Yale Electric ForkLift Truck: ERC030AF, ERC040AF, ERP030AF, ERP040AF Workshop Service Manual

Yale Electric ForkLift Truck: ERC030AF, ERC040AF, ERP030AF, ERP040AF Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Yale Electric Forklift Truck

Original factory manuals for Yale Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text

Covered models:
ERC030AF
ERC040AF
ERP030AF
ERP040AF

Format: PDF, XXX Pages
Language: English

Contents:
1. GENERAL INFORMATION
    SUPPORT INFORMATION
    SERVICE PARTS ORDERING
    INSTRUCTIONS
        How To Order Service Parts
        When Ordering Parts
    SPECIAL TOOLS
    TECHNICAL SERVICE PUBLICATIONS ....
    OPERATOR TRAINING
    DAILY OPERATOR CHECK-OFF LISTS ....
    SERVICE TRAINING COURSES
    SERVICE TRAINING MATERIALS
Section 2. GENERAL LIFT TRUCK INFORMATION AND LUBRICATION SCHEDULE
    SAFETY PROCEDURES WHEN
    WORKING NEAR THE MAST
    GENERAL LIFT TRUCK MAINTENANCE AND
    LUBRICATION SCHEDULE
    HOW TO PUT A LIFT TRUCK ON BLOCKS .
        How To Raise The Drive Wheels
        How To Raise The Steer Wheels
    MAINTENANCE SCHEDULE
    LEGEND
    EVERY 8 HOURS OR DAILY
    HOW TO MAKE CHECKS WITH
    THE KEY SWITCH "OFF"
        Tires And Wheels
        Forks
        Forks, Adjustment
        Forks, Removal
        Forks, Installation
        Inspection Of Forks, Mast, And Lift Chains
        Safety Labels
        Operator Restraint System
        Battery Restraint System
        Battery
        Hydraulic System
    HOW TO MAKE CHECKS WITH
    THE KEY SWITCH "ON"
        Gauges, Horn and Fuses
        Steering System
        Service Brakes
        Parking Brake
        Control Levers And Pedals
        Lift System Operation
    EVERY 350 HOURS OR TWO MONTHS ....
        Hydraulic Tank Breather
        Differential And Speed Reducer
        Wheel Bolts Or Nuts
        Steering Axle Spindles
        Mast
        Lift Chains, Check for Wear
        Forks
        Brake Fluid
        Other Lubrication
    SEAT BRAKE
        Electrical Inspection
        Contactors
        Motor Brushes
    EVERY 2000 HOURS OR YEARLY
        Wheel Bearings
        Change the Filter For The Hydraulic Oil ..
        Change The Hydraulic Oil
        Change The Oil In The Differential And
        Speed Reducer
        Service Brakes
        Service Brakes, Cleaning
        Lift Chains
        Contactors
    GENERAL PROCEDURES
    HOW TO CHARGE THE BATTERY
    HOW TO CHANGE THE BATTERY
    CHECK FOR LEAKS IN THE LIFT AND TILT
    SYSTEM
        Check the Lift Cylinders for Leaks
        Check the Tilt Cylinders for Leaks
    LIFT CHAIN ADJUSTMENTS
    HOW TO CHECK THE PMT CIRCUIT ...
    WELDING REPAIRS
    FRAME
        Battery Restraint And Hood
        Seat Brake And Seat Assembly
        Overhead Guard
        Counterweight
    HYDRAULIC TANK
        Inspection
    WHEELS AND TIRES
        General
    HOW TO CHANGE A SOLID RUBBER TIRE
        Remove The Wheels From The Lift Truck
        Remove And Install The Tire On The Wheel
        HOW TO REPAIR A PNEUMATIC TIRE ...
        Remove The Wheels From The Lift Truck
        Remove The Wheel From The
        Pneumatic Tire
        Install The Wheel In The Pneumatic Tire .
