Maintenance

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ESC030FA, ESC035FA, ESC040FA [A883]

PART NO. 524153627 8000 YRM 991

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Periodic Maintenance Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
How to Move Disabled Lift Truck ..................................................................................................................... 1
How to Tow Lift Truck .................................................................................................................................. 1
How to Put Lift Truck on Blocks....................................................................................................................... 2
How to Raise Load Wheels......................................................................................................................... 2
How to Raise Steer Wheel.......................................................................................................................... 3
Lift and Tilt System Leak Checks ........................................................................................................................ 3
Lift System ...................................................................................................................................................... 3
Tilt System ...................................................................................................................................................... 4
Safety Procedures When Working Near Mast ..................................................................................................... 4
Check Operation.................................................................................................................................................. 5
Gauges and Horn............................................................................................................................................ 5
Control Handle ................................................................................................................................................ 5
Steering System.............................................................................................................................................. 5
Maintenance Schedule ........................................................................................................................................ 5
Maintenance Procedures Every 8 Hours or Daily................................................................................................ 9
Before Operation Checks ................................................................................................................................ 9
Hydraulic System ........................................................................................................................................ 9
Battery ........................................................................................................................................................ 9
Battery Restraint System ............................................................................................................................ 10
Tires and Wheels ........................................................................................................................................ 10
Maintenance Procedures Every 350 Hours or 3 Months..................................................................................... 11
Hydraulic Tank Breather .................................................................................................................................. 11
Wheel Nut Torque ........................................................................................................................................... 11
Transaxle......................................................................................................................................................... 11
Lift System Operation...................................................................................................................................... 11
Mast ................................................................................................................................................................ 11
Lift Chains ....................................................................................................................................................... 12
Forks ............................................................................................................................................................... 13
Safety Labels .................................................................................................................................................. 13
Other Lubrication............................................................................................................................................. 13
Electrical Inspection ........................................................................................................................................ 13
Special Precautions .................................................................................................................................... 13
Contactors .................................................................................................................................................. 14
Motor Brushes ............................................................................................................................................ 14
Maintenance Procedures Every 2000 Hours or Yearly........................................................................................ 15
Hydraulic System ............................................................................................................................................ 15
Change the Hydraulic Oil Filter ................................................................................................................... 15
Check the Hydraulic Oil Strainer ................................................................................................................. 15
Change the Hydraulic Oil ............................................................................................................................ 15
Brakes ............................................................................................................................................................. 15
Transaxle......................................................................................................................................................... 15
Battery Maintenance ........................................................................................................................................... 16
How to Charge the Battery.............................................................................................................................. 16
How to Change the Battery ............................................................................................................................. 17
Wheels and Tires Maintenance ........................................................................................................................... 17
General ........................................................................................................................................................... 17
Wheels and Tires ............................................................................................................................................ 17
Remove the Wheel From Lift Truck ............................................................................................................. 17
Install the Tire on Wheel ............................................................................................................................. 17
Install the Wheel and Tire ............................................................................................................................... 17

©2002 Yale Materials Handling Corp. i

Table of Contents Periodic Maintenance

TABLE OF CONTENTS (Continued)

Mast and Lift Chains............................................................................................................................................ 18
Forks.................................................................................................................................................................... 18
Adjust .............................................................................................................................................................. 18
Remove ........................................................................................................................................................... 18
Inspect............................................................................................................................................................. 19
Install............................................................................................................................................................... 19

This section is for the following models:

ESC030FA, ESC035FA, ESC040FA [A883]

