL

COLD STORAGE HEATER
FOR TRUCKS EQUIPPED
WITH HEIGHT LIMIT
-ACCELERATOR
CONTROL HANDLE CONTROL COVER SWITCH
ft
BRAKE SWITCH
ÿ HORN SW
REVERSE FORWARD
SWITCH SWITCH
HEATER-COLD STORAGE
(OPTIONAL)
ÿR(y)R
5052567-00
Sheet 4 of 5
-
Figure 3-92 Wiring Diagram 5052567-00-Type "E" and "EE"-MTR-S/N A817N05791U and up (Cont.) Revision 1
3-137
Yale
FROM
MAIN HARNESS
HOUR METER
(CURTIS 701)
CONNECTION
SEE SHEET 3 OF S
CUTIS 701 HOUR METER (DIGITAL?
TO
MAIN HARNESS
HOUR METER
AND 0.0.1.
CONNECTION
SEE SHEET 3 OF 5

FROM
MAIN HARNESS
HOUR METER
AND B.D.I.
CONNECTION
5EE SHEET 3 OF 5
CURTIS 933/1 OR 933/4 B.D.I.

WITH HOUR METER (S) - 12 AND 24 VOLTS
SPLICE DETAILS
SPLICE 13-1
-
•13C
FROM
MAIN HARNESS
HOUR METER
ANO B.D.I.
CONNECTION
SEE SHEET 3 OF 5
BATTERY DISCHARGE INDICATOR W/HOUR METER SPLICE AO
5052567-00
Sheet 5 of 5
Figure 3-93 - Options Diagram 5052567-00-Type "E" and "EE"-MTR-S/N A817N05791 U and up Revision 1
3-138
Yale
NOTES
3-139
Yale
UJ
t—
c
CD
TO
OPTIONAL
EQUIPMENT
ON 12 VOLT TRUCK CONNECT WIRE #12A TO TERMINAL #1 ALL DEVICES ARE SHOWN IN THE NORMAL POSITION
AND ON 24 VOLT TRUCK CONNECT TO TERMINAL #S ON WHEN THE WIT IS STOPPED WITH NO OPERATOR.
BATTERY DISCHARGE INDICATOR WITH HOUR METER 'REVERSE* IS TRAVEL IN THE DIRECTION OF THE FORKS.
7524767-00
Sheet 1 of 5
-
Figure 3-94 Schematic 7524767-00-Type "E"-MLW-S/N B828N01501S and up Revision 2
3-140
ELECTRICAL SYSTEM
FROH
SHEET
1 OF 5
W ÿ M'
HEATER HEATER HOUR BATTERY BATTERY

CONTROL BRAKE METER DISCHARGE DISCHARGE
COVER SWITCH OPTIONAL INDICATOR INDICATOR
SWITCH OPTIONAL OPTIONAL W/HOUR METER
OPTIONAL OPTIONAL
At A\
13E 13H 13G
J_ I
FROM
SHfcEl
t OF 5
7524767-00
Sheet 2 of 5
Figure 3-94 - Schematic 7524767-00-Type "E"-MLW-S/N B828N01501S and up (Continued) Revision 2
3-141
Yale
KEY SWITCH BATTERY FOR ALL OTHER NOTES SEE SHEET 1 OF S

HOUR METER AND/OR C-) (ÿ)
BATTERY INDICATOR
CONNECT IONS
SEE SHEET 5 OF S
- CONTROL PANEL
Dl 02 03 JUMPER
I $ I $ I 0 I 9 I 01
El T
TRACTION, HOIST MOTOR

AND CONTROL HANOLE
SEE SHEET A OF 5
CR1 «ÿ
CONTROL PANEL - — FWD
HP
7524767-00
Sheet 3 of 5
Figure 3-95 - Wiring Diagram 7524767-00-Type "E"-MLW-S/N B828N01501S and up Revision 2
3-142
ELECTRICAL SYSTEM
X VIEW OF CONTROL HANOLE ANO COVER

ARE FACING CONTACTS. WIRING 15 SHOWN
WITH COVER REMOVED.
20 130 1 3D
PUMP MOTOR
2A 13D
TRACTION MOTOR
- KCONTROL HANDLE KCONTROL cover

ACCELERA10R 3E -CE®T - 13 -
0
BRAKE SWITCH
TRACTION REVERSE SWITCH J |
ICATER-COLO STORAGE
OPTIONAL
©(DUD©
7524767-00
Sheet 4 of 5
-
Figure 3-95 Wiring Diagram 7524767-00-Type "E"-MLW-S/N B828N01501S and up (Continued) Revision 2
3-143
Yale
FROM
MAIN HARNESS
HOUR METER FROM
AND B.D.I. MAIN HARNESS
SEE S1CET 3 OF S ANO B.D.I.
CONNECTION
SEE SHEET 3 OF S
FROM
SEE NOTE #1
MAIN HARNESS
HOUR METER
ANO B.D.I.
CONNECTION
SEE SHEET 3 OF S
BATTERY DISCHARGE INDICATOR WITH HOUR METER

CONNECT WIRE #12A AS FOLLOWS.
12 VOLT TRUCK CONNECT TO TERMINAL #1 ANO
TO
MAIN HARNESS
HOUR METER O" 12
ANO B.D. I.
CONNECTION
0-11-,3A==T3
SEE SHEET 3 OF S

$
is)©©000®
TO
MAIN HARNESS
HOUR METER
AND B.D. I.
CONNECTION
SEE SHEET 3 OF S
CURTIS 933/1 OR 933/4 BDI WITH METER (S) - 12 AND 24 VOLTS
REMOVE AND INSULATE

EXISTING 13 WIRECS) AT
LIFT CONTACTOR ANO
REPLACE WITH WIRE 113.
CURTIS 933/3D BAIIERY DISCHARGE IN01CAI0R

7524767-00
Sheet 5 of 5
Figure 3-96 - Options Diagram 7524767-00-Type "E"-MLW-S/N B828N01501S and up Revision 2
3-144
Yale
Industrial Trucks
SECTION 4
DRIVE UNIT
Yale
Industrial Trucks
DRIVE UNIT
DRIVE UNIT-GENERAL 4-1

DRIVE MOTOR ASSEMBLY 4-1
UPPER HOUSING 4-1
LOWER HOUSING 4-1
DRIVE WHEEL 4-1
REMOVAL 4-1
INSTALLATION 4-3
UPPER HOUSING 4-3
REMOVAL 4-3
INSTALLATION 4-3
LOWER HOUSING 4-4
DISASSEMBLY 4-4
ASSEMBLY 4-4
DRIVE UNIT 4-5
REMOVAL 4-5
INSTALLATION 4-6
BEVEL PINION AND GEAR ADJUSTMENT 4-7
yi
* -
lit
Wff ~: ,
ÿ
ÿ
-
'
?
;
'
Is;
;siA
&s*s
ÿÿIt
ÿ
Yale
Industrial Trucks DRIVE UNIT
DRIVE UNIT-GENERAL
The drive system consists of the drive motor assembly, the
upper housing, the ring bearing assembly and the lower
housing. The same drive system is installed in all Yale
motorized hand trucks.
The drive unit gear box is mounted on a large diameter ring

bearing to provide for easy steering. All rotating parts of the
drive unit are supported by either ball or roller bearings.
Lubrication for the drive unit is provided by maintaining a
specified level of gear oil in the lower housing. The ring bearing
is lubricated using the grease fittings that are accessible
through the openings provided in the drive unit compartment
floor plate.
Drive Motor Assembly

The drive motor is vertically mounted on top of the drive unit. In
some instances it may be necessary to remove the drive motor
to work on the drive unit, while in other cases the drive motor
may remain attached to the drive unit while repairs are made.
The complete drive unit, including the motor may also be
removed, if necessary. Determine the extent of disassembly
required before proceeding with any repairs. Refer to Section 3 1. DRIVE MOTOR
of this manual for a general description, maintenance and 2. UPPER HOUSING
repairs of the drive motor. 3. LOWER HOUSING
4. BEARING
Upper Housing 5. GREASE FITTING
6. FILL PLUG
The upper housing of the drive unit supports the drive motor. A 7. DRAIN PLUG
bevel pinion gear is attached to the drive motor shaft. The bevel
pinion gear drives the bevel gear which is mounted on a shaft. Figure 4-1 - Drive Unit
The shaft is machined with spur gear teeth that drives the idler
gear located in the lower housing. The brake drum is also DRIVE WHEEL
mounted on the bevel gear shaft. The upper housing can be Removal
removed from the lower housing without removing the
complete drive unit. WARNING: Put blocks under each side of the
truck under the drive unit frame. Position blocks on
Lower Housing both sides of the load wheels. The blocks must
prevent the motorized handtruck from falling and causing injury
The lower housing contains the idler gear which meshes with or damage.
the bevel gear shaft in the upper housing. The idler gear drives
the 2nd reduction gear. The 2nd reduction gear is keyed to the 1. Raise the drive wheel off the floor. Block the motorized
drive wheel shaft. A cover on the side of the lower housing hand truck. See Section 1-HOW TO PUT A LIFT TRUCK ON
contains both a drain plug and a fill plug. The fill plug is located BLOCKS. Disconnect the battery.
in the center of the cover and is also used to check the level of
gear oil in the drive unit. A machined surface around the center 2. Loosen and remove the five wheel bolts and washers
of the lower housing provides the mounting surface for the drive securing the clamp plate and drive wheel to the axle shaft . The
unit bearing. clamp plate will be free from the wheel hub after the last wheel
bolt is removed.
NOTE: The drive unit bearings used on these models no
longer require any adjustment for wear or steering effort. 3. Remove the drive wheel.
4-1
Yale
9. Put a 3 mm (0.12 in) bead of silicone sealer around the 3. Remove the four capscrews and washers retaining the
outer edge of a new expansion plug and tap the plug into place cover to the lower housing. Remove the cover.
in the housing bore.
4. Loosen and remove the five wheel bolts, washers and
10. Apply sealing compound,Yale part number 5020589-05 or clamp plate securing the drive wheel to the axle shaft. Remove
equivalent, to the lower housing. Align the upper housing with the drive wheel.
the dowel pin in the lower housing and install the four
capscrews and lockwashers. Tighten the three 1/2"-13 5. Remove the cotter pin and nut from the axle shaft. Use a
capscrews to 102-115 N*m (75-85 Ibf ft) and the 3/8"-16 brass bar to drive the shaft out of the 2nd reduction drive gear
capscrew to 54-61 N»m (40-45 Ibf ft) torque. and bearings. Remove the gear and key.
11. Assemble and adjust the brakes. Refer to Section 5 of this WARNING: Be careful when removing or
manual for the proper procedures. installing snap rings. These snap rings can come
loose during removal or installation with enough
12. Connect the motor wires and install the harness clamps. force to cause an injury. Always use the correct snap ring pliers
and wear eye and face protection during removal and
13. Installthe control handle. Refer to Section 6 of this manual installation.
for the correct installation procedures.
6. Remove the snap ring and inner bearing.
2-DRIVE UNIT COMPARTMENT-REMOVAL AND 7. Remove the oil seal and outer bearing.
INSTALLATION.
Assembly
1. Before assembling the lower housing, wash and
thoroughly clean all parts in a suitable solvent and dry. Make
service.
certain that all gasket material or sealing compound has been
removed from the housings and covers, and that all mating
LOWER HOUSING surfaces are smooth.
Disassembly
2. Check housing for cracks. Check housing bores for
The drive shaft, oil seal, bearings, and 2nd reduction gear can damage, especially around snap ring grooves. Check all
be serviced without removing the drive unit from the motorized threaded holes for damage. Check the drive unit breather.
hand truck.
3. Check all bearings for excessive wear or flat spots. Dip
WARNING: Put blocks under each side of the clean bearings in new, clean gear oil and wrap in a clean, lint
truck under the drive unit frame. Position blocks on free cloth until ready for assembly.
both sides of the load wheels. The blocks must
prevent the motorized hand truck from falling and causing injury 4. Check all gears and shafts for excessive wear, damaged
or damage. teeth or keyways. Check keys for rounded edges or cracks.
Check the keys for proper fit in the keyways of the shafts where
1. Drain the gear oil from the drive unit into a suitable they belong. If the keys do not fit properly, replace the key
container. Raise the drive wheel off the floor. Block the and/or shaft.
motorized hand truck. See Section 1-HOW TO PUT A LIFT
TRUCK ON BLOCKS. Disconnect the battery. 5. Replace all worn or damaged parts. When assembling the
drive unit use all new gaskets, O-rings and oil seals.
drive unit. Refer to Section 2-DRIVE UNIT 6. Install the outer bearing and new oil seal in the lower
COMPARTMENT-REMOVAL AND INSTALLATION. housing bore. Apply a light coat of gear oil to the I.D. of the oil
seal.
can hold an electrical charge after the battery is WARNING: Be careful when removing or
disconnected. To prevent electrical shock and installing snap rings. These snap rings can come
injury, discharge the capacitor before inspecting or repairing loose during removal or installation with enough
any component in the drive unit compartment. Wear safety force to cause an injury. Always use the correct snap ring pliers
glasses. Make certain the battery has been disconnected. and wear eye and face protection during removal and
Use a screwdriver or jumper wire to make a short-circuit across installation.
4-4
Yale
7. Installthe inner bearing with the shield toward the reservoir /\ WARNING: The capacitor in the motor controller
side of the housing. Lock in place using a snap ring. / I\ can hold an electrical charge after the battery is
8. Insert the key in the drive shaft, position the 2nd reduction injury, discharge the capacitor before inspecting or repairing
gear in the housing and carefully insert the drive shaft through any component in the drive unit compartment. Wear safety
the oil seal, outer bearing, inner bearing and the 2nd reduction glasses. Make certain the battery has been disconnected.
gear. Use a screwdriver or jumper wire to make a short-circuit across
9. Install the drive axle shaft nut on the shaft. Tighten the nut
to 95-122 N»m (70-90 Ibf ft) torque. Make certain that the hole in 3. Remove the control handle. Refer to Section 6 of this
the shaft and nut are aligned and install a new cotter pin. manual for the correct removal procedures for the type of
motorized hand truck being worked on.
10. Apply sealing compound, Yale part number 5020589-05 or
equivalent, to the cover surface of the housing. Align the cover 4. Tag and disconnect the motor wires and the harness
on the lower housing. Install the four capscrews and clamps on the motor.
lockwashers to retain the cover. Tighten the capscrews to 49
N«m (36 Ibf ft) torque. 5. Disassemble the brakes. Refer to Section 5 of this manual
for the proper procedures.
11. Mount the drive wheel on the axle shaft, install clamp plate,
washers, and wheel bolts. Tighten the wheel bolts to 190-217 6. If necessary, remove the drive motor. Refer to Section
N«m (140-160 Ibf ft) torque. 3-DRIVE MOTOR-REMOVAL. Attach a sling and an overhead
hoist to the drive unit.
2-DRIVE UNIT COMPARTMENT-REMOVAL AND INSTAL¬ 7. Loosen and remove the two capscrews and lockwashers
LATION. retaining the rear bearing clamp. (The front clamping device is
usually removed with the control handle.)
13. Lower the truck to the floor. Connect the battery. Test
operate the motorized hand truck before returning the truck to 8. Lower the drive unit to the floor, remove the sling and roll
service. the unit out from under the truck. Move the unit to a clean work
area.
DRIVE UNIT
9. Remove the six capscrews and nuts. Disassemble the
Removal bearing shield, the bearing spacers and the bearing.
/\ CAUTION: The steering bearing is attached to 10. Disassemble the upper housing from the lower housing.
11\ the frame floor plate and does not support the drive
Refer to UPPER HOUSING-REMOVAL. Remove the dowel
unit. Keep the drive unit supported at all times
pins that retain the idler shaft from the lower housing.
using a sling and an overhead hoist when removing the drive
unit from the motorized hand truck.
11. Installs 1/2"-20 capscrew or a slide hammer into the idler
shaft to remove the shaft. Remove the idler shaft assembly.
/\
I
WARNING: Put blocks under each side of the
I\ truck under the drive unit frame. Position blocks on
/\ WARNING: Be careful when removing or
prevent the motorized hand truck from falling and causing injury
II\ installing snap rings. These snap rings can come
or damage. force to cause an injury. Always use the correct snap ring pliers
1. Drain the gear oil from the drive unit into a suitable
installation.
container. Raise the drive wheel off the floor. Block the
motorized hand truck. See Section 1-HOW TO PUT A LIFT
12. Disassemble the idler shaft by removing the spacer, snap
TRUCK ON BLOCKS. Disconnect the battery.
rings, idler gear, bearing and O-ring. Discard the O-ring.
13. Remove the four capscrews and lockwashers retaining
drive unit. Refer to Section 2-DRIVE UNIT COMPARTMENT- the cover to the lower housing. Remove the cover and gasket.
REMOVAL AND INSTALLATION.
14. Loosen and remove the five wheel bolts, washers and
clamp plate securing the drive wheel to the axle shaft. Remove
the drive wheel.
4-5
Yale
IndustrialTrucks DRIVE UNIT
15. Remove the cotter pin and nut from the axle shaft. Use a 9. Installthe drive axle shaft nut on the shaft. Tighten the nut
brass bar to drive the shaft out of the 2nd reduction drive gear to 95-122 N*m (70-90 Ibf ft) torque. Makecertain that the hole in
and bearings. Remove the gear and key. the shaft and nut are aligned and install a new cotter pin.
WARNING: Be careful when removing or 10. Apply sealing compound, Yale part number 5020589-05 or
installing snap rings. These snap rings can come equivalent to the cover surface of the housing. Align the cover
loose during removal or installation with enough on the lower housing. Install the four capscrews and
force to cause an injury. Always use the correct snap ring pliers lockwashers to retain the cover. Tighten the capscrews to 49
and wear eye and face protection during removal and N*m (36 Ibf ft) torque.
installation.
11. Mountthe drive wheel on the axle shaft, install clamp plate,
16. Remove the snap ring and inner bearing. washers, and wheel bolts. Tighten the wheel bolts to 190-217
N*m (140-160 Ibf ft) torque.
17. Remove the oil seal and outer bearing.
12. Apply a light coating of grease to the O-ring and install it on
Installation the idler gear shaft.
1. Before assembling the drive unit, wash and thoroughly
WARNING: Be careful when removing or
clean all parts in a suitable solvent and dry. Makecertain that all
installing snap rings. These snap rings can come
gasket material has been removed from the housings and
covers, and that all mating surfaces are smooth.
force to cause an injury. Always use the correct snap ring pliers
2. Check housings for cracks. Check housing bores for
installation.
damage, especially around snap ring grooves. Check all
threaded holes for damage. Check the drive unit breather.
13. Installthe bearing in the idler gear and retain the bearing by
installing the two snap rings in the gear.
3. Check all bearings for excessive wear or flat spots. Dip
clean bearings in new, clean gear oil and wrap in a clean, lint
14. Position the spacer and gear in the housing and install the
free cloth until ready for assembly.
shaft through the housing, gear and spacer. Tap the shaft into
position. Use a screwdriver to turn the shaft to align the holes in
4. Check all gears and shafts for excessive wear, damaged
the housing and shaft and install the two dowel pins to retainthe
teeth or keyways. Check keys for rounded edges or cracks.
shaft.
Check the keys for proper fit in the keyways of the shafts where
they belong. If the keys do not fit properly, replace the key
15. Install the upper housing. Refer to UPPER
and/or shaft.
HOUSING-INSTALLATION.
5. Replace all worn or damaged parts. When assembling the 16. Positionthe steering bearing, bearing spacers and bearing
drive unit use all new gaskets, O-rings and oil seals. Use the kit
shield on the drive unit housing.
which contains all the normally replaceable items.
17. Move the drive unit into position under the motorized hand
6. Install the outer bearing and new oil seal in the lower truck and install a sling. Attach the sling to an overhead hoist.
housing bore. Apply a light coat of gear oil to the I.D. of the oil Raise the drive unit into alignment with the motorized hand
seal. truck frame. Attach the bearing to the frame using the six
capscrews and nuts. Make certain that the socket head
capscrews are installed in the countersunk holes of the
motorized hand truck to provide steering clearance. Tighten all
the capscrews to 76 N«m (56 Ibf ft) torque.
18. Install the rear bearing clamp and retain using the two
installation.
capscrews and lockwashers. Tighten the capscrews to
149-163 N«m (110-120 Ibf ft) torque.
7. Installthe inner bearing with the shield toward the reservoir
side of the housing. Lock in place using a snap ring.
19. Install the drive motor. Section 3-Refer to DRIVE
MOTOR-INSTALLATION.
8. Insert the key in the drive gear, position the drive gear in the
housing and carefully insert the axle through the oil seal, outer
20. Assemble and adjust the brakes. Refer to Section
bearing, inner bearing and the 2nd reduction gear.
5-BRAKE ADJUSTMENT.
21 . Connect the motor wires and attach the harness clamps.

4-6
Yale
22. Installthe control handle. Refer to Section 6 of this manual 3. Check that the proper number and the correct thickness of
for the correct installation procedures. shims have been installed.
23. Install the drive unit compartment cover. Refer to Section 4. Lightly apply gear marking compound on both sides to
2-DRIVE UNIT COMPARTMENT-REMOVAL AND eight or nine of the bevel gear teeth.
INSTALLATION, .
5. Rotate the bevel gear shaft in both directions at least one
24. Connect the battery. Lower the truck to the floor. Test turn. This will squeeze the gear marking compound away from
operate the motorized hand truck before returning the truck to the areas of tooth contact. When making adjustments check
service. both sides of the gear and pinion teeth. Remove or add shims at
the motor and retainer as necessary to obtain the correct tooth
contact. The correct tooth contact will also provide a proper
BEVEL PINION AND GEAR ADJUSTMENT
backlash of 0.076-0.127 mm (0.003-0.005 in).
1. Recordthe dimension etched on the head of the old pinion.
This dimension represents the distance from the face of the 6. Note the tooth contact patterns shown in Figure 4-3. Make
pinion to the center of the bevel pinion shaft. the necessary adjustments to obtain the correct tooth contact
pattern as listed:
2. Compare the dimensions of the old and new pinions. Add
a. If the contact pattern indicates a high narrow contact
or subtract the dimensions on the old pinion from that of the new
pattern, add a shim at the motor and add one at the
pinion. Determine the thickness of shims that must be used.
retainer.
b. If the contact pattern indicates a low narrow contact
EXAMPLE NO. 1 pattern, remove a shim at the motor and remove one at the
Old Dimension 43. 129 mm (1.698 in) retainer.
c. If the contact pattern indicates a short heel contact
New Dimension 43.002 mm (1 .693 in)
pattern, add a shim at the motor and remove one at the
Difference 0.127 mm (0.005 in) retainer.
d. If the contact pattern indicates a short toe contact
NOTE: In this example the old shim pack plus an additional pattern, remove a shim at the motor and add a shim at the
0.005 in (0.127 mm) shim pack must be used. retainer.
EXAMPLE NO. 2 7. After the proper shims have been installed to obtain the
correct tooth contact pattern, tighten the locknut on the
Old Dimension 43.129 mm (1.698 in) armature shaft to 53 N«m (39 Ibf ft) torque. Install the drive
motor. Refer to Section 3-DRIVE MOTOR-INSTALLATION.
New Dimension 43.256 mm (1.703 in) Fill the drive unit with the recommended gear oil to the proper
Difference 0.127 mm (0.005 in) level. Refer to Section 2.
NOTE: In this example the old shim pack less a 0.127 mm

(0.005 in) shim must be used.
4-7
Yale
ADJUSTMENT OF CORRECT CONTACT PATTERN OF

GEAR TEETH
STEP 1. Apply gear marking compound to
approximately 8 or 9 of the teeth of the
bevel gear.
CORRECT CONTACT PATTERN
STEP 2. Apply a small amount of resistance to
the drive wheel and rotate the drive
wheel using a wrench. Rotate the
wheel so the pinion makes at least one
revolution.
STEP 3. Check the tooth contact pattern on

the bevel gear. Check the pattern on
the side of the tooth where the pinion
teeth apply the force.
WRONG CONTACT PATTERN

HIGH NARROW CONTACT
/&
If the pattern shows the bevel pinion is too far
from the center of the bevel gear, an adjustment
v\ in the direction of the arrows is necessary.

