service repair manual

1. ERP030-040TH (F807)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524204497 0100 YRM 1073 06/04
DC MOTOR MAINTENANCE.......................................................................................... 524158039 0620 YRM 0294 03/08
AC MOTOR REPAIR...................................................................................................... 524214915 0620 YRM 1115 06/06
TRANSAXLE................................................................................................................... 524204498 1300 YRM 1074 07/09
STEERING SYSTEM...................................................................................................... 524204499 1600 YRM 1075 02/08
BRAKE SYSTEM............................................................................................................ 524204500 1800 YRM 1076 03/07
HYDRAULIC SYSTEM.................................................................................................... 524204501 1900 YRM 1077 09/13
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MANUAL CONTROL VALVE......................................................................................... 524204502 2000 YRM 1085 10/06
ELECTRO-HYDRAULIC CONTROL VALVE................................................................. 524204503 2000 YRM 1086 06/04
TILT CYLINDERS........................................................................................................... 524150790 2100 YRM 0103 03/07
CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507,
B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515,
C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND
E564).......................................................................................................................... 524223768 2100 YRM 1139 02/14
TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS
PROGRAM................................................................................................................. 524183085 2200 YRM 1058 04/11
ELECTRICAL SYSTEM.................................................................................................. 524204505 2200 YRM 1078 07/05
AC MOTOR CONTROLLERS/DISPLAY PANEL........................................................... 524204504 2200 YRM 1087 09/13
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
MAST - DESCRIPTION................................................................................................... 524158890 4000 YRM 0521 03/06
MAST - REPAIR.............................................................................................................. 524158891 4000 YRM 0522 07/10
MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508,
B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551,
C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ 524223776 4000 YRM 1148 02/14
FOUR STAGE (QUAD) MAST........................................................................................ 580061048 4000 YRM 1176 09/13
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
PERIODIC MAINTENANCE............................................................................................ 524204506 8000 YRM 1079 06/09
CAPACITIES AND SPECIFICATIONS........................................................................... 524204507 8000 YRM 1080 03/09
DIAGRAMS..................................................................................................................... 524204508 8000 YRM 1081 04/07
PART NO. 524204496 (12/14)

2. 100 YRM 1073 Introduction
Introduction
GENERAL
This section contains a description and the service pro-
cedures for the parts of the frame. These parts include
the frame, counterweight assembly, overhead guard,
hood and seat assembly, access panels, and labels.
Throughout this section, forward will refer to travel in
the direction of the forks and left and right will be deter-
mined by an operator sitting in the seat facing forward.
See Figure 1.
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 1. Truck Orientation
DESCRIPTION OF OPERATION
The frame is a single weldment with mounts for the
counterweight, overhead guard, mast, steering system,
hydraulic system and transaxles. See Figure 2. The
battery cover opens on hinges to give access to the bat-
tery compartment. The weight of the battery is a major
part of the counterweight system on an electric lift truck.
A slot in the overhead guard permits removal of the
battery without removing the overhead guard. Spacers
may be added under the battery as required on some
models.
Each model of lift truck has a cast-iron counterweight
with a weight necessary for the indicated capacity. An
access panel on the top/rear of the counterweight gives
access to the electronic controllers.
The hydraulic pump and motor, steering pump and mo-
tor, drive motors and transaxles, and hydraulic tank are
under the floor plates in the operator compartment. The
floor plates are held in position by tabs and can be re-
moved to give access to components underneath.
The hydraulic control valve is fastened to the front of the
battery compartment. Three covers protect the control
valve and control linkage. The covers are fastened in
position by machine screws. The top covers are locked
in place and must be released and swung open before
attempting to open the battery cover.
Figure 2. Frame
1