ii
8000 YRM 991
General
This section contains a Maintenance Schedule and the
instructions for maintenance and inspection. The Main-
tenance Schedule has time intervals for inspection,
lubrication, and maintenance. The time intervals are
based on a normal operation. A normal operation is
considered to be one 8-hour shift per day in a relatively
clean environment on an improved surface. Multiple
shifts, dirty operating conditions, etc., will require a
reduction in the recommended time periods in the
Maintenance Schedule.
When turning the key switch to the ON position, the
Brush Wear Indicator and Motor Temperature Indicator
will illuminate. Contact your dealer if the Brush Wear
Indicator and Motor Temperature indicator will not illu-
minate when turning the key switch to the ON position.
WARNING
Do not make repairs or adjustments unless you
have authorization and training. Repairs and
adjustments that are not correct can make a dan-
gerous operating condition.
Do not operate a lift truck that needs repairs. Report
the need for repairs to your supervisor immediately.
If repair is necessary, put a DO NOT OPERATE tag
on the control handle. Remove the key from the key
switch.
Your Yale lift truck dealer has the facilities and trained
personnel to do the maintenance. A complete program
of inspection, lubrication, and maintenance will help
your lift truck perform efficiently and operate over a
longer period of time.
Some users have service personnel and facilities to do
the items listed in the Maintenance Schedule. Service
Manuals are available from your Yale lift truck dealer to
help users who do their own maintenance.
Do not make repairs or adjustments unless specifically
authorized to do so.
Put the lift truck on a level surface. Lower the carriage
and forks, apply the parking brake, and turn the key
switch to OFF. Open the access panels and inspect for
leaks and conditions that are not normal. Clean any
oil spills. Make sure that lint, dust, paper, and other
materials are removed from the compartments.
General
HOW TO MOVE DISABLED LIFT TRUCK
How to Tow Lift Truck
WARNING
Use extra care when moving a lift truck during the
following conditions:
• Brakes do not operate correctly.
• Steering does not operate correctly.
• Tires are damaged.
• Traction conditions are bad.
• The lift truck must be moved on a steep grade.
If the steering pump motor does not operate, steer-
ing control of the lift truck can be slow. This can
make the control of the lift truck difficult. If there is
no electrical power, steering can be difficult. Do not
tow the lift truck if there is no power. Poor traction
can cause the disabled lift truck or towing vehicle
to slide. Steep grades will require additional brake
force to stop the lift truck.
Never carry a disabled lift truck unless the lift truck
MUST be moved and cannot be towed. The lift truck
used to carry the disabled lift truck MUST have a
rated capacity equal to or greater than the weight
of the disabled lift truck. The capacity must be for
a load center equal to half the width of the disabled
lift truck. See the nameplate of the disabled lift truck
for the approximate total weight. The forks must ex-
tend the full width of the disabled lift truck. Center
the weight of the disabled lift truck on the forks and
be careful not to damage the under side of the lift
truck.
1. The towed lift truck must have an operator.
2. Tow the lift truck slowly.
3. Raise the carriage and forks approximately 30 cm
(12 in.) from the surface. Install a chain to prevent
the carriage and mast channels from moving.
4. If another lift truck is used to tow the disabled lift
truck, that lift truck must have an equal or larger
capacity than the disabled lift truck. Install an ap-
proximate half-capacity load on the forks of the lift
truck that is being used to tow the disabled lift truck.
This half-capacity load will increase the traction of
the lift truck. Keep the load as low as possible.
5. Use a towing link made of steel that attaches to the
tow pins in the counterweights of both lift trucks.
1
General
HOW TO PUT LIFT TRUCK ON BLOCKS
How to Raise Load Wheels
WARNING
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the fol-
lowing assemblies will cause large changes in the
center of gravity: mast and load axle, battery, and
the counterweight. When the lift truck is put on
blocks, put additional blocks in the following posi-
tions:
a. Before removing the mast and load wheels, put
blocks under the rear of the frame so the lift
truck cannot fall backward or to the side.
b. Before removing the battery and/or the counter-
weight, put blocks under the mast assembly so
the lift truck cannot fall forward.
Put the lift truck on blocks only if the surface is
solid, even, and level. Make sure any blocks used
Figure 1. Putting the Lift Truck on Blocks
2
8000 YRM 991
to support the lift truck are solid, one-piece units.
Put blocks in front and back of the tires to prevent
movement of the lift truck.
NOTE: Some lift trucks have lifting eyes. These lift
points can be used to raise the lift truck so that blocks
can be installed.
1. Put blocks on each side (front and back) of the steer
tires to prevent movement of the lift truck. See Fig-
ure 1.
2. Use a hydraulic jack under the side of the frame
near the front. Make sure the jack has a capacity
equal to at least half the weight of the lift truck. See
the nameplate.
3. Put a block under each outer mast channel.
4. Put additional blocks under the frame behind the
drive tires.
8000 YRM 991
How to Raise Steer Wheel
WARNING
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the fol-
lowing assemblies will cause large changes in the
center of gravity: mast and load axle, battery, and
the counterweight. When the lift truck is put on
blocks, put additional blocks in the following posi-
tions:
a. Before removing the mast and load wheels, put
blocks under the rear of the frame so the lift
truck cannot fall backward or to the side.
b. Before removing the battery and/or the counter-
weight, put blocks under the mast assembly so
the lift truck cannot fall forward.
Put the lift truck on blocks only if the surface is
solid, even, and level. Make sure any blocks used
Lift and Tilt System Leak Checks
LIFT SYSTEM
WARNING
When working on or near the mast or carriage, see
Safety Procedures When Working Near Mast. Never
allow anyone under a raised carriage. Do not put
any part of your body in or through the lift mech-
anism unless all parts of the mast are completely
lowered, the key is removed, and the battery is dis-
connected.
Do not try to find hydraulic leaks by putting hy-
draulic components under pressure. Hydraulic oil
can be injected into the body by pressure.
During the test procedures for the hydraulic sys-
tem, fasten the load to the carriage with chains to
prevent it from falling. Keep all personnel away
from the lift truck during the tests.
1. Operate the hydraulic system. Put a capacity load
on the forks, and raise and lower the load several
times. Lower the load and tilt the mast forward and
backward several times. Check for leaks.
Lift and Tilt System Leak Checks
to support the lift truck are solid, one-piece units.
Put blocks in front and back of the tires to prevent
movement of the lift truck.
NOTE: Some lift trucks have lifting eyes. These lift
points can be used to raise the lift truck so that blocks
can be installed.
1. Apply the brake. Put blocks on both sides (front and
back) of the drive tires to prevent movement of the
lift truck. See Figure 1.
2. Use hydraulic jacks to raise the steer tire. Make
sure the jacks have a capacity of at least 2/3 of
the total weight of the lift truck as shown on the
nameplate.
3. Put the jacks under the rear of the frame to raise
the lift truck. Put blocks under the frame to support
the lift truck.
2. Raise the carriage and the load 1 m (3 ft). If the car-
riage lowers slowly with the control valve in a NEU-
