Yale Electric Forklift Truck: ERP030TFN, ERP035TFN, ERP040TFN Maintenance, Service Manual

Original Illustrated Factory Workshop Maintenance, Service Manual for 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:
ERP030TFN
ERP035TFN
ERP040TFN

Format: PDF,350 Pages
Language: English

Contents:
1 OPERATING INSTRUCTIONS
    OPERATING INSTRUCTIONS-GENERAL
        SERIAL NUMBER
        MODEL CODE
        TRUCK WEIGHT
        CAPACITY RATING
    SAFETY AND INFORMATIONAL LABELS
    OPERATOR PRECAUTIONS
    OPERATOR PRE-CHECKS AND INSPECTION
    OPERATING PROCEDURE
    SHUT DOWN PROCEDURE
    FORK ADJUSTMENT
    SAFETY AND OPERATIONAL CHECK LIST
    MODEL AND CONTROL INFORMATION
        INSTRUMENT PANEL A (STANDARD)
        INSTRUMENT PANEL B (OPTIONAL)
        INSTRUMENT PANEL C (OPTIONAL)
        TEMPERATURE INDICATOR LAMP
    SAFE MAINTENANCE PROCEDURES
    MOVING A DISABLED LIFT TRUCK
    HOW TO TOW THE LIFT TRUCK
    HOW TO PUTA LIFT TRUCK ON BLOCKS
        HOW TO RAISE THE STEER TIRE
        HOW TO RAISE THE DRIVE TIRES
    PRECAUTIONS FOR TRUCKS IN STORAGE
    PRECAUTIONS FOR BATTERIES IN STORAGE
2 GENERAL TRUCK AND LUBRICATION SCHEDULE
    INTRODUCTION - GENERAL TRUCK
    FRAME
    FLOOR PLATE
    REAR COMPARTMENT COVER
    FRONT COVER
    STEERING COLUMN COVER
    HYDRAULIC CONTROL VALVE COVERS
    BATTERY COVER
    OPEN
    CLOSE
    REMOVAL
    INSTALLATION
    BATTERY REMOVAL AND INSTALLATION
    BATTERY PLATFORM
    OVERHEAD GUARD
    REMOVAL
    INSTALLATION
    COUNTERWEIGHT
    REMOVAL
    INSTALLATION
    HYDRAULIC OIL TANK
    INSPECTION
    REPAIRS, SMALL LEAKS
    REPAIRS, LARGE LEAKS
    CLEANING
    STEAM METHOD OF CLEANING
    CHEMICAL SOLUTION METHOD OF CLEANING
    ADDITIONAL PREPARATIONS FOR REPAIR
    WELDING REPAIRS
    TIRES AND WHEELS
    PNEUMATIC TIRES
    HOW TO CHANGE THE TIRES
    REMOVE THE WHEEL FROM THE LIFT TRUCK
    REMOVE THE TIRE FROM THE WHEEL
    INSTALLING THE TIRE ON THE WHEEL
    ADD AIR TO THE TIRES
    PNEUMATIC SHAPED SOLID TIRES
    REMOVE THE WHEEL FROM THE LIFT TRUCKSOLID TIRES
    REMOVE THE ONE PIECE WHEEL AND TIRE
    INSTALL THE TIRE ON THE ONE PIECE WHEEL
    INSTALL THE WHEELS ON THE LIFT TRUCK
    LABEL REPLACEMENT
    YALE WARRANTY INFORMATION
    RECOMMENDED SCHEDULE OF MAINTENANCE
    LUBRICATION INSTRUCTIONS
    EVERY 8 HOURS
    EVERY 350 HOURS
    EVERY 2000 HOURS
    EVERY 4000 HOURS
    HYDRAULIC OILS
    GEAR OILS
    ANTI-SEIZE LUBRICATING COMPOUND
    GREASE
    FASTENERS - INTRODUCTION
    THREADS, NOMENCLATURE
    STRENGTH IDENTIFICATION
    REMOVE THE TIRE FROM THE WHEEL
    INSTALL THE TIRE ON THE WHEEL
3 ELECTRICAL SYSTEM
    ELECTRICAL SYSTEM-GENERAL
    EV-100LX MOTOR CONTROLLER
