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Yale Electric ForkLift Truck: ERC030AF, ERC040AF, ERP030AF, ERP040AF Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Yale 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:
ERC030AF
ERC040AF
ERP030AF
ERP040AF

Format: PDF, XXX 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
DAILY OPERATOR CHECK-OFF LISTS ....
SERVICE TRAINING COURSES
SERVICE TRAINING MATERIALS
Section 2. GENERAL LIFT TRUCK INFORMATION AND LUBRICATION SCHEDULE
SAFETY PROCEDURES WHEN
WORKING NEAR THE MAST
GENERAL LIFT TRUCK MAINTENANCE AND
LUBRICATION SCHEDULE
HOW TO PUT A LIFT TRUCK ON BLOCKS .
How To Raise The Drive Wheels
How To Raise The Steer Wheels
MAINTENANCE SCHEDULE
LEGEND
EVERY 8 HOURS OR DAILY
HOW TO MAKE CHECKS WITH
THE KEY SWITCH "OFF"
Tires And Wheels
Forks
Forks, Adjustment
Forks, Removal
Forks, Installation
Inspection Of Forks, Mast, And Lift Chains
Safety Labels
Operator Restraint System
Battery Restraint System
Battery
Hydraulic System
HOW TO MAKE CHECKS WITH
THE KEY SWITCH "ON"
Gauges, Horn and Fuses
Steering System
Service Brakes
Parking Brake
Control Levers And Pedals
Lift System Operation
EVERY 350 HOURS OR TWO MONTHS ....
Hydraulic Tank Breather
Differential And Speed Reducer
Wheel Bolts Or Nuts
Steering Axle Spindles
Mast
Lift Chains, Check for Wear
Forks
Brake Fluid
Other Lubrication
SEAT BRAKE
Electrical Inspection
Contactors
Motor Brushes
EVERY 2000 HOURS OR YEARLY
Wheel Bearings
Change the Filter For The Hydraulic Oil ..
Change The Hydraulic Oil
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
Battery Restraint And Hood
Seat Brake And Seat Assembly
Overhead Guard
Counterweight
HYDRAULIC TANK
Inspection
WHEELS AND TIRES
General
HOW TO CHANGE A SOLID RUBBER TIRE
Remove The Wheels From The Lift Truck
Remove And Install The Tire On The Wheel
HOW TO REPAIR A PNEUMATIC TIRE ...
Remove The Wheels From The Lift Truck
Remove The Wheel From The
Pneumatic Tire
Install The Wheel In The Pneumatic Tire .
Install The Wheels
Add Air To The Tires
SOLID RUBBER TIRES ON
PNEUMATIC WHEELS
Remove The Wheels From The Lift Truck
Remove The Solid Rubber Tire From The
Pneumatic Wheel
Install The Solid Rubber Tire On The
Pneumatic Wheel
Install The Wheels
PAINTING INSTRUCTIONS
LABEL INSTRUCTIONS
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
TORQUE VALUES FOR INCH FASTENERS .
TORQUE VALUES FOR
METRIC FASTENERS
Section 3. ELECTRICAL SYSTEM
ELECTRIC MOTOR MAINTENANCE,
GENERAL
TRACTION MOTOR AND
HYDRAULIC PUMP MOTOR
Disassembly
Assembly
BRUSH AND COMMUTATOR INSPECTION .
Normal Commutator Surface
Commutator Problems
BRUSH ALIGNMENT, TRACTION AND
HYDRAULIC MOTORS
BRUSH INSTALLATION, 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 For A Short-Circuit In A Field Coil . . .
Test For A Short-Circuit Between
The Field And The Motor Case
Brush Holder Test
EV-100ZXE SCR MOTOR CONTROLLER . .
GENERAL
Model Number Data For
EV-100ZX Controller
Tables For The Function Value Settings ...
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 Hand Set Is Connected To A
Control Card Installed In A Lift Truck
FUNCTION NUMBER DESCRIPTIONS ...