TRAL position, there are leaks inside the hydraulic
system. The maximum speed that the carriage is
allowed to lower is 50 mm (2 in.) per 10 minutes
when the hydraulic oil is 30 C (90 F). If the oil tem-
perature is 70 C (160 F), the maximum speed that
the carriage can lower is 150 mm (6 in.) per 10 min-
utes.
3. Check the lift cylinder for internal leaks. Remove
the load from the forks. Install a gate valve in the
supply line between the main control valve and the
mast. Put a capacity load on the forks again. Raise
the carriage 1 m (3 ft). Close the gate valve. If the
carriage or mast weldments lower slowly, the seals
in the lift cylinders have leaks.
4. If the carriage does not move, open the gate valve
and check for movement again. If the carriage low-
ers when the valve is open, check for leaks in the
hydraulic lines or fittings. If no leaks are found, the
main control valve might be damaged. Remove the
load from the forks.
3
Safety Procedures When Working Near Mast
TILT SYSTEM
WARNING
When working on or near the mast or carriage, see
Safety Procedures When Working Near Mast.
Never allow anyone under a raised carriage. Do not
put any part of your body in or through the lift mech-
anism unless all parts of the mast are completely
lowered, the key is removed, and the battery is dis-
connected.
Do not try to find hydraulic leaks by putting hy-
draulic components under pressure. Hydraulic oil
can be injected into the body by pressure.
During the test procedures for the hydraulic sys-
tem, fasten the load to the carriage with chains to
prevent it from falling. Keep all personnel away
from the lift truck during the tests.
1. Put a capacity load on the forks. Slowly tilt the
mast forward. If the mast continues to slowly tilt
forward when the control valve is in a neutral po-
sition, there are leaks inside the hydraulic system.
Safety Procedures When Working Near Mast
The following procedures must be used when inspect-
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re-
moving the mast. See the correct Service Manual sec-
tion for the specific mast being repaired.
WARNING
Mast parts are heavy and can move. Distances be-
tween parts are small. Serious injury or death can
result if part of the body is hit by parts of the mast
or the carriage.
• Never put any part of the body into or under the
mast or carriage unless all parts are completely
lowered or a safety chain is installed. Also make
sure the power is off and the key is removed. Put
a DO NOT OPERATE tag in the operator’s com-
partment. Disconnect the battery on electric lift
trucks and put a tag or lock on the battery con-
nector.
• Be careful of the forks. When the mast is raised,
the forks can be at a height to cause an injury.
• Do NOT climb on the mast or lift truck at any time.
Use a ladder or personnel lift to work on the mast.
• Do NOT use blocks to support the mast weld-
ments nor to restrain their movement.
4
8000 YRM 991
The maximum speed that the mast is allowed to tilt
forward when there are internal leaks in the lift sys-
tem is 13 mm (0.50 in.) per 10 minutes (measured
at the tilt cylinder). This maximum speed is mea-
sured when the hydraulic oil is 30 C (90 F). If the oil
temperature is 70 C (160 F), the maximum speed
is 39 mm (1.5 in.) per 10 minutes.
2. If the leak rate is greater than specifications, re-
move the load from the mast. Install a valve be-
tween the port at the front of the tilt cylinder and
the hydraulic line. Put the load on the forks again.
Close the valve. If the mast tilts slowly forward, the
cylinder seals are leaking. Be sure to check both
tilt cylinders.
3. If the mast does not move, open the gate valve and
check for movement again. If the mast moves for-
ward when the gate valve is open, check for leaks in
the hydraulic lines or fittings. If no leaks are found,
the main control valve might be damaged. Remove
the load from the forks.
• Mast repairs require disassembly and removal of
parts and can require removal of the mast or car-
riage. Follow the repair procedures in the correct
Service Manual section for the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. Lower the mast and carriage completely. Push the
lift/lower control lever forward and make sure there
is no movement in the mast. Make sure all parts of
the mast that move are fully lowered.
OR
2. If parts of the mast must be in raised position, install
a safety chain to restrain the moving parts of the
mast. Connect moving parts to a part that does not
move. Follow these procedures:
a. Put the mast in a vertical position.
b. Raise the mast to align the bottom crossmem-
ber of the weldment that moves in the outer
weldment with a crossmember on the outer
weldment. On the two-stage and free-lift mast,
the moving part is the inner weldment. On the
8000 YRM 991
three-stage mast it is the intermediate weld-
ment. On the four-stage mast it is the first in-
termediate weldment.
c. Use a 3/8-in. minimum safety chain with a
hook to fasten the crossmembers together so
the movable member cannot lower. Put the
hook on the back side of the mast. Make sure
the hook is completely engaged with a link in
the chain. Make sure the safety chain does
not touch lift chains or chain sheaves, tubes,
hoses, fittings, or other parts on the mast.
d. Lower the mast until there is tension in the
safety chain and the free-lift cylinder (free-lift,
Check Operation
Sit on the seat, turn the key switch to ON, and check
the following operations:
• Gauges and horn
• Lift, tilt, and attachment functions
• Service and parking brakes
• Steering system
• Direction control lever and accelerator pedal
GAUGES AND HORN
Check the operation of the gauges and horn. The horn
will operate when the key switch is OFF. The hourmeter
will operate when the key switch is ON and the seat
switch is closed.
WARNING
Make sure the key switch is OFF and the brake is
set before connecting the battery.
The battery indicator will operate when the key switch
is ON. If the battery is replaced with a fully charged bat-
tery, the battery indicator will not indicate a fully charged
Maintenance Schedule
The MAINTENANCE SCHEDULE has two time pe-
riods in which the service engineer can perform the
maintenance. For lift trucks operated less than 8 hours
each day, use Maintenance Procedures Every 8 Hours
or Daily, Maintenance Procedures Every 350 Hours or
3 Months, and Maintenance Procedures Every 2000
Maintenance Schedule
three-stage, and four-stage masts only) is com-
pletely retracted. If running, stop the engine.
Apply the brake. Install a DO NOT REMOVE
tag on the safety chain(s).
e. Install another safety chain (3/8 in. minimum)
between the top or bottom crossmember of the
carriage and a crossmember on the outer weld-
ment.
3. Apply the brake. After lowering or restraining the
mast, shut off the power and remove the key. Put a
DO NOT OPERATE tag in the operator’s compart-
ment. Disconnect the battery on electric lift trucks
and put a tag or lock on the battery connector.
battery until the lift truck has operated for a short period
of time. Tilt the mast backward until the hydraulic relief
valve operates. The battery indicator will then indicate
correctly. A battery indicator without "lift interrupt" will
only indicate battery charge when the hydraulic relief
valve operates.
CONTROL HANDLE
Check that the control handle and brake operate as de-
scribed in the Operator Manual.
STEERING SYSTEM
WARNING
The steering can be difficult when the power steer-
ing pump is not operating.
Check that the steering system operates smoothly and
gives good steering control.
Hours or Yearly schedules. For lift trucks operated
more than 8 hours each day, use Maintenance Proce-
dures Every 8 Hours or Daily, Maintenance Procedures
Every 350 Hours or 3 Months, and Maintenance Pro-
cedures Every 2000 Hours or Yearly schedules. See
Figure 2.
5
Maintenance Schedule 8000 YRM 991