Adjust the thickness of the shim sets as
described in the assembly procedure.
LOW NARROW CONTACT

If the pattern shows the bevel pinion is too close
to the center of the bevel gear, an adjustment in
the direction of the arrows is necessary. Adjust
the thickness of the shim sets as described in
the assembly procedure.
SHORT HEEL CONTACT

If the pattern shows the bevel pinion is too close
T
P to the center of the bevel gear, an adjustment in
the direction of the arrows is necessary. Adjust
the shim sets at the spiral bevel gear as
described in the assembly procedure.
p
SHORT TOE CONTACT If the pattern shows the bevel pinion is too far
from the center of the bevel gear, an adjustment
in the direction of the arrows is necessary.
Adjust the shim sets at the spiral bevel gear as
t described in the assembly procedure.
Figure 4-3 - Tooth Contact Pattern
4-8
Yale
IndustrialTrucks
SECTION 5
BRAKE SYSTEM
V-
..
'' ni
7.
'
'
ÿ
'.i •
'
s:
Yale
Industrial Trucks
BRAKE SYSTEM
BRAKE SYSTEM-GENERAL 5-1

BRAKE SHOE AND LINING ASSEMBLY 5-1
REMOVAL-MPW, MLW AND MPE 5-1
INSTALLATION-MPW, MLW AND MPE 5-2
REMOVAL-MPC AND MTR 5-3
INSTALLATION-MPC AND MTR 5-3
BRAKE RELEASE ARM 5-4
REMOVAL-MPW, MLW AND MPE 5-4
INSTALLATION-MPW, MLW AND MPE 5-5
BRAKE LINKAGE 5-5
REMOVAL-MPE 5-5
INSTALLATION-MPE 5-5
ADJUSTMENTS 5-9
BRAKE ADJUSTMENT-MPW, MLW AND MPE 5-9
BRAKE ADJUSTMENT-MPC AND MTR 5-10
SERVICE AND PARKING BRAKE LINKAGE-MPC AND MTR 5-10
M [J: "
f
ÿ
•: 4
'••i§
mm. m
ÿÿ•r ÿ
' :
'IIS
ÿ
: ;.
- ÿ
MMl '•
"
.. .. •
.
|
mm
I
is
Yale
Industrial Trucks BRAKE SYSTEM
BRAKE SYSTEM-GENERAL 1. Raise the drive wheel off the floor. Block the lift truck. See
Section 1-HOW TO PUT A LIFT TRUCK ON BLOCKS.
The brake system used on the motorized hand lift trucks is a
mechanically operated shoe brake system. The brakes are
applied when the control handle is either in the full up or full
down position on MPW, MLW and MPE models. The control
handle operates a mechanical linkage which applies the brake
shoes if the control handle is in either of these positions.
The brake system used on both the MPC and MTR units is a
mechanically operated shoe brake system. The hand brake
levers operate a mechanical linkage which applies the brake
shoes when either lever has pressure applied. The MPC and
MTR units also are provided with a parking brake.
brakes. Refer to Section 2-DRIVE UNIT COMPARTMENT
On all models an electrical cut-out switch operated by the
COVER-REMOVAL AND INSTALLATION.
linkage interrupts the power to the drive motor when the brake
is applied. The brake and cut-out switch, if properly adjusted,
3. Remove the grease fittings from the brake shoe pivot pins.
operate simultaneously.
BRAKE SHOE AND LINING ASSEMBLY installing snap rings. These snap rings can come
Removal-MPW, MLW and MPE
/\ WARNING: Put blocks under each side of the and wear eye and face protection during removal and
11\ truck underthe drive unit frame. Position blocks on installation.
1. NUT
2. THREADED ROD
3.
4.
5.
SPRING SEAT
SPRING
BRAKE SHOE W/LINING
O 00 o
-
6. PIVOT PIN
7. LINK
8. RETAINING RING
9. LUBE FITTING
10. SETSCREWSEAT
11. SETSCREW
12. STUD
13. BRAKE CAM 19-
14. ROLLER W/BUSHING
15. NUT 18-
16. ADJUSTING SCREW
17. BRAKE RELEASE ARM
18. LUBE FITTING
19. NUT 0
20. SWITCH ACTUATOR
21. SWITCH
22. MOUNTING BRACKET
23. CAPSCREW
24. CAPSCREW 13
25. LOCKWASHER
26. SPACER
Figure 5-1 - Brake Shoe Assembly-MPW and MLW
5-1
Yale
7. If the brake shoe and lining assembly requires further

disassembly, remove the two nuts from the spring retainer bolt.
Disassemble the spring seats, spring and spring retainer bolt.
Note that the spring retainer bolt head has a slotted head to
keep the bolt from turning.
8. Loosen the setscrews and remove the adjusting screws

from the brake shoe and lining assembly. Disassemble the
setscrews from the brake shoes and remove the setscrew
seats.
Installation-MPW, MLW and MPE

1. Assemble the setscrew seat and setscrew in the brake
shoe and lining assembly. Do not tighten the setscrew
completely. Install the adjusting screws into the brake shoe.
Refer to BRAKE ADJUSTMENT before tightening the
setscrews.
2. Insert the spring retainer bolt through the brake shoes and
adjusting screws. Install the spring seats, spring and nuts on
O the retainer bolt.
3. Position the brake shoe and lining assemblies on the pivot

1. NUT pins and between the brake release arm.
2. SPRING SEAT
3. SPRING WARNING: Be careful when removing or
4. BRAKE SHOE W/LINING installing snap rings. These snap rings can come
5. PIVOT PIN loose during removal or installation with enough
6. LINK force to cause an injury. Always use the correct snap ring pliers
7. RETAINING RING and wear eye and face protection during removal and
8. LUBE FITTING installation.
9. SETSCREW
10. SETSCREW SEAT 4. Installthe pivot pin link on the pivot pins and installthe snap
11. ADJUSTING SCREW rings. Assemble the grease fittings into the pivot pins. Grease
12. BRAKE RELEASE ARM the pivot pins. Refer to Section 2 of this manual.
13. LUBE FITTING
14. THREADED ROD 5. Adjust the nuts on the spring retainer bolt until the spring is
compressed to 100 mm (3.94 in) for 6000 lb handtrucks and 97
Figure 5-2 - Brake Shoe Assembly-MPE mm (3.81 in) for 8000 lb hand trucks.
4. Disassemble the snap rings and pivot pin link from the 6. Adjust the brakes. Refer to BRAKE ADJUSTMENT.
brake pivot pins.
5. Loosen the nuts that apply tension to the spring to release 2-DRIVE UNIT COMPARTMENT COVER-REMOVAL AND
the brake shoes from the drum. INSTALLATION.
6. The brake shoe and lining assembly can now be removed 8. Lower the lift truck so the drive wheel is on the floor.
by sliding the assembly off of the brake drum and pivot pins and Connect the battery and test operate the lift truck prior to
out of the slot in the brake release arm. returning the lift truck to service.
5-2
Yale
IndustrialTrucks BRAKE SYSTEM
4. Disassemble the snap rings from the brake pivot pins.

Remove the cotter pin and washer retaining the arm cam
weldment to the support weldment. Remove the capscrew and
lockwasher supporting the centering shaft to the support
weldment. Remove the support weldment. Check the bushing
in the support weldment for elongation or damage. Removethe
bushing if necessary.
5. Remove the two jam nuts from the bottom of the brake
shaft. Loosenthe hex. nut on the top of the brake shaft. Loosen
the setscrews retaining the adjusting screws. Loosen the
adjusting screws. Remove the brake shaft out of the arm cam
weldment, brake shoes and centering shaft. Support the
springs when removing the brake shaft.
Installation-MPC and MTR

1. Assemble the setscrew seat and setscrew in the brake
shoe and lining assembly. Do not tighten the setscrew
completely. Install the adjusting screws into the brake shoe.
Refer to BRAKE ADJUSTMENT before tightening the
setscrews.
Figure 5-3 - Adjusting Brake Spring Tension
2. Install the centering shaft in the drive unit housing and
Removal-MPC and MTR install the nut to retain the shaft. Make certain that the hole in
the centering shaft is aligned with the brake shoes before
/\ WARNING: Put blocks under each side of the tightening the nut.
II\ truck under the drive unit frame. Position blocks on
both sides of the load wheels. The blocks must 3. Position the brake shoe and lining assemblies on the pivot
prevent the lift truck from falling and causing injury or damage. pins.
1. Raise the drive wheel off the floor. Block the lift truck. See 4. Position the springs in the brake shoes and centering
Section 1-HOW TO PUT A LIFT TRUCK ON BLOCKS. shaft. Install the brake shaft through the centering shaft, brake
Disconnect the battery. shoes and springs. Install the two jam nuts on the bottom of the
brake shaft. Snug the adjusting nut on the top of the brake shaft
2. Remove the drive unit compartment cover to access the to contact the slot in the arm cam weldment. Refer to BRAKE
brakes. Refer to Section 2-DRIVE UNIT COMPARTMENT ADJUSTMENT before tightening the adjusting nut and the
COVER-REMOVAL AND INSTALLATION. retaining nut and lockwasher.
/\ WARNING: The capacitor in the motor controller /\ WARNING: Be careful when removing or
11\ can hold an electrical charge after the battery is II\ installing snap rings. These snap rings can come
disconnected. To prevent electrical shock and loose during removal or installation with enough
injury, discharge the capacitor before inspecting or repairing force to cause an injury. Always use the correct snap ring pliers
any component in the drive unit compartment. Wear safety and wear eye and face protection during removal and
glasses. Make certain the battery has been disconnected. installation.
the B+ and B- terminals of the motor controller. 5. Install the bushing in the support weldment. Position the
support weldment on the pivot pins and arm cam weldment.
3. Remove the grease fittings from the brake shoe pivot pins. Install the snap rings on the pivot pins. Assemble the grease
fittings into the pivot pins. Grease the pivot pins. Refer to
/\ WARNING: Be careful when removing or Section 2.
/ 1\ installing snap rings. These snap rings can come
loose during removal or installation with enough 6. Install the capscrew and washer to retain the support
force to cause an injury. Always use the correct snap ring pliers weldment to the centering shaft. Install the washer and a new
and wear eye and face protection during removal and cotter pin to attach the arm cam weldment to the support
installation. bracket.
5-3
Yalo
1. ARM CAM WELDMENT

2. COTTER PIN
3. FLAT WASHER
4. NUT
5. LOCKWASHER
6. ADJUSTING NUT
7. LUBE FITTING
8. SNAP RING
9. CAPSCREW
10. LOCKWASHER
11. SUPPORT WELDMENT
12. BUSHING
13. CENTERING SHAFT
14. NUT
15. NUT
16. BRAKE SHAFT
17. ADJUSTING SCREW-UPPER
18. SPRING
19. ADJUSTING SCREW-LOWER
20. SETSCREWSEAT
21. SETSCREW
22. BRAKE SHOE W/LINING
Figure 5-4 - Bake Shoe smbly-MPC and MTR

7. Adjust the brakes. Refer to BRAKE ADJUSTMENT. 2. Remove the drive unit compartment cover for to access
the brakes. Refer to Section 2-DRIVE UNIT COMPARTMENT
8. Install the drive unit compartment cover. Refer to Section COVER-REMOVAL AND INSTALLATION.
INSTALLATION. 3. Remove the brake assembly. Refer to BRAKE SHOE AND
LINING ASSEMBLY-REMOVAL.
BRAKE RELEASE ARM
4. Disassemblethe grease fitting from the brake release arm.
Removal-MPW, MLW and MPE
5. On the MPE models, remove the cotter pin and clevis pin
attaching the brake linkage to the brake release arm.
installation
6. Remove the retaining ring from the brake release arm. If
necessary, use a drift to remove the arm from the drive unit
housing.
7. On the MPW, MLW and MPE models, remove the stud and
nut retaining the cam roller and remove the cam roller from the
brake release arm. Remove the switch actuator and nut.
5-4
Yale
8. Tag and disconnect the wires to the brake release switch. /\ WARNING: The capacitor in the motor controller
Remove the nut retaining the switch to the drive unit housing / I\ can hold an electrical charge after the battery is
and remove the switch. CbIhJ disconnected. To prevent electrical shock and
9. Remove the capscrews and locknuts, spacer (MPW and any component in the drive unit compartment. Wear safety
MLW models only), wire clamp and bracket from the drive unit glasses. Make certain the battery has been disconnected.
housing. Use a screwdriver or jumper wire to make a short-circuit across
Installation-MPW, MLW and MPE
2. Remove the drive unit compartment cover for to access
1. Install the brake switch bracket on the drive unit housing
using the capscrews, lockwashers, spacer (MPW and MLW
models only) and wire clamp. Refer to Figure 5-1.
3. Straighten and remove the cotter pins retaining both the
2. Install the brake switch on the bracket using the nuts to
upper and lower clevis pins. Remove the clevis pins from the
retain the switch.
yoke ends.
3. Installthe wires to the brake switch. Make certain the wires
4. Straighten and remove the cotter pin retaining the bell
are installed correctly.
crank to the control handle pivot. Removethe clevis pin andthe
bellcrank.
4. On the MPW and MLW models install the cam roller, stud,
and nut on the brake release arm. Install the switch actuator
5. Removethe yoke ends, jam nuts and switch actuator plate
and nut on the brake release arm.
from the connecting rod.
5. Install the brake release arm in the drive unit housing. See
Installation-MPE
Figures 5-1 and 5-2.
1. Install the bellcrank on the control handle pivot using the
/\ WARNING: Be careful when removing or clevis pin and a new cotter pin.
II\ installing snap rings. These snap rings can come
loose during removal or installation with enough 2. Assemble the switch actuator plate, jam nuts, and yoke
force to cause an injury. Always use the correct snap ring pliers ends to the connecting rod. The correct length of the rod
and wear eye and face protection during removal and assembly must bedetermined prior to connecting the rod to the
installation. upper bellcrank and the brake release cam. Make certain that
the cam follower is touching the cam on the control handle.
6. Assemble the snap ring in the groove of the brake release Place a 0.38-0.76 mm (0.015-0.030 in) shim betweenthe brake
arm. Installthe grease fitting. Lubricate the brake release arm, release cam and the upper adjusting nut. It may be necessary
refer to Section 2 this manual. to adjust the nut. Loosenthe setscrew to make any adjustment.
Keep the shim between the nut and brake release arm. Adjust
7. Install and adjust the brake assembly. Refer to BRAKE the brake connecting rod to the length required to enable the
SHOE AND LINING ASSEMBLY-INSTALLATION AND upper and lower clevis pins to be installed in the brake release
BRAKE ADJUSTMENT. cam and the upper bellcrank. Install the clevis pins and new
cotter pins. Tighten the setscrew and remove the shim.
8. Install the drive unit compartment cover.
3. Installthe same shim on the lower side of the brake release
9. Lower the lift truck so the drive wheel is on the floor. cam. Loosenthe setscrew and adjust the lower adjusting nut to
Connect the battery and test operate the lift truck prior to obtain the same clearance. Tighten the setscrew when a
returning the lift truck to service. clearance of 0.38-0.76 mm (0.015-0.030 in) is obtained.
4. Adjust the brakes. Refer to BRAKE ADJUSTMENT.

BRAKE LINKAGE
Removal-MPE 5. Install the drive unit compartment cover. Refer to Section
/\ WARNING: Put blocks under each side of the
INSTALLATION.
If \ truck under the drive unit frame. Position blocks on
6. Lower the lift truck so the drive wheel is on the floor.
Connect the battery and test operate the lift truck prior to
returning the lift truck to service.
5-5
1'a/o

1
28 glasses. Make certain the battery has been disconnected.

24" COVER-REMOVAL AND INSTALLATION.
3. Remove the two capscrews and lockwashers retaining the

22
front cover and the two capscrews retaining the cover plate.
Remove the front cover and the cover plate.
26 NOTE: Before disassembling any of the brake linkage, mark

the yokes, brake rods and nuts so that the length of the linkage
is not changed. If components on the threaded rods are being
removed measure the rods and record their dimensions for the
proper alignment at assembly.
4. Remove the cotter pin retaining the clevis pin to the arm
cam weldment (53). Remove the clevis pin. Remove the cotter
pin (48) retaining the lower brake rod (47) to the bellcrank (46).
Removethe washers (49) and the lower brake rod (47) from the
bellcrank (46).
5. Remove the cotter pin retaining the clevis pin to the upper
threaded brake rod (34) and the bellcrank (46). Remove the
1. COTTER PIN 15. BRACKET
clevis pin.
2. YOKE PIN 16. WIRE HARNESS
3. BELLCRANK 17. SWITCH
4. CAM FOLLOWER 18. CAPSCREW installing snap rings. These snap rings_ can come
5. NUT 19. LOCKWASHER loose during removal or installation with enough
6. PIN 20. WASHER
7. YOKE-L.H. THREAD 21. CLAMP
8. JAM NUT 22. CLAMP
installation.
9. THREADED ROD 23. WASHER
10. SWITCH PLATE 24. LOCKWASHER
6. Remove the snap rings (45) retaining the bellcrank (46) to
11. YOKE-R.H. THREAD 25. CAPSCREW
the disc. Remove the pin (44) and bellcrank from the disc (50).
12. CAPSCREW 26. SUPPORT
13. LOCKWASHER 27. LOCKWASHER 7. Remove the cotter pins retaining the clevis pins to the arm
14. NUT 28. CAPSCREW and cam (36) and the cam (22). Remove the clevis pins and the
upper threaded brake rod (34).
Figure 5-5 - Brake Linkage-MPE
Removal-MPC and MTR
WARNING: Put blocks under each side of the loose during removal or installation with enough
truck under the drive unit frame. Position blocks on force to cause an injury. Always use the correct snap ring pliers
both sides of the load wheels. The blocks must and wear eye and face protection during removal and
prevent the lift truck from falling and causing injury or damage. installation.
1. Raise the drive wheel off the floor. Block the lift truck. See 8. Remove the snap rings (24) retaining the pivot pin (23) and
Section 1-HOW TO PUT A LIFT TRUCK ON BLOCKS. bellcrank (22) to the steer handle (25). Remove the pivot pin
Disconnect the battery. and the cam.
5-6
Yale
9. Remove the roll pins (13) retaining the plate weldments 5. Installthe pivot pin (23) for the bellcrank (22) in one side of
(12) to the handles (15 and 16). Remove the handles and the tower. Position the bellcrank on the pivot pin. Install the
bushings (14). snap rings (24) to retain the bellcrank. Complete installing the
pivot pin in the tower and install the outer snap rings to retain the
10. Remove the springs (11) from the rod weldments (10) and pivot pin.
the mounting brackets in the steer handle (25). Remove the
E-rings (9) retaining the rod weldments (10) to the plate 6. Align rod weldments ( 10) with the bellcrank (22) and install
weldments (12) and the pin (17) to the bellcrank (22). Remove pin (17). Install the E-rings (9) to retain the pin. Installthe return
the plate weldments, bellcrank, pin and the rodweldments from springs (11) between the plate weldments (10) and the
the steer handle. mounting brackets located in the steer handle (25).
11. Remove the snap rings (38) from the parking brake pivot 7. Align the upper threaded brake rod (34) with the bellcrank
pin (37). Remove the pivot pin and parking brake arm and cam (22) and installthe clevis pin and a new cotter pin (28). Align the
(36). Remove the cotter pin retaining the eye bolt (35), nut (30) parking brake arm and cam (36) with the upper brake rod and
and yoke (29) from the arm and cam. installthe clevis pin and a new cotter pin (28). Make certain that
the switch plate (32) contacts the switch (33).
12. Identify the wires to the brake switch (33). Remove the
brake switch wires. Remove the upper nut and remove the 8. Align the bellcrank (46) with the mounting brackets on the
switch from the tower. steering disc (50) and install the pivot pin (44). Install the snap
rings (45) on the pivot pin. Align the upper brake rod (34) with
Installation-MPC and MTR the bellcrank (46) and installthe clevis pin and a new cotter pin
(28).
1. Install the brake switch (33) in the tower (40) and installthe
upper nut to retain the switch to the housing. Installthe wires to
9. Align the lower brake rod (47) with the yoke (29) and nut
the switch.
(30) installed with the arm cam weldment (53) and install the
clevis and a new cotter pin (28). Install the lower brake rod in the
bellcrank and install the two washers (49) and new cotter pins
(48)
10. Adjust the brakes. Refer to BRAKE ADJUSTMENT-MPC
and MTR.
installation.
11. Install the cover plate and front cover. Install the drive unit
2. Assemble the eye bolt (35), nut (30) and yoke (29) to the
compartment cover.
parking brake and cam (36). Install the clevis pin (28) and a new
cotter pin. Align the pivot pin (37) and the arm and cam in the
12. Remove the blocks from under the lift truck. Install the
tower. Install the snap rings (38) to retain the pivot pin.
battery connector. Test operate the lift truck before returning the
truck to service.
3. Assemble the rod weldments (10) to the plate weldments
(12) using the E-rings (9).
4. Install the bushings (14) in the steer handle (25). Install the
handles (15 and 16) into the bushings. Align the holes in the
handles and plate weldments (12) and install the roll pins (13).
5-7
Yale
Industrial Trucks brake system
1. CONTROL HEAD
2. COVER PLATE
3. BACK COVER
4. CAPSCREW
5. LOCKWASHER
6. NUT ARM AND CAM
7. FRONT COVER PIN
8. KNOB SNAP RING
9. E-RING WIRE HARNESS
10. RODWELDMENT TOWER
11. SPRING NUT
12. PLATE WELDMENT, LOCKWASHER
13. ROLL PIN CAPSCREW
14. BUSHING PIN
15. HANDLE SNAP RING
16. HANDLE
17. PIN
18. CAPSCREW
19. PIVOT
20. LOCKWASHER
21. LOCKNUT
22. BELLCRANK
23. PIN
24. SNAP RING
35. STEER HANDLE

