Yale Forklift Truck HD (A839) Series: ERC070, ERC080, ERC100, ERC120 Workshop Manual

Yale Forklift Truck HD (A839) Series: ERC070, ERC080, ERC100, ERC120 Workshop Manual

Original Illustrated Factory Workshop Manual for Yale Forklift Truck HD (A839) Series.

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:
ERC 070 HD
ERC 080 HD
ERC 100 HD
ERC 120 HD

Format: PDF, 507 Pages
Language: English

Contents:

Section 1
     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 MAINTENANCE
     AND LUBRICATION SCHEDULE
     GENERAL
     HOW TO MOVE A DISABLED LIFT TRUCK .
     How to Tow a Lift Truck
     HOW TO PUT A LIFT TRUCK ON BLOCKS .
     How To Raise the Drive Tires
     How To Raise the Steering Tires
     MAINTENANCE SCHEDULE
     MAINTENANCE PROCEDURES
     EVERY 8 HOURS OR DAILY
     CHECKS WITH THE KEY "OFF"
     Hydraulic System
     Battery
     Battery Restraint System
     Operator Restraint System
     Inspection Of The Mast, Forks And
     Lift Chains
     Tires And Wheels
     Forks, Adjustment
     Forks, Removal And Installation
     SAFETY LABELS
     CHECKS WITH THE KEY "ON"
     Gauges and Horn
     Lift System Operation
     Service Brakes
     Parking Brake
     Steering System
     EVERY 350 HOURS OR TWO MONTHS
     HYDRAULIC TANK BREATHER
     DIFFERENTIAL AND SPEED REDUCER
     WHEEL NUT TORQUES
     STEERING AXLE SPINDLES
     MAST
     LIFT CHAINS
     Check for Wear
     Lubrication
     FORKS
     BRAKE FLUID
     OTHER LUBRICATION
     SEAT BRAKE
     ELECTRICAL INSPECTION
     Contactors
     Motor Brushes
     EVERY 2000 HOURS OR YEARLY
     HYDRAULIC SYSTEM
     Change the Filter for the Hydraulic Oil
     Change the Hydraulic Oil
     DIFFERENTIAL AND SPEED REDUCER ...
     SERVICE BRAKES
     CONTACTORS
     WHEEL BEARINGS
     Steer Wheels, Lubrication
     Drive Wheels, Lubrication
     LIFT CHAINS
     GENERAL PROCEDURES
     HOW TO CHARGE THE BATTERY
     HOW TO CHANGE THE BATTERY
     SAFETY PROCEDURES WHEN WORKING
     NEAR THE MAST
     CHECK FOR LEAKS IN THE LIFT AND TILT
     SYSTEM
     Check the Lift Cylinders for Leaks
     Check the Tilt Cylinders for Leaks
     LIFT CHAIN ADJUSTMENTS
     WELDING REPAIRS
     CHANGES TO THE OVERHEAD GUARD ..
     SOLID RUBBER TIRES (PRESS-ON) ...
     How To Change A Solid Rubber Tire ..
     Install The Wheels
     FRAME REPAIR
     Overhead Guard, Removal
     Overhead Guard, Installation
     Battery Restraint And Seat Assembly ..
     Counterweight
     Removal
     Installation
     TRACTION MOTOR
     Removal
     Installation
     HYDRAULIC TANK
     Inspection
     Repairs, Small Leaks
     Repairs, Large Leaks
     Cleaning
     Steam Method Of Cleaning
     Chemical Solution Method of Cleaning
     Additional Preparations For Repair
     PAINT INSTRUCTIONS
     LABEL REPLACEMENT
Section 3
     ELECTRICAL SYSTEM
     DC MOTOR MAINTENANCE, GENERAI
     BRUSH AND COMMUTATOR INSPECTION .