Figure 2. Maintenance Points

Table 1. Maintenance Schedule

Item Item 8 hr 350 hr 2000 hr or Procedure or Specification

No. or or 1 year 4 Quantity
1 day 4 3 month 4
5
1 Battery X Check Level See Battery
Battery Connector X Check Condition Maintenance
Battery Disconnect 3 X Check Operation Disconnect Bolt Installed
Battery Gates X Check Condition Lever Moves Freely and
Battery Rollers 3 Clean as Required Connector Separates
Secure and in Place
X = Check C = Change L = Lubricate R = Replace
1
Hydraulic Oil
2
Chevron EP - Hydraulic Oil 68 or equivalent
3
Silicone Spray
4
Whichever comes first
5
Equalization Charge approximately each month but not more than each week
6
Multipurpose Grease with 2-4% Molybdenum Disulfide for normal operations
7
Change fluid and filter on new trucks at first 350 hours
8
Do Not Lubricate
9
Low Temperature Grease
10
SAE 20W Motor Oil
11
At 2000 hours, remove, clean, and lubricate per Service Manual
NOTE: Never use steam to clean electrical parts.

6
8000 YRM 991 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr 350 hr 2000 hr or Procedure or Specification

No. or or 1 year 4 Quantity
1 day 4 3 month 4
2 Brakes X Check Operation
Brake Pads X Check Condition No Binding
Brake Pedal 10 X Check Operation Travel Disabled if
Brake Switch X Check Operation Pedal Up
3 Directional/Speed/Lift X Check Operation No Binding/Proper
Control 10 Operation
4 Electrical Circuits X X X Check Operation
Contactors X Check Condition
Motor Brushes Check Condition
5 Forks/Carriage/Load X X L Check for Damage 6
Backrest X X L Lubricate As
Fork Guides and Locks X Required 6
Sideshift Carriage
6 Gearbox Fluid Level X 7 C Check Operation SAE-80W-90 Gear Lube
Full Mark or Equivalent
7 Hydraulic Oil Leaks X 7 C Check for Leaks Above 0 C (32 F) 1
Hydraulic Oil Level X Middle Mark Below 0 C 2
Breather Cap X R See Parts Manual
Hydraulic Oil Filter 7 C Clean or Replace See Parts Manual
Hydraulic Tank Filler 7 R Replace See Parts Manual
Neck Strainer Clean or Replace
8 Lift Chains and Chain X L 11 Check for Damage Above 0 C (32 F) 10
Anchors Cotter Pins in Below 0 C 9
Place
X = Check C = Change L = Lubricate R = Replace
1
Hydraulic Oil
2
Chevron EP - Hydraulic Oil 68 or equivalent
3
Silicone Spray
4
Whichever comes first
5
Equalization Charge approximately each month but not more than each week
6
Multipurpose Grease with 2-4% Molybdenum Disulfide for normal operations
7
Change fluid and filter on new trucks at first 350 hours
8
Do Not Lubricate
9
Low Temperature Grease
10
SAE 20W Motor Oil
11
At 2000 hours, remove, clean, and lubricate per Service Manual
NOTE: Never use steam to clean electrical parts.

7
Maintenance Schedule 8000 YRM 991

Table 1. Maintenance Schedule (Continued)

Item Item 8 hr 350 hr 2000 hr or Procedure or Specification

No. or or 1 year 4 Quantity
1 day 4 3 month 4
9 Mast X X L Check Operation Above 0 C (32 F) 6
Pivots, Sliding Surfaces, X Lubricate As Below 0 C 9
Channels, Load Rollers X L Required 6
Cotter Pin at Tilt X L Cotter Pins in 6
Cylinder Pins L6 Place Place blocks under
Tilt Cylinder Pins Lubricate 4 outer upright channels
Mast Trunnion Bearings Fittings and tilt upright forward
Lubricate 2 to take the load off
Fittings top of bearings before
greasing.
10 Multifunction Control X Check Operation No Binding/Proper
Handle Switches - Horn, Operation
Tilt, and Aux. 10
11 Operator’s Display, Horn, X Check Operation
Lights, Fuses
12 Safety Labels and X Replace if See Parts Manual
Operating Manual Necessary
13 Steering Operation X Check Operation No Binding/Proper
Operation
14 Tire & Wheels - Drive X Check Condition
& Steer
X
15 Transaxle Outer Pinion 6 Lubricate 2 Remove the drive tires to
Bearing L Fittings access the fittings. Lube
L each fitting until grease
exits the relief hole.
Remove excess grease
from relief hole area.
16 Static Strap X Check for Damage Replace if Damaged
or Missing
X = Check C = Change L = Lubricate R = Replace
1
Hydraulic Oil
2
Chevron EP - Hydraulic Oil 68 or equivalent
3
Silicone Spray
4
Whichever comes first
5
Equalization Charge approximately each month but not more than each week
6
Multipurpose Grease with 2-4% Molybdenum Disulfide for normal operations
7
Change fluid and filter on new trucks at first 350 hours
8
Do Not Lubricate
9
Low Temperature Grease
10
SAE 20W Motor Oil
11
At 2000 hours, remove, clean, and lubricate per Service Manual
NOTE: Never use steam to clean electrical parts.