36. KNOB
37. NUT
38. CLEVIS PIN W/COTTER PIN BELLCRANK
39. YOKE BRAKE ROD
40. NUT COTTER PIN
41. JAM NUT FLAT WASHER
42. SWITCH PLATE DISC
43. SWITCH CAPSCREW
44. BRAKE ROD LOCKWASHER
45. EYE BOLT ARM CAM WELDMENT
Figure 5-6 - Brake Linkage-MPC and MTR
5-8
Yale
ADJUSTMENTS the actuator plate up or down as necessary to obtain the proper

adjustment. Tighten the nut retaining the actuator plate. On all
Brake Adjustment-MPW, MLW and MPE
models the actuator is properly adjusted when the brake switch
NOTE: The brake shoes are fully engaged when the control just opens as the brake is starting to apply.
handle is either in the vertical position or parallel to the floor.
The brakes may only be adjusted to obtain clearance between
the drum and the brake lining. BRAKE ON
MPW SHOWN
WARNING: Put blocks under each side of the MLW & MPE SIMILAR
BRAKE OFF
WARNING: The capacitor in the motor controller BRAKE ON

Use a screwdriver or jumper wire to make a short-circuit across Figure 5-7 - Brake Application-MPW, MLW and MPE
2. Remove the drive unit compartment cover for to access 2-DRIVE UNIT COMPARTMENT-REMOVAL AND INSTAL¬
the brakes. Refer to Section 2-DRIVE UNIT COMPARTMENT LATION.
3. Adjust the brakeshoe adjusting nutsto obtain a gap of 0.38 Connect the battery and test operate the lift truck prior to
-0.79 mm (0.015-0.031 in) between the adjusting nuts and the returning the lift truck to service. The brakes should be capable
brake release cam. of holding on a10% slope with a maximum rated load. The truck
should also be able to operate without any drag when the
a. Loosen the set screw retaining the upper adjusting handle is in the operating position.
nut, loosen the adjusting nut and install a feeler gauge
between the adjusting nut and the cam.
b. Leave the feeler gauge in place and tighten the
adjusting nut.
c. Lock the adjusting nut by tightening the set screw.
Remove the feeler gauge.
d. Repeat the operation to adjust the lower adjusting nut.
4. Lower the control handle to the operating position. (Brakes

are off.) Install a 0.127 mm (0.005 in) feeler gauge between the
upper brake shoe lining and brake drum at the point of least
clearance. The feeler gauge should slide freely. If an
adjustment is necessary, loosen the setscrew and turn the
adjusting screw. Turn the screw into the shoe to decrease the
clearance. Turn the screw out of the brake shoe to increase the
clearance between the brake shoe and drum. After the correct
adjustment is obtained, tighten the setscrew. Adjust the lower
brake shoe assembly in the same manner. Note that
compressing the brake spring too tight will increase the
effort to move the steer handle to the operating position. ©
5. To adjust the brake switch on MPW, MLW and MPE
models, loosen the nut retaining the switch actuator and adjust Figure 5-8 - Measuring Brake Clearance
5-9
Yale
Brake Adjustment-MPC and MTR Connect the battery and test operate the lift truck prior to
returning the lift truck to service. The brakes should be capable
NOTE: The brake shoes are fully engaged when hand
of holding on a10% slope with a maximum ratedload. The truck
pressure is applied to either one or both of the handles. The
should also be able to operate without any drag when the
brakes may only be adjusted to obtain clearance between the
handle is in the operating position.
drum and the brake lining.
Service and Parking Brake Linkage-MPC and MTR
truck underthe drive unit frame. Position blocks on NOTE: Adjust the brake shoes before attempting to adjust
both sides of the load wheels. The blocks must the service and parking brake linkage.
1. Adjust the yokes on the upper brake rod until the distance
1. Raise the drive wheel off the floor. Block the lift truck. See between centers is 360.7 mm (14.2 in).
a. The brake rod must extend into both yokes a minimum
of 12.7 mm (0.50 in).
WARNING: The capacitor in the motor controller b. Do not tighten the nuts on the brake rod until Step 3
can hold an electrical charge after the battery is has been completed.
injury, discharge the capacitor before inspecting or repairing 2. Use a Number 79 drill bit, or a rod with a diameter of 9.1
any component in the drive unit compartment. Wear safety mm (0.36 in) and a length of 19.05 mm (0.75 in) to temporarily
glasses. Make certain the battery has been disconnected. connect the lower yoke of the upper brake rod to the short arm
Use a screwdriver or jumper wire to make a short-circuit across on the bellcrank. Rotate the bellcrank until the drill bit bottoms
the B+ and B- terminals of the motor controller. out on the under side of the steer tower plate. Retain the
bellcrank in this position during Steps 3, 4 and 5.
the brakes. Refer to Section 2-DRIVE UNIT COMPARTMENT 3. Press down on the forward arm on the brake cam lever
COVER-REMOVAL AND INSTALLATION. until the pin bottoms in the slots in both brake rod weldments.
Adjust the upper yoke on the upper rod to align with the hole in
3. Makecertain the brakes are released. Releasethe parking the forward arm. Install the yoke pin and cotter pin. Center the
brake. Install a 0.127 mm (0.005 in) feeler gauge between the brake switch activator plate over the switch plunger. Tighten
lower brake shoe lining and brake drum at the point of least both the upper and lower lock nuts.
clearance. The feeler gauge should slide freely. If an
adjustment is necessary, loosen the setscrew and turn the 4. Adjust the lower brake rod to a length of 228.6 mm (9.0 in ),
adjusting nut. Turn the nut into the shoe to decrease the measuring from the center of the short leg to the center of the
clearance. Turn the nut out of the brake shoe to increase the yoke pin hole. Apply a light film of grease to the inside diameter
clearance between the brake shoe and drum. After the correct of the lower bellcrank bushing. Installthe short leg of the lower
adjustment is obtained, tighten the setscrew. Adjust the upper brake rodinto the long arm of the lower bellcrank, along with the
brake shoe assembly in the same manner. Note that spacer, washers and cotter pins.
compressing the brake spring too tight will increase the
effort to apply the parking brake. 5. Lift the brake actuating lever so the fork is resting flat
against the upper brake shoe adjusting screw. Adjust the yoke
4. Have an assistant operate the brake handles and check to on the lower brake rod so the holes in the lower brake rod and
see that the brakes are engaged when hand pressure is applied the actuating lever are aligned. Install the yoke pin and cotter
to the handles. pin. Tighten the yoke lock nut.
5. To adjust the brake switch on MPC and MTR models, 6. Remove the drill bit or rod installed in Step 2.
loosen the nut retaining the switch plate and adjust the plate up
or down as necessary to obtain the proper adjustment. Tighten 7. Squeeze and release the hand brake levers several times
the nut retaining the plate. On all models the plate is properly to allow the brake linkage to find it's normally off position.
adjusted when the brake switch just opens as the brake is
starting to apply. 8. Adjust the traction motor cut off switch with the brake
linkage in the BRAKE OFF position. Adjust by turning the nuts
6. Install the drive unit compartment cover. Refer to Section on the switch to raise or lower the switch on the mounting
2-DRIVE UNIT COMPARTMENT-REMOVAL AND bracket. The switch should be positioned so the activator plate
INSTALLATION. is depressing the brake switch plunger 3.05 mm (0.12 in).
Check the switch adjustment by applying the pressure to the
7. Lower the lift truck so the drive wheel is on the floor. hand brake levers. The switch should cut the power to the
Remove the blocks from in front and back of the load wheels. traction motor within a movement of 127 mm (0.50 in) of the
5-10
Yale
brake levers. At the same time the brake linings should just 12. Check the brake switch adjustment.
begin to lightly drag on the brake drum.
a. The traction motor must cut off within 12.7 mm (0.50
in) travel of the hand brake levers.
9. Adjust the parking brake with the linkage in the OFF
position and the brake levers released. Adjust the yoke on the b. The traction motor must operate when the hand brake
parking brake rod assembly so the pin in the yoke just contacts levers are released and the parking brake is released.
the upper end of the slot in the plate, which is part of the upper
c. The traction motor must cut-off when the parking
rod weldment. Install the cotter pin. Tighten the yoke locking
brake is applied.
nut.
10. Check the service brake adjustment with the parking brake
Connect the battery and test operate the lift truck prior to
OFF.
returning the lift truck to service. The truck should operate
a. The brake lining must not drag on the brake drum without any brake drag when the hand brake levers are
when the hand brake levers are released. released and the parking brake is off.
b. The brakes must meet the applicable stopping
distance and/or draw bar drag requirements without the
hand brake levers bottoming out on the direction/speed
control grips.
11. Check the parking brake adjustment. When the parking

brake is applied it must meet the applicable "HOLD ON
GRADE" or draw bar requirements. The brakes for the MPC
should be capable of holding on a 10% slope with a maximum
rated load. The brakes on the MTR units should be capable of
meeting the draw bar requirements of 700 lbs.
1. HAND BRAKE LEVER

2. PARKING BRAKE
3. UPPER BRAKE ROD
4. LOWER BRAKE ROD
Figure 5-9 - Brake Installation-MPC and MTR
5-11
YaleIndustrial Trucks
NOTES
5-12
Yale
IndustrialTrucks
SECTION 6
CONTROL HANDLE
'
; •
~
Yale
Industrial Trucks
CONTROL HANDLE
CONTROL HANDLE-GENERAL 6-1

REMOVAL-MPW AND MLW 6-1
INSTALLATION-MPW AND MLW 6-1
REMOVAL-MPE 6-2
INSTALLATION-MPE 6-3
CONTROL HANDLEHEAD 6-4
REMOVAL 6-4
INSTALLATION 6-4
CONTROL HANDLEAND TOWER 6-4
ÿM
a
.
ÿ
;v—
mi &
-
'
;
'
' ÿ;
ÿ "
V
Yale
IndustrialTrucks CONTROL HANDLE
CONTROL HANDLE-GENERAL WARNING: The capacitor in the motor controller

The control handle is designed to perform several functions.
The handle is used to steer the truck on the MPW, MLW, MPE,
MPC and MTR models and to apply the brakes on the MPW,
MLW and MPE models. The handle also contains the direction
controls, the lift controls and the brake on the MPC and MTR
models. The drive unit assembly isturned as the control handle
is pushed to the right or left to negotiate a turn. The drive unit is
supported by a bearing that is mounted to the frame. This
2. Disconnect the battery. Disconnect the wiring .harness
allows the lift truck to be maneuvered easily in any direction.
plug located in the area of the drive motor. Tag and disconnect
The brakes are operated by linkage connected directly to the
the wires to the brake switch.
handle. The brakes are applied when the handle is in the full up
or down position. The truck controls mounted in the handle are
3. Remove the lower cover weldment after removing the two
linked to the drive unit and hydraulic pump with a wiring harness
acorn nuts, and lockwashers located on the ends of the pivot
that passes through the center of the handle. Presently there
shaft, and the capscrew and lockwasher located behind the
are three different types of handles being used on the
drive motor. Install a regular 1/2"-20 hex. nut on each end of the
motorized lift trucks.
pivot shaft to retain the pivot shaft supports.
The bottom mounted control handle assembly is used on the
4. Remove the capscrews and flat washers retaining the left
current MPW and MLW series of motorized lift trucks. The
and right pivot shaft supports and control handle to the drive
handle is designed to be usedwhile the operator is walking with
unit housing. The complete handle assembly can be removed
the lift truck. The speed /direction control, as well as the buttons
from the lift truck.
for the horn, lift and lower operations are also found on the
control handle. The control handle moves to the left or right to
5. Unscrew the rubber bushing and washers. Remove the
steer the lift truck.
mounting block by removing the capscrew and flat washer
retaining the block to the drive unit housing.
The top mounted control handle assembly is used on the
walk/ride lift trucks such as the MPE series of motorized lift
WARNING: The return springs used on the
trucks. This model is designed to be used while the operator is
control handle has tension and can release with
either walking with the truck or riding on a small platform to the
enough force to cause injury.
left or right side of the control handle. The speed/direction
control, as well as the buttons for the horn, lift and lower
6. Carefully remove the pivot shaft supports, springs, pivot
operations are also found on the control handle. The control
shaft and brake cam.
handle moves to the left or right to steer the lift truck.
7. Drive the pivot shaft bushings from the control handle.
The third control handle assembly is used on the MPC and
MTR models. The control handle on these models does not
Installation-MPW and MLW
pivot and is positioned toward the riding platform where the
operator stands. The control handle moves to the left or right to 1. Install the bushings in the control handle. Align the brake
steer the lift truck. Brake levers are located on the control cam and the control handle and install the pivot shaft. Position
handle and are applied by hand pressure. The levers can be the springs on the shaft.
operated with either hand. The control handle has a three
position tilt control to adjust the height of the handle. A parking NOTE: The smaller of the two springs must be installed on
brake lever is mounted at the base of the control handle the right side when facing the drive unit.
column. The speed /direction control, as well as the buttons for
the horn, lift and lower operations are also found on the control 2. Align the pivot shaft supports and springs and position the
handle. supports on the shaft. Temporarily install two 1/2"-20 hex. nuts
on the shaft to retain the supports.
NOTE: The MPC and MTR models do not have an auto
reverse feature. 3. Install the mounting block on the drive unit housing using
the capscrew and flat washer. Install the washers and rubber
Removal-MPW and MLW bumper on the mounting block.
4. Align the pivot shaft supports with the drive unit housing
Section 2-DRIVE UNIT COMPARTMENT-REMOVAL AND
and install the two capscrews and flat washers. Tighten the
INSTALLATION.
capscrews to 49 N«m (36 Ibf ft) torque.
6-1
Industrial Trucks control handle
3
1. CAP NUT
2. LOCKWASHER 9. HARDENED WASHER 16. WIRE HARNESS
3. LOWER COVER WELDMENT 10. PIVOT SHAFT 17. BRAKE CAM
4. CAPSCREW 11. TORSION SPRING 18. RUBBER BUMPER
5. LOCKWASHER 12. TORSION SPRING 19. FLAT WASHERS
6. PIVOT SHAFT SUPPORT 13. STEER HANDLE WELDMENT 20. MOUNTING BLOCK
7. PIVOT SHAFT SUPPORT 14. BUSHINGS 21. CAPSCREW
8. CAPSCREW 15. LUBE FITTING 22. FLAT WASHER
Figure 6-1 - Control Ha Mounting-MPW and MLW

5. Remove the two nuts that were temporarily installed on the Removal-MPE
pivot shaft. Align and install the lower cover weldment and
1. Disconnect the battery. Remove the drive unit compart¬
installthe two acorn nuts and lockwashers. Installthe capscrew
ment cover to access the wiring and control handle mounting.
and lockwasher to retain the cover to the rear of the drive
Referto Section 2-DRIVE UNIT COMPARTMENT-REMOVAL
housing.
AND INSTALLATION.
6. Install the wires to the brake switch. Connect the wiring
2. Disconnect the wiring harness plug located under the
harness plug.
control handle steer disc (pivot). Tag and disconnect the wires
to the brake switch. Remove the clamps retaining the control
handle harness to the motor and control handle bracket. Be
certain to note the routing of the wiring before disconnecting
LATION.
any wiring. The wiring must be routed properly at assembly to
prevent steering problems and prevent chafing of the harness.
8. Connect the battery and test operate the truck prior to
6-2
Yale
3. Remove the two setscrews retaining the handle to the level, lock the jam nuts. The maximum handle pull down effort is
pivot pin. Note that the setscrews are positioned one behindthe 5.4 kg (12 lbs).
other in the same hole. Remove the pivot pin from the control
handle pivot. Remove the control handle assembly from the
control handle pivot. Remove the cam, spacers and the spring
from the control handle assembly.
4. Remove the cotter pin and clevis pin retaining the brake
linkage to the bellcrank. Remove the three capscrews and
lockwashers retaining the control handle pivot to the support
weldment. Remove the control handle pivot.
5. Disassemble the nut, lockwasher and screw retaining the

27, 28
bumper to the control handle pivot. Remove the bushings from
the control handle pivot. Remove the two jam nuts, capscrew
and adjusting bracket.
6. Disassemble the four capscrews and lockwashers

retaining the support weldment to the drive motor. Remove the
two capscrews and lockwashers retaining the bracket to the
drive unit housing and remove the support weldment.
Installation-MPE
1. Align the support weldment with the tapped holes in the
drive unit housing and install the capscrews and lockwashers.
Tighten the capscrews to 149-163 N«m (110-120 Ibf ft) torque.
2. Install the capscrews and lockwashers to retain the

support weldment to the drive motor. Tighten the capscrews to
49 N*m (36 Ibf ft) torque.
3. Install the bushings in the control handle pivot. Install the

bumper on the control handle pivot with the capscrew,
lockwasher and nut. Align the control handle pivot on the
support weldment and install the capscrews and lockwashers.
Tighten the capscrews to 49 N«m (36 Ibf ft) torque. 1. STEER HANDLE WELD. 15. ADJUSTER
2. BRAKE CAM 16. CAPSCREW
4. Align the control handle assembly, spacers, spring, cam 3. SETSCREW 17. LOCKNUT
and the control handle pivot and install the pivot pin. Install the 4. SPACER 18. CAPSCREW
setscrews, one behind the other to retain the pivot pin. 5. TORSION SPRING 19. COTTER PIN
6. CLAMP 20. SCREW, BUTTON HD.
5. Align the brake linkage to the bellcrank and install the 7. FLAT WASHER 21. RUBBER BUMPER
clevis pin. Install new cotter pin in the clevis pin. 8. LOCKWASHER 22. JAM NUT
9. SCREW, PAN HD. 23. PIVOT SHAFT
6. Installthe clamps to retain the wiring harness. Connect the 10. PIN 24. BUSHING
wires to the brake switch and connect the wiring harness plug. 11. BELLCRANK 25. STEER DISC
Make certain that the wiring is properly routed to prevent 12. SUPPORT WELDMENT 26. NUT
steering problems and chafing of the harness. 13. SCREW, BUTTON HD. 27. LOCKWASHER
14. LOCKWASHER 28. LUBE FITTING
7. Install the adjusting bracket on the control handle pivot.
Check thebrake spring adjustment before adjusting the tension
Figure 6-2 - Control Handle Mounting-MPE
of the control handle spring. Refer to Section 5-BRAKE
ADJUSTMENT. To adjust the tension of the control handle
spring by loosen the jam nuts and turn the capscrew. Turning
capscrew in will apply more tension to the spring, causing the
LATION.
control handle to return to the upright position with more force.
Loosening the capscrew will lessen the tension on the spring.
9. Connect the battery and test operate the truck prior to
After the spring tension has been adjusted to an acceptable
6-3
Yale
CONTROL HANDLE HEAD 1. Align the bottom holes in both arms with the holes in the
control handle and install the lower capscrew, flat washer,
Removal
lockwasher and nut. Align the two eyebolts with the slots in the
The control handle head mechanical components can be control handle and the two upper holes in the arms and install
removed and replaced when necessary. There are minor the capscrews, flat washers, lockwashers and capscrew.
differences between models. Make certain to follow the Tighten the capscrews to 31 N»m (20 Ibf ft) torque.
instructions for the model of lift truck being worked on. See
Figure 6-3, Figure 6-4, Figure 6-5, Figure 6-6 or Figure 6-7. 2. Install the plate, flat washers and nuts on the eyebolts.
Tighten the nuts to 16 N«m (12 Ibf ft) torque.
wiring harness. Refer to Section 2-DRIVE UNIT COMPART¬ 3. Install the handle grips and align the shaft and grips with
MENT-REMOVAL AND INSTALLATION. the holes in the arms and installthe button head capscrews, flat
washers and lockwashers. Tighten the button head capscrews
WARNING: The capacitor in the motor controller to 31 N*m (23 Ibf ft) torque.
disconnected. To prevent electrical shock and 4. Align the top and bottom covers and position the plunger,
injury, discharge the capacitor before inspecting or repairing spring, and traction reversing actuator between the covers.
any component in the drive unit compartment. Wear safety Install the four screws and washers.
Use a screwdriver or jumper wire to make a short-circuit across 5. Connect the wiring harness plug.
2. Disconnect the wiring harness plug located in the area of 2-DRIVE UNIT COMPARTMENT-REMOVAL AND INSTAL¬
the drive motor. LATION.
3. Remove the four screws and washers retaining the top 7. Connect the battery and test operate the truck prior to
cover to the base. returning the lift truck to service.
NOTE: The two center screws retain the travel switches to 8. Install the bushings in the control handle pivot. Install the
the base. Remove the top cover assembly andthe auto reverse adjusting bracket, capscrew and jam nuts on the bottom of the
actuator, springs, and plunger. pivot and assemble the bumper to the pivot using the screw,
lockwasher and nut. Attach the pivot to the control handle
4. Remove the button head capscrews, washers and bracket using the three capscrews and lockwashers. Tighten
lockwashers from both ends of the handle. Remove the handle the capscrews to 49 N«m (36 Ibf ft) torque.
grips and the shaft.
CONTROL HANDLE AND TOWER
5. Remove the nuts and lockwashers retaining the plate on
the eyebolts. Remove the plate. Removal-MPC and MTR
NOTE: To disassemble the control handle tower refer to
6. Disassemble the capscrews, flat washers, lockwashers
Section 5-BRAKE LINKAGE-DISASSEMBLY.
and nuts that retain the two arms to the control handle.
Remember to retain the eyebolts when removing the
1. Disconnect the battery. Remove the drive unit compart¬
capscrews so that they do not fall into the handle.
ment cover to access the wiring harness. Refer to Section
NOTE: To further disassemble the control handle refer to
LATION.
Section 3-STEERING HANDLE SWITCHES-REMOVAL.
Installation
NOTE: Make certain that the steering handle switches have disconnected. To prevent electrical shock and
been installed before installing the control handle head. Refer injury, discharge the capacitor before inspecting or repairing
to Section 3-STEERING HANDLE SWITCHES-INSTALLA¬ any component in the drive unit compartment. Wear safety
TION. Make certain to follow the instructions for the model of glasses. Make certain the battery has been disconnected.
lift truck being worked on. See Figure 6-3, Figure 6-4, Use a screwdriver or jumper wire to make a short-circuit across
Figure 6-5, Figure 6-6 or Figure 6-7. the B+ and B- terminals of the motor controller.
6-4
Yale
Industrial Trucks CONTROL HANDLE
2. Disconnect the wiring harness plug located in the area of 2. Align the upper brake rodandthe bellcrank attached to the
the drive motor. steer disc and install the pin. Install a new cotter pin.
3. Removethe two capscrews retaining the front cover to the 3. Align the front cover on the tower and install the two
tower and remove the cover. capscrews to retain the cover.
4. Remove the cotter pin and pin retaining the upper brake 4. Connect the wiring harness plug.
linkage to the bellcrank. The bellcrank is attached to the disc.
5. Remove the four capscrews, lockwashers and nuts
retaining the tower to the disc. The control head and the tower 6. Connect the battery.
can be removed from the lift truck as a complete unit.
Installation-MPC and MTR