3. Introduction 100 YRM 1073
DISCHARGING THE CAPACITORS
WARNING
Do not make repairs or adjustments unless you
have both authorization and training. Repairs
and adjustments that are not correct can create
dangerous operating conditions. Do not operate
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair
is necessary, attach a DO NOT OPERATE tag on
the steering wheel. Remove the key from the key
switch.
WARNING
Disconnect the battery before opening the drive
unit compartment cover or inspecting or repairing
the electrical system. If a tool causes a short
circuit, the high current flow from the battery can
cause personal injury or property damage.
WARNING
Some checks and adjustments are done with the
battery connected. Do not connect the battery until
the procedure tells you to do so. Never have any
metal on your fingers, arms, or neck. Metal items
can accidentally make an electrical connection and
cause injury.
WARNING
Before performing any tests or adjustments, block
the lift truck to prevent unexpected movement.
WARNING
The capacitor in the transistor controller(s) can
hold an electrical charge after the battery is dis-
connected. To prevent an electrical shock and
personal injury, discharge the capacitor(s) before
inspecting or repairing any component in the drive
unit compartment. Wear safety glasses. Make
certain that the battery has been disconnected.
CAUTION
To avoid controller damage, always disconnect the
battery, discharge the capacitor(s), and never put
power to the controller while any power wires are
disconnected. Never short any controller terminal
or motor terminal to the battery. Make sure to use
proper procedure when servicing the controller.
1. Turn key switch to OFF position and disconnect the
battery. Block load wheels to prevent lift truck from
moving.
2. Open the electrical compartment at the rear of the
truck.
a. Remove the two screws securing the electrical
compartment door closed.
b. Tilt the door back on its hinges to open the
compartment.
WARNING
DO NOT short across the motor controller terminals
with a screwdriver or jumper wire.
NOTE: Some lift trucks are equipped with a premium
controller, which controls the hydraulic motor as well as
the traction motors.
3. Discharge the capacitor in the controller by con-
necting a 200-ohm, 2-watt resistor across the con-
troller’s BT+ and B terminals for 10 seconds using
insulated jumper wires. See Figure 3.
4. On the premium controller, also connect the 200-
ohm, 2-watt resistor across the controller’s P+ and
B terminals for 10 seconds using insulated jumper
wires. See Figure 4.
5. Remove the 200-ohm, 2-watt resistor before recon-
necting the battery.
2

4. 100 YRM 1073 Covers and Floor Plates
1. POSITIVE CONNECTION (BT+)
2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 3. Discharging the Capacitors (Standard)
1. POSITIVE CONNECTION (BT+)
2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. POSITIVE CONNECTION (P+)
Figure 4. Discharging the Capacitors (Premium)
Covers and Floor Plates
Many system components, such as hydraulic hoses,
pump and motor, and wiring harnesses, are located in
the area around and under the operator compartment.
Various covers and floor plates provide access to these
components during service and securely cover these
areas during normal operation. See Figure 5.
3

5. Covers and Floor Plates 100 YRM 1073
1. CAPSCREW
2. ATTACHING HARDWARE
3. CLIP NUT
4. HARNESS COVER (ELECTRIC VALVE)
5. HARNESS COVER (MANUAL VALVE)
6. CAPSCREW
7. ANTI-SLIP PAD
8. ANTI-SLIP PAD
9. RIGHT FLOOR PLATE
10. CENTER FLOOR PLATE
11. LEFT FLOOR PLATE
12. HOSE COVER
Figure 5. Covers and Floor Plates
4

6. 100 YRM 1073 Overhead Guard Repair
Overhead Guard Repair
WARNING
The overhead guard is part of the operator protec-
tion system. Do not operate the lift truck without the
overhead guard correctly fastened to the lift truck.
The overhead guard is designed to provide protection
to the operator from falling objects and in the event of
a tip over. A high visibility design allows for an unob-
structed view while maintaining structural integrity. Re-
moval of the battery is simplified by the slot in the over-
head guard. This provides access to the battery with an
overhead lifting device without removing the overhead
guard.
REMOVE
WARNING
The overhead guard is heavy. Make sure the sling,
chain, eyebolts, and crane or lifting device have the
capacity to lift the overhead guard.
1. Remove the six capscrews, washers, and nuts that
secure the supports of the overhead guard to the
counterweight and cowl. See Figure 6.
2. Use an overhead lifting device and sling to lift the
overhead guard until it is just higher than the coun-
terweight mounts.
NOTE: Tie a cord around the wires from each post of
the overhead guard before removal. Remove the wires
from the post. Untie the cord from the wires and tape
each end of the cord to the overhead guard where it en-
ters the post. Use the cord to pull the wires up through
the post when installing the overhead guard.
3. Tag and disconnect the wiring from each post of
the overhead guard. Carefully remove the wiring
if necessary.
4. Completely remove the overhead guard from the lift
truck.
INSTALL
1. Position overhead guard just above mounts on the
counterweight and cowl using an overhead lifting
device and sling.
2. Route the wires through each overhead guard post
and install to lights as removed.
3. Lower overhead guard supports onto the mounts.
4. Install and tighten six capscrews, washers, and
nuts securing overhead guard to the lift truck.
Tighten capscrews to 134 N•m (99 lbf ft).
5. Remove sling and overhead guard.
1. OVERHEAD GUARD
2. COUNTERWEIGHT
3. FRAME
4. CAPSCREWS (4) FRONT
5. CAPSCREWS (2) REAR
6. CAPSCREWS (2) UPPER
7. CAPSCREWS (2) LOWER
Figure 6. Overhead Guard Mounting
5

