Yale Forklift Truck Type ERC040 RF/ZF, ERC050 RF/ZF, ERC060 RF/ZF, ERC065 RF/ZF Service Manual

Original Illustrated Factory Workshop Service Manual for Yale Forklift Truck Type E108.

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:
ERC040RF
ERC040ZF
ERC050RF
ERC050ZF
ERC060RF
ERC060ZF
ERC065RF
ERC065ZF

Format: PDF, 433 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
DAILYOPERATOR CHECK-OFF LISTS
SERVICE TRAINING COURSES
SERVICE TRAINING MATERIALS
2 GENERAL LIFT TRUCK INFORMATION AND LUBRICATION SCHEDULE
GENERAL LIFT TRUCK MAINTENANCEAND
LUBRICATIONSCHEDULE
HOW TO PUTA LIFT TRUCK ONBLOCKS
How To Raise The Drive Wheels
How To Raise The Steer Wheels
MAINTENANCESCHEDULE
EVERY8 HOURS OR DAILY
HOW TO MAKE CHECKS WITH THE KEYSWITCH "OFF ..
Hydraulic System
Battery
Forks
Forks, Adjustment
Forks, Removal
Forks, Installation
Inspection Of Forks, Mast, And Lift Chains
Tires And Wheels
Operator Restraint System
Battery Restraint System
Safety Labels
HOW TO MAKE CHECKS WITH THE KEYSWITCH "ON" ..
Gauges, Horn and Fuses
Control Levers And Pedals
Lift System Operation
Service Brakes
Parking Brake
Steering System
EVERY350 HOURS OR TWO MONTHS
Hydraulic Tank Breather
DifferentialAnd Speed Reducer
Wheel Nuts
Steering Axle Spindles
Mast
Lift Chains, Check for Wear
Forks
Brake Fluid
Other Lubrication
ElectricalInspection
Contactors
Motor Brushes
EVERY2000 HOURS OR YEARLY
Wheel Bearings
Change the Filter For The Hydraulic Oil
Change the Hydraulic Oil
Change The Oil In The DifferentialAnd Speed Reducer
Service Brakes
Service Brakes, Cleaning
Lift Chains
Contactors
GENERAL PROCEDURES
HOW TO CHARGE THE BATTERY
BATTERY SPECIFICATIONS
HOW TO CHANGE THE BATTERY
CHECK FOR LEAKS IN THE LIFTAND TILT SYSTEM .
Check the Lift Cylinders for Leaks
Check the Tilt Cylinders for Leaks
LIFT CHAINADJUSTMENTS
HOW TO CHECK THE PMT CIRCUIT
WELDING REPAIRS
FRAME
Battery Restraint And Hood
Seat Brake And Seat Assembly
Overhead Guard
Changes To The Overhead Guard
Counterweight
HYDRAULIC TANK
Inspection
WHEELS AND TIRES
How To Change A Solid Rubber Tire (Press-on)
Install The Steer Wheels
Install The Drive Wheels
PAINTING INSTRUCTIONS
LABEL INSTRUCTIONS
HOW TO PUTAN ELECTRIC SIT DOWN RIDER TRUCK
IN STORAGE
HOW TO PUT BATTERIES IN STORAGE
HOW TO MOVEA DISABLED LIFT TRUCK
How To Tow The Lift Truck
SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE VALUES FOR INCH FASTENERS
TORQUE VALUES FOR METRIC FASTENERS
3 ELECTRICAL SYSTEM
ELECTRIC MOTOR MAINTENANCE, GENERAL
TRACTION MOTOR AND HYDRAULIC PUMP MOTOR
Disassembly
Assembly
BRUSHAND COMMUTATOR INSPECTION
Normal Commutator Surface
Commutator Problems
BRUSHALIGNMENT, TRACTION AND HYDRAULIC MOTORS
BRUSHINSTALLATION, 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 ForA Short-Circuit In A Field Coil
Test For A Short-Circuit Between The Field
And The Motor Case
Brush Holder Test
EV-100ZXSCR MOTOR CONTROLLER
ModelNumber Data For EV-100ZX Controller
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 HandSet Is Connected To A
Control Card Installed In A Lift Truck
FUNCTIONNUMBER DESCRIPTIONS
Traction Control Cards (Label letters - ZH And ZY).
Pump Control Card (Label Letter ZP)
REGISTER PARAMETERS
TROUBLESHOOTING
Status Codes
REGISTER MAPS
STANDARD DISPLAY PANEL
PERFORMANCEDISPLAYPANEL
STATUS CODE CHARTS
REPAIRS
Fuses
Check An SCR
Replace An SCR
The SCR 1Assembly
Thermal Protector
InstallA New SCR 1Assembly
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 D3And 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 FluidSwitch
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 Indicators
CHECKS AND ADJUSTMENTS
Control Card
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 OFOPERATION
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 CardAdjustments (Traction Circuit)
Accelerator Control
SCR CONTROL (HYDRAULIC PUMP MOTOR)
CONTACTORS
CIRCUIT PROTECTION
Traction Circuit Fuse
Current Limit
Thermal Protection
Suppressors
SEQUENCE OF OPERATION
INPUTAND OUTPUT DEVICES FOR
THE MOTOR CONTROLLERS
Display Panels (Output Device)
Regular Display Panel
Performance Display Panel
OTHER CONTROL COMPONENTS
SCHEMATICS