1. Align the tower and control head to the holes located in the
steer disc. Install the four capscrews, lockwashers and nuts.
6-5
Yalo
Industrial Trucks CONTROL HANDLE
17. CAPSCREW
18. FLAT WASHER
19. LOCKWASHER
20. NUT
21. BUTTON HD. SCREW
22. LOCKWASHER
23. FLAT WASHER
24. ARM
25. PLATE
26. EYE BOLT
27. HANDLE GRIP
28. SHAFT
29. SWITCH ASSEMBLY
30. POTENTIOMETER
31. STANDOFF
32. INSULATOR
33. SWITCH
34. PLATE, SPACER
35. NUT PLATE
36. CAPSCREW
38. SETSCREW
39. SPUR GEAR
40. CAPSCREW
41. CONTROL LEVER
42. SETSCREW
43. ROLL PIN
44. SPUR GEAR
45. SHAFT
46. BUSHING
47. TORSION SPRING
48. CAM
49. ROLL PIN
50. CAPSCREW
51. LOCKWASHER
52. CAPSCREW
53. CAPSCREW
54. LOCKWASHER
55. BASE
1. ACTUATOR 9. SWITCH RETAINER 56. STEER HANDLE WELDMENT
2. SPRING 10. SWITCH 57. LOCKNUT
3. RUBBER STOPPER 11. SWITCH SUPPORT 58. FLAT WASHER
4. TOP COVER ASSEMBLY 12. CAPSCREW 59. HEATER BRACKET (OPT.)
5. ACTUATOR 13. LOCKWASHER 60. RESISTOR ASSY (OPT.)
6. ACTUATOR 14. CAPSCREW 61. CAPSCREW (OPT.)
7. ACTUATOR 15. TOP COVER 62. LOCKWASHER (OPT.)
8. SPRING 16. CAPSCREW 63. NUT (OPT.)
Figure 6-3 - Control Handle Head-MPW and MLW
6-6
Yale
IndustrialTrucks control handle
1. ACTUATOR
2. SPRING
3. RUBBER STOPPER
4. TOP COVER ASSEMBLY
5. ACTUATOR
6. ACTUATOR
7. ACTUATOR
8. SPRING
9. SWITCH RETAINER
10. SWITCH
11. SWITCH SUPPORT
12. CAPSCREW
13. LOCKWASHER
14. CAPSCREW
15. TOP COVER
16. CAPSCREW
17.
18.
CAPSCREW
FLAT WASHER ÿ ft
19. LOCKWASHER
20. NUT
21. CAPSCREW
22. LOCKWASHER
23. FLAT WASHER
24. ARM
25. PLATE
26. EYE BOLT
27. HANDLE GRIP
28. FLANGED BUSHING
29. SLEEVE WELDMENT
30. SHAFT
31. COTTER PIN
32. LINK ROD
33. SWITCH ASSEMBLY
34. POTENTIOMETER
35. STANDOFF
36. NUT PLATE
37. INSULATOR
38. SWITCH
39. PLATE, SPACER
40. SETSCREW
41. SPUR GEAR
42. CAPSCREW
44. CAPSCREW
45. CONTROL LEVER
46. SETSCREW
47. ROLL PIN
48. SPUR GEAR
49. SHAFT 56. LOCKWASHER
50. BUSHING 57. CAPSCREW
51. TORSION SPRING 58. LOCKWASHER 63. HEAT SHIELD (OPT.)
52. CAM 59. CAPSCREW 64. CAPSCREW (OPT.)
53. ROLL PIN 60. STEER HANDLE WELDMENT 65. RESISTOR ASSY (OPT.)
54. BASE 61. LOCKNUT 66. LOCKWASHER (OPT.)
55. CAPSCREW 62. FLAT WASHER 67. NUT (OPT.)
Figure 6-4 - Control Handle Head-MPE
6-7
Yale
COVER-BLANK
1.
FILLER
2.
3.
TOP COVER ASSEMBLY
4.
LABEL
ACTUATOR
5.
6. ACTUATOR
7. ACTUATOR
8. SPRING
9. SWITCH RETAINER
10. SWITCH
11. SWITCH SUPPORT
12. CAPSCREW
13. LOCKWASHER
14. CAPSCREW
15. TOP COVER
16. CAPSCREW
17. CAPSCREW
18. FLAT WASHER
19. LOCKWASHER
20. NUT
21. CAPSCREW
22. LOCKWASHER
23. FLAT WASHER
24. ARM
25. PLATE
26. EYE BOLT
27. HANDLE GRIP
28. FLANGED BUSHING
29. SLEEVE WELDMENT
30. SHAFT
31. COTTER PIN
32. LINK ROD
33. SWITCH ASSEMBLY
34. POTENTIOMETER
35. STANDOFF
36. NUT PLATE
37. INSULATOR
38. SWITCH
39. PLATE, SPACER
40. SETSCREW
41. SPUR GEAR
42. CAPSCREW
44. CAPSCREW
45. CONTROL LEVER
46. SETSCREW
47. ROLL PIN
48. SPUR GEAR
49. SHAFT
50. BUSHING 56. LOCKWASHER 62. FLAT WASHER
51. TORSION SPRING 57. CAPSCREW 63. HEAT SHIELD (OPT.)
52. CAM 58. LOCKWASHER 64. RESISTOR ASSY (OPT.)
53. ROLL PIN 59. CAPSCREW 65. CAPSCREW (1/2" LG.) (OPT.)
54. BASE 60. STEER HANDLE WELDMENT 66. LOCKWASHER (OPT.)
55. CAPSCREW 61. LOCKNUT 67. NUT (OPT.)
-
Figure 6-5 Control Handle Head-MPC
6-8
Yale
Industrial Trucks control handle
1. COVER
2. FILLER
3. TOP COVER ASSEMBLY
4. LABEL
5. ACTUATOR-BLANK
6. ACTUATOR-HORN
7. ACTUATOR-BLANK
8. SPRING
9. SWITCH RETAINER
10. SWITCH
11. SWITCH SUPPORT
12. CAPSCREW
13. LOCKWASHER
14. CAPSCREW 28
15. TOP COVER /
16. CAPSCREW :?J /
17. CAPSCREW
18. FLAT WASHER V
19. LOCKWASHER \
20. NUT
21. CAPSCREW
22. LOCKWASHER
23. FLAT WASHER
24. ARM f
25.
26.
PLATE
EYE BOLT
/
V
27. HANDLE GRIP

28. FLANGED BUSHING
29. SLEEVE WELDMENT
30. SHAFT
31. SWITCH ASSEMBLY INSULATOR
32. COTTER PIN 51. SWITCH
33. LINK ROD 52. MOUNTING BRACKET
34. BUSHING 53. CAPSCREW
35. SHAFT 54. LOCKWASHER
36. CAM 43. SPUR GEAR 55. CAPSCREW
37. ROLL PIN 44. CAPSCREW 56. LOCKWASHER
38. CONTROL LEVER 45. MOUNTING BRACKET 57. CAPSCREW
39. ROLL PIN 46. CAPSCREW 58. BASE
40. SPUR GEAR 47. POTENTIOMETER 59. STEER HANDLE WELDMENT
41. SHAFT 48. STANDOFF 60. FLAT WASHER
42. SET SCREW 49. NUT PLATE 61. LOCKNUT
Figure 6-6 - Control Handle Head-MTR
6-9
Yale
1. ACTUATOR 55. LOCKWASHER

2. SPRING 56. NUT
3. RUBBER STOPPER 57. STEER HANDLE WELDMENT
4. TOP COVER ASSEMBLY 58. HEAT SHIELD (OPT.)
5. COVER 59. RESISTOR (OPT.)
6. ACTUATOR 60. CAPSCREW (OPT.)
7. COVER 61. LOCKWASHER (OPT.)
8. SPRING 62. NUT (OPT.)
9. SWITCH RETAINER
10. SWITCH
11. SWITCH SUPPORT
12. CAPSCREW
13. LOCKWASHER
14. CAPSCREW
15. TOP COVER
16. CAPSCREW
17. CAPSCREW
18. WASHER
19. LOCKWASHER
20. NUT
21. CAPSCREW
22. LOCKWASHER
23. WASHER
24. ARM
25. PLATE
26. EYE BOLT
27. HANDLE GRIP
28. SHAFT
29. SWITCH ASSEMBLY
30. TORSION SPRING v
31. ROLL PIN
32. SPUR GEAR
\1
33. ROLL PIN
34. SHAFT
35. CONTROL LEVER 35
36. BUSHING . J
37. CAM j
38. STANDOFF j-sfe
)' |
39. SPUR GEAR
40. SET SCREW
42. SET SCREW
\\ :
43. CAPSCREW \
44. NUT PLATE
45. INSULATOR
3 \
46. SWITCH
47. POTENTIOMETER
48. NUT PLATE
49. BASE
50. CAPSCREW
51. LOCKWASHER
52. CAPSCREW
53. LOCKWASHER
54. CAPSCREW
Figure 6-7 - Control Handle Head-MLW
6-10
Yale
IndustrialTrucks
SECTION 7
LIFT LINKAGE AND LOAD WHEEL

1
Yale
IndustrialTrucks
LOAD LINKAGE AND LOAD WHEEL
LIFT LINKAGE AND LOAD WHEELS-GENERAL 7-1

LOAD WHEELS-MPW, MPEAND MPC 7-1
REMOVAL 7-1
INSTALLATION 7-1
LIFT LINKAGE AND LOAD WHEEL ASSEMBLY-MPW, MPEAND MPC ...7-1
REMOVAL 7-1
INSTALLATION 7-4
PULL ROD—MPW, MPE AND MPC 7-4
REMOVAL 7-4
INSTALLATION 7-6
ROCKER ARM-MPW, MPEAND MPC 7-6
REMOVAL 7-6
INSTALLATION 7-7
UPPER LINK-MPW, MPEAND MPC 7-7
REMOVAL 7-7
INSTALLATION 7-7
ADJUSTMENTS -MPW, MPE AND MPC 7-8
FORK HEIGHT 7-8
CASTER WHEELS-MPE AND MPC 7-10
REMOVAL 7-10
REPLACEMENT 7-10
DISASSEMBLY 7-10
ASSEMBLY 7-10
LOAD WHEELS-MTR AND MLW 7-11
REMOVAL 7-11
INSTALLATION 7-12
LOAD WHEEL AXLE-MTR AND MLW 7-12
REMOVAL 7-12
INSTALLATION 7-12
LOAD PLATFORM LINKAGE-MLW 7-12
REMOVAL 7-12
INSTALLATION 7-12
gg|
•**
:
•
: ÿ
V .i
;V'- ÿ
m<. « -
\
ÿ
m
,
/
*
; '* 4-4>f
Yale
Industrial Trucks LIFT LINKAGE AND LOAD WHEEL
LIFT LINKAGE AND LOAD WHEELS - GENERAL the axle shaft using a large screwdriver until tight and then back
off on the shaft until the roll pin hole in the load wheel support
The lifting mechanism is operated by the hydraulic system.
aligns with the nearest slot in the axle shaft. The load wheel end
With the exception of the MTR tractor and the MLW platform
play should be between 0.13-0.25 mm (0.005-0.010 in).
trucks, when the lift button on the control handle is pressed,
hydraulic oil is sent to the lift cylinder. When the lift cylinder
3. Installthe roll pin in the load wheel support and through the
extends, the fork weldment rises causing the upper links and
axle shaft.
the rocker arms to rotate upward. As the rocker arms rotate up,
the pull rods are pulled toward the drive unit. This movement
4. Use the lift button to raise the lift cylinder. Lubricate the
causes the loadwheel support assemblies to pivot down as the
load wheel. See Section 2 this manual.
fork weldment rises. Proper adjustment is required to raise and
lower the pallet forks evenly.
5. Remove the blocks from under the forks and from each
side of the drive tire. Lower the lift truck.
On the MLW platform lift truck, when the lift button on the control
handle is pressed, hydraulic oil is sent to the lift cylinder. As the
6. Test operate the truck before returning it to service.
cylinder extends, the load wheels are forced downward. The
downward motion of the load wheel pushes the link assemblies
outward. This causes the platform to rise. At full cylinder 7
extension, the height of the platform above the ground is 6 to 9
inches depending upon the link and the cylinder assembly
mounted on the truck. The battery platform of this truck does
not raise and lower with the platform.
LOAD WHEELS - MPW, MPE and MPC

Removal
1. Use the lift button to raise the lift truck to its maximum
height.
WARNING: Put blocks securely under the drive

unit frame and fork weldment to prevent them from
lowering. Place blocks on both sides of the drive
1
tire. The blocks must prevent the lift truck from falling and
1. SPACER
causing injury or damage. See Section 1 - HOW TO PUT A
2. OIL SEAL
LIFT TRUCK ON BLOCKS.
3. BEARING
4. LOAD WHEEL
2. Drive out the roll pin retaining the axle shaft to the load
5. LOAD WHEEL SUPPORT
wheel support assembly.
6. BUSHING
7. LUBE FITTING (CORROSION ONLY)
3. Check to ensure the truck is securely blocked in the raised
8. AXLE SHAFT
position. Lower the lift cylinder using the lower button in order to
9. ROLL PIN
raise the load wheels off the floor.
Figure 7-1 - Load Wheel Assembly - MPW, MPE and
4. Use a large screwdriver to remove the axle shaft. Remove
MPC
the spacers, oil seals, bearings and load wheel from the load
wheel support. It may be necessary to use a brass or hardwood
drift to drive the bearing races out of the wheel. Drive the LIFT LINKAGE AND LOAD WHEEL ASSEMBLY -
bearing races out from the opposite sides. MPW, MPE and MPC
Removal
5. Remove all old lubricant. Clean and inspect all parts.
Replace all defective parts. 1. Use the lift button to raise the lift truck to its maximum
height.
Installation
WARNING: Put blocks securely under the drive
1. Lubricate the bearings with the recommended grease.
unit frame and fork weldment to prevent them from
See Section 2. Install the bearings in the load wheel.
2. Align the load wheel and bearings, oil seals, and spacers
inside the load wheel support and insert the axle shaft. Tighten
7-1
Yale
IndustrialTrucks LIFT LINKAGE AND LOAD WHEEL
1. DRIVE UNIT FRAME

47
2. FORKWELDMENT
3. LIFT CYLINDER
4. ANCHOR PIN
5. SPIRAL ROLL PIN 45
6. SNAP RING
7. ANCHOR PIN
8. BUSHING
44
42
39
36
24
34
33
32
40
28
27
24
20
23
9. LUBE FITTING 22. BUSHING 35. PIVOT PIN
10. BUSHING 23. LOCKWASHER 36. LOAD WHEEL ASSEMBLY
11. PIVOT PIN 24. CAPSCREW 37. CAPSCREW
12. SPIRAL ROLL PIN 25. PIVOT PIN 38. PIVOT PIN
13. PIVOT PIN 26. PIVOT PIN 39. NUT
14. UPPER LINK 27. LOCKWASHER 40. SETSCREW
15. LUBE FITTING 28. CAPSCREW 41. SPACER
16. LUBE FITTING 29. BUSHING 42. PALLET GUIDE ROLLER
17. ROCKER ARM 30. PULL ROD 43. CAPSCREW
18. BUSHING 31. JAM NUTS 44. WEAR STRIP
19. CAPSCREW 32. PULL ROD YOKE 45. NUT
20. PIVOT PIN 33. BUSHING 46. ACCESS PLATE
21. NUT 34. LUBE FITTING 47. CAPSCREW
Figure 7-2 - Lift Linkage - MPW, MPE and MPC - Early Production Models
7-2
Yale
1. SPIRAL ROLL PIN

2. BUSHING
3. SNAP RING
4. LIFT CYLINDER
5. ANCHOR PIN
6. ANCHOR PIN
7. SPIRAL ROLL PIN
8. PIVOT PIN
9. PIVOT PIN
10. UPPER LINK
11. BUSHING
12. LUBE FITTING
13. ROCKER ARM
14. BUSHING
15. BUSHING
16. PIVOT PIN
17. SPRING PIN
18. LOCKWASHER
19. PIVOT PIN
20. CAPSCREW
21. LOCKWASHER
22. PIVOT PIN
23. PULL ROD
24. BUSHING
25. JAM NUTS
26. PULL ROD YOKE
27. BUSHING
28. LUBE FITTING
29. PIVOT PIN
30. SPIRAL PIN
31. KEEPER PLATE
32. LUBE FITTING
33. PIVOT PIN
34. CAPSCREW
35. SETSCREW
36. SPACER
37. PALLET GUIDE ROLLER
38. LOAD WHEEL ASSEMBLY
39. SUPPORT
40. BUSHING
41. SCREW
42. NUT
43. WEAR STRIP
44. CAPSCREW
45. LOCKNUT
Figure 7-3 - Lift Linkage - MPW, MPE and MPC - Late Production Models
7-3
Yale
2. Check to ensure the truck is securely blocked in the raised models) or the capscrew and nut (early production models) to
position. Lower the lift cylinder using the lower button in order to retain the pivot pin.
4. Align and installthe pallet guide roller, spacer and pivot pin
3. Removethe screws retaining the access coverto the top of to attach the pull rod yoke to the load wheel support. Installthe
the fork on early production models (late production models do capscrew and lockwasher on the single loadwheel assembly or
not have an access cover) and remove the access cover. the setscrew in the tandem load wheel assembly to retain the
pivot pin.
4. Remove the capscrew and lockwasher on the single load
wheel assembly or the setscrew on the tandem load wheel 5. Install the access cover on the fork on early production
retaining the pivot pin that fastens the pull rod yoke to the load models (late production models do not have an access cover)
wheel support. Remove the pivot pin and the pallet guide roller using the four screws to retain the cover to the fork. Tighten the
and spacer. screws to 19 N*m (14 Ibf ft) torque.
5. Remove the spiral roll pin (late production models) or the 6. Use the lift button to raise the lift cylinder. Lubricate the
capscrew and nut (early production models) retaining the pivot load wheel. See Section 2 this manual.
pin that fastens the load wheel assembly to the fork weldment.
Remove the pivot pin and the load wheel assembly. 7. Remove the blocks from under the forks and from each
side of the drive tire. Lower the lift truck.
6. Disassemble the load wheel. See LOAD WHEEL -
REMOVAL. 8. Test operate the truck before returning it to service.
7. Remove the bushings.