7. Hood and Seat Assembly 100 YRM 1073
Hood and Seat Assembly
The hood is the platform for the seat assembly and is
located above the battery. It functions as a battery re-
straint that completely covers the battery compartment.
See Figure 7. Its function as the battery restraint, when
correctly locked to the frame, is to hold the battery in the
battery compartment if an accident causes the lift truck
to tip over. The hood is composed of a plastic cover
attached to a metal frame. Two hinges at the back of
the hood attach it to the frame. A sliding latch mech-
anism on the front of the hood locks the hood closed
during operation. A double-dampened, gas-controlled
strut holds the hood in the open position.
Opening the sliding latch unlocks the hood from the
frame so the hood can be raised to access the battery.
See Figure 8. The latch can only be accessed after
releasing and raising the hydraulic levers and linkage
assembly up and out of the way. A button on each side
of the assembly can be pressed to release the assem-
bly so it can be moved clear of the hood on its hinged
bracket. The latch must be in good condition and prop-
erly secured before the lift truck can be operated. If the
latch does not lock the hood in the closed position, the
hydraulic levers and linkage assembly will not lock into
position and the lift truck will not operate.
A large, red button switch is mounted on the hood at
the right side of the seat assembly. This switch is an
emergency battery disconnect that allows the operator
to quickly disconnect the battery while seated on the lift
truck in case of an emergency.
The seat assembly slides on seat rails that are fas-
tened to the hood by four capscrews. A lever at the
left front side of the base controls the adjustment of the
seat to the forward and backward positions. Optional
seats are available in cloth or vinyl with features such
as semi-suspension, full suspension, and limited swivel.
All seats have a seat switch installed in the bottom cush-
ion that senses operator presence. When the operator
is not on the seat, the seat switch opens and interrupts
the controller stopping operation of the lift truck.
The hood, seat belt, hip restraint brackets, seat, and
seat mount are all parts of the operator restraint sys-
tem. Checks and adjustments for the operator restraint
system are described in the Operating Manual and the
section Periodic Maintenance 8000 YRM 1079.
To raise the hood and seat assembly, move the seat to
the rear of the hood if necessary. Move the steering
column to the most forward position. Release and raise
the hydraulic levers and linkage. Open the latch mech-
anism and raise the hood.
1. SEAT 2. HOOD 3. SEAT SWITCH CONNECTOR
Figure 7. Hood and Seat Assembly
6

8. 100 YRM 1073 Hood and Seat Assembly
1. SLIDING LATCH
MECHANISM
2. HOOD
3. FRAME
Figure 8. Latch Mechanism
REMOVE
1. Disconnect the battery connector.
2. Tag and disconnect the electrical connectors to the
emergency battery disconnect, the seat switch, and
the hood and latch position switches. Remove hood
and latch switches if necessary.
3. Remove the emergency battery disconnect switch
and hood and latch position switches, if necessary.
NOTE: The seat assembly does not have to be removed
from the hood to remove the hood from the lift truck. To
remove the seat, remove the four capscrews that fasten
the seat base to the hood. Lift the seat assembly from
the hood. If the seat is not being removed, raise the
hood.
4. Remove the stop screws from the seat assembly,
hold the slide function lever in the open position,
and slide the seat from the mounting bracket. Re-
move mounting bracket from hood if necessary.
5. Disconnect the double-dampened, gas-controlled
struts by removing the locking clips retaining the
struts to the hood and the capscrews securing the
lower ends to frame. Move the hood to the closed
position.
6. Remove capscrews securing hood mounting brack-
ets to hood and lift hood from truck.
7. Slide hood mounting brackets from studs on coun-
terweight brackets. Replace bushings if necessary.
8. Remove the capscrews, washers, and nuts retain-
ing the hood cover to its metal frame if necessary.
INSTALL
1. Install the capscrews, washers, and nuts to secure
the hood cover to its metal frame.
2. Install new bushings to mounting brackets if neces-
sary. Slide hood mounting brackets onto counter-
weight bracket studs as removed.
3. With the aid of an assistant or overhead lifting de-
vice and sling, position the hood on the hinges and
install the four capscrews. Tighten snugly but do
not torque at this time. Place the hood in the closed
position.
4. Open and close the hood to check for proper clear-
ance. The minimum clearance between the hood
and the front plate of the frame is 3.5 mm (0.14 in.).
Check to ensure the proper clearance.
5. Tighten the capscrews to 86 N•m (63 lbf ft).
6. Raise the hood. Align and install the gas-filled
struts and install the locking clips to retain the
struts to the hood and install capscrews to secure
the lower ends to frame.
7. If the seat assembly has been removed, install the
mounting bracket to the hood using capscrews,
washers, and nuts. Hold the slide function lever in
the open position and slide the seat into mounting
bracket tracks. Release the lever and install the
stop screws.
8. Install hood and latch switches and emergency bat-
tery disconnect switch, if removed, and adjust as
necessary.
9. Connect the wiring harnesses to the seat switch,
emergency battery disconnect, and the hood and
latch position switches.
10. Close the hood. Make certain that the locking
mechanism to retain the hood is properly engaged.
Close the hydraulic linkage and covers.
11. Connect the battery connector.
7

