Yale ERC030AG, ERC030BG, ERC040AG, ERC040BG Forklift Truck A814 Series Maintenance Service Manual

Original Illustrated Factory Workshop Maintenance Service Manual for Yale Forklift Trucks Type A814, modes ERC030AG, ERC030BG, ERC040AG, ERC040BG

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 030 AG
ERC 030 BG
ERC 040 AG
ERC 040 BG

Format: PDF, 415 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
    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
    CAPACITIES
    MAINTENANCE PROCEDURES
    EVERY 8 HOURS OR DAILY
    HOW TO MAKE CHECKS WITH THE KEY ''''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 ''''ON''''
    Gauges, Horn and Fuses
    Steering System
    Service Brakes
    Parking Brake
    Control Levers And Pedals
    Lift System Operation
    EVERY 250 HOURS OR SIX WEEKS
    Lower Spindle Bearings
    Steering Tie Rods
    EVERY 500 HOURS OR THREE 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 1000 HOURS OR SIX MONTHS .
    Lift Chains, Lubrication
    Check Upper And Lower Bearings, Integral
    Side-shift Carriage
    Fork Pins And Guides
    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
    King Pins And Rod Ends (Steering Cylinders)
    Contactors
    Replace Upper And Lower Bearings, Integral
    Side-shift Carriage
    Other Lubrication
    GENERAL PROCEDURES
    HOW TO CHARGE THE BATTERY
    HOW TO CHANGE THE BATTERY
    BATTERY SPECIFICATIONS
    CHECK FOR LEAKS IN THE LIFT AND TILT
    SYSTEM
    Check the Lift Cylinders for Leaks
    MAXIMUM CARRIAGE AND TILT CREEP
    RATES
    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
    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
    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 A 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
    TRANSISTOR MOTOR CONTROLLERS (SR AND SP)
    DESCRIPTION
    Model Number Data For Transistor Motor
    Controllers (SR and SP)
    MOTOR CONTROLLER, CHECKS AND ADJUSTMENTS
    CHECKS AND ADJUSTMENTS USING A
    HAND SET
    General
    Connect Hand Set
    Check Or Delete Stored Status Codes
    Returning The Lift Truck To Normal
    Operation
    Checks And Adjustments On The Work Bench
    How To Check And Adjust The Registers
    ADJUSTMENTS - FUNCTION
    PARAMETERS
    General
    Function Numbers
    When The Hand Set Is Connected To A Motor
    Controller In The Lift Truck
    FUNCTION NUMBER DESCRIPTIONS
    TRACTION MOTOR CONTROLLER (LABEL LETTER - SR)
    FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY
    PUMP MOTOR CONTROLLER (LABEL LETTER - SP)
    FUNCTIONS WITH PREMIUM DISPLAY
    PANEL ONLY
    TROUBLESHOOTING - STATUS CODE
    CHARTS
    TROUBLESHOOTING
    General
    Status Codes
    SEM DISPLAY PANEL, GENERAL
    SEM DISPLAY PANEL FEATURES
    Descriptions Of Common Features
    Additional Features Of Premium Display
    Panel
    Descriptions Of Additional Features
    (Available With The Premium Display)
    SEM DISPLAY PANEL INDICATORS
    LCD ''''Screen'''' (Standard Display Panel) ..
    Battery State-Of-Charge (BDI)
    All Indicator Symbols
    Hourmeter Indicator Symbol
    Wrench Indicator Symbol
    Battery Indicator Symbol
    Brake Fluid Too Low Symbol
    Parking Brake Symbol
    Fasten Seat Belt Symbol
    ADDITIONAL COMPONENTS OF THE
    PREMIUM DISPLAY PANEL
    Alpha Numerical ''''Screen''''
    ''''STAR'''' Push Button
    Push Buttons #1 Through #5
    ADJUSTMENTS WITH A COMPUTER
    Computer System
    Connect A PC To The SEM Display Panel . .
    ITW SWITCHES SOFTWARE PROGRAM (For SEM Display Panel)
    Description
    Where To Get Help
    Hardware and Software Requirements.
    How To Start The ITW SWITCHES
    Program
    Menus
    Create A Setup File
    REPLACEMENT
    Removal And Replacement
    SR (SEM) AND SP TRANSISTOR MOTOR
    CONTROLLER, PARAMETER TABLES
    Function Numbers
    MOTOR CONTROLLER CHECKS AND
    ADJUSTMENTS
    PARAMETER TABLES
    REPAIRS
    GENERAL MAINTENANCE
    INSTRUCTIONS
    Special Precautions
    FUSES
    SEM DISPLAY PANEL REMOVAL
    Removal And Replacement
    REPLACE MOTOR CONTROLLER (SR or SP)
    CONTACTORS
    Contactor Repair
    CONTACTOR DRIVER MODULE
    Replace Contactor Driver
    MOTOR CONTROLLER PLUG
    BRUSH WEAR INDICATORS
    OTHER CONTROL COMPONENTS (INPUT DEVICES)
    Key Switch
    Start Switch
    Brake Light Switch
    Seat Switch
    Switch For Optional Seat Brake
    Parking Brake Switch
    Direction Control Switches Of Direction
    Control Lever
    Direction Switches Of Foot Direction