Traction Control Cards (Label Letters - ZH And ZY)
Pump Control Card (Label Letter ZP)
REGISTER PARAMETERS
TROUBLESHOOTING
Status Codes
REGISTER MAPS
OPTIONAL BASIC DISPLAY
REGULAR DISPLAY
OPTIONAL PREMIUM DISPLAY
STATUS CODE CHARTS
REPAIRS
Fuses
Check An SCR
Replace An SCR
The SCR 1 Assembly
Thermal Protector
Install A New 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
Replace SCR 2 And SCR 5
Check Capacitor C1
Check Diodes D3 And 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 Fluid Switch
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 And Over
Temperature Indicators
CHECKS AND ADJUSTMENTS
Control Card
Checking Curtis Meter In The
Regular Display Panel
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 OF OPERATION
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 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
INPUT AND OUTPUT DEVICES FOR THE
MOTOR CONTROLLERS
Display Panels (Output Device)
Basic Display Panel
Regular Display Panel
Premium Display Panel
OTHER CONTROL COMPONENTS
SCHEMATIC AND WIRING DIAGRAMS
Figure 3-86. Schematic Diagram EV-100ZX SCR Control For Traction Motor
Figure 3-87. Schematic Diagram EV-100ZX SCR Control For Lift Pump Motor
Figure 3-88. Schematic Diagram Contactor Control For Lift Pump Motor
Figure 3-89. Wiring Diagram
Figure 3-90. Wiring Diagram
Figure 3-91. Wiring Diagram
Figure 3-92. Table Of Wiring Connections, Controller Panel-To-Panel
Figure 3-93. Truck Wiring
Figure 3-94. Truck Power Cables
Figure 3-95. EV-100ZX SCR Panel Wiring Of Traction And Pump Motor Controllers .
Figure 3-96. EV-100ZX SCR Panel Wiring Of Traction Motor Controller And Contactor Pump Control
Figure 3-97. EV-100ZX SCR Panel Wiring Of Traction Motor Controller And Contactor Pump Control
Figure 3-98. EV-100ZX SCR Traction Motor And SCR Pump Motor Controllers .
Figure 3-99. EV-100ZX SCR Traction Motor Controller With Contactor Control Of Pump Motor ....
Figure 3-100. EV-100ZX SCR Traction Motor Controller With Contactor Control Of Pump Motor
Figure 3-101. EV-1 00ZX Contactor Panel
Figure 3-102. Hydraulic Linkage Switch And Chassis Wiring Details
Figure 3-103. Steering Column Wiring Detail
Figure 3-104. Premium Display Panel And Plug Connector
Figure 3-105. Regular Display Panel And Plug Connectors
Figure 3-106. Basic Display Panel And Plug Connectors
Figure 3-107. Lighting Schematic Diagram
Figure 3-108. Lighting Wiring Diagram
Section 4. DRIVE UNIT ASSEMBLY.
GENERAL
DESCRIPTION
REMOVAL AND DISASSEMBLY OF
DRIVE UNIT
Removing Complete Drive Unit Assembly As A Unit
Removing Traction Motor
Removing Drive Unit And Speed Reducer
Assembly
Disassembly Of Drive Axle
Disassembly Of Differential And
Speed Reducer
CLEANING
INSPECTION
General
Inspection Of Gears, Bearings And Splines
ASSEMBLY OF DRIVE UNIT
Find The Correct Shim Set For
The Hypoid Gear Set
Assembly And Installation Of Pinion ...