9. Counterweight 100 YRM 1073
Counterweight
WARNING
Do not operate the lift truck if the capscrews for
the counterweight are not installed. When the
capscrews are removed, the counterweight can fall
from the lift truck.
A one-piece, cast iron counterweight is used to offset
the weight of the load. See Figure 9. The counterweight
is mounted to the rear of the truck using four mount-
ing bolts and is supported by a protruding flange of the
frame. See Figure 9. A compartment space, accessed
by a hinged door, has been designed into the center of
the counterweight to house the electrical connections.
A battery platform is used to support the battery on the
lift truck frame. The battery platform also serves as part
of the counterweight system and requires the use of an
overhead lifting device for removal or installation. Be
sure to replace the same battery platform, or one of
equal weight, if the platform must be removed.
Figure 9. Counterweight
REMOVE
1. Remove battery. See the section Periodic Mainte-
nance 8000 YRM 1079 for instructions on removing
the battery.
NOTE: It may not be necessary to remove the battery
platform. Perform only the steps necessary to complete
the required service.
2. Remove battery platform if necessary:
a. Remove the battery spacer and the acid tray
positioned on top of the battery platform.
b. Remove the two capscrews, washers, and nuts
retaining the platform to the frame.
c. Use a lifting device to lift the platform out of the
lift truck.
3. Remove overhead guard. See Overhead Guard
Repair.
4. Remove the two large screws securing the electri-
cal compartment access door in the closed position
and pull open the door.
5. Discharge the capacitor(s). See Discharging the
Capacitors.
NOTE: Make note of wires and cable routing for proper
reassembly.
6. Remove socket head screws and detach the con-
troller panel from the electrical compartment ac-
cess door. Remove wire ties securing wires and
cables to the door hinge mechanism.
7. Remove the electrical compartment access door
and hinges if necessary.
WARNING
The counterweight is very heavy. Make sure the
chains, eyebolts, and overhead lifting device have
the capacity to lift the counterweight.
8. Install a clevis on each of the overhead guard
mounts. See Figure 10. Install tempered, grade 8
bolts and nuts or the proper pins for each clevis.
Attach a chain to each clevis. Use an overhead
lifting device to hold the weight of the counter-
weight. Make sure the sling, chain, eyebolts, and
overhead lifting device have the capacity to lift the
counterweight.
8