     Hydraulic Pump Motor And Traction Motor
     Steering Pump Motor
     Commutator Problems
     BRUSH REPLACEMENT
     DISASSEMBLY OF MOTORS
     Traction Motor And Hydraulic Pump Motor
     Steering Pump Motor
     ASSEMBLY OF MOTORS
     Traction Motor And Hydraulic Pump Motor
     Steering Pump Motor
     BRUSH ALIGNMENT, 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
     One Armature Winding
     Test For A Short-Circuit To Armature Shaft
     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-1 00/200 LX MOTOR CONTROLLER
     EV-100LX AND EV-200LX MOTOR
     CONTROLLERS, GENERAL
     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
     THE CONTROL CARD
     Pulse Monitor Trip (PMT)
     (Traction Circuit Only)
     SRO Circuit (Traction Circuit Only) .
     Control Card Adjustments (Traction Circuit)
     Accelerator Control
     SCR CONTROL, DUAL HYDRAULIC
     PUMP MOTORS
     VOLTAGE ADJUSTMENTS, SCR
     CONTROL FOR HYDRAULIC PUMP.
     CONTACTORS
     CIRCUIT PROTECTION
     Traction Circuit Fuse
     Current Limit
     Thermal Protection
     Suppressors
     SEQUENCE OF OPERATION
     CONTROL CARD, CHECKS AND
     ADJUSTMENTS
     Status Codes
     HAND SET
     INSTRUMENT PANEL DISPLAY
     Battery Gauge With Lift Interrupt  (Curtis 933/1 or Curtis 933/4 Lift Interrupt Controller)
     Battery Gauge With Lift Interrupt And
     Brush Wear Indicator (General Electric) 
     Instrument Panel Display (I.T.W. Controller)
     Motor Temperature Indicators
     Brush Wear Indicators
     CONTROL CARD CONNECTIONS
     CHECKS AND ADJUSTMENTS,
     CONTROL CARD
     Function Codes
     Checks And Adjustments On The Bench . .
     When The Hand Set Is Connected To A
     Control Card Installed In A Lift Truck
     FUNCTION SETTINGS, CHECKS AND ADJUSTMENTS
     General
     How To Connect, Disconnect, And
     Check The Hand Set
     How To Check And Adjust Functions ...
     FUNCTION DESCRIPTIONS
     Traction Control Cards
     (label letters - LX, LXT and LXM)
     Pump Control Card (label letter PX) ...
     Tables for the Function Value Settings
     TROUBLESHOOTING
     REPAIRS
     FUSES
     CHECK AN SCR
     The SCR 1 Assembly
     Thermal Protector
     Replace The SCR 1 Assembly
     THE "OFF" CIRCUIT FOR SCR 
     Check The Reactor Assembly
     Check Suppressors For SCR 2 And SCR 
     Check SCR 2 And SCR 5
     REPLACE THE SCR 2 AND SCR 
     Check Capacitor C1
     DIODES D3 AND D4
     Check The Diodes D3 And D4
     Replacement, Diodes D3 and D4
     MOTOR CURRENT SENSOR
     CONTACTORS
     Contactor Repair
     CONTROL CARD
     CONTROL CARD PLUGS
     CONTROL SWITCHES
     Seat Switch
     Key Switch
     Direction Control Switch (Steering Column)
     Parking Brake Switch And Buzzer Alarm . .
     Start Switch
     Accelerator Circuit
     DIAGRAMS FOR THE EV-100/200 LX MOTOR
     CONTROLLER
     Figure 3-60. Schematic Diagram, EV-100LX
     EV-200LX SCR Traction Motor
     Control, 36-48 Volts
     Figure 3-61. Hydraulic Pump Motor Controls
     Figure 3-62. Hydraulic Pump Motor Controls
     Figure 3-63. Hydraulic Pump Motor Controls
     Figure 3-64. Hydraulic Pump Motor Controls
     Figure 3-65. Wiring Diagram, EV-100LX SCR
     Traction Motor Control With Single Or Dual
     Hydraulic Pump Motor Contactor Control .
