Yale Sit Down Rider RA, ZA Series: ERC040, ERC050, ERC060 Workshop Manual

Original Illustrated Factory Workshop Manual for Yale Sit Down Rider RA, ZA 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 040 RA
ERC 040 ZA
ERC 050 RA
ERC 050 ZA
ERC 060 RA
ERC 060 ZA

Format: PDF, 315 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
    HOW TO PUT A LIFT TRUCK ON BLOCKS .
    How To Raise The Drive Tires
    How To Raise The Steering Tires
    MAINTENANCE SCHEDULE
    GENERAL LUBRICATION INSTRUCTIONS .
    EVERY 8 HOURS OR DAILY
    HOW TO MAKE CHECKS WITH THE key swrrcH 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
    KEY SWITCH "ON "
    Gauges, Horn and Fuses
    Pedals And Control Levers
    Lift System Operation
    Sen/ice 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
    Forks
    Brake Fluid
    Other Lubrication
    Seat Brake
    Electrical Inspection
    Contactors
    Motor Brushes
    EVERY 2000 HOURS OR YEARLY.
    Wheel Bearings
    Change the Hydraulic Oil and Filter ..
    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
    OVERHEAD GUARD
    Changes To The Overhead Guard.
    Removal
    Installation
    HYDRAULIC TANK
    Inspection
    COUNTERWEIGHT
    Removal
    Installation
    TIRES AND WHEELS
    Solid Tires (Press-on)
    Install The Wheels
    LABEL REPLACEMENT
    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
    GENERAL GUIDE TO TORQUE
    VALUES (LBF-FT)
    GENERAL GUIDE TO TORQUE VALUES 
Section 3
    ELECTRIC MOTOR MAINTENANCE,
    GENERAL
    TRACTION MOTOR AND
    HYDRAULIC PUMP MOTOR
    Disassembly
    Assembly
    BRUSH AND COMMUTATOR INSPECTION .
    Normal Commutator Surface
    Commutator Problems
    BRUSH REPLACEMENT, 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 Held Coil ..
    Test For A Short-Circuit In A Held Coil . . .
    Test For A Short-Circuit Between The Field
    And The Motor Case
    Brush Holder Test
    EV-100LX MOTOR CONTROLLER, 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 (HYDRAULIC PUMP MOTOR)
    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 - TX and TT)
    Pump Control Card (label letter PX) ....
    Tables for the Function Value Settings ....
    TROUBLESHOOTING
    REPAIRS
    FUSES
    CHECKING AN SCR
    The SCR 1 Assembly
    Thermal Protector
    Replacing The 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
    REPLACING THE SCR 2 AND SCR 5 ...
    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
    SCHEMATIC AND WIRING DIAGRAMS ....
    Figure 3-55. Schematic Diagram,
    EV-100LX Motor Controller
    Figure 3-56. GE Battery Indicator With Brush
    Wear Indicator Display, Lift Interrupt, And With
    SCR Control Of The Hydraulic Pump ...
    Figure 3-57. Curtiss[ 933/4 Or 933/1
    Battery Indicator With Lift Interrupt And
    Without SCR Control Of The Hydraulic Pump
    Figure 3-58. Wiring Diagram, Curtiss[ 933/4
    Or 933/1 Battery Indicator With Lift Interrupt
    And Without SCR Control Of The
    Hydraulic Pump
    Figure 3-59. Wiring Diagram, EV-100LX Mot
    Controller
    Figure 3-60. Battery Indicator
    Without Lift Interrupt And Without
    SCR Control Of The Hydraulic Pump 
    Figure 3-61. Traction Circuit With Regenerative
    Braking, Field Weakening, And With SCR Control Of The Hydraulic Pump
    Figure 3-62. Battery Discharge Indicator
    With Lift Interrupt, With Brush Wear Indicator,
    And With SCR Control Of The
    Hydraulic Pump 3
Section 4
    DRIVE UNIT ASSEMBLY, GENERAL
    DESCRIPTION
    DRIVE UNIT ASSEMBLY, REMOVAL
    Traction Motor, Removal
    Traction Motor, Installation
    Drive Axle And Transmission Assembly,
    Removal
    Drive Axle, Disassembly
    Transmission and Differential, Disassembly
    CLEANING
    INSPECTION
    TRANSMISSION AND DIFFERENTIAL 
    Input Gear Assembly, installation
    DIFFERENTIAL, ASSEMBLY AND INSTALLATION
    When A New Ring And Pinion Assembly Is Installed 
    Installation Of The Pinion Assembly 
    Assemble The Differential And Ring Gear
    Drive Axle, Assembly
    DRIVE AXLE ASSEMBLY, INSTALLATION . .