10. 100 YRM 1073 Counterweight
1. CHAIN
2. OVERHEAD GUARD MOUNTS
3. CLEVIS
Figure 10. Lifting the Counterweight
9. Remove the four M20 × 2.5 × 60 capscrews and
hardened flat washers that hold the counterweight
to the frame. Four capscrews hold the counter-
weight to the frame from the inside and can be ac-
cessed from the battery compartment. Two of the
capscrews are located at the bottom of the coun-
terweight, while the other two are located approxi-
mately in the center of the counterweight. The nuts
for the capscrews are cast in the counterweight.
Refer to Figure 6.
10. Use the overhead lifting device to lift the counter-
weight off the mounting flange and away from the
frame. See Figure 9.
INSTALL
WARNING
The counterweight is very heavy. Make sure the
chains, eyebolts, and overhead lifting device have
the capacity to lift the counterweight.
1. Use an overhead lifting device to lift the counter-
weight into position. See Remove, Step 8. Some
assistance will be required to align the mounting
holes in the counterweight with those in the frame.
2. Install the four capscrews and hardened flat wash-
ers that hold the counterweight to the frame.
Tighten the capscrews to 435 N•m (321 lbf ft).
3. Disconnect the chain. Remove the clevis from each
overhead guard mount.
4. If removed, install the electrical compartment
hinges and door.
5. Install the controller panel to the inside of the electri-
cal compartment door using the proper socket head
screws. Secure wires and cables inside the electri-
cal compartment as removed.
6. Close the door to the electrical compartment and
secure using two large screws.
7. Install the battery platform and the acid tray in the
battery compartment.
a. Use an overhead lifting device to place the plat-
form into the lift truck.
b. Install the two capscrews, washers, and nuts
retaining the platform to the frame.
c. Install the battery spacer and the acid tray on
top of the battery platform.
8. Install the overhead guard. See Overhead Guard
Repair.
9. Install the battery. See the section Periodic Main-
tenance 8000 YRM 1079.
9

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12. Safety Labels 100 YRM 1073
Safety Labels
WARNING
Safety labels are installed on the lift truck to give
information about operation and possible hazards.
It is important that all safety labels are installed on
the lift truck and can be read.
DO NOT add to or modify the lift truck. Any change
to the lift truck, the tires, or its equipment can
change the lifting capacity. The lift truck must be
rated as equipped and the nameplate must show
the new capacity rating. Contact your Yale lift truck
dealer for a replacement nameplate.
If a label must be replaced, use the following procedure
to install a new label. See Figure 11, Figure 12, and
Figure 13.
WARNING
Always use solvents and paints in an area with ad-
equate ventilation. Do not use solvents or paints
near heat, fire, or electrical equipment that can cre-
ate sparks. Follow the manufacturer’s instructions
and cautions.
1. Clean the painted surface. Use household clean-
ing products to clean new paint and clean old paint
with cleaning solvent. DO NOT use solvent on new
paint. Make sure the surface is dry and is clean of
dirt, oil, and grease.
2. Remove the paper from the back of the label and
hold the label by the edges. Do not touch the ad-
hesive surface.
CAUTION
The label cannot be moved after it touches the sur-
face.
3. Carefully hold the label in the correct position above
the surface and carefully apply to the correct loca-
tion. Make sure that all air is removed from under
the label by smoothing any wrinkles or bubbles with
your fingers working from the center out. Check
that the corners and edges are tight against the sur-
face.
10

13. 100 YRM 1073 Safety Labels
A. SIDE VIEW B. REAR VIEW C. FRONT VIEW
1. OVERHEAD GUARD IMPACT RATING PLATE
2. MAST WARNING
3. YALE
4. OPERATOR RESTRAINT
5. TILT COLUMN
6. MAST WARNING
7. PINCH POINT
8. UNIT NUMBER DECAL
9. YALE
10. CORROSION/FREEZER
11. EE CONSTRUCTION
12. BATTERY SPACER WARNING
13. YALE
14. PATENTS AND TRADEMARKS
15. UL LABEL
16. AUXILIARY FUNCTION
17. SIDESHIFT
18. TILT
19. LIFT
20. LABEL (EUROPEAN ONLY)
Figure 11. Label Locations - General
11

14. Safety Labels 100 YRM 1073
1. BRAKE SYSTEM FLUID LABEL
2. HYDRAULIC OIL FILL LABEL
3. BRAKE SYSTEM FLUID TAG
Figure 12. Label Locations - Below Floor Plates
1. LOCK/UNLOCK
2. NAMEPLATE
3. PINCH POINT
4. PINCH POINT
5. OPERATOR WARNING
6. BATTERY DISCONNECT
7. PINCH POINT
8. NO RIDERS
9. PINCH POINT
Figure 13. Label Locations - Battery Compartment
Cover
12

