eee FOREWORD TO OWNERS, USERS AND OPERATORS: The safe and efficient operation of a lift truck requires skill and alertness on the part of the operator. To develop the required skills, the operator must: + receive training pursuant to OSHA 1910.178 (1), 112198, in the proper operation of the lft truck. + understand the capabilities and limitations of the lft. truck. : + become familiar with the construction of the lft truck ‘and make sure itis maintained in good condition. + read and understand the warnings and operating procedures contained in this OPERATING MANUAL. Its the employer's responsibilty to make sure the ‘operator can see, hear, and has the physical and mental ability to operate the equipment safely. Various laws and regulations require the employer to train lif truck operators. These laws and regulations ‘includ ‘Occupational Safety and Health Act (USA) Canada Material Handling Regulations NOTE: A comprehensive operator training program is available. For further details, contact your YALE Lift Truck Dealer. ‘This OPERATING MANUAL contains information necessary for the operation and maintenance of a basic fork ft truck. Optional equipment is sometimes installed that can change some operating characteristics, described in this OPERATING MANUAL. Make sure the necessary instructions are available and understood before operating the lit truck. ‘Some of the components and systems described in this, OPERATING MANUAL will NOT be installed on your unit. Ifyou have a question about any item described, ‘contact your dealer for YALE lift trucks.FOREWORD Additional information that describes the safe operation and use of it trucks is available from the following sources: + employment safety and health standards or regulations (examples: Occupational Safety and Heath Standards (USA), Canada Material Handling Regulations + safely codes and standards (example: American ‘National Standard, ANSI B56. 1, Safety Standard For Low Lift And high Lit Trucks) + publications from government safety agencies, {government insurers, private insurers, and private ‘organizations (example: Accident Prevention Manual For Industrial Operations front the National Safety Council) NOTE: YALE lift trucks are not intended for use on public roads. NOTE: The following symbols and words indicate safety Information in this manual: Av WARNING Indicates a condition that can cause injury or death 4 CAUTION Indicates @ condition that can cause property camage!CONTENTS YALE TABLE OF CONTENTS MODEL DESCRIPTION. 7 Hycratie System. 50 GENERAL 7 Fons» st NAMEPLATE Reach, Ti and Siestit 4 GENERAL. a Aicalation Stop Ajusiment 55 Stabity and Canter of Gravy Battery 5 OPERATING TECHNIQUES Wc 28 CHECKS WITH THE KEY SWITCH ON 5 Starting Sequence ; 28 Gauges, Hom and Fuses .... 57 Driving and Direction Changes . = Control Levers and Pedals... ST Sterng (Ting) 2 oa oe 4 lose Herding Generel nnn 30 me gS Lit ged Sy HOWTO GHARGE THe BATTERY 59 Hele $3 HOWTO CHANGE THE BATTERY a Highway Trucks, Railroad Cars and Docks .... 37 Battery Removal 6 MaWTENANee Battery Insalstion oe GENERAL... : i TIRESANDWHEELS » 66 HOW TO MOVE A DISABLED LIET TRUCK... 42 DrivelStcer Te 6 Howto Tow te LI TK soo e senses AB Load Whee & Howto puta Lit Tuck on Bloeks =o 8 Caster Whee sa MAINTENANGE PROCEDURES . Tro and Whoo Sizes se CHECKS WITH THE KEY SWITCH OFF... 50 CHANGES TO THE OVERHEAD GUARD... 68‘This WARNING is a label and must be on the lift truck. & WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN, CAUSE SERIOUS INJURY OR DEATH. ‘Authorized, trained operator only. Know the equipment: Know operating, inspecting, and ‘maintenance instructions listed in this OPERATING. MANUAL. Inspect the truck before use. Use auxiliary ‘equipment (attachments) for intended purpose only. Be ‘sure the truck Is equipped with an overhead guard. ‘Avoid lifting or hitting anything that may fal Know your loads: Handle only.stable loads which are within rated capacity (see nameplate). Space forks as far ‘apart as possible and center the load between forks. ‘Secure the pallet or load platform. Know the area: Never enter a trailer or railcar unless its wheels are blocked. Consider the floor strength. Check the dockboard's width, capacity, and security. Charge the battery only in a designated area, Avoid sparks or open flame. When charging the battery, keep the vent caps clear. Disconnect the battery during servicing. Protect others and yourself: Never transport other people on any part of the truck. When lifting people, use a secured safety platform. Allow no one under load or near the lift mechanism. Do not move the truck if anyone is between the truck and a stationary object. Keep arms, legs, and head inside the operator's compartment. When leaving the truck, lower the carriage, set the brake, shut off the power, and disconnect the battery connectors. ‘Travel withthe carriage as low as possible. Restrict, elevated travel to order-picking aisles. If you can't see, don’t go: Sound the horn at intersections. Watch clearances, especially overhead and tall swing.