4 DRIVE UNIT ASSEMBLY
DRIVE UNITASSEMBLY, GENERAL
DESCRIPTION
DRIVEUNITASSEMBLY, REMOVAL
Traction Motor, Removal
Traction Motor, Installation
Drive Axle And Speed Reducer Assembly, Removal
Drive Axle, Disassembly .
Speed Reducer and Differential, Disassembly
CLEANING
INSPECTION
SPEED REDUCER AND DIFFERENTIAL
Input Gear Assembly, Installation
DIFFERENTIAL, ASSEMBLY AND INSTALLATION
Installation Of The Pinion Assembly
Assemble The DifferentialAnd Ring Gear
Drive Axle, Assembly .
DRIVEAXLE ASSEMBLY INSTALLATION
TORQUE SPECIFICATIONS
TROUBLESHOOTING ....
5 BRAKE SYSTEM
BRAKESYSTEM, GENERAL
DESCRIPTIONAND OPERATION
Service Brakes
Master Cylinder
Parking Brake
REMOVAL AND DISASSEMBLYOF THE SERVICEBRAKES .
CLEANING
INSPECTION
ASSEMBLY AND INSTALLATION OF THE SERVICE BRAKES
REMOVAL AND DISASSEMBLY OF THE PARKINGBRAKE . .
ASSEMBLYAND INSTALLATION OF THE PARKING BRAKE ..
MASTER CYLINDER
Removal
Cleaning And Inspection
Repair
Installation
CHECKSAND ADJUSTMENTS
Remove The Air From The Brake System
Adjustments, Sen/ice Brakes
Adjustment, Brake Pedal
Adjustment, Master Cylinder
Adjustments, Parking Brake
Test The "Parking Brake Not Applied" Warning
Adjustments, Seat Brake
TORQUE SPECIFICATIONS
TROUBLESHOOTING
6 STEERING AXLE ASSEMBLY
STEERING AXLE ASSEMBLY, GENERAL
DESCRIPTION
STEERING AXLE ASSEMBLY
Removal
Installation
WHEELS
Removaland Disassembly
Cleaning
Assembly And Installation
SPINDLES, BEARINGS AND TIE RODS
RemovalAnd Disassembly
Cleaning
Assembly And Installation
STEERING CYLINDER
RemovalAnd Disassembly
Cleaning and Inspection
Assembly and Installation
TORQUE SPECIFICATIONS
TROUBLESHOOTING
7 POWER STEERING SYSTEM
POWER STEERING SYSTEM, GENERAL
STEERING WHEEL AND COLUMN ASSEMBLY
Removal Of The Assembly Components .
Installation Of The Assembly Components
POWER STEERING MOTOR AND PUMP
RemovalAnd 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
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
RemovalAnd Disassembly
Assembly And Installation
REPAIRS, MAINCONTROL VALVE
Removal
Disassembly
CleaningAnd Inspection
Assembly
Installation
REPAIRS, LIFTPUMP
Removal
New Seal Installation
Installation
REPAIRS, HYDRAULIC TANK
Removal
Inspection
Repairs, Small Leaks
Repairs, Large Leaks
Cleaning
Steam MethodOf Cleaning
Chemical Solution MethodOf Cleaning
Additional Preparations For Repair
Installation
CHECKSAND ADJUSTMENTS
Main Control Valve
Primary Relief Valve
Secondary Relief Valve
SPECIFICATIONS
TROUBLESHOOTING, HYDRAULIC SYSTEM
TROUBLESHOOTING, MAIN CONTROL VALVE
9 MAST
DESCRIPTION AND OPERATION
Carriages
Mast Mounts
SIMPLEX MAST
Description And Operation
DUPLEX MAST
Description
Operation
TRIPLEX MAST
Description
Operation
QUADPLEXMAST
Description
Operation
SAFETY PROCEDURES WHEN WORKING
NEAR THE MAST
REPAIRS
FORKS
Removal
Installation
CARRIAGES
Removal, Standard Carriage
Removal, Side-shift Carriage
Repairs
Installation, Standard Carriage
Installation, Side-Shift Carriage
MASTS
Removal
Disassembly Procedures For The Simplex
Or Duplex Mast
Disassembly Procedures For The
Triplex Mast
Disassembly Procedures For The
QuadplexMast
Cleaning and Inspection
Assembly Of The Simplex
And Duplex Mast
Assembly Of The Triplex
Assembly Of The Quadplex
Mast Installation
LIFT CYLINDERS
Removal Of The Main Lift Cylinders
Removal Of The Free-Lift Cylinder
Disassembly Of A Lift Cylinder
Assembly Of A Lift Cylinder
Installation Of The Main Lift Cylinders —
Installation Of The Free-Lift Cylinder —
TILT CYLINDERS
Removal
Disassembly
Cleaning
Assembly
Installation
HOSE TAKE UP ARRANGEMENTS
New Hose Installation, Simplex Mast ..
Adjustment Of Hoses After Installation,
Simplex Mast
New Hose Installation, Duplex
Adjustment Of Hoses After Installation,
Duplex
New Hose Installation, Triplex
Adjustment Of Hoses After Installation.
Triplex
Hose Take Up Installation, Quadplex ..
CHECKS AND ADJUSTMENTS
CHECK FOR LEAKS IN THE LIFT AND TILT
SYSTEM
Check The Lift Cylinders For Leaks ...
Check The Tilt Cylinders For Leakage —
ADJUST THE TILT CYLINDERS
ADJUST THE LIFT CHAINS
ADJUST THE MAST
ADJUST THE CARRIAGE
TROUBLESHOOTING
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
INDEX
Powered by