     Figure 3-66. Wiring Diagram, EV-200LX SCR
     Traction Motor Control With EV-100LX SCR
     Hydraulic Pump Motor Control
     Figure 3-67. Control Switches
     Figure 3-68. Wiring Diagram, Control Switches Without On-Demand Power Steering
     Figure 3-69. Wiring Diagram, Control Switches, On-Demand Power Steering ..
     Figure 3-70. Hydraulic Pump Motor Controls
     Figure 3-71. Hydraulic Pump Motor Controls
     Figure 3-72. EV-100 "LX" Series GE Or ITW 
     Display With Lift Interrupt - Without
     Pump Motor SCR Control Schematic ....
     Figure 3-73. Battery Indicators
     Figure 3-74. Battery Indicators
     Figure 3-75. "LX" SCR Hydraulics
     Wiring Diagram
     Figure 3-76. Contactor Hydraulics Wiring Diagram
     EV-1 00/200 ZX MOTOR CONTROLL
     EV-100ZX AND EV-200ZX MOTOR
     CONTROLLERS, GENERAL
     ELECTRONIC SPEED CONTROLLERS 
     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
     SCR Control, Dual Hydraulic Pump Motors
     VOLTAGE ADJUSTMENTS, SCR CONTROL
     FOR HYDRAULIC PUMP
     CONTACTORS
     CIRCUIT PROTECTION
     Traction Circuit Fuse
     Current Limit
     Thermal Protection
     Suppressors
     SEQUENCE OF OPERATION
     CONTROL CARD, CHECKS AND
     ADJUSTMENTS
     Status Codes
Table 16. STATUS CODES LIST
     INSTRUMENT PANEL DISPLAY
     Motor Temperature Indicators
     Brush Wear Indicators
Table 17. Terminal And Plug Wire Connections
     For Control Card ZY, SCR Control Of Traction Circuit, Contactor Control Of
     Hydraulic Pump, Standard or GE Panel Display, Without Regenerative Braking, Without Brush
     Wear or Motor Temperature Indicators 
Table 18. Terminal And Plug Wire Connections For Control Card ZH, SCR Control Of Traction
     Circuit, Contactor Control Of Hydraulic Pump, Performance Panel Display, With Regenerative
     Braking, With Brush Wear And Motor Temperature Indicators 3-144
Table 19. Terminal And Plug Wire Connections For Control Card ZH, SCR Control Of Traction
     Circuit, SCR Control Of Hydraulic Pump, Performance Panel Display, With Regenerative
     Braking, With Brush Wear And Motor Temperature Indicators 3-145
Table 20. Terminal And Plug Wire Connections For Controller With SCR Control Of Traction
     Installation
     TROUBLESHOOTING (DANFOSS)
     CHECKS AND ADJUSTMENTS
     Remove Air From The System
     Steering Relief Valve
     Check Optical Encoder And Activator
     Circuits For "ON-DEMAND" Steering 
Section 8
     HYDRAULIC SYSTEM
     DESCRIPTION, HYDRAULIC SYSTEM ...