        Install The Wheels
        Add Air To The Tires
    SOLID RUBBER TIRES ON
    PNEUMATIC WHEELS
        Remove The Wheels From The Lift Truck
        Remove The Solid Rubber Tire From The
        Pneumatic Wheel
        Install The Solid Rubber Tire On The
        Pneumatic Wheel
        Install The Wheels
    PAINTING INSTRUCTIONS
    LABEL INSTRUCTIONS
    HOW TO PUT AN ELECTRIC SIT
    DOWN RIDER TRUCK IN STORAGE ....
    HOW TO PUT BATTERIES IN STORAGE . . .
    HOW TO MOVE A DISABLED LIFT TRUCK .
        How To Tow The Lift Truck
    SPECIFICATIONS
    TORQUE SPECIFICATIONS
    TORQUE VALUES FOR INCH FASTENERS .
    TORQUE VALUES FOR
    METRIC FASTENERS
Section 3. ELECTRICAL SYSTEM
    ELECTRIC MOTOR MAINTENANCE,
    GENERAL
    TRACTION MOTOR AND
    HYDRAULIC PUMP MOTOR
        Disassembly
        Assembly
    BRUSH AND COMMUTATOR INSPECTION .
        Normal Commutator Surface
        Commutator Problems
    BRUSH ALIGNMENT, TRACTION AND
    HYDRAULIC MOTORS
    BRUSH INSTALLATION, TRACTION AND
    HYDRAULIC MOTORS
    TESTS FOR A DAMAGED
    FIELD AND ARMATURE
        Test For An Open Circuit In The Armature
        Test For A Short-Circuit In An
        Armature Winding
        Test For An Short-Circuit In The Armature
        Test For An Open Circuit In A Field Coil . .
        Test For A Short-Circuit In A Field Coil . . .
        Test For A Short-Circuit Between
        The Field And The Motor Case
        Brush Holder Test
    EV-100ZXE SCR MOTOR CONTROLLER . .
    GENERAL
        Model Number Data For
        EV-100ZX Controller
        Tables For The Function Value Settings ...
    REGISTER PARAMETERS
        General
        Function Numbers
    CONTROL CARD, CHECKS AND
    ADJUSTMENTS
    COMPUTER SYSTEM
        When A PC Is Connected To A
        Control Card
        Help
        Communications Program (MODEM)
        Monitor Program
    HAND SET
        How To Check And Adjust The Registers .
        How To Scroll Through The
        Fault Codes And Clear Them
        Checks And Adjustments On
        The Work Bench
        When The Hand Set Is Connected To A
        Control Card Installed In A Lift Truck
    FUNCTION NUMBER DESCRIPTIONS ...
        Traction Control Cards (Label Letters - ZH And ZY)
        Pump Control Card (Label Letter ZP)
    REGISTER PARAMETERS
    TROUBLESHOOTING
        Status Codes
    REGISTER MAPS
    OPTIONAL BASIC DISPLAY
    REGULAR DISPLAY
    OPTIONAL PREMIUM DISPLAY
    STATUS CODE CHARTS
    REPAIRS
        Fuses
        Check An SCR
        Replace An SCR
        The SCR 1 Assembly
        Thermal Protector
        Install A New SCR 1 Assembly
    THE "OFF' CIRCUIT FOR SCR 1
        Check The Reactor Assembly
        Check Suppressors For
        SCR 2 And SCR 5
        Check SCR 2 And SCR 5
        Replace SCR 2 And SCR 5
        Check Capacitor C1
        Check Diodes D3 And D4
        Replace Diodes D3 and D4
        Motor Current Sensor
    CONTACTORS
        Contactor Repair
    CONTROL CARD
        Control Card Plugs
    OTHER CONTROL COMPONENTS (INPUT DEVICES)
         Key Switch
         Start Switch
         Seat Switch
         Switch For Optional Seat Brake
         Parking Brake Switch
         Direction Control Switches
         Brake Fluid Switch
         Motor Temperature Switches
         Rocker Switches For Lights
         Accelerator Position Sensor
         On-Demand Steering Components ..
