PARTS MANUAL
ERP1.6-2.0ATF
(D807)
MODEL NOMENCLATURE
NOTE:
This parts manual contains alternate pages for certain assemblies. The truck model code can be used to determine
many of the assemblies on your lift truck (power, tire type, mast type). The complete truck model and serial number
are stamped into the nameplate. See Identification of Truck Serial Number on Page x for further information.
SECTIONS
1 GENERAL TRUCK
2 ELECTRICAL SYSTEM
3 DRIVE UNIT
4 STEERING SYSTEM
5 BRAKE SYSTEM
6 HYDRAULIC SYSTEM
7 MAST-TWO STAGE LIMITED FREE-LIFT
8 MAST-THREE STAGE FULL FREE-LIFT
9 MAST-TWO STAGE FULL FREE-LIFT
10 HEADER HOSE GROUP
11 OPTIONS
12 NUMERICAL INDEX
This Parts Manual is divided into 13 major sections which are listed above. Quick reference to these sections can
be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the
pages to the corresponding tab.
GENERAL INFORMATION
ALPHABETICAL INDEX
DESCRIPTION PAGE NO.
A
ABBREVIATIONS QUICK REFERENCE SHEET .................................................................................................. vii
ACCELERATOR PEDAL AND LINKAGE ............................................................................................................. 5.8
ALPHABETICAL INDEX............................................................................................................................................ i
B
BACK-UP ALARM ............................................................................................................................................ 11.16
BATTERY COMPARTMENT AND COVERS ........................................................................................................ 1.4
BATTERY CONNECTOR ................................................................................................................................... 2.14
BRAKE ASSEMBLY ........................................................................................................................................... 5.10
C
CALIPER ASSEMBLY
FOOT-OPERATED PARKING BRAKE............................................................................................................ 5.11
CARRIAGE
SIX ROLLER
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9.16
SIX-ROLLER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8.16
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7.10
CONTROL VALVE LINKAGE
LOWER
THREE AND FOUR FUNCTION
D/B 07/2003⇒ ......................................................................................................................................... 6.10
⇒D/B 07/2003 ........................................................................................................................................... 6.6
UPPER
THREE AND FOUR FUNCTION ................................................................................................................... 6.4
UPPER LIFT AND TILT..................................................................................................................................... 6.2
COUNTERWEIGHT ........................................................................................................................................... 1.24
D
DASH DISPLAY .................................................................................................................................................. 2.52
DC CONVERTER ............................................................................................................................................... 11.2
DECAL AND PLATE LOCATION ........................................................................................................................ 1.18
DRIVE TIRE AND WHEEL ASSEMBLY
SUPER CUSHION
ERP-20ATF ................................................................................................................................................. 3.13
E
ELECTRICAL ASSEMBLY
S/N D807A-3883Y⇒......................................................................................................................................... 2.6
S/N D807A02684W⇔S/N D807A03882Y ........................................................................................................ 2.2
i
GENERAL INFORMATION
DESCRIPTION PAGE NO.
F
FOOT DIRECTIONAL CONTROL
D/B 12/2002⇒ ................................................................................................................................................ 5.16
⇒D/B 12/2002 ................................................................................................................................................ 5.14
FREE LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8.10
FREE LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8.14
FREE-LIFT
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9.8
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9.14
FRONT HEADLIGHTS ..................................................................................................................................... 11.10
G
GENERAL TRUCK ............................................................................................................................................... 1.2
H
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7.16
HOSE TAKE-UP
FOUR FUNCTION
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10.12
TWO STAGE FULL FREE-LIFT .................................................................................................................. 10.8
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 10.4
THREE FUNCTION
THREE STAGE FULL FREE-LIFT ............................................................................................................ 10.10
TWO STAGE FULL FREE-LIFT .................................................................................................................. 10.6
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 10.2
HOSE TAKE-UP CONNECTION ...................................................................................................................... 10.14
HOW TO FIND THE DESIRED PART NUMBER..................................................................................................... ix
HOW TO USE THE ILLUSTRATED PARTS MANUAL ............................................................................................ ix
HYDRAULIC BRAKE SYSTEM ............................................................................................................................ 5.4
HYDRAULIC CALIPER ASSEMBLY..................................................................................................................... 5.2
HYDRAULIC CONTACTOR ASSEMBLY
ONE-SPEED................................................................................................................................................... 2.20
TWO SPEED .................................................................................................................................................. 2.22
HYDRAULIC CONTROL VALVE
FOUR SPOOL ................................................................................................................................................ 6.16
THREE SPOOL .............................................................................................................................................. 6.14
HYDRAULIC HOSE AND FITTINGS.................................................................................................................. 6.22
HYDRAULIC MOTOR
12 CC PUMP
⇒S/N D807A-04122Z .......................................................................................................................................... 2.48 , 2.50
S/N D807A-04123Z⇒ ................................................................................................................................. 2.46
19 CC PUMP
⇒S/N D807A-04122Z .......................................................................................................................................... 2.40 , 2.42
S/N D807A-04123Z⇒ ................................................................................................................................. 2.44
HYDRAULIC PUMP ASSEMBLY
12 CC
ii
GENERAL INFORMATION
DESCRIPTION PAGE NO.