8
8000 YRM 991
Maintenance Procedures Every 8 Hours or Daily
WARNING
Do not operate a lift truck that needs repairs. If a
repair is necessary, put a DO NOT OPERATE tag in
the operator’s area. Remove the key from the key
switch.
Inspect the lift truck every 8 hours or daily before use.
Put the lift truck on a level surface. Lower the carriage
and forks, and turn the key switch to OFF. If repair is
required, put a tag in the operator’s area that indicates
the lift truck cannot be operated. DO NOT operate a lift
truck until the problems are corrected.
BEFORE OPERATION CHECKS
Make the following checks:
• Oil level in the hydraulic tank
• Electrolyte and specific gravity of the battery
• Make sure the battery is clean and is the correct size
and weight for the lift truck
• Operation of the battery restraint and latch mecha-
nism
• Condition of the wheels and tires
• Condition of the forks, carriage, mast, and overhead
guard
• Leaks in the hydraulic system
Hydraulic System
WARNING
At operating temperature the hydraulic oil is HOT.
Do not permit the oil to contact the skin and cause
a burn.
CAUTION
Do not permit dirt to enter the hydraulic system
when the oil level is checked or the filter is changed.
Never operate the pump without oil in the hydraulic
system. The operation of the hydraulic pump with-
out oil will damage the pump.
Check the hydraulic oil level when the oil is at operat-
ing temperature, the carriage is lowered, and the key
switch is OFF. Add hydraulic oil only as needed. If more
hydraulic oil is added than the FULL level permits, hy-
draulic oil will leak from the breather during operation.
The oil level indicated by the dipstick is most accurate
when the oil temperature is 53 to 93 C (130 to 200 F).
Maintenance Procedures Every 8 Hours or Daily
Battery
WARNING
Make sure the key switch is OFF and the brake is
set before connecting the battery.
If the lift truck was operated with a discharged bat-
tery, check all contactors for welded tips before a
charged battery is connected.
WARNING
Do not put tools on the battery.
The acid in the electrolyte can cause injury. If the
electrolyte is spilled, use water to flush the area.
Make the acid neutral with a solution of sodium bi-
carbonate (soda). Acid in the eyes must be flushed
with water immediately.
Batteries generate explosive fumes. Keep the vents
in the caps clean. Keep sparks or open flames away
from the battery area. Do not make a spark from the
battery connections. Disconnect the battery when
doing maintenance.
The battery must fit the battery compartment so the
battery restraint will operate correctly. Use spac-
ers to prevent the battery from moving more than
13 mm (0.5 in.) in any direction.
Check the hydraulic oil level when the oil is at operat-
ing temperature, the carriage is lowered, and the key
switch is OFF. Add hydraulic oil only as needed. If more
hydraulic oil is added than the FULL level permits, hy-
draulic oil will leak from the breather during operation.
Make sure the battery weight is within the maximum and
minimum weight shown on the nameplate.
Keep the battery case, top cover, and the area for the
battery clean and painted. Leakage and corrosion from
the battery can cause a malfunction in the electric con-
trols of the lift truck. Use a water and sodium bicarbon-
ate solution (soda) to clean the battery and the battery
area. Keep the top of the battery clean, dry, and free of
corrosion.
Make sure the battery is charged and has the correct
voltage and ampere hour rating for the lift truck. See
the nameplate.
Inspect the battery case, connector, and cables for
damage, cracks, or breaks. See the battery dealer in
9
Maintenance Procedures Every 8 Hours or Daily
the area to repair any damage. Check the level of the
electrolyte daily on a minimum of one cell. The correct
level is halfway between the top of the plates and the
bottom of the fill hole. Add only distilled water.
Battery Restraint System
WARNING
The battery restraint and its latch mechanism must
operate correctly before the lift truck is operated.
The hood assembly is also a battery restraint. The func-
tion of the battery restraint, when the hood is correctly
locked to the frame, is to hold the battery in the battery
compartment if the lift truck tips over. A sliding latch
mechanism on the front of the hood locks the hood to
the frame. The sliding latch unlocks the hood from the
frame so the hood can be raised to the open position
for access to the battery. The hood is also the support
for the seat. A spring brace holds the seat and hood
assembly in the open position.
Make sure the latch mechanism operates correctly.
Check that the latch is not worn and fully engages the
frame. The hood must be locked in the closed position
when the lift truck is operated. Try to raise the seat and
hood when the hood is locked in the closed position.
If the latch mechanism does not lock the hood in the
closed position, do not operate the lift truck.
Tires and Wheels
WARNING
Air pressure in tires can cause tire and wheel parts
to explode. This action can cause serious injury or
death.
Completely deflate the tire before loosening the
wheel nuts.
When adding air to the tires, use a remote air noz-
zle. The person adding air pressure to the tire must
stand to the side and not in front of the tire.
Keep the tires at the correct air pressure. See the
nameplate. Check the air pressure with a gauge when
the tires are cold. See Figure 3.
10
8000 YRM 991
1. CHECK TIRE 2. CHECK FOR
PRESSURE DAMAGE
Figure 3. Check Tires
If it is necessary to add air to a warm tire, check one of
the other tires and add air to the tire that has low pres-
sure so the air pressures are equal. The air pressure of
warm tires must always be equal to or greater than air
pressures specified for cold tires.
Inspect the tires for wire, rocks, glass, pieces of metal,
holes, cuts, and other damage. Remove any object that
will cause damage. Check pneumatic wheels for bent
or damaged rims. Check for loose or missing hardware.
Remove any wire, strapping, or other material that is
wrapped around the axle.
WARNING
When working on or near the mast or carriage, see
Safety Procedures When Working Near Mast.
CAUTION
When the wheels have been installed, check all
wheel nuts after 2 to 5 hours of operation. Tighten
the nuts in a cross pattern to the correct torque
value shown in the . When the nuts stay tight
after an 8-hour check, the interval for checking the
torque can be extended to 350 hours.
Make sure the wheel nuts are tight. Tighten the wheel
nuts in a cross pattern to the correct torque value shown
in the Maintenance Schedule .
8000 YRM 991
Maintenance Procedures Every 350 Hours or 3 Months
NOTE: Do these procedures in addition to the 8-hour
checks.
HYDRAULIC TANK BREATHER
The hydraulic tank breather is on top of the hydraulic
tank. Remove and clean the breather. Replace when
the breather is dirty and will not permit the easy pas-
sage of air.
WHEEL NUT TORQUE
Tighten wheel nuts as required.
TRANSAXLE
Each transaxle has its separate oil supply. Make certain
the lift truck is parked in a level area. Remove the level
plug to check the level of the oil. The oil should be level
with the bottom of the level hole. If it is necessary to
add oil, remove the fill plug and add the oil through the
fill plug until the oil starts to run out of the oil level hole.
Replace both the oil level plug and the fill plug.
Make certain to check both transaxles.
LIFT SYSTEM OPERATION
WARNING
When working on or near the mast or carriage, see
Safety Procedures When Working Near Mast.
Lower the lift mechanism completely. Never allow
anyone under a raised carriage. Do not put any part
of your body in or through the lift mechanism un-
less all parts of the mast are completely lowered
and the key switch is OFF.
Do not try to locate hydraulic leaks by putting hands
on pressurized hydraulic components. Hydraulic
oil can be injected into the body by pressure.
1. Check for leaks in the hydraulic system. Check the
condition of the hydraulic hoses and tubes.
NOTE: Parts of the mast move at different speeds dur-
ing raising and lowering.
2. Slowly raise and lower the mast several times with-
out a load. The mast components must raise and
lower smoothly in the correct sequence. The car-
riage raises first, then the inner weldment and the
intermediate weldment (three-stage masts only).
Maintenance Procedures Every 350 Hours or 3 Months
3. The inner weldment(s) and the carriage must lower
completely.
4. Raise the mast 1 m (3 ft), with a capacity load.
The inner weldment(s) and carriage must raise
smoothly. Lower the mast. All moving components
must lower smoothly.
5. With the load lowered, tilt the mast backward and
forward. The mast must tilt smoothly and both tilt
cylinders must stop evenly.
6. Check that the controls for the attachment operate
the functions of the attachment. (See symbols by
each of the controls.) Make sure all of the hydraulic
lines are connected correctly and do not leak.
MAST
WARNING
When working on or near the mast or carriage, see
Safety Procedures When Working Near Mast.
Do not work under a raised carriage. Lower the car-
riage or use a safety chain to prevent the carriage
from lowering when doing maintenance on the mast
and lift chains.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer.
Be careful when cleaning with steam. Steam can
cause serious burns. Wear protective clothing, eye
protection, and gloves. Never expose your skin to
steam.
CAUTION
DO NOT use steam or high pressure water to clean
the load rollers or the lift chains. Steam and high
pressure water can remove the lubrication from the
bearings in the load rollers. Water in the bearings
of the sheaves and the link pins of chains can also
shorten the service life of these parts.
1. Lubricate the sliding surfaces and the load roller
surfaces along the full length of the channels, as
shown in Figure 4. Apply lubricant only to the indi-
cated surfaces.
11
Maintenance Procedures Every 350 Hours or 3 Months 8000 YRM 991