         Lights And Reverse Alarm
         Horn And Horn Button
         Hydraulic Pump Switches
         Replace A Display Panel
         Brush Wear And Over
         Temperature Indicators
    CHECKS AND ADJUSTMENTS
        Control Card
        Checking Curtis Meter In The
        Regular Display Panel
        Adjustment Of Curtis Meter In
        The Regular Display Panel
        Control And Power Fuses
        Adjust The Start Switch
        Adjusting Brake Light Switch
        Check The Seat Switch
        Adjust The Switch For Optional Seat Brake
        Adjust The Parking Brake Switch
        Direction Switches
        Hydraulic Pump Switches
        Adjust The Accelerator Pedal
        Adjust The Accelerator Position Sensor . .
        THEORY OF OPERATION
    ELECTRONIC SPEED CONTROLS
        The Silicon Controlled Rectifier (SCR)
        A Motor Circuit That Operates With Pulses
        Traction Circuit
        Hydraulic Pump Motor
        The SCR 1 "OFF" Circuit
    INDUCTION CURRENT FROM THE MOTOR
        Pulse Monitor Trip (PMT) (Traction Circuit Only)
        SRO Circuit (Traction Circuit Only) 
        Control Card Adjustments (Traction Circuit)
        Accelerator Control
    SCR CONTROL (HYDRAULIC PUMP MOTOR)
    CONTACTORS
    CIRCUIT PROTECTION
        Traction Circuit Fuse
        Current Limit
        Thermal Protection
        Suppressors
    SEQUENCE OF OPERATION
    INPUT AND OUTPUT DEVICES FOR THE
    MOTOR CONTROLLERS
        Display Panels (Output Device)
        Basic Display Panel
        Regular Display Panel
        Premium Display Panel
    OTHER CONTROL COMPONENTS
    SCHEMATIC AND WIRING DIAGRAMS 
        Figure 3-86. Schematic Diagram EV-100ZX SCR Control For Traction Motor
        Figure 3-87. Schematic Diagram EV-100ZX SCR Control For Lift Pump Motor
        Figure 3-88. Schematic Diagram Contactor Control For Lift Pump Motor 
        Figure 3-89. Wiring Diagram
        Figure 3-90. Wiring Diagram
        Figure 3-91. Wiring Diagram
        Figure 3-92. Table Of Wiring Connections, Controller Panel-To-Panel
        Figure 3-93. Truck Wiring
        Figure 3-94. Truck Power Cables 
        Figure 3-95. EV-100ZX SCR Panel Wiring Of Traction And Pump Motor Controllers .
        Figure 3-96. EV-100ZX SCR Panel Wiring Of Traction Motor Controller And Contactor Pump Control
        Figure 3-97. EV-100ZX SCR Panel Wiring Of Traction Motor Controller And Contactor Pump Control
        Figure 3-98. EV-100ZX SCR Traction Motor And SCR Pump Motor Controllers .
        Figure 3-99. EV-100ZX SCR Traction Motor Controller With Contactor Control Of Pump Motor ....
        Figure 3-100. EV-100ZX SCR Traction Motor Controller With Contactor Control Of Pump Motor
        Figure 3-101. EV-1 00ZX Contactor Panel
        Figure 3-102. Hydraulic Linkage Switch And Chassis Wiring Details
        Figure 3-103. Steering Column Wiring Detail
        Figure 3-104. Premium Display Panel And Plug Connector
        Figure 3-105. Regular Display Panel And Plug Connectors
        Figure 3-106. Basic Display Panel And Plug Connectors
        Figure 3-107. Lighting Schematic Diagram
        Figure 3-108. Lighting Wiring Diagram 
Section 4. DRIVE UNIT ASSEMBLY.