H (continued)
OPTIONAL .................................................................................................................................................. 6.30
STANDARD ................................................................................................................................................. 6.32
12CC SPLINED SHAFT
D/B 06/2002⇒............................................................................................................................................. 6.34
19 CC
D/B 06/2000⇒............................................................................................................................................. 6.37
⇒D/B 06/2000 ............................................................................................................................................. 6.36
OPTIONAL .................................................................................................................................................. 6.38
I
IDENTIFICATION OF ATTACHMENT AND SIDE-SHIFT CARRIAGE SERIAL NUMBERS................................... xii
IDENTIFICATION OF MAST SERIAL NUMBER ..................................................................................................... xi
IDENTIFICATION OF TRUCK SERIAL NUMBER .................................................................................................... x
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8.6
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9.4
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7.4
INTEGRAL SIDE-SHIFT CARRIAGE ................................................................................................................. 9.18
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8.18
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7.12
INTEGRAL SIDE-SHIFT HYDRAULIC HOSES
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8.20
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9.20
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7.14
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8.4
L
LIFT
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7.6
LIFT CYLINDER
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7.8
LIFT PUMP AND MOTOR ATTACHING PARTS
12 CC.............................................................................................................................................................. 6.26
19 CC.............................................................................................................................................................. 6.28
LIFT PUMP CONTACTOR ASSEMBLY
ONE-SPEED................................................................................................................................................... 2.16
TWO-SPEED .................................................................................................................................................. 2.18
LINE CONTACTOR ............................................................................................................................................ 2.24
LOAD BACKREST ............................................................................................................................................. 1.10
LOAD FORK ASSEMBLIES
D/B 10/2001⇒ ................................................................................................................................................ 1.22
⇒D/B 10/2001 ................................................................................................................................................ 1.20
iii
GENERAL INFORMATION
DESCRIPTION PAGE NO.
M
MAIN CYLINDER
LEFT HAND
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9.10
RIGHT HAND
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9.12
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8.12
MAIN LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8.8
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9.6
MASTER DRIVE UNIT ......................................................................................................................................... 3.2
MOTOR COOLING FAN ................................................................................................................................... 11.18
N
NON-SUSPENSION SEAT ................................................................................................................................ 1.12
O
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8.2
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9.2
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7.2
OVERHEAD GUARD............................................................................................................................................ 1.8
P
PARKING BRAKE
FOOT-OPERATED ........................................................................................................................................... 5.6
POWER STEERING ASSEMBLY
ON-DEMAND.................................................................................................................................................. 2.10
WITHOUT ON-DEMAND ................................................................................................................................ 2.12
POWER STEERING CONTACTOR.................................................................................................................... 2.26
R
REAR DRIVING LIGHTS.................................................................................................................................... 11.8
S
SEMISUSPENSION SEAT
SHEET 1 OF 2 ................................................................................................................................................ 1.14
SHEET 2 OF 2 ................................................................................................................................................ 1.16
SHIFT LEVERS .................................................................................................................................................... 4.8
SIDE-SHIFT ASSEMBLY.................................................................................................................................... 6.44
SIDE-SHIFT CYLINDER
D/B 10/2000⇒ ................................................................................................................................................ 6.43
⇒D/B 10/2000 ................................................................................................................................................ 6.42
SPOTLIGHT ..................................................................................................................................................... 11.14
STEER AXLE
S/N D807-03890Y⇒ ....................................................................................................................................... 4.14
S/N D807A02684W⇔S/N D807A03890Y ...................................................................................................... 4.12
STEER TIRE AND WHEEL ASSEMBLY
PNEUMATIC
ERP-16ATF AND ERP-18ATF ..................................................................................................................... 4.26
iv
GENERAL INFORMATION
DESCRIPTION PAGE NO.