PULL ROD - MPW, MPE and MPC
8. Remove all old lubricant. Clean and inspect all parts for Removal
damage. Replace all defective parts.
height.
Installation
NOTE: Bushings for late production assemblies have a /\ WARNING: Put blocks securely under the drive
groove on the outside diameter. Early production bushings do
not. Specify the correct parts when replacing bushings. Refer
/ I\ unit frame and fork weldment to prevent them from
LbJ lowering. Place blocks on both sides of the drive
to Figure 7-4. tire. The blocks must prevent the lift truck from falling and
'////////////A V7777>r777777\
W/////////// ///////7////A
EARLY LATE /\ WARNING: Batteries are heavy and can cause
PRODUCTION PRODUCTION / 1\ an injury. Use care to avoid injury. Do NOT put
hands, arms, feet and or legs between the battery
Figure 7-4 - Bushings and a solid object. Make sure the capacity of the lifting device
and spreader bar is greater than the weight of the battery. The
1. For late production assemblies, refer to Figure 7-5 to weight of the battery is normally shown on the battery case. The
properly align the bushings. Press new bushings into the load maximum battery weight is shown on the lift truck nameplate.
wheel support. For early production assemblies, after the The spreader bar must NOT be made of metal or it must have
bushings are installed, line drill a 3.05 mm (0.12 in) diameter insulated straps.
hole through each bushing, using the grease fitting hole as a
guide. Installthe grease fitting. Late production bushings do not 3. Move the key to the OFF position. Disconnect the battery.
need to be drilled. Remove the battery. See Section 2 - BATTERY - REMOVAL
AND INSTALLATION.
2. Assemble the load wheel. Refer to LOAD WHEEL -
INSTALLATION. 4. Remove the capscrew and lockwasher on the single load
wheel assembly or the setscrew on the tandem load wheel
3. Align the load wheel assembly into the fork weldment and retaining the pivot pin that fastens the pull rod yoke to the load
install the pivot pin. Install the spiral roll pin (late production wheel support. Remove the pivot pin and the pallet guide roller
and spacer.
7-4
Yale
UPPER
LINK
ROCKER
ARM
PULL ROD YOKE
WHEEL
SUPPORT
Figure 7-5 - Bushing Alignment - Late Production Models

7-5
Yale
5. Remove the capscrew and lockwasher retaining the pivot ROCKER ARM - MPW, MPE and MPC
pin that fastens the pull rod to the rocker arm. Use a drift to drive
Removal
the pivot pin out of the pull rod and rocker arm.
6. Remove the nuts retaining the pull rods to the pull rod height.
yokes. Early production models have two nuts on each side of
the yoke. Late production models have one nut on each side of WARNING: Put blocks securely under the drive
the yoke and a keeper plate to retain the nuts. Remove the unit frame and fork weldment to prevent them from
keeper plate, as required. lowering. Place blocks on both sides of the drive
7. Remove the bushings from the yoke assembly and pull causing injury or damage. See Section 1 - HOW TO PUT A
rod. LIFT TRUCK ON BLOCKS.
8. Remove all old lubricant. Clean and inspect all parts. 2. Check to ensure the truck is securely blocked in the raised
Replace all defective parts. position. Lower the lift cylinder using the lower button in order to
Installation
WARNING: Batteries are heavy and can cause
1. For late production assemblies, refer to Figure 7-5 to
an injury. Use care to avoid injury. Do NOT put
properly align the bushings. Press new bushings into the pull
rod yoke and the pull rod. For early production assemblies,
and a solid object. Make sure the capacity of the lifting device
after the bushings are installed, line drill a 3.05 mm (0.12 in)
and spreader bar is greater than the weight of the battery. The
diameter hole through each bushing, using the grease fitting
weight of the battery is normally shown on the battery case. The
hole as a guide. Install the grease fitting. Late production
maximum battery weight is shown on the lift truck nameplate.
bushings do not need to be drilled.
The spreader bar must NOT be made of metal or it must have
insulated straps.
2. Assemble the pull rods to the pull rod yokes. Refer to
Figure 7-2 and Figure 7-3 to determine the arrangement of the
nuts and keeper plate, as required. Do not tighten the nuts until
Remove the battery. See Section 2 - BATTERY - REMOVAL
the fork height adjustment has been made. The fork height
AND INSTALLATION.
adjustment is made after the linkage has been completely
assembled. 4. Remove the capscrew and lockwasher retaining the pivot
pin that fastens the pull rod to the rocker arm. Use a drift to drive
3. Position the pull rod and yoke assembly between the the pivot pin out of the pull rod and rocker arm.
rocker arm and the load wheel support assembly. Install the
pivot pins in the rocker arms. Align the recess in the pivot pins 5. Remove the capscrews and locknuts (early production) or
with the hole in the rocker arms and install the capscrew and the roll pin (late production) retaining the pivot pins that fasten
lockwasher to retain the pivot pins. the rocker arms to the drive unit frame. Use a drift to drive the
pivot pin out of the rocker arm and the drive unit frame.
4. Lubricate the grease fittings. See Section 2.
6. Remove the capscrew and lockwasher retaining the
5. Installthe battery in the battery compartment. See Section rocker arm pivot pin to the fork weldment. Remove the pivot pin
2 -BATTERY - REMOVAL AND INSTALLATION. Connect the from the fork weldment and the rocker arm.
battery.
7. Remove the bushings from the rocker arm.
6. Use the lift button to raise the lift cylinder. Remove the
blocks from under the forks and from each side of the drive tire. 8. Remove all old lubricant. Clean and inspect all parts.
Lower the lift truck. Replace all defective parts.
7. Adjust the fork height so the lift truck lifts and lowers evenly.
Refer to FORK HEIGHT ADJUSTMENT.
7-6
Yale
Installation WARNING: The capacitor in the transistor

controller can hold an electrical charge after the
NOTE: Bushings for late production assemblies have a
battery is disconnected. To prevent electrical
groove on the outside diameter. Early production bushings do
shock and injury, discharge the capacitor before inspecting or
repairing any component in the drive unit compartment. Wear
to Figure 7-4.
safety glasses. Make certain the battery has been
disconnected. Use a screwdriver or jumper wire to make a
1. For late production assemblies, refer to Figure 7-5 to
short-circuit across the B + and B - terminals of the transistor
properly align the bushings. Install new bushings into the rocker
controller.
arm. For early production assemblies, after the bushings are
installed, line drill a 3.05 mm (0.12 in) diameter hole through
3. Remove the drive unit compartment cover to access one
each bushing, using the grease fitting hole as a guide, install
end of the upper link.
the grease fitting. Late production bushings do not need to be
drilled.
4. Use a drift pin to remove the roll pin retaining the pivot pin
to the drive unit frame. Drive the pivot pin out of the frame and
2. Align the rocker arm with the fork weldment and install the
upper link.
pivot pin. Installthe capscrew and lockwasher to retainthe pivot
pin.
5. Use a drift pin to remove the roll pin retaining the pivot pin
to the fork frame (at the rear of the battery box). Drive the pivot
3. Align the rocker arm with the drive unit frame and install the
pin out of the fork frame and upper link.
pivot pin. Install the capscrew and nut (early production) or
spiral roll pin (late production) to retain the pivot pin.
6. Remove the bushings from the upper link.
4. Align the pull rod and the rocker arm and install the pivot
Installation
pin. Installthe capscrew and lockwasher to retain the pivot pin.
NOTE: Bushings for late production assemblies have a
5. Lubricate the grease fittings. See Section 2, this manual. groove on the outside diameter. Early production bushings do
6. Installthe battery in the battery compartment. See Section to Figure 7-4.
2 - BATTERY - REMOVAL AND INSTALLATION. Connect the
battery. 1. For late production assemblies, refer to Figure 7-5 to
properly align the bushings. Install new bushings into the upper
7. Use the lift button to raise the lift cylinder. Remove the link. For early production assemblies, after the bushings are
blocks from under the forks and from each side of the drive tire. installed, line drill a 3.05 mm (0.12 in) diameter hole through
Lower the lift truck. each bushing, using the grease fitting hole as a guide. Install
the grease fitting. Late production bushings do not need to be
8. Adjust the fork height so the lift truck lifts and lowers evenly. drilled.
Refer to FORK HEIGHT ADJUSTMENT.
2. Align the pivot pin with the fork frame and upper link and
9. Test operate the truck before returning it to service. install the pivot pin. Install a roll pin to retain the pivot pin.
3. Align the pivot pin with the drive unit frame and the upper
UPPER LINK - MPW, MPE and MPC
link and install the pivot pin. Install a roll pin to retain the pivot
Removal pin.
/\ WARNING: Put blocks securely under the drive
II\ unit frame and fork weldment to prevent them from
5. Remove the blocks from under the forks and from each
side of the drive tire. Connect the battery.
2. Disconnect the battery.
7-7
Yale
ADJUSTMENTS - MPW, MPE and MPC

CHECK HERE
Fork Height
The fork height must be adjusted so that the machined surface
on the top of the load wheel support is flush to the underside of
the fork weldment when the lift truck is in the lowered position. If
the load wheel support machined surface is not flush to the fork
weldment or if the loadwheels are not carrying the load equally, o
an adjustment must be made. Make certain to check both forks
and both load wheels.
CAUTION: Improper adjustment of the fork height

can cause excessive wear to one of the load
wheels and poor pallet entry and exit. When
making any adjustments be certain that the measurements are FL1256
the same on both forks. If an equal measurement cannot be Figure 7-6 - Check for Load Wheel Support Completely
obtained, the problem may be a twisted frame. A twisted frame Lowered
must be replaced.
5. On early production models with double pallet length forks
1. Lower the forks completely (the cylinder should be and all late production models, adjust the rear fork height
bottomed out). adjustment screws on each side, with the battery in place, to
obtain a fork height of 85.9 to 88.9 mm (3.38 to 3.5 in) at the rear
2. On early production models, remove the four capscrews of the forks. Refer to Figure 7-7.
retaining the access covers on each fork. Late production
models do not have an access cover. 6. Early production models have two nuts on each side of the
pull rod yoke. Late production models have one nut on each
3. Loosen the nuts on the pull rod on each side of the pull rod side of the pull rod yoke and a keeper plate to retain the nuts.
yoke. Early production models have two nuts on each side. On For early production models, adjust both outer jam nuts and
late production models, bend the keeper plate up to give adjust the inner jam nuts to obtain a fork height (measured at
access to the one nut on each side of the pull rod yoke. Refer to the front of the forks) of 82.5 to 84.1 (3.25 to 3.31 in). On late
Figure 7-8. production models, bend the keeper plate away from the inner
and outer nuts, then adjust the nuts to obtain a fork height
4. Ensure that load wheel supports are completely lowered. (measured at the front of the forks) of 82.5 to 84.1 (3.25 to 3.31
Check that the top of the load wheel support is flush with the in). To lowerthe load wheels, turn the inner nut(s) clockwise. To
underside of the fork weldment. Refer to Figure 7-6. raise the load wheels, turn the inner nut(s) counterclockwise.
Ensure that the measurements are the same on eadh side and
that the forks lift at the same time.
JAM NUT
ADJUSTMENT
SCREW
Figure 7-7 - Rear Fork Height Adjustment
7-8
Yale
Industrial Trucks lift linkage and load wheel
BEND LEGS OF KEEPER PLATE

OVER AGAINST FLATS ON NUTS
- ..... TZZZZZZZZZÿ
TIGHTEN BOTH NUTS AND POSITION

FLATS SO THEY FACE UP AS SHOWN
SECTION "A-A'
Figure 7-8 - Keeper Plate

7. After the adjustments have been made, tighten the jam g Hold each screw in the correct position with a wrench
nut(s) to 176 N«m (130 Ibf ft) torque. On late production models, and tighten the jam nut securely against the support block.
bend the keeper plate to retain the nuts. Refer to Figure 7-8. Maintainthe 1.6 mm (1/16 in) clearance between the head
of the screw and the yoke.
8. Adjust the yoke stops, if equipped, as follows:
d Raise the forks to the full lift height. 9. On early production models, install the access covers and
secure them using the four access cover capscrews. Tighten
e Loosen the jam nuts on the yoke stop adjustment
the capscrews to 19 N»m (7 Ibf ft) torque.
screws. Refer to Figure 7-9.
f Turn the adjustment screws out from the threaded 10. Operate the lift truck to check for correct operation. Seethe
support blocks until the heads of the screws have 1.6 mm OPERATING MANUAL.
(1/16 in) clearance between the heads of the screws and
the pull rod yokes.
ADJUSTMENT
SCREW
JAM NUT
SUPPORT
BLOCK
ADJUST SCREW
FOR 1.6 MM (1/16 IN)
CLEARANCE
Figure 7-9 - Yoke Stop Adjustment
7-9
Yale
CASTER WHEELS - MPE and MPC 2. Remove the locknut retaining the wheel on the wheel axle.
Drive the wheel axle out of the arms and remove the wheel.
Removal
A
WARNING: Put blocks under both forks and on 3. Remove the locknut retaining the spacer between the
both sides of the drive tire. The blocks must arms. Remove the capscrew, washers and spacer.
prevent the lift truck from falling and causing injury
or damage. 4. Remove the locknuts retaining the spacers and springs.
Remove the spacers, springs and capscrews.
Section 1 - HOW TO PUT A LIFT TRUCK ON BLOCKS.
2. Remove the four countersunk screws and nuts retaining

the caster and spacer to the frame. Remove the caster wheel.
3. Repeat the same procedure for the other caster, if

necessary.
Installation
1. Align the caster and spacer with the holes in the frame and
install the four countersunk screws and nuts. Tighten the nutsto
115 N»m (85 Ibf ft) torque.
2. Repeat Step 1 to install the other caster, if necessary.
3. Remove the blocks from under the lift truck and lower the
truck to the floor. Test operate the truck prior to returning the
truck to service.
Replacement
NOTE: The caster wheel does not have to be removed from
the lift truck frame to replace the wheel or the wheel axle. To
replace the wheel or wheel axle follow the steps outlined. \
A
WARNING: Put blocks under both forks and on 1. YOKE ASSEMBLY 10. SPACER
both sides of the drive tire. The blocks must 2. BUSHING 11. SPRING
prevent the lift truck from falling and causing injury 3. PIN 12. CAPSCREW W/NUT
or damage. 4. PIN 13. BUSHING
5. CAPSCREW W/NUT 14. WASHER
1. Raise the drive wheel off the floor. Block the lift truck. See 6. RETAINING RING 15. SPACER
Section 1 - HOW TO PUT A LIFT TRUCK ON BLOCKS. 7. ARM 16. CAPSCREW
Disconnect the battery. 8. WHEEL AXLE W/NUT 17. SPACER
9. WHEEL 18. NUT
2. Remove the locknut retaining the wheel on the wheel axle.
Drive the wheel axle out of the arms and remove the wheel.
Figure 7-10 - Caster Wheels
3. Align the wheel between both arms and install the wheel
5. Remove one of the E-rings retaining the pin and bushings
axle. Install the nut on the wheel axle. Tighten the nuts to 34-47
between the arms. Disassemble the pin, bushings and arms.
N«m (25-35 Ibf ft) torque.
6. Remove one of the E-rings retaining the pin and bushings
4. Remove the blocks from under the lift truck and lower the
to the yoke. Disassemble the pin and bushings from the yoke.
truck to service.
Assembly
Disassembly 1. Align the bushings in the yoke and install the pin. Installthe
E-rings on the pin to retain the pin and bushings to the yoke.
1. Remove the caster wheel from the frame. Refer to
CASTER WHEELS - REMOVAL.
7-10
Yale
2 . Align the arms, spacer and washers in the yoke and install
MODEL SIZE TIRE
the capscrew and locknut. Tighten the locknut to 0-4 N«m (0-3
Ibf ft) torque. MTR 5x5.5 RUBBER
3. Align the spacer between the arms and install the E-rings MLW (6 INCH LIFT) 5.5x4.5 STEEL
on the pin to retain the bushings and pin to the arms.
MLW (6 INCH LIFT) 5.5 x 5.5 RUBBER
4. Align the holes in the pins and install the capscrews, MLW (6 INCH LIFT) 5.5x5.5 POLY
springs, spacers and locknuts. The springs should be
preloaded to 1.75 MPa (250 lbs). Install Caster Spring MLW (9 INCH LIFT) 8x4.5 STEEL
Adjustment Tool 5180968-99 over the caster spring. Tighten
the nuts until the edge of the spring is even with the edge of the MLW (9 INCH LIFT) 8x5.5 RUBBER
adjustment tool. The final spring length should range between MLW (9 INCH LIFT) 8x5.5 POLY
48.00 and 48.51 mm (1.890 and 1.910 in).
Table 7-1 - Tire Size and Composition
5. Align the wheel between the arms and install the wheel
axle. Tighten the nuts to 34-47 N*m (25-35 Ibf ft) torque. 1. Put blocks under both sides of the frame near the load
wheels. Place blocks on both sides of the drive tire. See Section
6. Remove the blocks from under the lift truck and lower the 1 - HOW TO PUT A LIFT TRUCK ON BLOCKS.
truck to service. 2. Remove the three capscrews retaining the hub cap.
Remove the hub cap.
LOAD WHEELS - MTR and MLW
3. Straighten and remove the cotter pin retaining the castle
The load wheels used on these models are as listed in nut on the axle. Remove the castle nut.
Table 7-1. The removal and installation for the different load
wheels will be the same for all of these models. 4. Remove the load wheel, flat washers, dust collar, felt
washer, bevel washer and bearings from the axle.
Removal
5. Clean and inspect all parts. Remove all old lubricant. If the
/\ WARNING: Put blocks under both sides of the
bearings are worn or damaged, remove the bearings from the
If\ truck frame by the load wheels. Place blocks on
wheel.
both sides of the drive tire. The blocks must
1. CAPSCREW
2. HUB CAP FELT WASHER
3. CASTLE NUT BEVELED WASHER
4. FLAT WASHER NUT
5. ROLLER BEARING, OUTER LOCKWASHER
6. LOAD WHEEL FLAT WASHER
7. ROLLER BEARING, INNER CAPSCREW
8. WASHER LOAD AXLE
9. DUST COLLAR COTTER PIN
Figure 7-11 - Load Wheel and Axle - MTR and MLW
7-11
Yale
Installation LOAD PLATFORM LINKAGE - MLW

1. Pack the bearings and load wheel cavity with grease. See Removal
Section 2 for the recommended grease. Install the bearings in
WARNING: Put blocks under both sides of the
the load wheel.
truck frame by the load wheels. Place blocks on
both sides of the drive tire. The blocks must
2. Install the beveled washer on the axle shaft. The beveled
edge of the washer must face the axle shoulder. Install the dust
collar and flat washer.
1. Put blocks under both sides of the frame near the load
3. Carefully install the load wheel on the axle shaft. Install the
1 - HOW TO PUT A LIFT TRUCK ON BLOCKS.
flat washer and castle nut. Tighten the castle nut while turning
the load wheel by hand. The load wheel should turn freely. The
2. Disconnect the battery. Use a suitable lifting device to
wheel bearing end play should be 0. 13-0.25 mm (0.005-0.010
remove the battery from the lift truck.
in). If necessary, back off on the castle nut to align the castle nut
with the hole in the axle shaft. Install a new cotter pin.
3. Remove the breather from the hydraulic unit and the
breather from the drive unit. Install pipe plugs in the hydraulic
4. Align the hub cap on the load wheel and install the
unit and the drive unit. Use a suitable lifting device to raise the
capscrews to retain the hub cap.
lift truck and lay the lift truck on its side. Support the lift truck
while it is positioned on its side to keep the lift truck from falling.
5. Remove the blocks from under the lift tractor and lower the
tractor to the floor. Test operate the truck before returning the
4. Measure and record the distance that the thread of the
tractor to service.
spring protrudes beyond the nut.
LOAD WHEEL AXLE - MTR and MLW 5. Remove the nut. Unhook the spring from the frame of the
lift truck.
Removal
WARNING: Put blocks under both sides of the 6. Remove the cotter pins retaining the pivot rod to the link
truck frame by the load wheels. Place blocks on assembly. Remove the setscrew retaining the pivot rod.
both sides of the drive tire. The blocks must Remove the roll pin retaining the shaft to the link assembly. Use
prevent the lift truck from falling and causing injury or damage. a drift pin to drive the shaft and pivot rod out of the link
assembly. Remove the link assembly and flat washers between
1. Put blocks under both sides of the frame near the load the frame and the link assembly.
1 - HOW TO PUT A LIFT TRUCK ON BLOCKS. 7. Repeat the procedure to remove the other link assembly.
Remove the lift platform.
2. Remove the load wheels. See LOAD WHEEL -
REMOVAL. 8. Inspect the shafts, pivot rods, link assemblies and spring
for damage. Replace any part found to be damaged. Inspect
3. Disassemble the nut, lockwasher, flat washer and the bushings in the link assemblies. If damaged or worn,
capscrew retaining the axle to the tractor frame. Remove the remove the bushings.
axle from the frame.
9. If the lift cylinder must be removed, see Section 8 -
4. Inspect and repair or replace the axle as required. HYDRAULIC CYLINDER - REMOVAL.
Installation Installation
1. Install and align the axle with the mounting hole in the 1. Install the bushings in the link assembly, if removed.
tractorframe. Install the capscrew, flat washer, lockwasherand
nut to retain the axle to the tractor frame. Tighten the nut to 41 2. Align the lift platform with the frame. Lubricate the shafts
N«m (30 Ibf ft). with oil or light grease. Align the link assembly with the load
platform, align new flat washers and install the shaft. Use the
2. Install the load wheels. Refer to LOAD WHEEL - slot in the end of the shaft and align the shaft with the hole in the
INSTALLATION. load platform. Install the roll pin to retain the shaft to the load
platform.
3. Remove the blocks from under the lift tractor and lower the 3. Align the pivot pin in the opposite end of the link assembly
tractor to the floor. Test operate the truck before returning the and install the pivot pin in the link assembly and load platform.
tractor or lift truck to service. Install new cotter pins at each end of the pivot pin. Install the
setscrew to retain the pivot rod.
7-12
Yale
4. Repeat the procedure for installing the other link assembly. 7. Use a suitable lifting device and installthe battery in the lift
truck.
5. Hook the spring in the hole provided in the load platform.
Install the nut. Tighten the nut to obtain the dimension 8. Remove the plugs from the drive unit and the hydraulic
previously recorded. (The length of thread of the spring that unit. Check the oil level in both units. If necessary add the
protrudes beyond the nut.) recommended oil to the proper level. See Section 2. Install the
breather in both the drive unit and the hydraulic unit.
6. Use a suitable lifting device to return the lift truck to the
normal operating position. Position blocks under the load 9. Remove the blocks from under the load wheels. Test
wheels. operate the lift truck before returning the lift truck to service.
LOAD PLATFORM
HEX. NUT
SPRING
LINK ASSEMBLY
BUSHINGS
LUBE FITTING
COTTER PIN
PIVOT ROD
SETSCREW
ROLL PIN
_
SHAFT
FLAT WASHER
BUSHING
PIN - LIFT CYLINDER LOWER
COTTER PIN
SNAP RING
LIFT CYLINDER
PIN - LIFT CYLINDER UPPER
PIVOT ROD
ROLL PIN
SHAFT
Figure 7-12 - Load Platform Lift Linkage - MLW

7-13
YaleIndustrial Trucks
NOTES
7-14
Yale
IndustrialTrucks
SECTION 8
8 HYDRAULIC SYSTEM
1
p.;
•
,
>• .
ÿ ÿ;
iiSF
Ira *
ÿm .
">
. ' "**
jS m
*!i
'a.
,
Yale
Industrial Trucks
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM-GENERAL 8-1

SYSTEM OPERATION 8-1
LIFTING A LOAD 8-1
LOWERING A LOAD 8-1
HYDRAULIC LINES 8-1
HYDRAULIC OIL 8-1
CLEANLINESS 8-2
SOUND LEVEL 8-2
HYDRAULIC UNIT 8-2
REMOVAL 8-2
INSTALLATION 8-3
HYDRAULIC PUMP 8-4
REMOVAL 8-4
INSTALLATION 8-4
HYDRAULIC PUMP RESERVOIR 8-4
REMOVAL 8-4
INSTALLATION 8-5
HYDRAULIC CYLINDER 8-5
REPACKING 8-5
REMOVAL 8-6
INSTALLATION 8-6
RELIEF VALVE ADJUSTMENT 8-7
TROUBLESHOOTING-LIFT ASSEMBLIES 8-8
TROUBLESHOOTING-HYDRAULIC PUMP 8-8
TROUBLESHOOTING-HYDRAULIC CYLINDERS 8-9
Yale
IndustrialTrucks HYDRAULIC SYSTEM
HYDRAULIC SYSTEM-GENERAL Lowering a Load

A load is lowered by depressing the lower button. When the
The hydraulic system provides the force required to lift the lower button is depressed electric current is sent to the normally
loads on all walkie/rider lift trucks except the MTR. closed solenoid lowering valve which causes it to change
position and open a path for the trapped hydraulic oil to flow
The hydraulic system on the motorized hand truck consists of from the cylinder back to the reservoir.
the following individual components:
The hydraulic pump and motor assemblies are mechanically
• Pump Motor Assembly joined together as a compact unit combining the reservoir, the
pump, and the motor together as a single assembly. The pump
• Hydraulic Pump Assembly is located inside of the hydraulic tank and coupled to the motor
by an adapter plate, coupler drive and four capscrews.
• Solenoid Release Valve
• Flow Control Valve Hydraulic unit servicing is best performed by removing the unit
from the truck to a clean work area. Brush replacement for the
• Pilot Relief Valve motor can be easily performed with the pump installed on the
truck. Refer to Section 3.
• Lift Cylinder
• Hydraulic Tank
Lowering
SYSTEM OPERATION
Lifting a Load
Solenoid
Valve I To Lift Cylinder
To lift, pull the lift control handle back. Moving this lever will turn
on the pump motor. The electrical energy is converted into
mechanical energy by the motor. This torque is transferred to SV Check Valve
the pump from the motor through the motor shaft and shaft T~1
coupling. )(
Hydraulic oil is pumped through the system as the pump begins

to turn. A vacuum created inside of the pump draws oil out of the
reservoir through the suction line. Air which is drawn into the
reservoir through the breather displaces the pumped oil
&
Pump Motor
Suction
allowing it to be sent through the system. If the breather is Line
clogged or blocked in any way the ability of the system to lift a
load will be greatly reduced.
Oil which is pushed out of the pump passes first through a