15. 100 YRM 1073 Painting Instructions
Painting Instructions
WARNING
Always use solvents and paints in an area with
ventilation. Do not use solvents or paints near
heat, fire, or electrical equipment that can make
sparks. Follow the manufacturer’s instructions
and cautions.
1. Remove all dirt from the surface to be painted.
Clean the area to be painted. Use a solvent for
painted surfaces to remove grease and oil before
sanding. Do not use solvent on new paint. Make
sure all oil and grease is removed.
2. Use sandpaper to remove the top surface of paint
and rust from the metal. All metal surfaces where
the paint is completely removed, must be primed.
Apply primer before applying the paint.
CAUTION
DO NOT put tape on cylinder rods to protect from
paint. Use a thick layer of multipurpose grease to
protect cylinder rods. Cylinders can be damaged if
operated with tape on the cylinder rod.
3. Protect all surfaces that will not be painted.
DO NOT paint:
Pedal Pads
Lever Knobs
Instrument Panel
Steering Wheel
Labels and Information Plates
Seat Assembly and Rails
Information Case
Tires
Mast Chains and Hoses
Battery Connector
Key Switch
Cylinder Rods
All Plastic Covers
CAUTION
Do not paint the pads, plastic covers or knobs, ca-
bles, labels, information plates, or controls. Paint
can make some assemblies not operate correctly.
4. Paint the surfaces. Use the correct paint from your
dealer for Yale lift trucks. Follow the directions on
the container.
WARNING
Make sure all labels are installed after painting is
complete. Safety labels are installed on the lift truck
to give information about possible hazards. It is
important that all safety labels are installed on the
lift truck and can be read.
5. Check that all labels are installed in the correct lo-
cations on the lift truck. See Safety Labels.
NOTE: Use colors approved by Yale Material Handling
Corporation.
13

16. 1300 YRM 1074 Introduction
Introduction
GENERAL
This section contains the removal, disassembly, repair,
inspection, assembly, and installation instructions for
the transmission and traction motor that make up the
transaxle assemblies used on these models.
Some components associated with the transaxle are
not covered in this section because they are more
closely associated with other systems.
See the section Brake System 1800 YRM 1076 for
information on the electric brake and the service
brake lines and master cylinder.
See the section Periodic Maintenance 8000 YRM
1079 for information on the tire and wheel assem-
blies.
WARNING
DO NOT make repairs or adjustments unless you
are properly trained and have authorization to do
so. Improper repairs and adjustments correct can
create dangerous operating conditions. Do not op-
erate a truck in need of repair. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag to the
steering wheel and disconnect the battery connec-
tor.
Throughout this section, forward will refer to travel in
the direction of the forks and left and right will be deter-
mined by sitting in the seat facing forward. See Figure 1.
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 1. Truck Orientation
DISCHARGING THE CAPACITORS
WARNING
DO NOT make repairs or adjustments unless you
are properly trained and have authorization to do
so. Improper repairs and adjustments correct can
create dangerous operating conditions. Do not op-
erate a truck in need of repair. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag to the
steering wheel and disconnect the battery connec-
tor.
WARNING
Disconnect the battery before opening the electric
compartment cover or inspecting or repairing the
electrical system. If a tool causes a short circuit,
the high current flow from the battery can cause
personal injury or equipment damage.
WARNING
Some checks and adjustments are performed with
the battery connected. DO NOT connect the bat-
tery until the procedure tells you to do so. Never
wear jewelry or other metal items on your fingers,
arms, or neck when performing service to the lift
truck. Metal items can accidentally make an electri-
cal connection and cause injury.
WARNING
Block the lift truck drive tires to prevent unexpected
movement before performing any tests or adjust-
ments.
WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is dis-
connected. To prevent an electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component in the elec-
trical compartment. Wear safety glasses. Make
certain that the battery has been disconnected.
1

17. Introduction 1300 YRM 1074
CAUTION
To avoid controller damage, always disconnect the
battery and discharge the capacitor before perform-
ing service or repairs inside the electrical compart-
ment. NEVER apply power to the controller when
any wires are disconnected. NEVER short any con-
troller terminal or motor terminal to the battery. Al-
ways use proper procedure when servicing the con-
troller.
1. Block load wheels to prevent lift truck from moving.
2. Turn the key switch to the OFF position and discon-
nect the battery.
3. Open the electrical compartment:
a. Remove two screws securing the electrical
compartment door.
b. Pull the compartment door open on its hinges.
WARNING
DO NOT short across the motor controller terminals
with a screwdriver or jumper wire.
NOTE: Some lift trucks are equipped with a premium
controller, which controls the hydraulic motor as well as
the traction motors.
4. Discharge the capacitor in the controller by con-
necting a 200-ohm, 2-watt resistor across the con-
troller’s BT+ and B terminals for 10 seconds using
insulated jumper wires. See Figure 2.
5. On the premium controller, also connect the 200-
ohm, 2-watt resistor across the controller’s P+ and
B terminals for 10 seconds using insulated jumper
wires. See Figure 3.
6. Remove the 200-ohm, 2-watt resistor before recon-
necting the battery.
1. POSITIVE CONNECTION (BT+)
2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 2. Discharging the Capacitors (Standard)
1. POSITIVE CONNECTION (BT+)
2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. POSITIVE CONNECTION (P+)
Figure 3. Discharging the Capacitors (Premium)
2