S (continued)
SOLID PNEUMATIC ....................................................................................................................................... 4.24
STEERING COLUMN........................................................................................................................................... 4.6
STEERING HAND PUMP................................................................................................................................... 4.10
STEERING HYDRAULIC SYSTEM
D/B 07/2003⇒ .................................................................................................................................................. 4.4
⇒D/B 07/2003 .................................................................................................................................................. 4.2
STEERING MOTOR
PREMIUM
D/B 04/2003⇒............................................................................................................................................. 2.30
⇒D/B 04/2003 ............................................................................................................................................. 2.32
STANDARD..................................................................................................................................................... 2.28
STEERING PUMP
⇒S/N D807A-03320X ..................................................................................................................................... 4.18
S/N D807A-03321X⇒..................................................................................................................................... 4.20
STROBE LIGHT/REAR LIGHT COMBINATION............................................................................................... 11.12
T
TAIL, BRAKE, AND BACK-UP LIGHTS
⇒S/N D807A04993A ...................................................................................................................................... 11.4
S/N D807A04994A⇒ ...................................................................................................................................... 11.6
TILT CYLINDER
ROD ENDS AND PINS ................................................................................................................................... 6.18
TILT CYLINDER ASSEMBLY ............................................................................................................................. 6.20
TIRE AND WHEEL ASSEMBLY
CUSHION ....................................................................................................................................................... 4.22
PNEUMATIC
ERP-16ATF AND ERP-18ATF ..................................................................................................................... 3.14
SOLID PNEUMATIC ....................................................................................................................................... 3.15
SUPER CUSHION
ERP-16ATF AND ERP-18ATF ..................................................................................................................... 3.12
TIRE AND WHEEL MOUNTING
DRIVE ............................................................................................................................................................. 3.11
TRACTION MOTOR
PREMIUM
⇒S/N D807A-03462Y ................................................................................................................................. 2.36
S/N D807A-03463Y⇒..................................................................................................................................... 2.38
STANDARD
⇒S/N D807A-03462Y ................................................................................................................................. 2.34
TRANSMISSION
D/B 06/2001⇒ .................................................................................................................................................. 3.4
⇒D/B 06/2001 .................................................................................................................................................. 3.8
TWO-SPEED HYDRAULIC CONTACTOR ASSEMBLY ..................................................................................... 6.40
W
WIRE HARNESS
MAIN
SHEET 1 0F 2
⇒S/N D807A3882Y ................................................................................................................................. 2.54
v
GENERAL INFORMATION
DESCRIPTION PAGE NO.
W (continued)
SHEET 1 OF 2
S/N D807A3883Y⇒................................................................................................................................. 2.58
SHEET 2 OF 2
⇒S/N D807A3882Y ................................................................................................................................. 2.56
S/N D807A3883Y⇒................................................................................................................................. 2.60
vi
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Yale (D807) ERP1.6-2.0ATF Forklift Parts Manual
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Description
Yale (D807) ERP1.6-2.0ATF Forklift Parts Manual is an electronic manual that provides comprehensive information for the repair and maintenance of Yale (D807) ERP1.6-2.0ATF forklifts. This manual is beneficial for both professional mechanics and DIY enthusiasts.
- General Truck
- Electrical System
- Drive Unit
- Steering System
- Brake System
- Hydraulic System
- Mast-Two Stage Limited Free-Lift
- Mast-Three Stage Full Free-Lift
- Mast-Two Stage Full Free-Lift
- Header Hose Group
- Options
- Numerical Index
The manual is written in a detailed, step-by-step format, making it easy to understand and use for self-repair, potentially saving on expenses.
File Format: .PDF
Compatibility: All Versions of Windows & Mac
Language: English
Requirements: Adobe Reader