Tank
-- .Ji I1
-
Figure 8-1 - Hydraulic Schematic
Pilot Operatedÿ
Relief Valve
one-way check valve, then to the lift cylinder. The check valve
prevents oil from flowing back to the pump when lifting ceases, Hydraulic Lines
keeping the lift cylinder in the raised position until lowered.
1. All hydraulic lines must be thoroughly cleaned before
installation.
The piston will begin to lift the load when fluid pressure acting
against it is high enough to overcome the weight of the load at 2. When making repairs use the least number of fittings and
rest on the forks/platform. connections to minimize flow resistance and the possibility of
leakage.
When the piston is fully extended to the end of its stroke or if the
load is too heavy to be lifted by this particular truck, pressure Hydraulic Oil
will continue to build inside of the cylinder against the piston The hydraulic oil in the system performs the dual function of the
until the rated pressure needed to operate the relief valve is power transmission and lubrication. Using the correct fluid is
reached. When this occurs, the relief valve, which is normally essential to proper system operation. Refer to the Lubrication
closed, is forced back against its spring. This creates a path for Charts for the recommended Hydraulic Oil to be used.
the fluid to flow back to the reservoir.
The level in the reservoir should be checked first when
Once relief valve pressure is reached, hydraulic oil will continue troubleshooting lifting problems. Low oil levels will make it
to be diverted from the lift cylinder to the reservoir until the lift appear that a problem exists with the battery or hydraulic
button is released or electrical power is interrupted. system.
8-1
Yale
Industrial Trucks HYDRAULIC SYSTEM
Cleanliness
Adhere to the following precautionary steps to insure that the

hydraulic system remains clean. 1
1. Clean (flush) the entire system when a failure is
encountered to make sure all paint, metal chips, welding shot
and debris is removed.
2. Filter each change of oil to prevent the introduction of

contaminants into the system.
3. Provide continuous protection from airborne

contamination by keeping the breather clean and serviceable.
Sound Level
Hydraulic system noise is caused by both improperly selected

oil and loose or damaged system components.
• Hydraulic oil with high or moderately high viscosities-At

startup, temperatures can cause pump noises due to
cavitation and also impedes the release of trapped air. Air
1. LIFT CYLINDER ASSEMBLY
does not have sufficient time to purge itself from the fluid
2. ELBOW
while in the reservoir before recycling through the system.
3. ELBOW W/O-RING
4. HYDRAULIC POWER UNIT
• Aerated Hydraulic Oil-Results in system noise that is similar
to cavitation. Aerated oil is caused by the ingestion of air 5. HOSE
through the pipe joints of the inlet lines and high velocity 6. ELBOW W/O-RING
discharge lines as well as cylinder rod packing. Aeration can 7. HOSE ASSEMBLY
also be caused by oil discharging above the fluid level.
Figure 8-2 - Hydraulic System
HYDRAULIC UNIT WARNING: Put blocks under each side of the

/f\ truck under the drive unit frame. Position blocks on
Removal both sides of the load wheels. The blocks must
A? \ CAUTION: Make certain all

cylinders are fully collapsed.
the hydraulic 2. Raise the drive wheel off the floor and put blocks under
both sides of the drive unit frame. See Section 1-HOW TO PUT
A LIFT TRUCK ON BLOCKS.
/\ WARNING: Batteries are heavy and can cause
/ 1\ an injury. Use care to avoid injury. Do NOT put
and a solid object. Make sure the capacity of the crane and
spreader bar is greater than the weight of the a battery. The
weight of the battery is normally shown on the battery case. The WARNING: The capacitor in the motor controller
maximum battery weight is shown on the lift truck nameplate / I\ can hold an electrical charge after the battery is
The spreader bar must NOT be made of metal or it must have disconnected. To prevent electrical shock and
insulated straps. injury, discharge the capacitor before inspecting or repairing
1. Move the key to the OFF position. Disconnect the battery. Use a screwdriver or jumper wire to make a short-circuit across
Use a spreader bar and lifting device to remove the battery. Do the B+ and B- terminals of the motor controller.
not let the battery move from side to side. Make sure the battery
cables have clearance. 4. Discharge the capacitor in the motor controller.
8-2
Yale
5. Tag and disconnect all electrical wires to the hydraulic unit. 7. Loosen and remove the two capscrews retaining the
hydraulic unit to the frame. Support the hydraulic unit as the
6. Disassemble and plug the hydraulic lines to the hydraulic
capscrews are being removed.
unit.
1. LIFT PUMP MOTOR 43. O-RING

2. CONTACTOR 44. DOWEL PIN
3. COUPING 45. FILTER (24V ONLY)
4. ADAPTER
5. O-RING
6. RELIEF VALVE SEAT
7. RELIEF VALVE PLUNGER
8. RELIEF VALVE SPRING
9. GASKET
10. RELIEF VALVE CAP
11. O-RING
12. RELIEF VALVE ADJ. SCREW
13. RETAINER
14. CAPSCREW (SELF TAPPING)
15. O-RING
16. PUSH-ON RING
17. SHIM
18. RETURN TUBE
19. O-RING
20. PUSH-ON RING
21. WASHER
22. RETURN TUBE
23. O-RING
24. CAPSCREW (12 POINT)
25. BREATHER CAP
27. RESERVOIR
28. MAGNET
29. STRAINER
30. INLET TUBE
31. O-RING
32. O-RING RETAINER
33. LOCKRING RETAINER
35. HYDRAULIC PUMP
36. O-RING
37. O-RING
38. O-RING
39. SOLENOID RELEASE VALVE KIT
40. FLOW CONTROL VALVE
41. FLOW CONTROL VALVE SPRING
42. CHECK VALVE KIT
Figure 8-3 - Hydraulic Unit
Installation 4. Remove the blocks and lower the lift truck to the floor.
1. Align the hydraulic unit with the mounting holes in the 5. Remove the breather and addthe recommended hydraulic
frame and install the two capscrews. Tighten the hydraulic unit oil until the oil is visible in the fitting for the breather/fill plug.
mounting capscrews to 36 Ibf ft (49 N«m) torque. Replace the breather. If too much hydraulic oil is added, the oil
will leak from the breather during operation.
2. Install the hydraulic lines to the hydraulic unit.
6. Install the battery. See Section 2-BATTERY-REMOVAL
AND INSTALLATION. Connect the battery. Operate the lift
3. Connect all the electrical wires to the hydraulic unit. truck until the hydraulic oil reaches operating temperature.
8-3
Yale
Remove the breather and check the hydraulic oil level. If 7. Remove the retainer and replace the O-ring. Lightly
necessary add additional oil. Check for hydraulic oil leaks. grease the O-ring before installation.
7. Install the drive unit compartment cover. Test operate the 8. Align the reservoir so the hose connections will be in the
lift truck prior to returning the truck to service. same position as they were prior to removal. Install the four
capscrews to retain the reservoir.
HYDRAULIC PUMP
9. Install the hydraulic unit. Refer to HYDRAULIC
Removal UNIT-INSTALLATION.
1. Remove the hydraulic unit from the lift truck. Refer to 10. Remove the breather and fill the reservoir with the
HYDRAULIC UNIT-REMOVAL. recommended oil. Refer to Section 2 this manual. Add oil until
the oil is visible in the tee fitting for the breather. If too much oil is
2. Clean the reservoir and pump area to prevent added, the oil will leak from the breather during operation. If too
contaminants from entering the hydraulic system. much oil has been added, drain the excess or use a suction
device to remove some of the oil.
3. Remove the four capscrews retaining the reservoir to the
hydraulic unit. Tap around the perimeter to break the seal and 11. Jog the pump motor three or four times to insure that the
separate the reservoir from the motor assembly. pump draws oil and the pump components are lubricated.
Operate the forks up and down three or four times to remove air
4. Remove the spring retaining screw from the suction tube. from the system. Operate the lift truck until the hydraulic oil
reaches operating temperature. Remove the breather and
check the hydraulic oil level. If necessary add additional oil.
5. Remove the suction tube and strainer by pulling down
Check for hydraulic oil leaks.
and out.
6. Remove the four capscrews retaining the pump to the 2-DRIVE UNIT COMPARTMENT COVER-REMOVAL AND
drive motor. INSTALLATION. Test operate the motorized hand truck before
returning the truck to service.
7. Disassemble the pump assembly and coupling from the
HYDRAULIC PUMP RESERVOIR
adapter.
Removal
Installation
The reservoir of the hydraulic pump unit can be removed
NOTE: When servicing the hydraulic pump always replace all without removing the complete hydraulic unit.
seals and O-ring. Clean or replace the strainer as required.
1. Clean and lubricate all components using clean hydraulic CAUTION: Make certain the hydraulic cylinder is
oil. fully collapsed.
2. Replace all O-rings and seals. 1. Move the key to the OFF position. Disconnect the battery.
3. With the motor resting with the adapter plate up, grease the 2. Remove the drive unit compartment cover. Refer to
coupler and coupler cavity. Align the pump mounting holes with Section 2-DRIVE UNIT COMPARTMENT COVER-RE¬
the holes in the motor. Insure that the tang is seated into the MOVAL AND INSTALLATION.
motor.
4. Install the four capscrews and tighten to 10 to12 Ibf ft disconnected. To prevent electrical shock and
(13.6 to 16.3 N«m) torque. injury, discharge the capacitor before inspecting or repairing
5. Install the O-rings into the pump cavities. Apply grease to glasses. Make certain the battery has been disconnected.
the return tubes. Insert tubes into pump cavities and O-rings. Use a screwdriver or jumper wire to make a short-circuit across
Grease the suction tube and insert into locking device with hole. the B+ and B- terminals of the motor controller.
Install and tighten the spring retaining screw to secure the
suction tube. 3. Discharge the capacitor in the motor controller.
6. Make certain the magnet is clean. Install the magnet into 4. Disassemble and plug the hydraulic lines to the hydraulic
the reservoir. unit.
8-4
Yale
NOTE: The reservoir must be lowered below the suction tube 6. Manually collapse the piston into the cylinder while
before attempting to move the reservoir away from the lift truck. depressing the lower switch.
Remember the reservoir may contain hydraulic oil. Dispose all
used oil in accordance with local regulations. 7. Move the cylinder toward the rear of the truck. Loosen the
gland nut. Extract the piston, gland nut and rod from the
5. Remove the four capscrews retaining the reservoir to the cylinder.
hydraulic unit. Carefully remove the reservoir.
8. Disassemble the nut and piston from the cylinder rod.
6. Clean the reservoir, the magnet and the suction screen. Remove the spacers, if used, and slide the rod out of the
Inspect the screen for damage and replace if necessary. gland nut.
Installation 9. Replace all seals, packing and O-rings.

1. Lubricate a new O-ring using clean hydraulic oil and install
CAUTION: Lubricate the seals, packing and
into the pump body.
O-rings with clean hydraulic oil before assembling.
Make certain to install spacers, if any were
2. Align the reservoir in the proper position and install the four removed.
capscrews to retain the reservoir to the hydraulic unit.
10. Installthe seals, packing and O-rings as necessary into the
3. Install the hydraulic lines to the hydraulic unit. gland and piston after coating them with clean hydraulic oil.
4. Remove the blocks and lower the lift truck to the floor. 11. Carefully install the rod through the gland nut. Install the
piston, spacer (if necessary), and the locknut. Tighten the
5. Removethe breather and add the recommended hydraulic locknut (lubricated) to 110 Ibf ft (150 N«m) torque.
oil until the oil is visible in the fitting for the breather/fill plug.
Replace the breather. If too much hydraulic oil is added, the oil CAUTION: Make certain that none of the sealant
will leak from the breather during operation. If too much oil has gets into the cylinder. Allowing sealant to get into
been added, drain the excess or use a suction device the hydraulic system may cause damage to the
to remove some of the oil. components within the hydraulic system.
6. Connect the battery. Jog the pump motor three or four 12. Carefully install the rod assembly into the cylinder. Apply
times to insure that the pump draws oil and the pump sealant 5017029-02 or equivalent to the threads of the gland
components are lubricated. Operate the forks up and down nut. Tighten the gland nut to 20 Ibf ft (27 N«m) torque.
three or four times to remove air from the system. Operate the
lift truck until the hydraulic oil reaches operating temperature. 13. Align and install the top clevis pin into the frame and
Remove the breather and check the hydraulic oil level. If cylinder rod. Install the roll pin to retain the clevis pin in the
necessary add additional oil. Check for hydraulic oil leaks. frame.
7. Install the drive unit compartment cover. Refer to Section 14. Remove the blocks and lower the lift truck to the floor.
INSTALLATION. Test operate the lift truck prior to returning the 15. Remove the breather and add the recommended hydraulic
truck to service. oil until the oil is visible in the fitting for the breather/fill plug.
HYDRAULIC CYLINDER Replace the breather. If too much hydraulic oil is added, the oil
will leak from the breather during operation. If too much oil has
Repacking been added, drain the excess or use a suction
device to remove some of the oil.
1. Raise the motorized lift truck forks/platform to one half its
maximum height. 16. Jog the pump motor three or four times to insure that the
pump draws oil and the pump components are lubricated.
2. Place blocks under the forks. Block the drive wheel. Refer Operate the forks up and down three or four times to remove air
to Section 1, this manual for the blocking procedure. from the system. Operate the lift truck until the hydraulic oil
reaches operating temperature. Remove the breather and
3. Remove the drive unit compartment cover. Refer to check the hydraulic oil level. If necessary add additional oil.
Section 2, this manual. Check for hydraulic oil leaks.
4. Relieve pressure from the hydraulic cylinder. 17. Install the drive unit compartment cover. Refer to Section
5. Drive the roll pin retaining the top clevis pin out of the frame INSTALLATION. Test operate the lift truck prior to returning the
and clevis pin. Remove the top clevis pin. truck to service.
8-5
YaleIndustrial Trucks HYDRAULIC SYSTEM
1. LOCKNUT
2. PISTON
3. CYLINDER TUBE
4. PISTON ROD
5. PISTON HEAD
6. BUSHING
7. SEAL
Figure 8-4 - Hydraulic Cylinder

Removal /\ WARNING: Be careful when removing or
/ I\ installing snap rings. These snap rings can come
1. Raise the motorized lift truck forks/platform to one half of loose during removal or installation with enough
its maximum height. force to cause an injury. Always use the correct snap ring pliers
installation.
/\ WARNING: Put blocks under each fork. Position
6. Disassemble the snap ring retaining the bottom clevis pin.
/l\ blocks on both sides of the drive wheel. The blocks
Remove the bottom clevis pin and the hydraulic cylinder.
must prevent the lift truck from falling and causing
injury or damage.
Installation
1. Align the bottom of the cylinder with the frame and install
2. Place blocks under the forks. Block the drive wheel. See the bottom clevis pin.
/\ WARNING: Be careful when removing or
/ I\ installing snap rings. These snap rings can come
force to cause an injury. Always use the correct snap ring
Section 2-DRIVE UNIT COMPARTMENT-REMOVAL AND
pliers and wear eye and face protection during removal and
INSTALLATION.
installation.
2. Install the snap ring to retain the clevis pin.

4. Relieve pressure from the hydraulic cylinder.
3. Align the top of the cylinder rod with the frame and install
the top clevis pin. Install the roll pin to retain the clevis pin.
5. Drive the roll pin retaining the top clevis pin out of the frame
and clevis pin. Remove the top clevis pin. 4. Remove the blocks and lower the lift truck to the floor.
8-6
Yalo
5. Remove the breather andaddthe recommended hydraulic capacity or Yale Special Tool 5180968-12 Quadrigauge
oil until the oil is visible in the fitting for the breather/fill plug. with an adapter.
Replace the breather. If too much hydraulic oil is added, the oil
will leak from the breather during operation. If too much oil has 5. The relief valve adjustment screw is covered with a
been added, drain the excess or use a suction device to silicone sealant to prevent unauthorized adjustments. Remove
remove some of the oil. the sealant. Adjust the relief valve by turning the adjusting
screw until the proper setting is obtained on the gauge. The
6. Jog the pump motor three or four times. Operate the forks relief pressure should be taken with the pump running and the
up and down three or four times to remove air from the system. forks or platform fully raised. It may be necessary to stop the
Operate the lift truck until the hydraulic oil reaches operating pump, make a minor adjustment and take the pressure reading
temperature. Remove the breather and check the hydraulic oil again. The pressure readings should be:
level. If necessary add additional oil. Check for hydraulic oil
leaks. MODEL RELIEF SETTING *
MPW, MPE, MPC 060 2850 psi (19.65 MPa)
MPW, MPE, MPC 080 3500 psi (24.13 MPa)
INSTALLATION. Test operate the lift truck prior to returning the MLW 040-060 2850 psi (19.65 MPa)
truck to service.
* + 87 - 0 psi ( + 0.6 - 0.0 MPa) @ 70° F (21°C) Oil
RELIEF VALVE ADJUSTMENT Temperature Full Flow
6. Remove the pressure gauge and tee from the supply line.
/\ WARNING: Do not make repairs or adjustments Apply a small amount of sealant over the adjustment screw.
I I\ unless you have both authorization and training.
CJLJ Repairs and adjustments that are not correct can 7. Removethe breather andaddthe recommended hydraulic
make a dangerous operating condition. Do not operate a lift oil until the oil is visible in the fitting for the breather/fill plug.
truck that needs repairs. Report the need for repairs to your Replace the breather. If too much hydraulic oil is added, the oil
supervisor immediately. If repair is necessary, put a "DO NOT will leak from the breather during operation. If too much oil has
OPERATE" tag on the control handle. Remove the key from been added, drain the excess or use a suction device to
the key switch. remove some of the oil.
1. Remove the drive unit compartment cover. Refer to 8. Jog the pump motor three or four times. Operate the forks
Section 2-DRIVE UNIT COMPARTMENT-REMOVAL AND up and down three or four times to remove air from the system.
INSTALLATION. Operate the lift truck until the hydraulic oil reaches operating
temperature. Remove the breather and check the hydraulic oil
level. If necessary add additional oil. Check for hydraulic oil
2. Clean any build up of dirt from around the hydraulic unit.
leaks.
3. Relieve pressure from the hydraulic cylinder. 9. Install the drive unit compartment cover. Refer to Section
4. Disassemble the supply line from the pump and install a INSTALLATION. Test operate the lift truck prior to returning the
tee. Install the supply line and a pressure gauge of the proper truck to service.
8-7
Yale
TROUBLESHOOTING-LIFT ASSEMBLIES
PROBLEM POSSIBLE CAUSE CORRECTION

Forks fail to elevate Faulty hydraulic equipment See Troubleshooting Pumps and
Hydraulic Cylinders
Deformed lifting components Disassemble and replace damaged parts
Slow lifting speed and insufficient Faulty hydraulic equipment See Troubleshooting Pumps and
handling capacity Hydraulic Cylinders
Deformed lifting components Disassemble and replace damaged parts
Forks fail to lower Deformed forks Disassemble, repair or replace
Deformed lifting components Disassemble, repair or replace

Bent hydraulic cylinder piston rod See Troubleshooting Hydraulic Cylinders
TROUBLESHOOTING-HYDRAULIC CYLINDERS

Oil leaks from cylinder head through Foreign matter on packing Replace packing
piston rod (An oil ring appears on the
piston rod)
Score on piston rod Remove any foreign matter. Smooth rod
surface with an oil stone. If oil still leaks,
disassemble and repack cylinder.
Scores on wiper ring lip Replace wiper ring
Unusual distortion of wiper ring Replace wiper ring
Chrome plating is stripped Replace piston rod or renew chrome

plating
Oil leaks from welded portion Cylinder tube damaged Replace cylinder tube
Rod spontaneously retracts Scores on inner surface of tube Smooth surface with an oil stone
Score on tube Replace cylinder tube
Score on piston ring Replace piston ring
Foreign matter on packing ring Replace packing
Considerable score on lip of packing ring Replace packing
Unusual distortion of packing ring Replace packing
Wear limit (Clearance between cylinder Excessive clearance between cylinder Replace wear ring (Included in packing
tube and wear ring) tube and wear ring kit)
8-8
Yale
TROUBLESHOOTING-HYDRAULIC PUMP

Pump not delivering oil Pump does not draw oil Check pump, piping and valves for leaks
Low oil level in tank Check fluid level
Clogged screen at pump inlet Change oil and clean screen

Pump pressure fails to rise Improperly adjusted relief valve Increase to specified pressure using a
pressure gauge
Relief valve clogged Disassemble and clean with fresh oil
Interfering relief valve or broken relief Disassemble valve and replace spring
spring
Air suction Check piping on suction side for leaks
Add oil to tank

Check pump seals
Pump produces noise Cavitation caused by collapsed suction Drain and clean system
hose or clogged screen
Faulty oil suction Add oil to specified level
Air suction through loose connections on Tighten all hose connections on suction
suction side side
Air suction from from pump oil seal Disassemble pump and replace oil seals
Breather clogged Clean or replace breather
Cavitation caused by high oil viscosity Change to recommended oil and operate
pump in recommended temperature
ranges
Abnormal temperature rise of hydraulic Overwork Adjust workload to fall within pump's
oil operating range
Improper viscosity or contaminated oil Drain and replace oil with recommended
oil
Pump case or drive gear broken Incorrect pressure setting Check for excessive resistance in
hydraulic circuit. Make certain relief
pressure is properly adjusted and valve is
working properly.
8-9
Yale
IndustrialTrucks
NOTES
8-10
Yale
Industrial Trucks
SECTION 9
BATTERY AND CHARGING SYSTEM