    EV-100LX DESCRIPTIONAND OPERATION
    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
    THE CONTROL CARD
    PULSE MONITOR TRIP (PMT) (TRACTION CIRCUIT ONLY)
    SRO CIRCUIT (TRACTION CIRCUIT ONLY)
    CONTROL CARD ADJUSTMENTS (TRACTION CIRCUIT)
    ACCELERATOR CONTROL
    SEQUENCE OF OPERATION
    CONTROL CARD
    STATUS CODES
    SCR CONTROL (HYDRAULIC PUMP MOTOR)
    CONTROL CARD CONNECTIONS
    HANDSET
    CHECKS AND ADJUSTMENTS, CONTROL CARD
    FUNCTION CODES
    BENCH TESTS
    TESTS-CONTROL CARD INSTALLED INA LIFT TRUCK
    FUNCTION SETTINGS
    GENERAL
    CONNECT, DISCONNECT, AND CHECK THE HAND SET
    CHECK AND ADJUST FUNCTIONS
    FUNCTION DESCRIPTIONS
    TRACTION CONTROL CARDS (LABEL LETTER DX OR DT)
    TRACTION CONTROL CARDS (LABEL LETTER FX OR FT)
    PUMP CONTROL CARD (LABEL LETTER PX)
    TABLES FOR FUNCTION VALUE SETTINGS
    TROUBLESHOOTING
    TROUBLESHOOTING
    CONTACTORS
    TESTING CONTACTORS
    REMOVAL
    INSTALLATION
    REMOVAL-"EE" CONTACTORS
    INSTALLATION-'EE" CONTACTORS
    DISASSEMBLY-EE" CONTACTORS
    ASSEMBLY-EE" CONTACTORS
    TMM 1 CARD
    REMOVAL
    INSTALLATION
    CIRCUIT PROTECTION
    CURRENT LIMIT
    THERMAL PROTECTION
    SUPPRESSORS (FILTER BLOCKS)
    FUSES
    PRINTED CIRCUIT BOARDS
    STEERING ANGLE CONTROL BOARD
    OPERATION
    TESTING
    LIFT PUMP CONTROL BOARD
    OPERATION
    TESTING
    BY-PASSING THE LIFT PUMP CONTROL BOARD
    ACCELERATOR
    REMOVAL
    INSTALLATION
    ON-DEMAND POWER STEERING
    KEY SWITCH
    INSTRUMENT PANEL
    STANDARD INSTRUMENT PANEL
    INDICATOR LAMPS
    OPTIONAL INSTRUMENT PANEL A
    INDICATOR LAMPS
    OPTIONAL INSTRUMENT PANEL B
    INDICATOR LAMPS
    MOTOR MAINTENANCE -GENERAL
    BRUSH AND COMMUTATOR INSPECTION
    NORMAL COMMUTATOR SERVICE
    COMMUTATOR PROBLEMS
    BRUSH REPLACEMENT, DRIVEAND
    HYDRAULIC PUMP MOTORS
    TRACTION MOTOR
    HYDRAULIC PUMP MOTOR
    POWER STEERING PUMP MOTOR
    MOTOR REMOVAL AND INSTALLATION
    TRACTION MOTOR REMOVAL
    TRACTION MOTOR INSTALLATION
    LIFT PUMP AND MOTOR REMOVAL
    LIFT PUMP AND MOTOR INSTALLATION
    POWER STEERING PUMPAND MOTOR REMOVAL
    POWER STEERING PUMP AND MOTOR INSTALLATION
    TRACTION MOTOR REPAIR
    DISASSEMBLY
    ASSEMBLY
    COMMUTATOR REPAIRS
    TESTS
    DAMAGED FIELD AND ARMATURE
    SHORT-CIRCUIT INAN ARMATURE WINDING
    SHORT-CIRCUIT IN THE ARMATURE
    OPEN CIRCUIT INA FIELD COIL
    SHORT-CIRCUIT INA FIELD COIL
    SHORT-CIRCUIT BETWEEN FIELD AND MOTOR CASE
    BRUSH HOLDER
    WIRING SCHEMATIC-CONTACTOR CONTROLLED LIFT PUMP.
    WIRING SCHEMATIC-CONTACTOR
    CONTROLLED LIFT PUMP (CONTINUED)
    OPTIONS SCHEMATIC-CONTACTOR CONTROLLED LIFT PUMP .
