Yale ESC030ZA, ESC035ZA, ESC040ZA, ESC050ZA Electric Forklift Truck Service Maintenance Manual

Original Illustrated Factory Workshop Service Maintenance Manual for Yale Electric Forklift Truck Models ESC030ZA, ESC035ZA, ESC040ZA, ESC050ZA

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:
    ESC030ZA
    ESC035ZA
    ESC040ZA
    ESC050ZA

Format: PDF, 248 Pages
Language: English

Contents:
    1 OPERATING INSTRUCTIONS
        NAMEPLATE
        SAFETYAND INFORMATION LABELS
        GENERAL
        OPERATOR PRE-CHECKS AND INSPECTION
        OPERATING PRECAUTIONS
        SAFETY AND OPERATIONAL CHECKS (PRIOR TO EACH SHIFT)
        DESCRIPTION .
        STARTING SEQUENCE
        PERFORMANCE PROGRAMMING
        LOW LEVEL PASSWORD
        PROGRAM MENUITEMS
        FWDSPEED & REVSPEED (3.0-7.0 MPH, DEFAULT+7)
        DRIVEA/D (HARD, MEDIUM*, SOFT)
        LIFTA/D (HARD, MEDIUM*, SOFT)
        COASTDEC (SHORT, MEDIUM*, LONG)
        TILT SPD (FAST, MEDIUM*, SLOW)
        SIDESHFT (FAST, MEDIUM*, SLOW)
        AUX SPD (FAST, MEDIUM*, SLOW) POS HOLD (DISABLE, ENABLE*)
        DEFAULT (RESET Y)
        STOPPING
        PARKING
        SAFE MAINTENANCE PROCEDURES
        HOW TO PUTA LIFT TRUCK ON BLOCKS
        HOW TO RAISE THE DRIVE TIRES
        HOW TO RA HE STEER TIRE
        PRECAUTIONS FOR TRUCKS IN STORAGE
        PRECAUTIONS FOR BATTERIES IN STORAGE
    2 GENERAL TRUCK AND LUBRICATION
        GENERAL
        DESCRIPTION
        OVERHEAD GUARD
        REMOVAL
        INSTALLATION .
        OVERHEAD GUARD REAR POST
        REMOVAL
        TALLATION
        FRONT COVER
        REMOVAL
        INSTALLATION
        TOP COVER
        REMOVAL
        INSTALLATION
        CONTROL COVER
        REMOVAL
        INSTALLATION
        OPERATOR COMPARTMENT PADS
        REMOVAL
        INSTALLATION
        FLOOR MAT/BRAKE PEDAL PAD
        REMOVAL
        INSTALLATION
        TIRES AND WHEELS
        REMOVING TIRE AND WHEEL FROM TRUCK
        REMOVING TIRE FROM WHEEL HUB
        INSTALLING THE TIRE ON THE WHEEL HUB
        INSTALLING THE TIRE AND WHEEL ON THE LIFT TRUCK
        LABEL REPLACEMENT
        PAINTING INSTRUCTIONS
        CHANGING THE BATTERY
        BATTERY SPECIFICATIONS - ESC-ZA
    3 ELECTRICAL SYSTEM
        GENERAL
        THEORY OF OPERATION
        POWER DISTRIBUTION
        START-UP
        STEERING CONTROL
        DESCRIPTION
        `NSTRUMENTS/CONTROLS
        MULTI-FUNCTION CONTROLS
        REPAIRS AND ADJUSTMENTS
        CAPACITOR
        DISCHARGE PROCEDURE
        FUSES
        REMOVAL AND INSTALLATION
        CONTROL HANDLEASSEMBLY
        REMOVAL
        INSTALLATION
        CONTROL HANDLE POTENTIOMETER
        REMOVAL
        INSTALLATION
        HORNBUTTON
        REMOVAL
        INSTALLATION
        SYSTEM CONTROLLER/OPERATOR DISPLAYASSEMBLY
        REMOVAL
        INSTALLATION
        OPERATOR DISPLAY BOARD
        REMOVAL
        INSTALLATION
        BATTERY-STATE-OF-CHARGE INDICATOR
        KEY SWITCH
        REMOVAL
        INSTALLATION
        AUXILIARY SELECTOR SWITCHAND LIGHT SWITCH
        REMOVAL
        INSTALLATION
        HORN
        REMOVAL
        INSTALLATION
        ACCELERATION CONTROL
        CONTROLLER FAILURE CHECKLIST
        TRACTION CONTROLLER .
        REMOVAL .