    GENERAL
    DESCRIPTION
    REMOVAL AND DISASSEMBLY OF
    DRIVE UNIT
        Removing Complete Drive Unit Assembly As A Unit
        Removing Traction Motor
        Removing Drive Unit And Speed Reducer
        Assembly
        Disassembly Of Drive Axle
        Disassembly Of Differential And
        Speed Reducer
    CLEANING
    INSPECTION
        General
        Inspection Of Gears, Bearings And Splines
    ASSEMBLY OF DRIVE UNIT
        Find The Correct Shim Set For
        The Hypoid Gear Set
        Assembly And Installation Of Pinion ...
        Assembly And Installation Of
        Differential And Ring Gear
        Assembly Of Input Gear For
        Speed Reducer 
        Assembly Of Drive Axle And Hub Assembly 
    INSTALLATION OF DRIVE UNIT 
        Installing The Drive Unit 
        Installing Traction Motor 
        TORQUE SPECIFICATIONS 
    TROUBLESHOOTING 
Section 5.BRAKE SYSTEM
    BRAKE SYSTEM, GENERAL
    DESCRIPTION AND OPERATION
        Service Brakes
        Master Cylinder
        Parking Brake
    REMOVAL AND DISASSEMBLY OF
    THE SERVICE BRAKES
    CLEANING
    INSPECTION
    ASSEMBLY AND INSTALLATION OF
    THE SERVICE BRAKES
    MASTER CYLINDER
        Removal
        Cleaning And Inspection
        Repair
        Installation
    REMOVAL AND DISASSEMBLY OF
    THE PARKING BRAKE
    ASSEMBLY AND INSTALLATION OF
    THE PARKING BRAKE
    REPLACING THE PARKING BRAKE SWITCH
    CHECKS AND ADJUSTMENTS
        Remove The Air From The Brake System
        Adjustments, Service Brakes
        Adjust The Brake Pedal
        Adjust The Master Cylinder
        Adjust The Parking Brake
        Adjust The Parking Brake Switch
        Test The "Parking Brake Not
        Applied" Warning System
        Adjust The Seat Brake
    TORQUE SPECIFICATIONS
Section 6. STEERING AXLE ASSEMBLY
    STEERING AXLE ASSEMBLY, GENERAL ...
    DESCRIPTION
    STEERING AXLE ASSEMBLY
        Removal
        Installation
    WHEELS
        Removal and Disassembly
        Cleaning
        Assembly And Installation
    SPINDLES, BEARINGS AND LINKS
        Removal And Disassembly
        Cleaning
        Assembly And Installation
    STEERING CYLINDER
        Removal And Disassembly
        Cleaning and Inspection
        Assembly and Installation
    TORQUE SPECIFICATIONS
    TROUBLESHOOTING
Section 7. POWER STEERING SYSTEM.
    POWER STEERING SYSTEM, GENERAL 
    STEERING WHEEL AND COLUMN ASSEMBLY
        Removal Of Components
        Installation Of Components
    POWER STEERING MOTOR AND PUMP ...
        Removal And Disassembly
        Assembly And Installation
    STEERING CONTROL UNIT
        Description
        Removal
        Disassembly
        Cleaning
        Assembly
        Installation
    CHECKS AND ADJUSTMENTS
        Remove Air From The System
        Steering Relief Valve
    CHECK OPTICAL ENCODER AND
    ACTIVATOR CIRCUITS FOR "ON-DEMAND" STEERING
    TROUBLESHOOTING
Section 8. HYDRAULIC SYSTEM
    HYDRAULIC SYSTEM, GENERAL
        Description, Hydraulic System
        Operation, Hydraulic System
        Hydraulic (Lift) Pump
        Main Control Valve
        Lift Section
        Tilt Section
        Relief Valve
    REPAIRS, CONTROL LEVER LINKAGE ....
        Removal
        Disassembly
        Assembly And Installation
    REPAIRS, CONTROL VALVE LINKAGE ..