Assembly And Installation Of
Differential And Ring Gear
Assembly Of Input Gear For
Speed Reducer
Assembly Of Drive Axle And Hub Assembly
INSTALLATION OF DRIVE UNIT
Installing The Drive Unit
Installing Traction Motor
TORQUE SPECIFICATIONS
TROUBLESHOOTING
Section https://www.tradebit.comAKE SYSTEM
BRAKE SYSTEM, GENERAL
DESCRIPTION AND OPERATION
Service Brakes
Master Cylinder
Parking Brake
REMOVAL AND DISASSEMBLY OF
THE SERVICE BRAKES
CLEANING
INSPECTION
ASSEMBLY AND INSTALLATION OF
THE SERVICE BRAKES
MASTER CYLINDER
Removal
Cleaning And Inspection
Repair
Installation
REMOVAL AND DISASSEMBLY OF
THE PARKING BRAKE
ASSEMBLY AND INSTALLATION OF
THE PARKING BRAKE
REPLACING THE PARKING BRAKE SWITCH
CHECKS AND ADJUSTMENTS
Remove The Air From The Brake System
Adjustments, Service Brakes
Adjust The Brake Pedal
Adjust The Master Cylinder
Adjust The Parking Brake
Adjust The Parking Brake Switch
Test The "Parking Brake Not
Applied" Warning System
Adjust The Seat Brake
TORQUE SPECIFICATIONS
Section 6. STEERING AXLE ASSEMBLY
STEERING AXLE ASSEMBLY, GENERAL ...
DESCRIPTION
STEERING AXLE ASSEMBLY
Removal
Installation
WHEELS
Removal and Disassembly
Cleaning
Assembly And Installation
SPINDLES, BEARINGS AND LINKS
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.
POWER STEERING SYSTEM, GENERAL
STEERING WHEEL AND COLUMN ASSEMBLY
Removal Of Components
Installation Of Components
POWER STEERING MOTOR AND PUMP ...
Removal And 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
Section 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 ..
Removal And Disassembly
Assembly And Installation
REPAIRS, MAIN CONTROL VALVE
Removal
Disassembly
Cleaning And Inspection
Assembly
Installation
REPAIRS, LIFT PUMP
Removal
New Seal Installation
Installation
REPAIRS, HYDRAULIC TANK
Removal
Inspection
Repairs, Small Leaks
Repairs, Large Leaks
Cleaning
Steam Method Of Cleaning
Chemical Solution Method Of Cleaning . . .
Additional Preparations For Repair ....
Installation
CHECKS AND ADJUSTMENTS
Main Control Valve
Primary Relief Valve
Secondary Relief Valve
SPECIFICATIONS
TROUBLESHOOTING, HYDRAULIC SYSTEM
TROUBLESHOOTING, MAIN
CONTROL VALVE
Section 9. MAST
MAST
DESCRIPTION AND OPERATION
Carriages
Mast Mounts
TWO-STAGE LFL MAST
Description
Operation
TWO-STAGE FFL MAST
Description
Operation
THREE-STAGE FFL MAST
Description
Operation
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
MAST REPAIRS
FORKS
Removal
Installation
CARRIAGES
Removal, Standard Carriage
Removal, Side-Shift Carriage
Repairs
Installation, Standard Carriage
Installation, Side-Shift Carriage
MASTS
Removal
Disassembly, Two-Stage LFL And Two-Stage Mast
Disassembly, Three-Stage FFL Mast
Cleaning and inspection
Assembly, Two-Stage LFL And Two-Stage FFL Mast
Assembly, Three-Stage FFL Mast
Installation, Mast
LIFT CYLINDERS
Removal, Main Lift Cylinders
Removal, Free-Lift Cylinder
Disassembly, Lift Cylinder
Assembly, Lift Cylinder
Installation, Main Lift Cylinders
Installation, Free-Lift Cylinder
HEADER HOSE ARRANGEMENTS
Installation of New
Hoses, Two-Stage LFL Mast
Adjustment Of Hoses Afte
r Installation, Two-Stage LFL Mast ....
Installation of New
Hoses, Two-Stage FFL Mast
Adjustment Of Hoses After
Installation, Two-Stage FFL Mast.
Installation of New
Hoses, Three-Stage FFL Mast
Adjustment Of Hoses After
Installation, Three-Stage FFL Mast ...
TILT CYLINDERS
Removal
Disassembly
Cleaning
Assembly
Installation
CHECKS AND ADJUSTMENTS
Check For Leaks In The Lift And
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
TORQUE SPECIFICATIONS
TROUBLESHOOTING
Section 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
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