    Control
    Brake Fluid Switch
    Rocker Switches For Lights
    Position Sensor For Accelerator Or Foot
    Direction Control Pedal
    On-Demand Steering Components
    Lights And Reverse Alarm
    Horn And Horn Button
    Hydraulic Pump Switches
    Thermal Sensors
    Brush Wear Sensors
    REPLACE MOTOR CONTROLLER
    CHECKS AND ADJUSTMENTS
    Motor Controllers
    Control And Power Fuses
    Adjust The Start Switch
    Adjust The Brake Light Switch
    Check The Seat Switch
    Adjust The Switch For Optional Seat
    Brake
    Adjust The Parking Brake Switch
    Direction Switches (Steering Column)
    Direction Switches (Foot Direction Control Pedal)
    Hydraulic Pump Switches
    Adjust The Accelerator Or Foot Direction
    Control Pedal
    Adjust The Position Sensor For Accelerator
    Or Foot Direction Control
    Pedal
    THEORY OF OPERATION
    GENERAL
    DESCRIPTION of SEM SYSTEM
    OPERATION OF SEM SYSTEM
    (SR MOTOR CONTROLLER)
    Reverse Circuit
    Performance and Efficiency
    Field Weakening
    Regenerative Braking
    INTRODUCTION
    General
    Creep Speed
    Controlled Acceleration
    Current Limit
    BRAKING
    Regenerative Braking to Zero Speed.
    Pedal Position Braking
    Auto Braking
    AUXILIARY SPEED CONTROL
    Field Weakening
    Speed Limits
    RAMP OPERATION
    Ramp Start
    Anti-Rollback
    STEER PUMP CONTACTOR TIME
    DELAY
    COIL DRIVERS AND INTERNAL COIL
    SUPPRESSION
    SYSTEM PROTECTIVE OVERRIDE SRO (Static Return to Off)
    Accelerator Volts Hold Off
    Pulse Monitor Trip (PMT)
    Thermal Protector (TP)
    Low Voltage
    SP PUMP MOTOR CONTROLLERS
    CONTACTOR DRIVER MODULE
    DIAGNOSTICS
    Systems Diagnostics
    Standard Status Codes
    Stored Status Codes
    Hourmeter Readings
    Maintenance Management Capability ...
Section 4
    DRIVE UNIT ASSEMBLY
    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 GUIDE
Section 5
    BRAKE SYSTEM
    DESCRIPTION AND OPERATION
    Service Brakes
    Master Cylinder
    Parking Brake
    SERVICE BRAKES
    Removal And Disassembly
    Cleaning
    Inspection
    Assembly And Installation
    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
    TROUBLESHOOTING GUIDE
Section 6
    STEERING AXLE ASSEMBLY, GENERAL
    DESCRIPTION
    STEERING AXLE ASSEMBLY
    Removal
    Installation
    WHEELS
    Removal and Disassembly
    Cleaning
    Inspection
    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
     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 GUIDE
     Section 8
     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
     DESCRIPTION AND OPERATION
     Carriages
     Mast Mounts
     TWO-STAGE LIMITED FREE-LIFT MAST.
     Description And Operation
     TWO-STAGE FULL FREE-LIFT MAST
     Description
     Operation
     THREE-STAGE FULL FREE-LIFT MAST
     Yale
     IndustrialTrucks
     Description
     Operation
     CYLINDER CUSHION DURING LIFTING SEQUENCE
     CYLINDER CUSHION DURING LOWERING SEQUENCE
     MAST REPAIRS
     SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
     FORKS
     Removal
     Installation
     CARRIAGES
     Removal, Standard Carriage
     Removal, Hang-On Side-Shift Carriage.
     Repairs
     Installation, Standard Carriage
     Installation, Hang-On Side-Shift Carriage
     Removal, Integral Side-Shift Carriage
     Cleaning and Inspection, Integral Side-Shift Carriage
     Repairs, Integral Side-Shift Carriage
     Installation, Integral Side-Shift Carriage
     MASTS
     Removal
     Disassembly Procedures For The Two-Stage Limited Free-Lift Or Two-Stage Full Free-Lift Mast
     Disassembly Procedures For The Three-Stage Full Free-Lift Mast
     Cleaning and Inspection
     Assembly Of The Two-Stage Limited Free-Lift And Two-Stage Full Free-Lift Mast
     Assembly Of The Three-Stage Full Free-Lift 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
     HEADER HOSE ARRANGEMENTS
     New Hose Installation, Two-Stage Limited
     Free-Lift Mast
     Adjustment Of Hoses After Installation, Two-Stage Limited Free-Lift Mast
     New Hose Installation, Two-Stage Full Free-Lift Mast
     Adjustment Of Hoses After Installation, Two-Stage Full Free-Lift Mast
     New Hose Installation, Three-Stage Full Free Lift Mast
     Adjustment Of Hoses After Installation, Three-Stage Full Free-Lift 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
     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
     HOW TO CHANGE THE BATTERY
     BATTERY CONNECTOR
     BATTERY CARE