        Removal And Disassembly
        Assembly And Installation
    REPAIRS, MAIN CONTROL VALVE
        Removal
        Disassembly
        Cleaning And Inspection
        Assembly
        Installation
    REPAIRS, LIFT PUMP
        Removal
        New Seal Installation
        Installation
    REPAIRS, HYDRAULIC TANK
        Removal
        Inspection
        Repairs, Small Leaks
        Repairs, Large Leaks
        Cleaning
        Steam Method Of Cleaning
        Chemical Solution Method Of Cleaning . . .
        Additional Preparations For Repair ....
        Installation
    CHECKS AND ADJUSTMENTS
        Main Control Valve
        Primary Relief Valve
        Secondary Relief Valve
    SPECIFICATIONS
    TROUBLESHOOTING, HYDRAULIC SYSTEM
    TROUBLESHOOTING, MAIN
    CONTROL VALVE
Section 9. MAST
    MAST
    DESCRIPTION AND OPERATION
        Carriages
        Mast Mounts
    TWO-STAGE LFL MAST
        Description
        Operation
    TWO-STAGE FFL MAST
        Description
        Operation
    THREE-STAGE FFL MAST
        Description
        Operation
    SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
    MAST REPAIRS
    FORKS
        Removal
        Installation
    CARRIAGES
        Removal, Standard Carriage
        Removal, Side-Shift Carriage
        Repairs
        Installation, Standard Carriage
        Installation, Side-Shift Carriage
    MASTS
        Removal
        Disassembly, Two-Stage LFL And Two-Stage Mast
        Disassembly, Three-Stage FFL Mast
        Cleaning and inspection
        Assembly, Two-Stage LFL And Two-Stage FFL Mast
        Assembly, Three-Stage FFL Mast
        Installation, Mast
    LIFT CYLINDERS
        Removal, Main Lift Cylinders
        Removal, Free-Lift Cylinder
        Disassembly, Lift Cylinder
        Assembly, Lift Cylinder
        Installation, Main Lift Cylinders
        Installation, Free-Lift Cylinder
    HEADER HOSE ARRANGEMENTS
        Installation of New
        Hoses, Two-Stage LFL Mast
        Adjustment Of Hoses Afte
        r Installation, Two-Stage LFL Mast ....
        Installation of New
        Hoses, Two-Stage FFL Mast
        Adjustment Of Hoses After
        Installation, Two-Stage FFL Mast.
        Installation of New
        Hoses, Three-Stage FFL Mast
        Adjustment Of Hoses After
        Installation, Three-Stage FFL Mast ...
    TILT CYLINDERS
        Removal
        Disassembly
        Cleaning
        Assembly
        Installation
    CHECKS AND ADJUSTMENTS
        Check For Leaks In The Lift And
        Tilt System
        Check The Lift Cylinders For Leaks ...
        Check The Tilt Cylinders For Leaks ...
        Adjust The Tilt Cylinders
        Adjust The Lift Chains
        Adjust The Mast
        Adjust The Carriage
    TORQUE SPECIFICATIONS
    TROUBLESHOOTING
Section 10. BATTERY AND CHARGER SYSTEM
    BATTERY AND CHARGER
    SYSTEM, GENERAL
    LEAD-ACID BATTERIES
    SPECIFIC GRAVITY
    THE CHEMICAL REACTION IN A CELL ...
    ELECTRICAL TERMS
    HOW TO SELECT THE BATTERY
    VOLTAGE OF A BATTERY
    THE BATTERY AS A COUNTERWEIGHT ..
    BATTERY RATINGS
        Kilowatt-Hours
    BATTERY MAINTENANCE
        Safety Procedures
        Maintenance Records
        The New Battery
        How To Clean The Battery
        How To Add Water
        The Hydrometer
        Battery Temperature
    CHARGING THE BATTERY
        Types Of Battery Charges
        Methods Of Charging
        Troubleshooting The Charger
        How To Know When The
        Battery Is Fully Charged
    WHERE TO CHARGE THE BATTERIES ...
        Equipment Needed
    BATTERY CONNECTOR
    BATTERY CARE
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