Yale Electric Forklift Truck ERP030TFN, ERP035TFN, ERP040TFN Workshop Service Manual

MAINTENANCE MANUAL For Models ERP 030-040 TFN 3000 Lb. Capacity 3500 Lb. Capacity and 4000 Lb. Capacity For Service & Parts Contact Yale Materials Handling Corp 1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011 Authorized Dea er 1582 © Augustl 997

Yale Industrial Trucks EXPLANATION OF MODEL CODE USER INFORMATION POWER E - Electric - TYPE R - Sit Down Rider TIRES P - Pneumatic/Cushion RATED CAPACITY S030 - 3,000 Lbs., Short Chassis 030 - 3,000 Lbs., Long Chassis 035-3,500 Lbs. 040 - 4,000 Lbs. SPECIAL DESIGNATION As Assigned E R P 030 T F N 36 S V 072 — COLLAPSED MAST HEIGHT Measured in Inches -MAST TYPE V - Simplex E - Triplex) F - Duplex) Q - Quadplex) - CONTROL S - SCR -VOLTAGE - 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. SPECIAL NOTE This Maintenance Manual contains complete and accurate information available at the time of publication for the components and systems listed. Yale Materials Handling Corporation reserves the right to make changes to its product at any time and the possibility exists that later changes are not included in this manual. If your lift truck is equipped with special options that are not covered in this Maintenance Manual, you should contact your local Yale industrial truck dealer for additional information. 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 TRAIL AXLE AND STEERING SYSTEM 7 HYDRAULIC SYSTEM 8 MAST 9 BATTERY AND CHARGING SYSTEM 10 USER SUPPORT SYSTEM 11 ALPHABETICAL INDEX

Yale Industrial Trucks SECTION 1 OPERATING INSTRUCTIONS

Yale Industrial Trucks SECTION 1 - CONTENTS OPERATING INSTRUCTIONS 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 1-2 OPERATOR PRECAUTIONS 1-2 OPERATOR PRE-CHECKS AND INSPECTION 1-3 OPERATING PROCEDURE 1-3 SHUT DOWN PROCEDURE 1-5 FORK ADJUSTMENT 1-5 SAFETY AND OPERATIONAL CHECK LIST 1-5 MODEL AND CONTROL INFORMATION 1-7 INSTRUMENT PANEL A (STANDARD) 1-9 INSTRUMENT PANEL B (OPTIONAL) 1-10 INSTRUMENT PANEL C (OPTIONAL) 1-10 TEMPERATURE INDICATOR LAMP 1-11 SAFE MAINTENANCE PROCEDURES 1-12 MOVING A DISABLED LIFT TRUCK 1-13 HOW TO TOW THE LIFT TRUCK 1-13 HOW TO PUTA LIFT TRUCK ON BLOCKS 1-14 HOW TO RAISE THE STEER TIRE 1-14 HOW TO RAISE THE DRIVE TIRES 1-15 PRECAUTIONS FOR TRUCKS IN STORAGE 1-15 PRECAUTIONS FOR BATTERIES IN STORAGE 1-15