     OPERATION, HYDRAULIC SYSTEM
     Hydraulic Pump
     Steering Pump
     HYDRAULIC PUMP, REPAIRS
     Removal
     Seal Replacement
     Installation
     CHECKS AND ADJUSTMENTS
     Main Control Valve
     Linkage and Switches
     Relief Valve
     Steering Relief Valve
     SPECIFICATIONS, HYDRAULIC SYSTEM 
     TABLE 1. TROUBLESHOOTING, HYDRAULIC SYSTEM
     LIFT CYLINDERS
     Lowering Control Valve
     Lift Cylinders, Removal
     Standard and Full Free-Lift Masts with the
     Lift Cylinder Fastened to a Crosshead 
     Lift Cylinders, Disassembly
     Main Lift Cylinders, Assembly
     Main Lift Cylinders, Installation
     Free-Lift Cylinder, Installation
     CHECKS AND ADJUSTMENTS
     Check For Leaks In The Lift System 
     TABLE 3. TROUBLESHOOTING, LIFT CYLINDERS
     TILT CYLINDERS
     Description
     Tilt Cylinders, Removal
     Tilt Cylinders, Disassembly Cleaning
     Tilt Cylinders, Assembly
     Tilt Cylinders With O-Ring or Single Lip Seals
     Tilt Cylinders, Installation
     Check The Tilt Cylinders For Leaks 
     TABLE 4.TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS
     TABLE 5. INTERNAL LEAK RATES
     (MAXIMUM) FOR TILT CYLINDERS
     TABLE 6.TROUBLESHOOTING, TILT CYLINDERS
     MAIN CONTROL VALVE
     Description
     Operation
     Lift Section
     Tilt Section
     Relief Valve
     SOLENOID VALVE FOR
     AUXILIARY FUNCTION
     REPAIRS
     Main Control Valve, Removal and
     Disassembly
     Cleaning and Inspection
     Main Control Valve, Assembly
     Installation
     Solenoid Valve For Auxiliary Function,
     Removal and Disassembly
     Solenoid Valve For Auxiliary Function,
     Assembly and Installation
     CHECKS AND ADJUSTMENTS
     Relief Valves
     Primary Relief Valve
     Secondary Relief Valve
     CONTROL LEVER ARRANGEMENT
     TABLE 7. RELIEF VALVE SETTINGS
     TABLE 8. TROUBLESHOOTING
     TROUBLESHOOTING, SOLENOID VALVE FOR
     AUXILIARY FUNCTION
Section 9
     MAST
     DESCRIPTION AND OPERATION
     Carriages
     Simplex Mast With Limited Free-lift
     Duplex Mast With Full Free-lift
     Triplex Mast With Full Free-lift
     TABLE 1.WEIGHT OF MAST PARTS
     SAFETY PROCEDURES WHEN WORKING
     NEAR THE MAST
     REPAIRS
     Forks
     Forks, Removal And Installation
     Carriage, Removal
     Side-shift Carriage, Removal
     Side-shift Carriage, Repairs
     Side-shift Carriage, Installation
     Simplex Mast With Limited Free-lift,
     Removal
     Simplex Mast With Limited Free-lift,
     Disassembly
     Cleaning and Inspection
     Simplex Mast With Limited Free-lift,
     Assembly
     Simplex Mast With Limited Free-lift,
     Installation
     Duplex Mast With Full Free-lift, Removal .
     Disassembly
     Cleaning and Inspection
     Duplex Mast With Full Free-lift, Assembly .
     Duplex Mast With Full Free-lift, Installation
     Triplex Mast With Full Free- Lift, Removal .
     Triplex Mast With Full Free
     Lift, Disassembly
     Cleaning And Inspection
     Triplex Mast With Full Free- Lift, Assembly
     Installation
     CHECKS AND ADJUSTMENTS
     Check The Operation Of The Mast
     Adjust The Tilt Cylinder Stroke And
     The Backward Tilt Angle
     Lift Chain Adjustments
     Mast Adjustments
     Carriage Adjustments
     TROUBLESHOOTING, MAST
Section 10
     THE INDUSTRIAL BATTERY
     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
     BATTERY INDICATORS
     Description, "LX" Series
     Battery Indicators Replacement
     Controller For The Battery Indicator,
     Replacement
     BATTERY INDICATORS USED WITH THE "ZX"
     MOTOR CONTROLLER
     Battery Indicator, Standard Display Panel .
     Battery Indicator, Diagnostic Display Panel
     Battery Indicator, Performance
     Display Panel
     CHECKS AND ADJUSTMENTS
     "LX" Battery Indicator Without Lift Interrupt
     "LX" Battery Indicator With Lift Interrupt . . .
     Reset Potentiometer
     Discharge Potentiometer
     LED Display With Lift Interrupt
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