18. 1300 YRM 1074 Description
Description
TRANSMISSION
The lift truck uses two transmissions. One transmission
is mounted on each side of the lift truck frame beneath
the cowl. The transmission is an in-line gear set that in-
corporates a wet disk brake assembly within the trans-
mission housing. The traction motor is mounted on one
side of the transmission, and the drive wheel and tire
assemblies are mounted to the other side of the trans-
mission. See Figure 4. The transmission is secured
to the lift truck frame using a series of five capscrews.
The transmission housing provides the mounts needed
to attach the mast to the lift truck.
Power from the traction motor is transmitted to the trans-
mission through an internal spline in the input gear. The
input gear drives the first reduction gear. The input and
first reduction gear are helical gears. The first reduc-
tion gear acts as the power input to a three-planet, sin-
gle-reduction, planetary gear set. This planetary gear
set drives the output (wheel hub) to rotate the drive tire
and move the lift truck.
Figure 4. Transmission Mounting
Legend for Figure 4
1. LEFT TRANSMISSION
2. TRACTION MOTORS
3. RIGHT TRANSMISSION
TRACTION MOTOR
The traction motor is a three-phase AC induction motor.
DC battery current is converted into AC current in the
motor controller and then supplied to the traction motor.
The traction controller controls motor speed and direc-
tion. Each traction motor contains a speed encoder de-
vice that provides continuous motor speed and direction
information to the motor controller. Each traction mo-
tor also contains a temperature sensor that continually
monitors motor temperature and communicates that in-
formation to the motor controller. See Figure 5.
Figure 5. Traction Motor
3

19. Maintenance 1300 YRM 1074
Maintenance
OIL LEVEL CHECK
Each transaxle has a separate oil supply which must
be maintained. See Figure 6. Make sure the lift truck
is parked in a level area. To check the oil level, remove
the oil fill plug. The oil should be level with the bottom
of the oil fill hole. If necessary, add oil through the oil
fill hole until the oil is level with the bottom of the hole.
Replace the oil fill plug and torque to 40 N•m (30 lbf ft).
Check the oil level in both transaxles every 500 hours
or every three months.
1. OIL FILL PLUG
2. R.H. TRANSAXLE
3. TRACTION MOTOR
4. PARKING BRAKE
Figure 6. Transaxle Oil Fill Plug
OIL CHANGE
WARNING
The oil is hot at normal operating temperatures. Be
careful when draining the oil.
NOTE: Operate the lift truck for 5 minutes or until the
transaxle is warm to the touch. Oil is thick and will drain
easier and more thoroughly when it is warm. Each
transaxle uses separate, self-contained oil supplies.
The oil in the transaxle should be changed after the
first 200 hours of operation and every 1000 hours or
every six months thereafter.
1. Raise and safety-chain the mast to access the
transaxle assemblies. See Periodic Maintenance
8000 YRM 1079.
2. Turn the key switch to the OFF position and discon-
nect the battery. Block the wheels to prevent unex-
pected movement.
3. Place a drip pan with at least a 3.8 liter (4 qt) ca-
pacity under each transaxle.
4. Remove the fill plugs on each transaxle. See Fig-
ure 7.
5. Remove the drain plugs on each transaxle.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
6. After both transaxles have drained completely,
replace the drain plugs and torque to 40 N•m
(30 lbf ft). Remove the drip pans and dispose of
waste oil properly.
7. Fill the transaxles with oil until level with the bottom
of the oil fill holes. See Figure 6.
8. Install the fill plugs and torque to 40 N•m (30 lbf ft).
1. BRAKE BLEED VALVE
2. TRANSAXLE HOUSING
3. DRAIN PLUG
Figure 7. Transaxle Drain Plug
4