(WARNING Use common sense: Avoid bumps, holes, and loose ‘materials. Avoid sudden starts or stops. Do not turn on, or angle across, amvineline. Go slowly when turning —use ‘special care when traveling without a oad. Observe trafic rules, Be in complete control at all times. Yield right-of-way to pedestrians. YALE FAILURE TO FOLLOW THESE INSTRUCTIONS CAN, CAUSE THE LIFT TRUCK TO TIP. Rithough there is no sure way in all circumstances to. njury, where possible, in the event of an imminent tipover or off-the-dock accident, the ‘operator should STEP OFF AND AWAY FROM THE TRUCK. These actions are intended to reduce the risk of serious injury or death.MODEL DESCRIPTION GENERAL This Operating Manual describes the operation and basic, maintenance of the YALE Narrow Aisle lift trucks. The lift trucks are available with 24 volt or 36 volt systems, ‘depending upon the model selected. These battery powered lift trucks have lifting capacities of 1,134 to 2,268 kg (2,500, to 5,000 Ib) at a 24 inch load center and are available with two or three stage masts, ‘These trucks feature a SEM (Separately Excited Motor) traction control system as well as neutral braking. The controller has diagnostic capabilties and thermal protection. ‘Travel acceleration, top speed and operator drive modes are ‘at through the traction controller. Proportional plugging is standard, ‘A multi-function control handle provides controtof direction, litviower, extendiretract, tit and optional sideshift. The horn ‘button is also on the side of the control handle. ‘The instrument display includes a battery discharge indicator with HR interrupt, ourmeters, LED function ton lights, operator selectable drive modes for speed of traction and an LCD display which provides the status of systems and fault messages in English, not in numerical codes. AAI lit trucks have operator protection equipment. The ‘overhead guard is intended to offer reasonable protection to the operatar from falling objects, but cannot protect against ‘every possible impact. Therefore, it must not be considered substitute for good judgement and care when handling loads. A rear overhead guard leg provides protection for the ‘operator and unobstructed operation of the lift tuck. A full height wire mast guard is mounted to the rear of the mast, Do not remove any equipment provided for the protection of the operator. The battery compartment must have spacers to prevent horizontal movement of more than 13 mm (0.5 in). The battery restraint panels must be in place before the lit truck. is operated. The battery can be removed from either side of the lif ruck, although right side removal is preferred to avoid damage to the battery cables. A roller rack under the battery permits easy battery movement. For correct battery sizes, See the Battery Specifications in the Maintenance SectioNAMEPLATE 4 WARNING Any change tothe lift truck, the tres or its equipment can change the liting capacity. the nameplate does not show the maximum capacity, or if the lift truck equipment, including the battery, does not match that showin on the nameplate, then the lift truck must not be operated. ‘Te it truck nameplate is located inside the operator's companment. The shown is for a lit tuck equipped 2s shown on t jate. The capacty ts speciied in kilograms. (kg), and pounds "(b). The eapaciy Is. the maximum load the it tuck can handle forthe load conation Shown on the nameplate, ‘The maximum capacity for the lift truck must be shown on the nameplate. If the lit tuck nameplate already has a capacity for special load handling equipment, it willbe listed Make sure the nameplate data is complete and fully understood before operating the lif truck. The lift ruck serial code number is on the nameplate. The serial code number is also stamped on the lift truck frame, a FIGURE 1 NAMEPLATE NOTICE TO USER FIGURE 2 LABEL When a unit is shipped incomplete from the factory