A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE SURFACES WHERE LOAD
ROLLERS TRAVEL NOTE: THE INSTRUCTIONS FOR MEASURING
3. LOAD ROLLER CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR
SCALE.
Figure 4. Mast Lubrication
Pitch Wear Limit
NOTE: The load rollers and sheaves have sealed bear- Total length of
ings that do not need additional lubrication. The maximum
20 links (pitch)
length of 20
of new chain
2. Lubricate the mast pivots with multipurpose grease links.
at the grease fittings on the pivot pins.
12.7 mm 254.0 mm 261.6 mm
LIFT CHAINS (0.50 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
WARNING 19.1 mm 381.0 mm 392.4 mm
When working on or near the mast or carriage, (0.75 in.) (15.0 in.) (15.4 in.)
see Safety Procedures When Working Near Mast 25.4 mm 508.0 mm 523.3 mm
located in Maintenance Procedures Every 8 Hours (1.00 in.) (20.0 in.) (20.6 in.)
or Daily. 31.8 mm 635.0 mm 654.1 mm
(1.25 in.) (25.0 in.) (25.75 in.)
Do not work under a raised carriage. Lower the car-
44.5 mm 889.0 mm 915.7 mm
riage or use a safety chain to prevent the carriage
(1.75 in.) (35.0 in.) (36.05 in.)
from lowering when doing maintenance on the mast
50.8 mm 1016.0 mm 1046.5 mm
and lift chains.
(2.00 in.) (40.0 in.) (41.2 in.)
1. Lubricate the lift chains with 30W engine oil. The
best procedure is to remove the chains from the lift 1. CHAIN WEAR SCALE
truck and soak them in oil.
Figure 5. Lift Chains Check

12
8000 YRM 991
2. If a section of chain is 3% longer than a similar
section of new chain, the chain is worn and must be
replaced. If a chain scale is available, check the lift
chains as shown in Figure 5. If a chain scale is not
available, measure 20 links of chain. Measure from
the center of a pin to the center of another pin 20
pitches away. Compare the length with the chart in
Figure 5. Replace the chain if the length of 20 links
of the worn section is more than the maximum wear
limit.
FORKS
WARNING
Never repair damaged forks. Do not heat, weld, or
bend the forks. Forks are made of special steel us-
ing special methods. Replace damaged forks.
Do not try to move a fork without a lifting device.
Each hook fork for these lift trucks can weigh 45 to
115 kg (100 to 250 lb).
1. Check the heel and attachment points of the forks
with a penetrant or magnetic particle inspection.
2. Inspect the forks for cracks and wear. Check the
alignment of the fork tips. The height of the fork
tips must be within 3% of the length of each other.
Some applications can require closer alignment.
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.
Make sure the safety labels are clearly readable. Install
new and correct labels if necessary. For installation in-
structions, see the section Frame 100 YRM 994.
OTHER LUBRICATION
Lubricate hinges, pins, linkages, cables, pedals, and
levers as necessary. Use SAE 30 oil, multipurpose
grease, or silicone spray lubricant as needed. See the
Maintenance Schedule.
Maintenance Procedures Every 350 Hours or 3 Months
ELECTRICAL INSPECTION
Special Precautions
WARNING
Disconnect the battery connector to prevent injury
from electric shock before you make any inspec-
tions or repairs. Attach a tag to the connector that
states DO NOT CONNECT.
WARNING
To avoid personal injury and prevent electrical
shock or damage to the equipment, disconnect the
battery and separate the connector before opening
the compartment cover or inspecting/repairing the
electrical system. The capacitor in the traction
motor controller can hold an electrical charge after
the battery is disconnected. Discharge the capaci-
tor before inspecting or repairing any component.
Wear safety glasses.
WARNING
Make sure the switch is OFFand the park brake is
set before connecting the battery.
CAUTION
To avoid controller damage:
1. ALWAYS disconnect the battery when servicing
the controllers.
2. ALWAYS discharge the capacitors using the
proper procedure before performing any ser-
vice.
3. NEVER put power to the controller with any
power wire disconnected.
4. NEVER short any controller terminal or motor
terminal to the battery or frame.
5. If no 200-ohm, 2-watt resistor is available, make
certain the battery has been disconnected and
honk the horn until no further sound is heard to
discharge the controllers.
1. Block the lift truck so the drive wheels are off the
floor. See How to Put Lift Truck on Blocks.
2. Turn the key switch to the OFF position and unplug
the battery.
13
Maintenance Procedures Every 350 Hours or 3 Months 8000 YRM 991

3. Discharge the capacitors in the controllers by con-
necting a 200-ohm, 2-watt resistor across the con-
troller’s POS and NEG terminals (outer two power
cable terminals). See Figure 6 and Figure 7.
or damaged and that the operation of the motor is
correct. Worn motor brushes must be replaced be-
fore they damage the surface of the commutator.
Move the brush spring to remove a brush from the
brush holder. When the brush wears within approx-
imately 1.5 mm (0.060 in.) of where the brush wire
joins the brush, the brush must be replaced. For
the traction motors, the minimum brush length is
21.5 mm (0.846 in.). For the hydraulic motor, the
minimum brush length is 15.9 mm (0.626 in.).

2. Inspect the brush holders for burns or damage.

Make sure the brush holder is fastened tightly to
the mountings at the end of the motor. Make sure
the brushes will move freely and smoothly in the
brush holders.

3. Check the brush springs for damage from heat and

corrosion. Replace a damaged brush spring.