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

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

This section describes selection and maintenance of large
/?\ case electrolyte accidentally splashes on your skin
or clothing. Extreme care should be taken in
batteries used in electric lift trucks. This information pertains to
flushing electrolyte from the eye. Use plain water only and
the service personnel that maintain industrial truck batteries.
obtain medical attention immediately.
SAFETY TIPS FOR HANDLING Why-Volumes of water applied quickly and continuously will
INDUSTRIAL TRUCK BATTERIES prevent serious injury to the skin. Quick medical attention is
necessary to assure proper care and treatment.
WARNING: Disconnect the battery from the lift
truck when doing maintenance and repair work.
5./\ WARNING: Apply strong neutralizer such as
/ I\ baking soda when acid is spilled on the floor and
clean up promptly.
Why-The live current may cause arcing or a short circuit with
attendant damage to equipment or injury.
Why-Baking soda will neutralize the acid and make it safe to
clean or flush from the floor.
2. /\ WARNING: Wear rubber apron, gloves, boots
/f\ and goggles, when handling, checking, filling, 6. /\ WARNING: Take proper care in melting the
charging or repairing batteries.
/f\ sealing compound when preparing to seal a
LmJ battery. Avoid puncturing the hard surface of
Why-To protect yourself against burns resulting from
partially melted compound with a screwdriver or other sharp
accidental spillage of electrolyte - a mixture of sulfuric acid
tool. Compound may ignite if it is heated too rapidly.
and water.
Why-The hot liquid may squirt up and burn your hand, face or
3. /\ WARNING: Keep open flames away from
body. If it should catch fire it creates the hazard of an open
I \ batteries - do not check electrolyte level with a
f flame. Burning consumes oil in the compound and impairs its
cigarette lighter or match. USE A FLASHLIGHT
useful characteristics.
OR PERMANENT LIGHT. Do not smoke or create sparks.
Why-The space between the underside of the cover and the

top of the electrolyte in the cell usually contains a hydrogen
oxygen mixture which is explosive when ignited.
LEAD BUSHING VENT AND FILLER CAP

TERMINAL POST
CELL COVER
POSITIVE NEGATIVE
PLATE PLATE
SEPARATOR
CONTAINER
Figure 9-1 - Lead-Acid Industrial Truck Battery
9-1
Yale
Industrial Trucks BATTERY AND CHARGING SYSTEM
7. Remove vent caps from nearby cells when preparing to 13. Allow only authorized personnel (qualified by training and
assemble a repaired cell into the battery. Cover the vent holes experience) in the battery room.
with layers of damp cloth before using lead burning equipment
on the intercell connectors in order to integrate the cell into the Why-An untrained or inexperienced person may unknowingly
battery circuit. Also, use dark glasses to protect the eyes. break normal rules for proper handling, causing injury to
themselves and damage to batteries and equipment.
Why-To prevent a possible hydrogen oxygen concentration
from exploding when a flame is lit. 14. Enclose all bare wires and buss bars in the battery room by
wire guards, guard rails or other means of isolation from
8. Be sure to shut off the power when changing or repairing general plant traffic.
plugs or receptacles that are connected to the charging
equipment. This will prevent a short circuit and arcing. Why-Any open high current transmission equipment is a
possible hazard to you, other workers and equipment.
Why-A short circuit may injure you. Arcing may cause
explosion and fire. 15. Never lay metal tools such as wrenches or other material
on top of an open battery.
9. Before removing the terminal lugs from the receptacle
when repairing a damaged or dirty plug or receptacle Why-Sparking and short-circuiting will occur and the battery
connected to a battery, the battery circuit must be opened or will quickly be discharged or may explode.
"broken".
16. Check batteries for cracks or leaks. Repair at once.
Why-The leads which terminate in the receptacle are live or
"hot" with the total voltage of the battery existing across the Why-Electrolyte will spill on floor or equipment, causing
terminals. If the terminal lugs are accidentally touched together corrosion of the steel tray and related equipment. Continuous
a short-circuit or arcing will occur with its attendant danger. flow of leaking electrolyte can cause a ground bath that reduces
battery life and capacity.
10 /% WARNING: When mixing acid to prepare
/ \
I electrolyte, ALWAYS POUR ACID SLOWLY INTO
WATER and never water into acid. Always store
17. When batteries are disposed of as scrap at the end of
useful life, they should be sent to a authorized recycling center
acid in plastic or glass container. or salvage dealer.
Why-lf water should be added to acid it will not readily mix and Why-Even an old battery no longer capable of useful life may
will splash the acid due to the great difference in the specific have enough residual voltage left to cause a spark if filled with
gravity of the two liquids. The effect of splashed acid is electrolyte.
dangerous.
18. Familiarize yourself as completely as possible with
11.ÿ% WARNING: Always lift batteries with mechanical batteries and the proper rules for their charging, handling and
I f\ equipment such as a hoist, crane or lift truck. Move maintenance.
batteries horizontally with power tracks, conveyors
or rollers. Make sure that hoist hooks, spreader bars and other Why-Full knowledge of batteries and the dangers of improper
tools are of ample strength and properly installed. Cover top of handling will pay dividends in the elimination of injuries and
battery with rubber mat or other insulating material to prevent damage.
external short-circuits from chains or cables falling on top of
battery. CAUTION: Keep vent plugs in the cells at all
times, except when taking hydrometer readings,
Why-Batteries are a heavy concentrated load and might easily adjusting specific gravity and electrolyte levels,
cause painful strains or injury to your feet or hands. Batteries troubleshooting or assembling a repaired cell.
may be seriously damaged or electrolyte spilled if the battery is
dropped. NOTE: Your company, industry and government safety
regulations should be reviewed to help reduce accidents and
12. Make sure that charging plugs and receptacle are properly damage to equipment.
locked and all other connections tight, secure and free from
friction. NOTE: If batteries are not in use, keep them charged. Check
specific gravities monthly and give a freshening charge (3 to 4
Why-A loose connection may mean sparking or even arcing hours at the finish rate) if the gravities have fallen 30 points
with attendant danger of gas explosion. (0.030) or more, otherwise, give freshening charge every three
months.
9-2
Yale
LEAD-ACID BATTERIES Chemical Reaction

A lead-acid battery converts chemical energy into electrical The cell generates a voltage (potential difference) when two
energy. The battery is discharged when the chemical reaction different types of metal are in the electrolyte. The two metals in
has occurred and the battery will not supply its rated voltage a lead-acidcell are lead peroxide (Pb03) for positive plates, and
and current. A reverse chemical action must occur so that the sponge lead (Pb) for negative plates. A potential difference of
battery can be used again. The batteries can be charged by an approximately two volts per cell is generated. The potential
electric voltage and current from an outside source to provide difference does not vary according to the size of the cell.
the reverse chemical action. The lead-acid chemicals store the
electrical energy until needed. During the discharging of the cell, lead peroxide and sponge
lead mix with sulfuric acid to make lead sulfate (PbS04) on both
A lead-acid battery is made from several lead-acid batteries plates. This action decreases the voltage in the cell. When the
called cells. Each cell has positive and negative plates with sulfuric acid is removed from the electrolyte, the specific gravity
dielectric spacers between each plate. All of the plates are in a of the electrolyte decreases. The potential difference of a
solution of electrolyte. discharged cell is approximately 1.75 volts.
Specific Gravity
The strength of the electrolyte is measured in points of specific
gravity. For example, a solution of sulfuric acid has a specific LESS THAN
gravity of 1.835. Water has a specific gravity of 1.000. 2.06 VOLTS
Electrolyte is 27% acid and 73% water and has a specific
gravity of 1.275.
F35
DECREASED
/\ CAUTION: NEVER pour water into acid. The SULFURIC
I
? \ quick production of heat can cause the acid to boil ACID
and splash out of the container. ALWAYS pour acid
into water when making a dilute solution of acid.
INCREASED
WATER
ss'
v,
2.06
VOLTS
DECREASED DECREASED
LEAD LEAD
SPONGE PEROXIDE
INCREASED LEAD SULFATE

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

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

1.270 to 1.130. NEVER discharge a battery below a specific
Figure 9-2 - Fully Charged Cell
gravity of 1.130. The battery can have permanent damage if
discharged below 1.130.
9-3
Yale
per day is normally equal to the number of batteries needed.

1.75
VOLTS The capacity of the battery you need is found as follows:
• The size of the lift truck and the attachments.
• The type of work. Heavy duty operation or normal
operation for one eight hour work period.
2ÿ MINIMUM OF
SULFURIC \ The battery voltage you need is found as follows:
\ S
N ACID \
\ \ • Will your lift truck operate on more than one voltage?
\ s
\
MAXIMUM \ • If you have more than one lift truck in operation, do the
\ battery voltages need to be the same?
N WATER .rs
s
ÿ£2 N
Lift trucks are available in various voltage ranges. The small
MINIMUM MINIMUM "Motorized Hand" trucks are normally 12 to 24 volts. Larger
SPONGE LEAD "Sit-Down Rider" lift trucks are normally 24 to 48 volts.
LEAD PEROXIDE
Voltage of a Battery
MAXIMUM LEAD SULFATE
To reach the necessary battery voltage, the cells are connected
in series. For example:
Figure 9-4 - Discharged Cell • 24 volts 12 cell battery

• 36 volts 18 cell battery
BATTERY • 48 volts 24 cell battery
CHARGER +
2.33
VOLTS
v
s
555
I
V INCREASED
s \
SULFURIC -WC" I.r.r* •
s V ACID
\
s \
> \ DECREASED
s
N
s WATER
rv zr
INCREASED INCREASED
SPONGE LEAD
LEAD PEROXIDE
DECREASED LEAD SULFATE
Figure 9-5 - Cell Charging
HOW TO SELECT THE BATTERY Figure 9-6 - Cell Voltage

The battery needed to operate a period of eight hours depends
on many conditions. Operations that require the lift truck to go Battery Ratings
up ramps or require the use of additional attachments The ratings of batteries are measured in ampere-hours (AH)
increases the use of power from the battery. Some work and kilowatt-hours (KWH) at a constant rate of discharge. The
conditions require that more than one battery must be used number and size of plates increases the amp-hour rating. A
during a work period. The number of eight hour work periods rating of six hours is the standard. Ampere-hours is the
9-4
Yale
measurement of battery capacity. To calculate ampere-hours, new batteries may require cycling 7 to 10 times before the
multiply amperes by hours. For example, 5 amperes times 5 battery accepts a full charge. (Cycling is charging and then
hours is 25 ampere-hours. You cannot change the potential discharging the battery at a prescribed rate. Refer to the
difference of a cell. You can increase the ampere-hour rating by instructions shipped with the battery.) Make sure the battery is
increasing the number of plates in a cell, or by installation of correctly installed in the lift truck. Use a correct spreader bar
larger plates. The constant rate of discharging can be with slings to lift and move the battery.
compared to a measurement of the battery capacity and
ampere-hours. For example, a battery with a rating of 600 CAUTION: Always use a spreader bar and slings
ampere-hours during a work period of six hours will generate that lift vertically on the lifting eyes of the battery.
100 amperes per hour for six hours. (The same battery cannot DO NOT use a chain or sling without a spreader
generate 300 amperes for two hours. The heat generated with bar or you will damage the battery.
the battery will damage the battery.)
Use the correct blocks or spacers to hold the battery in
Kilowatt Hours position in the lift truck. Make sure that the battery
compartment is clean and dry. All of the vents caps must be in
__--
A kilowatt is 1000 watts. A watt is a measure of electric power.
position when the battery is in service. If the vent caps are
The capacity in kilowatt-hours is the total power generated by
not installed, the electrolyte will leak, causing corrosion of the
the battery. Watt-hours are measured by multiplying the voltage
battery case and in the battery compartment.
by ampere-hours. To measure the kilowatt-hours, divide the
watt-hours by 1000.
/volls x ampare x hours \

y 1,ooo )
_ NON-METALLIC
STRAPS
v.
To calculate the kilowatt-hours for a battery that has a rating of
600 ampere-hours and a 48 volt system, use this formula.
48 x 600 ( Power available from a fully i

28 8 KWH
i"000 ÿ charged battery.
J
All the electrical operations figure a specific watt-hours in
electric energy. These operations include distances, loads,
ramps, lifting heights, attachments, etc. The watt-hours can be
converted to kilowatt-hours to indicate the battery needed for
the operation. Always select the correct type of battery.
Remember, a battery that has a rating of 300 ampere-hours will
not do the same job as a battery that has a rating of 600
ampere-hours. Do not permit the specific gravity to go below
the limits shown in the manual.
THE BATTERY AS A COUNTERWEIGHT

On electric lift trucks that use the battery as part of the
counterweight, the battery is part of the capacity of the lift truck Figure 9-7 - Lifting the Battery
to lift loads. The minimum weight of the battery is shown on the
nameplate. If the battery is not the minimum weight, the BATTERY MAINTENANCE
capacity of the lift truck is reduced. If the battery used in the lift
truck is less than the size of the battery compartment, blocks Battery maintenance must include a good battery charger, a
and spacers must be installed to hold the battery in position. clean battery, keeping the electrolyte at the correct level, and
The maximum allowable movement of a battery is 12.7 mm keeping a record of the battery.
(0.5 in) from side to side and 12.7 mm (0.5 in) fore and aft.
1. Keep batteries clean and free of acid spills.
(Reference ANSI B-56.1.)
2. Do not over discharge. Excessive discharge shortens
Inspect every new battery for damage. Make sure the
electrolyte in each of the cells is at the correct level. Charge the battery life.
battery for six hours or until the specific gravity is correct. Some
9-5
Yale
3. Do not overcharge. Overcharging produces corrosion of too high a charging current and excessive heating. Charging
positive grids and excessive gassing, which loosens the active with a lower ampere-hour charger will cause no harm, but may
material of the plates. require longer than 8 hours to fully charge.
4. Charge batteries in a well ventilated area to remove the Maintenance Records

explosive gases and acid fumes.
Always complete the Battery Inspection Report and the Daily
Battery Report.
5. Maintain electrolyte at the proper level. If low, add water.
Before charging, make sure tops of plates are covered; after
NOTE: Follow the same sequence when you record the cell
charge, fill to recommended level. Do not add acid.
number. Always begin the record with a positive cell. Follow a
sequence so that the last cell is always the cell for the
6. Keep batteries from freezing.
negative cable.
7. Keep batteries in a charged state.
Record the beginning ampere reading of the charger each time
the battery is charged. Any difference in the daily ampere
8. Do not charge a battery with a charger that has an
reading can indicate a problem with the battery or the charger.
ampere-hour rating higher than that of the battery. This will give
_
Battery Inspection Report
_ _.
Oml MM to
hm. MIL
CILL mcipic CILL antantc

VOLT* anavitv VOLTS OHAVITV
Figure 9-8 - Battery Inspection Report
9-6
Yale
Daily Battery Record

»M«rv
-
* irn
few m .....
....
Hut Cvtfu H Mtawk
TRUCK
_
VICJTIC 0 RAVITV TCM».
Hut Cvrtn U Dm
TlMC nwi
-
INITIAL WAT* A
Mil OTt RATON
WO. IW OUT HLOTCCU. CMCHAMQC W04AMK uwt AOMO
Figure 9-9 - Daily Battery Record

Cleaning the Battery 9-10 shows a general rule forthe incorrect electrolyte level. See
the instructions from the manufacturer of your battery for the
Keep the battery compartment clean and dry. Use a clean cloth
operating level of the electrolyte.
to wash the battery with water. Dry with compressed air.
A CAUTION: Do not clean the battery with steam or

hot water. Do not use a high pressure hose.
Remove any electrolyte from the battery compartment to

CELL HEIGHT
Less than 38 cm (15 in)
38-61 cm (15-24 in)
DIMENSION "A"
3 mm (1/8 in)
6 mm (1/4 in)
prevent corrosion. If there is electrolyte on the top of the battery, Greater than 61 cm (24 in) 12 mm (1/2 in)
apply a solution of bicarbonate of soda. Mix a solution Table 9-1 - Electrolyte Level
containing 1.1 lb (0.5 kg) of soda for every 4.22 qts (4 litres) of
water. Apply the solution, then flush the solution from the
battery with clean water. Wash the battery and battery
BOTTOM OF FILL TUBE
compartment as needed. Six months between cleaning is the
COVER \
/ FILL HOLE
_ i-A>
maximum recommended interval.
NOTE: If the top of the battery is wet from electrolyte, check

X v.y>vÿv T
HIGH LEVEL
to see if the electrolyte level is too high or the battery charger

is not operating correctly. LOW LEVEL i
Adding Water 2 i.
Some water is lost from the electrolyte of each cell during the
charge and discharge cycle when the battery is in service. ELECTROLYTE
Check the electrolyte level daily. Some service persons check
some of the cells each day so that all of the cells are checked PLATE PROTECTOR TOP OF SEPARATORS
each week. If the level of the electrolyte goes below the level of
the top of the separators for the plates, the cell can be
damaged.
Figure 9-10 - Electrolyte Level
NOTE: Keeping the electrolyte level within the correct limits
Hydrometer
is the most important item of battery maintenance. Always use
distilled water. If you add distilled water, wait five minutes Use a hydrometer to measure the specific gravity of the battery.
before measuring the specific gravity with a hydrometer. Do not Make sure there is enough electrolyte in the battery cells. A
add distilled water to a cell during the charging cycle. The high level or low level of the electrolyte can change the specific
electrolyte can flow out of the cell through the fill hole. Figure gravity measurement. When the electrolyte level is low, the
9-7
Yale
percent of sulfuric acid in the electrolyte increases. When the

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

in the barrel to let the float move freely. The float must not touch
the side, top, or bottom of the barrel for the correct method of
reading the hydrometer.
LIQUID
SPECIFIC GRAVITY LEVEL
SCALE
FLOAT
Figure 9-12 - Battery Thermometer
Never charge or discharge a battery at a rate that will raise the

Figure 9-11 - Hydrometer temperature of the electrolyte above 50° C (120° F). A
temperature above this amount will damage the battery. The
Battery Temperature cells in the center of the battery are normally at the highest
temperature. If the battery temperature is too hot, make sure
The temperature of the electrolyte will change the reading of the
the ventilation of the battery is increased and make sure that the
specific gravity. When the temperature increases
charge or discharge rate is not too high. A recommendation for
approximately 6° C ( 10° F) , the specific gravity will decrease by
a battery in service is 8 hours of use (discharge), followed by 8
0.003 points. Refer to Figure 9-12 for making specific gravity
hours of cooling, followed by 8 hours of charging.
corrections.
The normal electrolyte temperature is 25° C (77° F). At this
SPECIFIC temperature the electrolyte has a specific gravity of
GRAVITY ELECTROLYTE CORRECTION CORRECT 1.285-1.295 with no correction for temperature. If the
READING TEMP. POINTS VALUE hydrometer you are using does not have a temperature
correction, you will have to use a thermometer. Special battery
1.210 31° C (87° F) +0.003 1.213
thermometers are available that will indicate the correction
1.210 27° C (80° F) +0.001 1.211 factor directly and add or subtract the correct number of points.
1.210 25° C (77° F) +0.000 1.210

CHARGING THE BATTERY
1.210 18° C (64° F) -0.004 1.206
WARNING: Batteries produce explosive hydro¬
+ 0.001 for each 1.7° C (3° F) from the 25° C (77° F) gen gas when charging. Always open the battery
Base Value Degrees C° + 17.8 x 1.8 = Degrees F°. cover or hood and provide good ventilation
when charging.
Table 9-2 - Specific Gravity Corrections
9-8
Yale
To charge the battery, a direct current must pass through the during the charging cycle. The increase in the voltage from the
cells in the opposite direction to the discharging current. The charger is approximately the same as the increase in the
ampere-hours must be equal to the discharging ampere-hours specific gravity in the cells.
plus the energy lost as heat. This additional amount of charge
will vary according to the battery and the temperature, but the 2. MODIFIED CONSTANT VOLTAGE-This method uses a
average additional charge is 12%. When the battery is nearly generator to generate a constant voltage that is controlled by a
charged, the final charging must be at a low rate. A charging resistor. When the charging current decreases, the voltage
rate that is too high will cause heating in the battery and a high across the resistor causes an increasing voltage at the battery
loss of water from the electrolyte. The charging of the battery terminals. The charging is similar to the gradual charge. The
must be done correctly or the service life of the battery will be resistor must be correctly set or the charging rate will be wrong.
decreased.
3. TWO-RATE CHARGE-This method also uses a high
NEVER discharge a battery below 1.130 to 1.110. Discharging charging rate at the beginning followed by a lower rate. Two
a battery beyond the design limits will decrease the service life resistors control the charging rate. One resistor controls the
of the battery. charging rate at the beginning of the cycle and a second
resistor reduces the charging rate when the voltage in the cells
If lift truck operation results in only partial discharges (50% or reach 2.37 volts. A relay automatically controls the second
less) and specific gravities are 1.210 to 1.220 or more at the end resistor.
of the shift, recharging may be deferred and the battery used for
another shift providing the work load is not expected to Troubleshooting the Charger
increase. Hydrometer readings and experience will disclose
Battery chargers normally operate automatically without
the frequency of charge intervals under these circumstances.
constant attention. It is necessary to make a periodic check to
determine if the charger is operating correctly. Check for the
/\ CAUTION: A battery should always be recharged
following conditions:
Xl\ immediately following a complete discharge.
Never allow it to remain in a discharged condition,
1. Battery temperature is too high-The temperature in a
since permanent damage may result.
battery will not normally rise more than 14° C (25° F) during an
eight hour charging period. Higher temperatures indicate that
Types of Battery Charges
the charging rate needs adjustment.
1. DAILY CHARGE-This charge is normally eight hours and
will keep the battery fully charged if the battery is not 2. Continuous operation of the charger-Check the automatic
discharged below the limit. controls on the charger. Check the charging rate. A low
charging rate can be the problem.
2. EQUALIZING CHARGE-This charge is at a low rate and
balances the charge in all of the cells. The equalizing charge is 3. Continuous operation of a charger at a high rate-Normally,
normally given approximately once per week and isthree hours the charging rate begins at a high rate and decreases as the
at a low rate in addition to the regular charging cycle. The most battery becomes charged. If the rate does not decrease, the
accurate specific gravity measurements for a charged battery control need repair or adjustment.
will be after an equalizing charge.
WARNING: Always connect the positive cable to
NOTE: Sometimes the capacity of a battery is not enough to the positive terminal and connect the negative
complete a work period. Check for the following conditions: terminal. Any other connection will cause injury
and damage.
• The battery is too small for the job.
• The battery is not fully charged. WARNING: Always charge the battery at the end
of the work period (shift). Never let the specific
• The battery charger is not operating correctly. gravity reach a level less than the limits shown in
• The battery is near the end of its service life. the manual.
Methods of Charging WARNING: Always deenergize the charger

before you connect or disconnect the charger from
There are three methods of charging a battery. the battery.
1. GRADUAL CHARGE-This method uses a solid state How to Know when the Battery is Fully Charged
automatic battery charger. The charging rate begins at 20-25
amps/100 amp-hours and decreases to less than 5 amps/100 1. During charging, the voltage increases slowly. When the
amp-hours when the battery is 80% charged. The charging battery is fully charged, the voltage level is constant.
current decreases when the voltage across the cell increases
9-9
Yale
2. Remove a vent cap and look in the opening. If you see Equipment Needed
bubbles in the electrolyte, the battery is either fully charged
or in the final stage of charging.
• A lifting device to remove the battery from the lift truck.
• Racks to hold the batteries during charging and
3. The specific gravity reading is constant and within the storage. These racks must be made of wood and must not
limits of a charged battery. If the temperature increases after be metal unless the metal racks are covered with an
the battery is charged, the specific gravity will decrease a small insulating material.
amount.
• A battery charger that will charge your batteries.
4. Constant meter indications on the charger will indicate the • Tools for maintenance.
end of the charging cycle.
• An area with a drain for cleaning batteries and battery
compartments.
Battery Charging Area
To increase the service life and reduce maintenance, a special • Distilled water.
area is needed for charging the batteries. The following • Air and water supplies for cleaning.
information should be considered when setting up an area.
• Maintenance records.
1. Location of power supply. • A work bench.
2. Ventilation. Hydrogen gas comes from the batteries during • Spare parts and repair equipment.
charging. • Protective clothing and safety equipment for handling
batteries.
3. Drains for cleaning the batteries.
• Water sources for washing eyes and preventing acid
4. Type and size of the batteries. burns.
• Install a NO SMOKING sign in the service area.
5. Type of lift truck.
• Keep the charger in a clean, dry area with good
6. Distances that the lift trucks must travel for service. ventilation.
7. Safety regulations and instructions.