        INSTALLATION
        LIFT CONTROLLER
        REMOVAL
        INSTALLATION
        BRAKE SWITCH
        REMOVAL
        INSTALLATION
        ADJUSTMENT
        STEER POSITIC POTENTIOMETER
        REMOVAL
        INSTALLATION
        ADJUSTMENT
        MAIN POWER CONTACTOR
        REMOVAL
        INSTALLATION
        CONTACTOR TIPS
        REMOVAL
        INSTALLATION
        BATTERY DISCONNECT LEVER
        REMOVAL
        INSTALLATION
        ELECTRIC MOTOR MAINTENANCE, GENERAL
        REPAIRS
        DRIVE MOTOR AND HYDRAULIC PUMP MOTOR
        DISASSEMBLY
        ASSEMBLY
        POWER STEERING PUMP MOTOR
        DISASSEMBLY
        ASSEMBLY
        BRUSHAND COMMUTATOR INSPECTION
        NORMAL COMMUTATOR SURFACE
        COMMUTATOR PROBLEMS
        DRIVE MOTOR BRUSHES
        REMOVAL
        INSTALLATION
        LIFT PUMP MOTOR BRUSHES
        REMOVAL
        INSTALLATION
        STONING THE COMMUTATOR
        L CUTOUT (0-30%, DEFAULT+20)
        STEERING (STANDARD`, REVERSE)
        LANGUAGE (ENGLISH, ESPANOL, FRENCH, DEUTSCH)
        BALARM (REVERSE`, FORWARD, OFF, BOTH)
        BA DUR (LONG`, MEDIUM, SHORT)
        SHCKSENS (0. 1-10.0 G OR OFF, DEFAULT+5.0)
        IMPACT (RESET Y)
        IDLETIME (5-60 MINOR OFF, DEFAULT+15)
        PMI-TRACTION, LIFT, STEER(1 00-400 HRS, DEFAULT+350)
        RESETPMI (RESET Y)
        UNITS (ENGLISH`, METRIC)
        PASSWORD-HIGH LVL, LOW LVL, ELEC KEY
        SOFTVER
        DEFAULT (RESET Y)
        DIAGNOSTIC MENU(DIAGNSTC)
        DIAGNOSTIC INPUT TESTS
        DIAGNOSTIC OUTPUT TESTS
        OPERATIONAL FEEDBACK DEVICES
        BATTERY-STATE-OF-CHARGE INDICATOR WITH LIFT INTERRUPT .
        WHEEL POSITION INDICATOR ....
        SPEED INDICATOR
        OVERWEIGHTALERT ICON
        LIFT LIMITALERT ICON (OPTIONAL)
        SERVICEALERT ICON
        DOTMATRIX DISPLAY
        OPERATIONAL MODES
        POWER-ON SELF TEST
        RUNMODE
        RESTRICTED MODE
        SHUTDOWN MODE
        WARNING MESSAGES/TROUBLESHOOTING
        SYSTEM FAULT CODES/TROUBLESHOOTING
        SCHEMATIC
        WIRING DIAGRAM
        ELECTRICAL SYSTEM LEGEND
    4 DRIVE UNIT ASSEMBLY
        DESCRIPTION
        REPAIRS-DRIVE UNIT
        REMOVAL
        INSTALLATION
        DRIVE MOTOR
        BRUSH REMOVAL AND INSTALLATION
        GEARBOX
        y,lCHANGE
        DRIVE WHEEL ASSEMBLY
        REMOVAL AND INSTALLATION
        DRIVE WHEEL SEAL
        REMOVAL
        INSTALLATION
        DRIVE WHEEL SPINDLE
        REMOVAL
        INSTALLATION
        ENCODER ASSEMBLY
        (SEE FIGURE 4-2)
        REMOVAL
        INSTALLATION
        ENCODER BELTADJUSTMENT
        DRIVE SHAFT INSERT
        DRIVE UNITREBUILD
        DISASSEMBLY
        PINION GEAR TO MOTOR ASSEMBLY
        GEAR HOUSING TO MOTOR ASSEMBLY
        PROCEDURE!
        GEAR HOUSING TO MOTOR ASSEMBLY
        PROCEDURE II
        GEAR HOUSING TO MOTOR ASSEMBLY
        CARRIER TO GEAR HOUSING ASSEMBLY
        CARRIER REBUILD
        CARRIER DISASSEMBLY
        CARRIER ASSEMBLY
    5 BRAKE SYSTEM
        GENERAL
        DESCRIPTIONAND OPERATION
        THEORY OF OPERATION
        DISC BRAKE UNIT-REPAIRS
        REMOVAL
        INSTALLATION
        Lsi ivw \C ACTUATOR ASSEMBLY
        REMOVAL
        INSTALLATION
        MASTER CYLINDER
        REMOVAL
        INSTALLATION
        CLEANING AND INSPECTION
        DISASSEMBLY
        ASSEMBLY
        BRAKE PEDAL
        REMOVAL
        INSTALLATION
        BLEEDING THE BRAKE SYSTEM
        CHECKS AND ADJUSTMENTS
        BRAKE PEDAL HEIGHT
        BRAKE SWITCH
        BRAKE PUSH ROD LENGTH
        DISC BRAKE CLEARANCE
        BRAKE PRESSURE
        TROUBLESHOOTING
    6 STEERING SYSTEM
        GENERAL
        DESCRIPTION
        STEER PUMP & MOTOR ASSEMBLY-REPAIRS
        REMOVAL
        INSTALLATION
        STEER PUMP
        pr-yoVAL
        INSTALLATION
        STEER CONTROL VALVE
        REMOVAL
        INSTALLATION
        HYDRAULIC MOTOR
        REMOVAL
        INSTALLATION
        STEERING GEAR
        REMOVAL .