to th dealer, the nameplate is covered by a label as shown in FIGURE 2. If your lft truck has this type of label, do not operate the lif truck. Contact your dealer for VALE lift trucks 10 obtain a complete nameplate.Function Handle Label, Freezer Identification Label, Underwriters Laboratory Label, Cooler Identification Label, Operator Warning Label, Fork Warning Label, Overhead Guard Label, Identification EE Label, Manual Lowering Operating Manual W # g 8 3 G 8 g 8 4 a 3 a g zZ 2 g 5 5. Label, Pinch Points 6. Label, Articulation 1 u. 12, WARNING LABELS FIGURE 3 ie fi fil ch fe iat it eal a iCac eat foc FIGURE 4 WARNING LABELSOverhead Guard . Mast Load Backrest | Forks Basearms 5. Battery Compartment . DrivelSteer Wheel Load Wheels, ‘Operator's Compartment Carriage FIGURE 5 MAJOR COMPONENTS OF THE LIFT TRUCK.INSTRUMENTS AND CONTROLS Instrument Display Steering Control Handle Operating Menual Battery Power Disconnect Key Switch Multifunction Control Handle Operator Sensing Switch Brake PedalTABLE 1. INSTRUMENTS AND CONTROLS WARNING: If any of the instruments or controls do not operate as described in this table, report the problem immediately. DO NOT operate the lift truck until the problem is corrected. Instrument Display a ogee re AIRE The insttumient display is mounted in the instrument panel, beside the ‘leering cont} harigle and has the folowing features: a. Message Center b. Function Selection Lights c. Battery Indicator d. Drive Mode Feature e. Hourmeter £ Warning Lights The instrument display Is powered even ‘when the vehicle Is not being operated. When the battery Is disconnected, the dashboard contains an internal back-up battery, capable of memory retention of the battery indicator and hourmeter.‘The Message Center is a 16 character, dot matrix LCD (Liquid Crystal Display) with green backlighting, The 16 character, alpha-numeric display shows the hourmeter readings? lit truck performance status, and warning ‘or fault conditions in English. When a warning message is received, the ‘warning/fault indicator will blink as a yellow light. When a fault message is received, the warning/fault indicator will blink as a red light ‘The Function Selection Lights display the selected hydraulic function. Status messages will be displayed for LIFT, REACH, TILT AND IDESHIFT. The function selection lights will display the current hydraulic. function, independent of the present LCD display.FUNCTION "The Battery Indicator has a 10 bar multicolor LED (Light Emitting Diode) to indicate battery charge status. The bars are green, yellow and red. AS battery power is used, the LED light bars tun OFF, first green, then yellow, then red. The next to bottom red bar will flash indicating a\nearly discharged battery. Atempty, the bottom red bar wil alternately fash with the LO-BATT indicator LED (a crossed battery symbol). Thelitfunction will be locked out at this point. Continued operation with a discharged battery ‘can damage the battery, motors or the contactors. "The Drive Mode Display allows the operator to select the traction motor controller speed most Suited to the application. Operation of the drive mode switch will cause the green indicators and corresponding drive modes to increase from Turtlo to Mid to Rabbit. Turtle mode provides slower acceleration and reduced top speed. itis also a valuable setting when training new operators or on wet floors for better traction. Mid mode reduces acceleration with full travel speed. Rabbit mode provides ‘maximum acceleration and travel speed. When the key switch is turned to OFF, the selected drive mode Is retained. When the battery is disconnected the drive mode returns to the Rabbit mode. The rates of ‘acceleretion and travel speeds are programmable and can be adjusted by 2 qualified service technician, The drive mode can only be selected while In neutral“WODEL DESCRIPTION The Hourmeter switch is controlled by the operator and is used for ‘on-demand display of hourmeter information. The hourmeter data can be displayed at any time by pressing the hourmeter switch, The switch is fnarked with an hour glass symbol. Press the switch once to display truck hours to 1/10 of an hour. Press twice to display drive motor hours, Press three times to display the li motor hours. Press four times toreturn tothe normal display mode. if the hourmeter is left in any of the first three positions, the display will return to the normal display mode, which Indicates the current operational status of the lift truck after 30 seconds. ‘The steering control handle controls lit truck direction with 4 turns lock to lock, A warns: Reverse steering is available for this lift truck. ‘The operator should check the steering direction before operating the lift truck.