    TORQUE SPECIFICATIONS
    TROUBLESHOOTING
Section 5
    BRAKE SYSTEM, GENERAL
    DESCRIPTION AND OPERATION
    Service Brakes
    Parking Brake
    Seat Brake
    REMOVAL AND DISASSEMBLY OF THE SERVICE BRAKES
    CLEANING
    INSPECTION
    ASSEMBLY AND INSTALLATION
    OF THE SERVICE BRAKES
    PARKING BRAKE
    CHECKS AND ADJUSTMENTS
    Remove The Air From The Brake System
    Adjustments, Service Brakes
    Adjustments, Parking Brake
    Adjustment, Parking Brake Switch
    Adjustment, Brake Pedal
    MASTER CYLINDER
    Removal And Disassembly
    Inspection
    Assembly
    SEAT BRAKE
    Inspection
    Removal
    Installation
    TORQUE SPECIFICATIONS
    TROUBLESHOOTING
Section 6
     STEERING AXLE ASSEMBLY, GENERAL ...
     DESCRIPTION
     STEERING AXLE ASSEMBLY
     Removal
     Installation
     WHEELS AND HUBS
     Removal and Disassembly
     Cleaning
     Assembly And Installation
     SPINDLES. BEARINGS AND TIE RODS 
     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, GENERAL 
     STEERING WHEEL AND COLUMN ASSEMBLY
     Removal Of The Assembly Components .
     Installation Of The Assembly Components
     POWER STEERING MOTOR AND PUMP ...
     Removal And Disassembly
     Assembly And Installation
     Repairs, Power Steering Pump
     Seal Replacement
     STEERING CONTROL UNIT (ROSS HGF) 
     Control Valve Section
     Metering Section
     Disassembly And Inspection
     Assembly
     Installation
     TROUBLESHOOTING (ROSS HGF)
     STEERING CONTROL UNIT (DANFOSS) .
     Description
     Removal
     Disassembly
     Cleaning
     Assembly
     Installation
     TROUBLESHOOTING (DANFOSS)
     CHECKS AND ADJUSTMENTS
     Remove Air From The System
     Steering Relief Valve
     CHECK OPTICAL ENCODER AND ACTIVATOR
     CIRCUITS
Section 8
     HYDRAULIC SYSTEM, GENERAL
     Description, Hydraulic System
     Operation, Hydraulic System
     Hydraulic Pump
     Main Control Valve
     Lift Section
     Tilt Section
     Relief Valve
     REPAIRS, MAIN CONTROL VALVE
     Removal and Disassembly
     Cleaning and Inspection
     Assembly
     Installation
     REPAIRS, HYDRAULIC PUMP
     Removal
     Seal Replacement
     Installation
     CHECKS AND ADJUSTMENTS, HYDRAULIC
     SYSTEM
     Main Control Valve, Linkage and Switches
     Main Control Valve, Relief Valve
     TILT CYLINDERS
     Removal
     Disassembly
     Cleaning
     Assembly
     Installation 
     Check The Tilt Cylinders For Leakage
     Adjust The Tilt Cylinder Stroke
     And The Backward Tilt Angle
     HYDRAULIC SPECIFICATIONS 
     TROUBLESHOOTING. HYDRAULIC SYSTEM 
     TROUBLESHOOTING, MAIN CONTROL VALVE 
     TROUBLESHOOTING, TILT CYLINDER 
     Section 
     SAFETY PROCEDURES WHEN WORKING NEAR
     THE MAST
     FOUR-STAGE MAST, GENERAL
     REPAIRS
     Forks, Removal
     Forks, Installation
     CARRIAGE
     Removal
     Installation
     MAST
     Removal
     Disassembly
     Cleaning 
     Inspection of Forks, Mast, and Lift Chains 
     Assembly 
     Installation 
     LIFT CYLINDERS 
     Lowering Control Valve 
     Lift Cylinder Removal 
     Lift Cylinder Disassembly 
     Lift Cylinder Assembly 
     Main Lift Cylinders, Installation 
     Free-Lift Cylinder, Installation 
     CHECKS AND ADJUSTMENTS 
     Check For Leaks In The Lift System 
     Check the Lift Cylinders for Leaks
     Adjust The Tilt Cylinder Stroke
     And The Backward Tilt Angle
     Lift Chain Adjustments
     Mast Adjustments
     Carriage Adjustments
     TORQUE SPECIFICATIONS 
     TROUBLESHOOTING
     Section 10
     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
     Section 11
     SIDE-SHIFT CARRIAGE
     (SIMPLEX AND TRIPLEX MASTS)
     Removal, Side-Shift Carriage . .
     Inspection
     Repairs, Side-Shift Cylinder . .
     Installation, Side-Shift Carriage
     SIDE-SHIFT CARRIAGE
     (FOUR-STAGE MAST ONLY) ...
     Removal
     Repairs
     Installation
     TORQUE SPECIFICATIONS
     TROUBLESHOOTING
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