    WIRING DIAGRAM-CONTACTOR CONTROLLED LIFT PUMP
    WIRING DIAGRAM-CONTACTOR CONTROLLED LIFT PUMP (CONTINUED)
    OPTIONS DIAGRAM-CONTACTOR CONTROLLED LIFT PUMP
    OPTIONS DIAGRAM-CONTACTOR CONTROLLED LIFT PUMP (CONTINUED) 
    WIRING SCHEMATIC-SCR CONTROLLED LIFT PUMP
    WIRING SCHEMATIC-SCR CONTROLLED LIFT PUMP (CONTINUED)
    OPTIONS SCHEMATIC-SCR CONTACTOR CONTROLLED LIFT PUMP
    WIRING DIAGRAM-SCR CONTACTOR CONTROLLED LIFT PUMP
    WIRING DIAGRAM-SCR CONTACTOR CONTROLLED LIFT PUMP (CONTINUED)
    OPTIONS DIAGRAM-SCR CONTACTOR CONTROLLED LIFT PUMP
    OPTIONS DIAGRAM-SCR CONTACTOR CONTROLLED LIFT PUMP (CONTINUED) 3-11
    WIRING SCHEMATIC-OPTIONAL EQUIPMENT WIRING DIAGRAM-OPTIONAL EQUIPMENT
    WIRING DIAGRAM-OPTIONAL EQUIPMENT (CONTINUED) 
4 DRIVE UNIT
    TRANSAXLE
    GENERAL
    LUBRICATION
    REMOVAL
    INSPECTION
    INSTALLATION
    S1 SERIES TRANSAXLE
    DISASSEMBLY
    ASSEMBLY
    S2 SERIES TRANSAXLE
    DISASSEMBLY
    ASSEMBLY
    GENERAL
    RING GEAR INSTALLATION
    INTERMEDIATE SHAFT INSTALLATION
    AXLE SHAFT INSTALLATION
    PINION GEAR INSTALLATION
    FINAL ASSEMBLY
    TROUBLESHOOTING
5 BRAKE SYSTEM
    BRAKES - GENERAL
    SPECIFICATIONS
    PARK BRAKEADJUSTMENT
    SERVICE BRAKEADJUSTMENT
    SERVICE BRAKE PADS - REMOVAL
    SERVICE BRAKE PADS - INSTALLATION
    SERVICE BRAKE CALIPER - REMOVAL
    SERVICE BRAKE CALIPER - INSTALLATION
    SERVICE BRAKE CALIPER - DISASSEMBLY
    SERVICE BRAKE CALIPER -ASSEMBLY
    PARK BRAKE CALIPER - REMOVAL
    PARK BRAKE CALIPER - INSTALLATION
    PARK BRAKE CALIPER - DISASSEMBLY
    PARK BRAKE CALIPER -ASSEMBLY
    MASTER CYLINDER - REMOVAL
    MASTER CYLINDER - INSTALLATION
    MASTER CYLINDER - DISASSEMBLY
    MASTER CYLINDER -ASSEMBLY
    FOOT OPERATED PARK BRAKE LEVER ASSEMBLY 
    REMOVAL
    INSTALLATION
    ELECTRICALLY RELEASED PARK BRAKE 
    MECHANICAL OPERATION
    REMOVAL
    INSTALLATION
    ELECTRICAL COMPONENTS - ELECTRICALLY RELEASED 
    PARK BRAKE
    CONTROL BOX - REMOVAL
    CONTROL BOX - INSTALLATION
    TERMINAL BLOCK - REMOVAL ..
    TERMINAL BLOCK - INSTALLATION
    TROUBLESHOOTING
6 TRAIL AXLE AND STEERING SYSTEM
    STEERING AXLE
    WHEEL ASSEMBLY
    REMOVAL
    INSTALLATION
    WHEEL HUB
    REMOVAL
    INSTALLATION
    STEER AXLE ASSEMBLY
    REMOVAL
    INSTALLATION
    POWER STEERING SYSTEM
    GENERAL
    DESCRIPTION
    STEERING WHEEL AND COLUMN ASSEMBLY
    REMOVAL
    INSTALLATION
    STEERING CONTROL UNIT
    DISASSEMBLY
    ASSEMBLY
    INSTALLATION
    POWER STEERING CYLINDER
    REMOVAL
    INSTALLATION
    DISASSEMBLY
    ASSEMBLY
    CHECKS AND ADJUSTMENTS
    REMOVEAIR FROM THE SYSTEM
    CHECK THE OPERATION
    STEERING PRESSURE
    TROUBLESHOOTING
7 HYDRAULIC SYSTEM
    HYDRAULIC SYSTEM -GENERAL
    LIFT SYSTEM
    TILT SYSTEM
    AUXILIARY FUNCTIONS
    THIRD FUNCTION LOCATION
    FOURTH FUNCTION LOCATION
    HYDRAULIC OIL TANK
    SPECIFICATIONS
    HYDRAULIC TANK
    LIFT PUMP
    POWER STEER PUMP
    STRAINERS
    HYDRAULIC OIL FILTER
    LIFT PUMP
    REMOVAL
    INSTALLATION