‘The Operating Manual is sent with the lift truck and Is located in the container on the wire mast guard mounted behind the mast. The (Operating Manualis a permanent reference and must be available for the operator's use at all. times. Read and understand this manual before operating the lift truck. The red battery power disconnect switch is located nextto the key switch. ‘When pressed, power is shut off to all circuits in the lit truck. Power is restored to the lit truck by pulling the switch upward.JOVEL DESCRIP LION. Brake Pedal and Operator Sensing Switch ‘The key switch is a three position switch. The first position is OFF (marked 0}. The second position is RUN (marked I). The third position is unmarked and not used. Its spring loaded and automatically returns the key to the: RUN position after the key is released. The key switch is located o the right side of the battery power disconnect knob. “The brake is designed for both service and parking brake use. The brake ring applied and hydraulically released. The push down brake pedal ‘on the floor in the rear of the operator's compartment, The brake is ‘automatically applied when the brake pedal is released. ‘An operator sensing switch is on the floor to the right of the brake pedal ‘and must be closed with the brake pedal switch before lift truck operation is permitted. The operator must step into the operator's compartment and close both switches before driving or operating any hydraulics. When the operator leaves the lift ruck the parking brake Is automatically applied.FUNCTION ‘Multifunction Control Handle | The muli-funcion controihandie allows the operator to control travel, Tit, lower, tt, sideshif horn, and extend and retract functions. Each function has an independent control device. Travel is activated by tig the entire control handle in the direction of Tur /SIDESHET DISK | travel, Pushing the control handle toward the forks makes the lift Tuck travel forward. To change direction, move the mult-unction handle in the HORN teh ‘opposite direction the it truck is traveling, regardless oftravel speed. The lietruck will come to a stop, then accelerate in the opposite direction. This ‘control is proportional: therefore, the farther the control handle is pushed, the faster the fit truck will accelerate or decelerate. If the multifunction handle is released, it will return to neutral, and the truck will decelerate at 2 programmed rate to a stop, ‘The multifunction handle controls the direction and speed at which the Carriage moves vertically on the mast. LiftyLoweris activated by ting the EXTEND’) RETRACT BUTTONS entire control handle toward the lft or right side of the ift ruck. If the ARE ON THE UNDERSIDE OF Control haridle i tiked toward the right, the carriage its; if the contro! THE HANDLE. ruses | handle is tited toward the left, the carriage lowers. The farther the lever is tited, the faster the carriage lis or lowers. “The Horn button is located on tne side of the muterfunction Manate faeiNg the operator, just to the lef of the ti/sideshift disk. The horn is activate by pressing the button with the thumb,siDesHir RIGHT \ TILT FORWARD ‘The Tilt/Sideshift Disk, located at the top of the multifunction handle lever, controls the iting and side-shifting of the carriage. The disk is ‘operated withthe thumb of the righthand, Totiltthe carriage forward, press the top of the disk: Toit the carriage back, press the bottom of the disk. On lft trucks equipped with a side-shifting carriage, press the left side of the disk to move the carriage to the left, and press the right side ofthe disk to move the carriage to the right. Tit and sideshift are single speed functions, The Extend and Retract buttons are located on the shaft of the multifunction handle. Press the top button to provide low speed extend. While the top button is stil actuated, press the bottom button to provide high speed extend, Press the bottom button to provide low speed retract. While the.bottom button fs stil actuated, press the top button to provide high speed retract. “The multi-function handle is capable of providing variable traction, variable lift oF lower, 2 single auxiliary function and the horn simultaneously for improved productivity.