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, 406 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
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