Yale Forklift Truck A839 Series: ERC 070 HD, ERC 080 HD, ERC 100 HD, ERC 120 HD Workshop Manual

Yale Forklift Truck A839 Series: ERC 070 HD, ERC 080 HD, ERC 100 HD, ERC 120 HD Workshop Manual

Original Illustrated Factory Workshop Manual for Yale Forklift Truck 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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