    DISASSEMBLY - SEAL REPLACEMENT
    ASSEMBLY
    POWER STEERING PUMP AND MOTOR
    REMOVAL
    INSTALLATION
    DISASSEMBLY
    ASSEMBLY
    CONTROL VALVE
    SETTINGS
    REMOVAL
    INSTALLATION
    DISASSEMBLY
    ASSEMBLY
    MAST TILT ADJUSTMENT
    CONTROL VALVE - EMERGENCY REPAIR
    (PLUNGER AND PLUNGER HOUSING SECTION)
    TROUBLESHOOTING
8 MAST
    MAST-GENERAL
    DESCRIPTION AND OPERATION
    CARRIAGE
    MAST MOUNTS
    SIMPLEX MAST
    DESCRIPTION
    OPERATION
    DUPLEX MAST
    DESCRIPTION
    OPERATION
    TRIPLEX MAST
    DESCRIPTION
    OPERATION
    SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
    MAST REPLACEMENT
    MAST REPAIRS
    FORKS
    REMOVAL
    INSTALLATION
    CARRIAGES
    REMOVAL, STANDARD CARRIAGE
    REMOVAL, SIDESHIFT CARRIAGE
    REPAIRS
    INSTALLATION, STANDARD CARRIAGE
    INSTALLATION, SIDESHIFT CARRIAGE
    MAST REPAIRS
    REMOVAL
    DISASSEMBLY SIMPLEX AND DUPLEX MASTS
    DISASSEMBLY TRIPLEX MAST
    CLEANING AND INSPECTION
    ASSEMBLY OF THE SIMPLEX AND DUPLEX MAST
    ASSEMBLY OF THE TRIPLEX MAST
    MAST INSTALLATION
    LIFT CYLINDERS
    REMOVAL OF THE MAIN LIFT CYLINDERS
    REMOVAL OF THE FREE LIFT CYLINDER
    DISASSEMBLY OFA LIFT CYLINDER
    ASSEMBLY OFA LIFT CYLINDER
    INSTALLATION OF THE MAIN LIFT CYLINDERS
    INSTALLATION OF THE FREE LIFT CYLINDER
    HOSE TAKE-UP ARRANGEMENTS
    INSTALLATION OF HOSE TAKE-UP ARRANGEMENT
    FOR SIMPLEX MAST
    INSTALLATION OF HOSE TAKE-UP ARRANGEMENT
    FOR DUPLEX MAST
    INSTALLATION OF HOSE TAKE-UP ARRANGEMENT
    FOR TRIPLEX MAST
    TILT CYLINDERS
    REMOVAL
    DISASSEMBLY
    CLEANING
    ASSEMBLY
    INSTALLATION
    CHECKS AND ADJUSTMENTS
    CHECK FOR LEAKS IN THE LIFTAND 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
    TROUBLESHOOTING
    QUAD MAST
    REMOVAL
    INSTALLATION
    DISASSEMBLY
    ASSEMBLY
    DISASSEMBLY FREE LIFT CYLINDER
    ASSEMBLY FREE LIFT CYLINDER
    DISASSEMBLY MAIN CYLINDER
    ASSEMBLY MAIN CYLINDER
    CHAIN-CHECKS AND ADJUSTMENTS
    MASTADJUSTMENTS
    BLEEDING THE CYLINDERS
    TROUBLESHOOTING
9 BATTERY AND CHARGING SYSTEM
    BATTERYAND CHARGING SYSTEM-GENERAL
    SAFETY TIPS FOR HANDLING
    INDUSTRIAL TRUCK BATTERIES
    TROUBLESHOOTING
    TROUBLESHOOTING
    LEAD-ACID BATTERIES
    SPECIFIC GRAVITY
    CHEMICAL REACTION
    HOW TO SELECT THE BATTERY
    VOLTAGE OFA BATTERY
    BATTERY RATINGS
    KILOWATT HOURS
    THE BATTERY AS A COUNTERWEIGHT
    THE NEW BATTERY
    BATTERY MAINTENANCE
    MAINTENANCE RECORDS
    CLEANING THE BATTERY
    ADDING WATER
    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
    BATTERY CHARGING AREA
    EQUIPMENT NEEDED
10 USER SUPPORT SYSTEM
    SERVICE PARTS ORDERING INSTRUCTIONS
    HOW TO ORDER SERVICE PARTS
    WHEN ORDERING PARTS
    TECHNICAL PUBLICATIONS
    PARTS MANUAL
    OPERATING MANUAL-1 565 (5189768-11)
    OPERATOR TRAINING
    SERVICE TRAINING COURSES
    SERVICE TRAINING MATERIALS
11 ALPHABETICAL INDEX
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