        INSTALLATION
        STEER FORKASSEMBLY
        REMOVAL
        INSTALLATION
        STEER WHEEL ASSEMBLY
        REMOVAL
        INSTALLATION
        STEER POSITION POTENTIOMETER
        REMOVAL
        INSTALLATION
        STEER POSITION POTENTIOMETER ADJUSTMENT
        CHANGING STEER TIRES
        STEERING PRESSUREADJUSTMENT
        STEER PUMP MOTOR
        BRUSH REMOVAL AND INSTALLATION
    7 HYDRAULIC SYSTEM
        GENERAL
        DESCRIPTION
        OPERATION
        MULTI-FUNCTION CONTROL HANDLE
        REPAIRS
        LIFT PUMP & MOTOR / °
        REMOVAL
        INSTALLATION
        LIFT PUMP
        REMOVAL . ...... ....
        INSTALLATION ... ..... .
        LIFT PUMP MOTOR
        BRUSH REMOVAL AND INSTALLATION
        STEER PUMP & MOTOR ASSEMBLY
        HYDRAULIC GEAR PUMPS
        DESCRIPTION
        FLOW CONTROL VALVE
        RELIEF VALVE
        REPAIRS
        DISASSEMBLY
        CLEANING
        INSPECTION
        ASSEMBLY
        CHECKS .ND ADJUSTMENTS
        CHECKING THE OUTPUT OF THE PUMP
        CHECKING FOR AIR IN THE HYDRAULIC SYSTEM
        SPECIFICATIONS .
        HYDRAULIC VALVE CARTRIDGE
        REMOVAL
        INSTALLATION
        PRESSURE RELIEF VALVE
        REMOVAL
        INSTALLATION
        MANUAL LOWERING VALVE
        REMOVAL
        INSTALLATION
    8 MAST
        LIFT CHAINADJUSTMENT
        SHEAVES
        REMOVAL-FREE LIFT CYLINDER SHEAVES
        INSTALLATION-FREE LIFT CYLINDER SHEAVES
        REMOVAL-SECONDARY MAST SHEAVES
        INSTALLATION-SECONDARY MASTSHEAVES
        HYDRAULIC COMPy`ENTS
        REMOVAL-MAIN HYDRAULIC MANIFOLD BLOCK
        INSTALLATION-MAIN HYDRAULIC MANIFOLD BLOCK
        REMOVAL-FREELIFT CYLINDER MANIFOLD BLOCK
        INSTALLATION
        REMOVAL-OPTIONAL AUXILIARY HOSE TAKE-UP
        INSTALLATION-OPTIONAL AUXILIARY HOSE TAKE-UP
        REMOVAL-STANDARD HOSEASSEMBLY
        INSTALLATION-STANDARD HOSEASSEMBLY
        TROUBLESHOOTING - LIFT CYLINDERS
        TROUBLESHOOTING - MASTS
    9 BATTERY AND CHARGING SYSTEMS
        BATTERYAND CHARGING SYSTEM-GENERAL
        SAFETY TIPS FOR HANDLING INDUSTRIAL TRUCK BATTERIES
        BATTERY TROUBLESHOOTING
        BATTERY TROUBLESHOOTING
        LEAD-ACID BATTERIES
        SPECIFIC GRAVIV
        CHEMICAL REACTION
        HOW TO SELECT THE BATTERY
        VOLTAGE OFA BATTERY
        BATTERY RATINGS
        KILOWATT HOURS
        THE BATTERYAS A COUNTERWEIGHT
        THE NEW BATTERY
        BATTERYMAINTENANCE
        MAINTENANCE RECORDS
        CLEANING THE BATTERY
        ADDING WATER
        HYDROMETER
        BATTERY TEMPERATURE
        CHARGING THE BATTERY
        TYPES OF BATTERY CHARGES
        METHODS OF CHARGING
        TROUBLESHOOTING THE CHARGER
        HOW `O KNOW WHEN THE ATTERY IS FULLY CH, RGED
        BATTERY CHARGING AREA
        EQUIPMENT NEEDED
    10 USER SUPPORT INFORMATION
    11 ALPHABETICAL INDEX