Yale Industrial Trucks OPERATING INSTRUCTIONS-GENERAL Before attempting to operate this truck, carefully read and understand these operating procedures. Make sure the truck is in proper operating condition. Be sure all safety devices such as the overhead guard and the load backrest extension are in place and properly secured. Visually inspect the entire truck for any damage that may have occurred during shipment. NOTE: Throughout this manual the terms right, left, front and rear relate to the viewpoint of an operator walking with or riding on the truck. Familiarize yourself with the information contained on the nameplate which is located on the cowl to the left of the steering column. See Figure 1-1 and Figure 1-2. Information on this nameplate is as follows: Serial Number A. This is an identification number assigned to this particular truck and should be used when ordering service parts or when requesting any information from your Yale Industrial Truck Dealer. The serial number is a six digit number preceded by a letter and is stamped on the truck frame and on the nameplate. Model Code B. An explanation of the model code is located on Page B of this manual. Truck Weight C. This is the approximate weight of the truck without a load on the forks. This weight plus the weight of the load to be moved OPERATING INSTRUCTIONS must be considered when operating on elevated floors, elevators, etc. Capacity Rating D. This rating shows the maximum load capacity of this truck with relation to load centers and fork heights (see diagram on nameplate). Personal injury and damage to the truck can occur if the capacity rating is exceeded. Safety and informational labels are located in conspicuous locations on this truck and should be strictly followed. Check the nameplate of each truck before operation. These safety and informational labels must be replaced immediately if missing or defaced. Labels will vary with type of truck and equipment installed. Refer to the Parts Manual for part number and location for all labels. The location of the labels is also shown in Section 2 of this manual. This truck meets all applicable mandatory requirements of ANSI B56.1 Safety Standard for Powered Industrial Trucks at the time of manufacture. In addition, these trucks are classified by Underwriters' Laboratories, Inc. and /or approved by Factory Mutual Engineering Corporation for the type designation shown on the nameplate. Consult UL Index of Classified Products and FM Approval Guide. No additions, omissions or modifications should be made that will affect compliance to the previously stated requirements or in any way minimize the effectiveness of the safety devices. NOTICE TO USER The U.S.A. Occupational Safety and Health Act of 1970 and other national safety codes require a new plate if this unit is equipped other than as stated on plate. Obtain the correct plate from your authorized dealer. If a truck is shipped incomplete from the factory, the nameplate will be covered by the decal shown above. Do not operate the lift truck until you obtain a complete nameplate from your Yale Industrial Truck Dealer. CAPACITIES AND CAUTIONS CONTAINED ON THE NAMEPLATE MUST BE STRICTLY FOLLOWED. B 'o Truck Modal No. o) jlattsry Only Max. A.M. (S Hour Rata) Truck Weight Lesa Battery f I *>- Truck Weight with Battery T lb- Allowable Battery Weight Range lb. to lb. Tlra Size Tlra Type Praaaura: Load Tires P.S.I. Stear Tires P.SJ. Drtve Treed Width Degrees A WARNING DO NOT OVERLOAD Capacity ralingi _ÿ*i ÿhown ara for ' svenly dislibutad, laterally cantered loads, with mast vertical. Truck must be equipped as apeciled on s- this plate. ÿ Yale Attachment ModeVSerial No. Miilmum Capacity Pounda Dim. A .oad Canter Dim. B Fork Halohl 31m. C oad anlar Maximum Capacity Pounda Dim A Load Ceniar Dim. B Fork Haiqht Dim C .old Ceniar _ 1 I , 1 _ ( Figure 1-1 - Nameplate 1-1

Yale Industrial Trucks NAMEPLATE Figure 1-2 - Nameplate Location SAFETY AND INFORMATIONAL LABELS Safety and informational labels are located in conspicuous locations on this truck and should be strictly adhered to. These safety and informational labels must be replaced immediately if missing or defaced. Labels will vary with type of truck and equipment installed. Refer to Parts Manual for part number of labels. HAZARD INTENSITY LEVEL IS DANGER I DANGER: Identified by a Red Label, immediate hazards which WILL result in severe personal injury or death. s WARNING WARNING: Identified by an Orange Label, hazards or unsafe practices which MAY result in personal injury or death. s CAUTION CAUTION: Identified by a Yellow Label, hazards or unsafe practices which MAY result in minor personal injury or product or property damage. OPERATING INSTRUCTIONS THE READER MAY FIND ANY OR ALL OF THE FOLLOWING LABELS USED IN THIS PUBLICATION. AN UNDERSTAND¬ ING OF THEIR USE, AS GIVEN BELOW WILL AID THE READER. NOTE An advisory procedure, practice, condition, etc., which is essential to emphasize. /j\ CAUTION Directs attention to hazards or unsafe practices which may result in minor personal injury, product or property damage if the proper precautions are not taken. /j\ WARNING Directs attention to unsafe practices which could result in personal injury or death if proper precautions are not taken. /j\ DANGER Directs attention to unsafe practices and/or existing hazards which WILL result in severe personal injury or death if proper precautions are not taken. OPERATOR PRECAUTIONS The following precautions have been prepared for your safety and the safety of yourfellow workers. Read and understand this information before operating the lift truck. /\ WARNING: Use special care when traveling 1 1 \ without a load as THE RISK OF OVERTURN IS GREATER when cornering and at high speed. Check all gauges and indicator lights for correct operation. Frequent reading of the instrument panel should be a habit. Follow the Recommended Schedules of Maintenance. Maintain your lift truck for dependable and economical operation. Report all accidents involving personnel, building structures and equipment to the proper authority. Before each shift, every 8 hours, it is the operator's responsibility to carry out the following checks and inspections before beginning truck operation. Do not operate truck if it is in need of repair, if it is in an unsafe condition, or might contribute to an unsafe condition. Remove the key and report the 1-2

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Yale Electric Forklift Truck ERP030TFN, ERP035TFN, ERP040TFN Workshop Service Manual

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