1. POSITIVE CONNECTION
2. NEGATIVE CONNECTION
3. JUMPER WIRES
4. 200-OHM 2-WATT RESISTOR

Figure 6. Lift Controller

Contactors
The contact surfaces are silver alloy on a copper base.
In normal operation, the contact surfaces become
rough and black. Cleaning is not necessary. Do not
use a file or emery cloth on the contacts. Replace the
contacts when the surface wears through to the copper
base. Always replace the contacts in sets. Check for
equal spring tension if the contacts do not wear evenly.
1. POSITIVE CONNECTION
Motor Brushes 2. NEGATIVE CONNECTION
3. JUMPER WIRES
1. Visually inspect the commutator and brushes every 4. 200-OHM 2-WATT RESISTOR
350 hours on all electric lift trucks. Make sure the
Figure 7. Traction Controller
surface of the commutator is not streaked, grooved,

14
8000 YRM 991
Maintenance Procedures Every 2000 Hours or Yearly
NOTE: Do these procedures in addition to the 8-hour
and 350-hour checks.
HYDRAULIC SYSTEM
Change the Hydraulic Oil Filter
Replace the filter element after the first 350 hours of
operation on a new lift truck. Replace the oil filter every
2000 hours or yearly after the first 350 hours. Remove
the oil filter and replace it with a new filter. Clean the
breather.
Check the Hydraulic Oil Strainer
Remove the hydraulic oil strainer located on top of the
hydraulic tank. Clean the strainer. If the strainer cannot
be cleaned, it should be replaced.
Change the Hydraulic Oil
WARNING
The hydraulic oil can be HOT. Use care when drain-
ing the hydraulic oil.
Put the lift truck on a level surface. Lower the mast. Put
a drip tray with a minimum of 27.5 liter (29 qt) capacity
under the hydraulic tank. Remove the drain plug on the
bottom of the hydraulic tank and drain the hydraulic oil.
When the oil has drained, install the drain plug. Fill the
hydraulic tank with the oil described in the Maintenance
Schedule.
BRAKES
Check the friction disc for wear. Minimum thickness is
5.5 mm (0.22 in.).
Maintenance Procedures Every 2000 Hours or Yearly
Readjust brake if friction disc is replaced or if air gap
exceeds 0.51 mm (0.02 in.).
See 1800 YRM 997 .
TRANSAXLE
Each transaxle has its separate oil supply. Remove the
drain plug from the transaxle compartment cover. Drain
the oil into a drip tray. Install the drain plug, and remove
both the level plug and the plug from the fill port. Add oil
to the transaxle through the fill port until the oil starts to
run out of the level port. Install both plugs. Make sure
the breather cap is clean. Fill the transaxles with the oil
described in the maintenance schedule. See the repair
procedures described in 630 YRM 993 . See Table 2.
Table 2. Transaxle Capacity
S2 Series Transaxle
Gear Oil Capacity 1.71 liter (0.45 gal)
Apply multipurpose grease with 2-4% molybdenum
disulfide with a high pressure gun to each transaxle
outer pinion bearing grease fitting. Clean lube fitting
and relief hole before and after lubricating.
The transaxle fitting is located behind each drive tire.
Drive tire removal is necessary to access the fittings.
Refer to Remove the Wheel From Lift Truck for drive
tire removal instructions.
15
Battery Maintenance 8000 YRM 991

Battery Maintenance
HOW TO CHARGE THE BATTERY

WARNING
If the lift truck was operated with a low battery,
check all contactors for welded contacts before a
charged battery is connected.

Make sure the key switch is OFF and the brake is

set before connecting the battery.

The acid in the electrolyte can cause injury. Use

water to flush the area and make the acid neutral
with a water and soda solution. Acid in the eyes
must be flushed with water. Batteries generate ex-
plosive fumes when they are being charged. Keep
fire, sparks, and burning material away from the
battery charger area. Avoid sparks from the bat-
tery connections. Charge batteries only in the spe- Specific
cial area for charging batteries. When the battery is Electrolyte Correction Correct
Gravity
being charged, keep the vent caps clear. The bat- Temp. Points Value
Reading
tery charger area must have ventilation, so explo-
sive fumes are removed. Open the battery cover on 1.210 31 C (87 F) +0.003 1.213
a covered battery. Disconnect the battery when do- 1.210 27 C (80 F) +0.001 1.211
ing cleaning and maintenance.
1.210 25 C (77 F) 0.000 1.210

CAUTION 1.210 18 C (64 F) −0.004 1.206

Never connect the battery charger plug to the plug
of the lift truck. You can damage the electronic con-
troller. Make sure the battery charger voltage is the
correct voltage for the battery.
Correct use of the hydrometer and proper operation of
the battery charger is important. See Figure 8. Follow
the instructions of the charger manufacturer. Never let
the battery discharge below the minimum value given
by the battery manufacturer. A fully charged battery
will have a specific gravity of 1.265 to 1.310 at 25 C
(77 F). Never charge a battery at a rate that will raise
the electrolyte temperature above 49 C (120 F). Never
let a battery stay discharged for long periods.
NORMAL CHARGE: This charge is the charge that is
normally given to a battery that is discharged from nor-
mal service. Many users give this charge at a regular
interval based on usage. This practice will keep the bat-
tery fully charged if the battery is not discharged below
the limit. Always use a hydrometer to check the battery
if the interval charge cycle is used. Frequent charging
of a battery that has a 2/3 or more charge can decrease
battery life.
+0.001 or −0.001 for each 2 C from the 25 base
value.
Figure 8. Battery Check
EQUALIZING CHARGE: This charge is at a low rate
and balances the charge in all of the cells. The equal-
izing charge is normally given approximately once a
month. It is a charge at a slow rate for 3 to 6 hours
in addition to the regular charging cycle.
Do NOT give an equalizing charge more than once a
week. The most accurate specific gravity measure-
ments for a charged battery will be after an equalizing
charge. If the specific gravity difference is more than
0.020 between cells of the battery after an equalizing
charge, there can be a defective cell. Consult your bat-
tery dealer.
Also see the section Industrial Battery for additional
information on the charging and maintenance of a bat-
tery.
NOTE: Many users have battery chargers that can fol-
low a program to automatically charge a battery accord-
ing to recommendations of the battery manufacturer.