Yale
TROUBLESHOOTING-BATTERY

Battery overheats on discharge Over discharge Limit discharge to 1.110 specific gravity.
Put more batteries into service. Set up
more frequent charging schedule.
Excessive load Determine cause of overload and correct.
Put more batteries into service if
equipment requirements exceed battery
capacity
Not fully charged prior to work Needs more frequent and complete
assignment, resulting in over discharge charging
Electrolyte levels low Add water as required. Do not assign
battery to work if levels are below top of
plates.
When overheating is confined to few Install heat insulating material between
cells, nearby operating equipment may equipment cells with air circulating space
be source between
Operating in high ambient temperatures Provide cool location for charging and
good ventilation
Low electrolyte level Broken or cracked jar Replace jar
Water additions neglected or cell missed Better maintenance supervision. Add
in previous water addition. water as required to all cells.
Overcharging Adjust charging equipment
a. Voltage relay set for many cells a. Connect relay for proper number of
cells
b. Timer set for too many hours b. Reduce time
c. Voltage change rate relay operating c. Reduce voltage value at which voltage
relay operates
Specific gravity between cells not uniform Overfilled with water Do not fill above high level - give
equalizing charge and adjust acid
Operating cell with cracked jar Replace jar and adjust acid
Acid not adjusted properly after jar Adjust acid specific gravity
change
Vent caps removed during operation Keep vent caps securely in place. Give
equalizing charge and adjust acid.
Electrolyte leaking through sealing Reseal and adjust acid
compound
Operating battery with broken coil cover Replace cover and adjust acid
Neutralizing agent in cell Keep vent caps in place at all times
except when adding water. Keep battery
clean.
Unequal cell voltages Refer to Unequal Cell Voltages
Unequal cell voltages Over discharge. Also more than .020 Give an equalizing charge and do not
points spread in specific gravity from discharge below 1.110
average.
Lack of equalizing charges Give an equalizing charge periodically
Internal shunt Make internal inspection of low voltage
cell and correct cause. Check for split
separator and moss short.
9-11
Yale
TROUBLESHOOTING-BATTERY

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

Half tap on cells for lower voltage circuit Remove tap and connect load to battery
terminals through resistance
External source heating certain cells Install heat insulating material between
heat source and battery
Impurities in cell Add only distilled or approved water to
electrolyte
Variation in charge rate Take readings when charge rate is
constant
Battery will not work full shift Uneven cell voltages Give an equalizing charge
Low electrolyte levels Refer to Low Electrolyte Level

Battery not charged before work cycle Check charging schedules. Do not assign
discharged battery to work.
One or more jars leaking electrolyte Replace broken jars
Incorrect battery (number of cells) Install battery with correct voltage and
assigned to equipment capacity to equipment
Fully charged specific gravity below Adjust specific gravity to normal

normal
Impurities in electrolyte Add only distilled or approved water to
electrolyte
Operator "riding the brake" Discourage practice
Using reverse in place of braking Discourage practice
Inexperienced operator Instruct him on power conservation

Load excessive Use larger battery or reduce load
Wheels, axles and bearings need grease Plan lubrication schedule
Tires under inflated or wrong type Plan periodic check of air pressure
Brakes dragging Adjust brakes properly
Series field in motor shorted or grounded Replace field and remove ground
Armature needs repair Replace or repair armature
Ground on equipment Find ground and insulate
Excessive grades Use larger battery or revise battery

charge schedule
Capacity or equipment assigned to job Reassign equipment
is inadequate
9-12
Yale
Industrial Trucks
SECTION 10
10 USER SUPPORT INFORMATION

Yale
Industrial Trucks
USER INFORMATION
SERVICE PARTS ORDERING INSTRUCTIONS 10-1

TECHNICAL PUBLICATIONS 10-1
PARTS MANUAL 10-1
OPERATING MANUAL 10-1
OPERATOR TRAINING 10-1
SERVICE TRAINING COURSES 10-1
SERVICE TRAINING MATERIALS 10-1
iCK
.. - i
'ÿ
'
"
WM/ -
Yale
Industrial Trucks user support information
Your investment in a Yale® industrial truck is important to you and to your Yale industrial truck dealer. You measure the return on your
investment through the drivers who operate the trucks and the mechanics who service them safely and efficiently.
A "Guide to Lift Truck Use and Maintenance", which addresses lift truck safety in the workplace, good maintenance practices and training
programs, is available from your Yale industrial truck dealer. Order manual #2020.
The following information and programs are intended to help you achieve your investment objectives.
SERVICE PARTS ORDERING INSTRUCTIONS The Operating Manual describes various operating techniques
and safety warnings for the operator. The Operating Manual
also contains a guide to safe maintenance practices and
In order to avoid delay, unnecessary correspondence and to
recommended schedules for maintenance.
have your orders filled correctly, promptly and at the least
possible expense, the following is the recommended
If the Operating Manual is missing from any Yale industrial
procedure to use when ordering replacement parts.
truck, it should be replaced. Replacement copies are available
for a nominal fee from your Yale industrial truck dealer.
Contact your authorized Yale industrial truck dealer and give
him the following information: OPERATOR TRAINING
1. Your Purchase order number.

Yale "Basic Operator Training" program helps industrial truck
2. Complete invoicing and shipping address. users increase materials handling productivity and safety
through proper lift truck operation training and motivation. The
3. Specify the method of shipment, otherwise the least Yale program is based upon real life experience-not theoretical
expensive method will be used. concepts. We developed a "complete" program that is totally
self-contained-incorporating the most modern instructional
4. Correct part number(s) and description(s). Use your parts techniques, including elements of self-study, audio-visual
manual as a reference. support (both video and slides) and classroom study.
SERVICE TRAINING COURSES
5. Model and serial number of the truck.
TECHNICAL PUBLICATIONS User and Yale industrial truck dealer service technicians can
improve their technical ability for maintaining and repairing Yale
Technical literature, with detailed information, is available at a Industrial Trucks and reduce down-time and cost by
nominal fee to assist users to effectively maintain Yale participating in Yale sponsored Service Training courses. A
industrial trucks in a safe, useful condition. Parts Manuals with variety of mechanical, electrical and electronic subjects are
complete replacement parts identification, Service offered at published tuition rates. Courses are available at user
Maintenance Manuals which provide service and overhaul and Dealer facilities in addition to regularly scheduled courses
procedures and additional copies of this Operating Manual, can which are conducted at Yale Corporate Headquarters in
be obtained from your Yale industrial truck dealer. Flemington, New Jersey.
PARTS MANUAL-MPW, MPE, MPC, MLW-1604 SERVICE TRAINING MATERIALS
Your own service training efforts are supported through a

OPERATING MANUAL- MRW, MSW, MCW-1605
complete line of Yale Service Training materials. An index is
(5192838-06)
available from your Yale industrial truck dealer which lists
textbooks, audio-visual programs, films and their cost which
To provide instructions for safely operating and servicing Yale will provide your trainer with everything necessary to conduct
industrial trucks, each truck is equipped with an Operating service training for your organization.
Manual.
For additional information or assistance in obtaining these user support publications and programs, contact your Yale industrial truck
dealer or the Yale Materials Handling Corporation, 15 Junction Road, Flemington, New Jersey 08822-9499.
10-1
Yale
Industrial Trucks
NOTES
10-2
Yale
Industrial Trucks
SECTION 11
11 ALPHABETICAL INDEX
'
'
;j ;
:
-It ÿ .
ÿ
"f ÿ
v>
sis
ÿ
. M
ÿ
'
Yale
IndustrialTrucks ALPHABETICAL INDEX
A C
Accelerator - Adjustment 3-22 Charging the Battery 9-8
Adjustments 5-9, 7-8 Methods of Charging 9-9
Brake Adjustment-MPC, MTR 5-9 CoastControl 1-11
Brake Adjustment-MPW, MLW and MPE 5-9 Commutator 3-31
Pull Rod- MPW, MPE, MPC 7-8 Problems 3-33
Rear Forks 7-8 Repairs 3-40
Service and Parking Brake Linkage-MPC, MTR ... 5-10 Contactors 3-24
ANSI Information 1-14 Component Replacement 3-26
Replacement 3-25
Testing 3-25
B Control Handle 1-7, 6-1
Battery 2-1 Direction and Speed Control 1-7
Connector 1-9 Horn Button 1-7
Indicator 1-10 Installation-MPE 6-3
.....
Removal and Installation 2-1 Installation-MPW and MLW 6-1
_...._
Storage 1-18 Lift Button 1-9,1-18
Battery and Charging System 9-1 Lower Button 1-9, 1-18
Battery Maintenance 9-5 Removal-MPE 6-2
Adding Water 9-7 Removal-MPW and MLW 6-1
Battery Charging Area 9-10 Reversing Button 1-7
Battery Temperature 9-8 Control Handle and Tower 6-4
Cleaning the Battey 9-7 Installation-MPC and MTR 6-5
Equipment Needed 9-10 Removal-MPC and MTR 6-4
How to Know when the Battery is Fully Charged 9-9 Control Handle Head 6-4
Hydrometer 9-7 Installation 6-4
Manitenance Records 9-6 Removal 6-4
Troubleshooting the Charger 9-9 Controller 3-15
Types of Battery Charges 9-9 Replacement 3-16
Bevel Pinion and Gear Adjustment 4-7 Conversion Table - Metric / English 2-26
Bolts and Screws 2-19, 2-20 Current Limit - Adjustment 3-16
Brake Linkage 5-5 Curtis PMC Transistor Controller 3-15
Installation-MPC, MTR 5-7
Installation-MPE 5-5
Removal-MPC, MTR 5-6 D
Removal-MPE 5-5 Direction and Speed Control 1-7
Brake Release Arm 5-4 Disabled Lift Truck 1-14
Installation-MPW, MLW and MPE 5-5 Drive Motor 3-38
Removal-MPW, MLW and MPE 5-4 Assembly 3-40
Brake Shoe and Lining Assembly 5-1 Brush Replacement 3-37
Installation-MPC, MTR 5-3 Testing 3-41
Installation-MPW, MLW and MPE 5-2 Drive Unit 4-5
Removal-MPC, MTR 5-3 General 4-1
Removal-MPW, MLW and MPE 5-1 Installation 4-6
Brake Switch 3-26 Removal 4-5
Brake System 5-1 Drive Unit Compartment Cover 2-1
Brakes 1-8 Removal and Installation 2-1
Braking 1-8 Drive Wheel 4-1
.......
Brush Replacement 3-36 Installation 4-3
Removal 4-1
C
Capacity Rating 1-1 E
Caster Wheels, Replacement-MPE, MPC 7-10 Electrical System 3-1
Caster Wheels 2-4,7-10 General 3-1
Assembly-MPE, MPC 7-10 Electronic Logic Module (ELM) 3-22
Disassembly-MPE, MPC 7-10 General 3-22
Installation-MPE, MPC 7-10 Operation 3-23
Removal-MPE, MPC 7-10 Testing 3-23
11-1
Yalo
IndustrialTrucks ALPHABETICAL INDEX
F L
Fast Speed Control 1-10 Lower Housing 4-4
Fasteners Assembly 4-4
Bolts and Screws 2-19, 2-20 Disassembly 4-4
Introduction 2-18 Lubrication Instructions 2-4
Strength Identification 2-18 MPC 2-8
Studs and Nuts 2-21 MPE 2-6
Thread Nomenclature 2-18 MPW, MLW 2-5
Torque Nuts with Nylon Inserts 2-22 MTR 2-10
Torque Value Guide 2-23
M
Frame 2-2
Maintenance Schedules
Assembly 2-2
Drive Unit 2-13
Separation 2-2
Electrical System 2-13
Fuses 3-26
Hydraulic System 2-12
Lubrication 2-12
G Mast/Carriage & Attachment 2-12
Gear Oils 2-16 Safety and Operational 2-11
Approved Sources 2-16 Model Code 1-1
Grease 2-17
O
Operating Instructions, General 1-1
H Operating Procedures 1-13
Handrail Control 1-10 General 1-3
Fast Speed Button 1-10 Operator Pre-Checks and Inspection 1-3
Height Limit Switch 3-27
P
Horn Button 1-7
Parking Brake 1-8
Hourmeter 1-10
Parts Ordering Instructions 10-1
How to Select the Battery 9-4
Pick Assist - MPE 1-12
Battery Ratings 9-4
Pick Assist Switches-MPE (Optional) 3-30
Kilowatt Hours 9-5
Installation 3-30
Voltage of a Battery 9-4
Removal 3-30
Hydraulic Cylinder 8-5
Plugging 3-15
Hydraulic Oils 2-15
Adjustment 3-21
Hydraulic Pump 8-4
Pull Rod 7-4
Reservoir 8-4
Installation-MPW, MPE, MPC 7-6
Hydraulic Pump Motor 3-36
Removal-MPW, MPE, MPC 7-4
Brush Replacement 3-37
Tests 3-41 R
Hydraulic System 8-1 Raise Drive Tire 1-16
Raise Load Wheel 1-16
Rear Linkage and Load Wheel Assembly 7-1
L
Lead-Acid Batteries 9-3
Chemical Reaction 9-3
Recommended Schedule of Maintenance 2-11
Specific Gravity 9-3
Relays 3-27
Lift Button 1-8
Relief Valve 8-7
Lift Linkage and Load Wheels, General 7-1
Reversing Button 1-7
Load Platform Linkage-MLW 7-12
Rocker Arm 7-6
Installation 7-12
Removal 7-12
Load Wheel Axle 7-12
Installation-MTR, MLW 7-12 S
Removal-MTR, MLW 7-12 Safe Maintenance Procedures 1-13
Load Wheels 2-4,7-1,7-11 Safety and Informational Labels 1-3
Installation-MPW, MPE, MPC 7-1 Safety and Operational Check List 1-4
Installation-MTR, MLW 7-12 Safety Tips-Industrial Batteries 9-1
Removal-MPW, MPE, MPC 7-1 Serial Number 1-1
Removal-MTR, MLW 7-12 Service Courses 10-1
Lower Button 1-8 Shut Down Procedure 1-4
11-2
Yale
Industrial Trucks ALPHABETICAL INDEX
s W
Solid Tires 2-3 MPC Type "E" And "EE"-S/N A803N08600U and up
Install the Tire on Wheel 2-3 5052547-00 Diagram, 3-88
Remove Tire from Wheel 2-3 5052547-00 Options Diagram, 3-90
Steering 1-9 5052547-00 Schematic, 3-86
Steering Handle Switches 3-28 MPC Type "E" and "EE"-S/N A899N01501U and up
Installation 3-28 5051147-00 Diagram, 3-94
Removal 3-28 5051147-00 Options Diagram, 3-96
Studs and Nuts 2-21 5051147-00 Schematic, 3-92
System Operation 8-1 MPC Type "E"-From S/N 576761 to A803N08599U
Lifting a Load 8-1 5048737-00 Diagram, 3-82
5048737-00 Options Diagram, 3-84
5048737-00 Schematic, 3-80
T
MPC Type "E"-Up to S/N 576760
Technical Publications 10-1
9-5
5046247-00 Diagram, 3-70
The Battery as a Counterweight
1-11 5046247-00 Options Diagram, 3-72
Tilt Control
2-2, 2-5 5046247-00 Schematic, 3-68
Tires and Wheels
4-8 MPC Type "EE"
Tooth Contact Pattern
Torque Nuts with Nylon Inserts 2-22 5048037-00 Diagram, 3-76
Torque Value Guide 2-23 5048037-00 Options Diagram, 3-78
Torque Values, Hydraulic Fittings 2-25 5048037-00 Schematic, 3-74
Training 10-1 MPE Type "E" and "EE"-S/N A803N08541 U and up
Materials 10-1 5052537-00 Diagram, 3-64
Operator Courses 10-1 5052537-00 Options Diagram, 3-66
Transistor Motor Controller 3-15 5052537-00 Schematic. See Wiring
Control 3-15 MPE Type "E"-From S/N 576761 to A803N08540U
Current Limit 3-15 5048687-00 Diagram, 3-58
General 3-15 5048687-00 Options Diagram, 3-60
Low Voltage Protection 3-16 5048687-00 Schematic, 3-56
Replacement 3-16 MPE Type "E"-Up to S/N 576760
Static-Return-To-Off 3-15 5045797-00 Diagram, 3-46
Thermal Protection 3-15 5045797-00 Options Diagram, 3-48
Troubleshooting 8-8 5045797-00 Schematic, 3-44
Battery 9-11 MPE Type "EE"-Up to S/N 576760
Fault Procedures - Electrical System 3-17 5047437-00 Diagram, 3-52
Hydraulic Cylinders 8-8 5047437-00 Options Diagram, 3-54
Hydraulic Pump 8-9 5047437-00 Schematic, 3-50
Lift Assemblies 8-8 MPW - Type "E" And "EE"-S/N A838N06614U and up
Truck Weight 1-1 5052557-00 Diagram, 3-118
Trucks in Storage 1-16 5052557-00 Options Diagram, 3-120
5052557-00 Schematic, 3-116
MPW Type "E"-From S/N 576820 to A838N06613U
U 5048727-00 Diagram, 3-112
Upper Housing 4-3 5048727-00 Options Diagram, 3-114
Installation 4-3
5048727-00 Schematic, 3-110
Removal 4-3
MPW Type "E"-Up to S/N 576819
Upper Link 5045807-00 Diagram, 3-100
5045807-00 Schematic, 3-98
MPW Type "EE"-Up to S/N 576819
W 5047447-00 Diagram, 3-106
Warranty Information 2-4 5047447-00 Options Diagram, 3-108
Wiring 5047447-00 Schematic, 3-104
MLW Type "E"-S/N B828N01501S and up MTR Type "E" and "EE"-S/N A817N05791U and up
7524767-00 Diagram, 3-142 5052567-00 Diagram, 3-136
7524767-00 Options Diagram, 3-144 5052567-00 Options Diagram, 3-138
7524767-00 Schematic, 3-140 5052567-00 Schematic, 3-134
11-3
Yale
Industrial Trucks ALPHABETICAL INDEX
w
MTR Type "E"-From S/N 576846 to A817N05790U
5048747-00 Diagram, 3-130
5048747-00 Schematic, 3-128
MTR Type "E"-Up to S/N 576845
5046677-00 Diagram, 3-124
5046677-00 Schematic, 3-122
11-4

Yale MPE060 Service Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Yale MPE060 Service Manual

Uploaded by

Copyright:

Available Formats

MAINTENANCE MANUAL

For Service & Parts Contact

Yale Materials Handling Corp

OVERALL PALLET FORK LENGTH

OVERALL PALLET FORK WIDTH

2 GENERAL TRUCK AND LUBRICATION SCHEDULE

7 LIFT LINKAGE AND LOAD WHEEL

9 BATTERY AND CHARGING SYSTEM

10 USER SUPPORT INFORMATION

DESCRIPTION PAGE NUMBER

OPERATING INSTRUCTIONS-GENERAL 1-1

OPERATING INSTRUCTIONS-GENERAL be considered when operating on elevated floors, elevators,

Serial Number No additions, omissions or modifications should be made that

1. LABEL, DIRECTION ARROW

Truck Weiqht With

Volts Use a Type

Figure 1-2 - Serial Number, Nameplate, and Warning Label Locations-MPC

Figure 1-3 - Serial Number, Nameplate, and Warning Label Locations-MTR

LABEL, DIRECTION ARROW

ÿ Do not run over objects on the roadway surface as truck

Record of Fluid Added

Figure 1-5 - Motorized Hand Trucks and Tractor

OPERATING CONTROLS-CONTROL HANDLE

WARNING: The reversing button will cause rapid

Direction and Speed Control

Lower Button BRAKE OFF

Figure 1-9 - Hand Brake Levers-MPC and MTR

Make sure there is adequate turning clearance. When traveling

Figure 1-14 - Steering Directions-MTR

Figure 1-13 - Steering Directions-MPC

BATTERY INDICATOR AND HOURMETER

Figure 1-17 - Handrail Controls-MPE

1 CURTIS Fast Speed Button, return the direction/speed control to

2. BATTERY INDICATOR 3. HOURMETER

Figure 1-16 - Battery Indicator/Hourmeter

The battery indicator features a 10 LED (Light Emitting Diode)

The hourmeter continually displays total operation hours. The

Figure 1-18 - Fast Speed Control-MPC and MTR

PICK ASSIST-MPE (OPTIONAL)

to travel in the forward direction (forks trailing). Release the

COAST CONTROL-MPE (OPTIONAL)

A coast control feature is available forthe MPE truck as optional

Travel with forks trailing when possible. Steering the truck is

Figure 1-22 - Forks Trailing Position

Operate forks first when entering a confined area or elevator.

Figure 1-23 - Forks First Position

SAFE MAINTENANCE PROCEDURES

No additions, omissions or modifications should be made that

HOW TO RAISE LOAD WHEELS

Figure 1-28 - Blocking MPC Models

Figure 1-29 - Blocking MTR Models

Battery chargers should be disconnected from the AC power

GENERAL TRUCK AND LUBRICATION SCHEDULE

DESCRIPTION PAGE NUMBER

GENERAL BATTERY-REMOVAL AND INSTALLATION

/\ WARNING: Do not make repairs or adjustments

The drive unit compartment cover must be removed for access

1. Move the key to the OFF position. Disconnect the battery.

2. To remove the cover, loosen and remove the four button

/\ WARNING: The capacitor in the motor controller

6. Remove the blocks from under the truck.

WARNING: The lifting and carrying of solid tires is

Install the Tire on Wheel

MPW 080 10x5 POLY