16
8000 YRM 991
Use the recommendations of the battery manufacturer
for charging the battery.
HOW TO CHANGE THE BATTERY
WARNING
Batteries are heavy. Use care to avoid injury.
Wheels and Tires Maintenance
GENERAL
WARNING
The lift truck capacity can change with different
types of tires. Make sure the capacity on the
nameplate is for the type of tires installed.
The type of tire is shown on the nameplate. Make sure
the nameplate is correct for the type of tires on the lift
truck.
WHEELS AND TIRES
Remove the Wheel From Lift Truck
WARNING
Wheels must be changed and tires repaired
by trained personnel only. Always wear safety
glasses.
1. Loosen the wheel lug nuts. Put the lift truck on
blocks. See Putting the Lift Truck on Blocks.
WARNING
The tires weigh approximately 45.3 kg (100 lb).
Where applicable, use a wheel or tire dolly to assist
in the removal and installation of the wheel.
2. Remove the wheel lug nuts, and remove the wheel
and tire from the lift truck. Lift truck tires and wheels
are heavy.
Install the Tire on Wheel
WARNING
Wheels can explode and cause injury or death if the
following procedures are not followed:
• Clean and inspect all parts of the wheel before
installing the tire. Paint any parts that have rust
or corrosion.
• Do NOT use any damaged or repaired wheel parts.
Wheels and Tires Maintenance
The replacement battery must fit the battery area cor-
rectly. Use spacers to prevent the battery from moving
in the battery compartment. The weight of the replace-
ment battery must be within the maximum and mini-
mum weights shown on the nameplate. The key switch
should be OFF and the brake set before connecting the
battery.
• Make sure all parts of the wheel are the correct
parts for that wheel assembly. Make sure the rim
is the correct size for the tire. Lubricate the part
of the wheel that contacts the bead and flap.
• Do NOT mix parts between different types or man-
ufacturers of wheels.
• Do NOT mix types of tires, types of tire tread, or
wheel assemblies of different manufacturers on
any one lift truck.
• Do NOT use a steel hammer on the wheel. Use
a rubber, lead, plastic, or brass hammer to put
parts together. Make sure the side ring is in the
correct position. The ends of the side ring must
not touch.
• Apply a rubber lubricant or a soap solution to the
tire bead and tube.
• Do not lubricate the tire bead with antifreeze or
petroleum based liquid. Vapors from these liq-
uids can cause an explosion during inflation or
use.
Keep tire tools in firm contact with the wheel parts. If
the tool slips, it can move with enough force to cause
injury.
INSTALL THE WHEEL AND TIRE
WARNING
Do not lubricate the tire bead with antifreeze or
petroleum-based liquid. Vapors from these liquids
can cause an explosion during inflation or use.
CAUTION
The lifting and carrying of cushion tires is not rec-
ommended 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.
1. Install the tire and wheel on the hub. Tighten the
lug nuts so they are snug.
17
Forks 8000 YRM 991

2. Raise the lift truck high enough to remove the
blocks. Lower the lift truck to the floor.
3. Tighten the nuts in a cross pattern to the torque
value shown in the Maintenance Schedule.
NOTE: Check all wheel nuts after 2 to 5 hours of op-
eration when new lift trucks begin operation and on all
lift trucks when the wheels have been removed and in-
stalled. Tighten the nuts in a cross pattern to the correct
torque value. When the nuts stay tight for 8 hours, the
interval for checking the torque can be extended to 350
hours.

Mast and Lift Chains

chains must be done by authorized personnel. See
WARNING Lift Chain Adjustments for adjustment procedures.
When working on or near the mast or carriage, see
Safety Procedures When Working Near Mast.

1. Inspect the welds on the mast and carriage for

cracks. Make sure the hexagon head bolts and
nuts are tight.

2. Inspect the channels for wear in the areas where

the rollers travel. Inspect the rollers for wear or
damage.

3. Inspect the load backrest extension for cracks and

damage.

4. Lubricate the lift chains with 30W engine oil. The

best procedure is to remove the chains from the lift
truck and soak them in oil.

5. Inspect the lift chains for cracks or broken links and

pins. See Figure 9.

6. Inspect the chain anchors and pins for cracks and 1. WORN PIN 5. LOOSE LEAVES
damage. 2. CRACKS 6. DAMAGED PIN
3. EDGE WEAR 7. RUST
4. HOLE WEAR
7. Make sure the lift chains are adjusted so they have
equal tension. Adjustment or replacement of lift Figure 9. Check Lift Chains

Forks
The identification of a fork describes how the fork is sure the lock pin is engaged in the carriage bar to lock
connected to the carriage. These lift trucks have hook- the fork in position after the width adjustment is made.
type forks. See Figure 10.
REMOVE
ADJUST
The forks are connected to the carriage by hooks and
WARNING
lock pins. These lock pins are installed through the top Do not try to move a fork without a lifting device.
fork hooks and fit into slots in the top carriage bar. Ad- Each hook fork for these lift trucks can weigh 45 kg
just the forks as far as possible for the maximum sup- to 115 kg (100 to 250 lbs).
port of the load. Hook forks will slide along the carriage
A fork can be removed from the carriage for replace-
bars to adjust for the load to be lifted. Raise the lock pin
ment of the fork or other maintenance. Slide the fork
in each fork to slide the fork on the carriage bar. Make
to the fork removal notch on the bottom of the carriage

18
8000 YRM 991 Forks

bar. Lower the fork onto blocks so the bottom hook of disengaged from the top carriage bar. Move the car-
the fork moves through the fork removal notch. See Fig- riage away from the fork, or use a lifting device to move
ure 11. Lower the carriage further so the top hook is the fork away from the carriage.

1. FORKS 3. LOAD BACKREST EXTENSION

2. CARRIAGE 4. LOCK PIN ASSEMBLY

Figure 10. Carriage and Forks

INSPECT to move the lower hook through the fork removal notch.
Slide the fork on the carriage so both upper and lower
WARNING hooks engage the carriage. Engage the lock pin with a
notch in the upper carriage bar.
Never repair damaged forks by heating or welding.
Forks are made of special steel using special pro-
cedures. Replace damaged forks.

Inspect the forks for cracks and wear. Check the align-
ment of the fork tips. The height of the fork tips must
be within 3% of the length of each other. Some appli-
cations can require closer alignment.

Check that the bottom of the fork is not worn. Check

the heel of the fork using a fork tool.

INSTALL

WARNING
Do not try to move a fork without a lifting device. 1. CARRIAGE BARS 3. BLOCKS
Each hook fork for these lift trucks can weigh 45 to 2. HOOK FORK
115 kg (100 to 250 lb).
Figure 11. Hook Fork Removal
Move the fork and carriage so the top hook on the fork
can engage the upper carriage bar. Raise the carriage

19
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20
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

8000 YRM 991 4/02 (12/01) Printed in U.S.A.