Yale ERC040RG/ZG, ERC050RG/ZG, ERC060RG/ZG, ERC065RG/ZG Forklift Truck E108 Serie Maintenance Manual

Original Illustrated Factory Workshop Manual for Yale Forklift Truck Models ERC040RG, ERC050RG, ERC060RG, ERC065RG, ERC040ZG, ERC050ZG, ERC060ZG, ERC065ZG

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 RG
ERC 050 RG
ERC 060 RG
ERC 065 RG
ERC 040 ZG
ERC 050 ZG
ERC 060 ZG
ERC 065 ZG

Format: PDF, 420 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
     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
    Start Sequence
    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
    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
    Replace the Flashing Light Assembly
    Replace the Converter
    Replace the Relay
    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 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 ..
    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
Section 4
     DRIVE UNIT ASSEMBLY
     DESCRIPTION
     DRIVE UNIT ASSEMBLY, REMOVAL
     Traction Motor, Removal
     Traction Motor, Installation
     Drive Axle And Speed Reducer Assembly,
     Removal
     Drive Axle, Disassembly
     Speed Reducer and Differential,
     Disassembly
     CLEANING
     INSPECTION
     SPEED REDUCER AND DIFFERENTIAL
     Input Gear Assembly, Installation
     DIFFERENTIAL, ASSEMBLY AND
     INSTALLATION
     Installation Of The Pinion Assembly
     Assemble The Differential And Ring Gear
     Drive Axle, Assembly
     DRIVE UNIT ASSEMBLY, INSTALLATION
     TORQUE SPECIFICATIONS
     TROUBLESHOOTING GUIDE
Section 5
     BRAKE SYSTEM, GENERAL
     DESCRIPTION AND OPERATION
     Service Brakes
     Master Cylinder
     Parking Brake
     SERVICE BRAKES
     Removal And Disassembly
     Cleaning
     Inspection
     Assembly And Installation
     PARKING BRAKE
     Removal And Disassembly
     Assembly And Installation
     MASTER CYLINDER
     Removal
     Cleaning And Inspection
     Repair
     Installation
     CHECKS AND ADJUSTMENTS
     Remove The Air From The Brake System
     Adjustments, Service Brakes
     Adjustment, Brake Pedal
     Adjustment, Master Cylinder
     Adjustments, Parking Brake
     Test The ''''Parking Brake Not Applied''''
     Warning
     Adjustments, Seat Brake
     TORQUE SPECIFICATIONS
     TROUBLESHOOTING GUIDE
Section 6
     STEERING AXLE ASSEMBLY
     DESCRIPTION
     STEERING AXLE
     Removal
     Installation
     WHEELS
     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 GUIDE
Section 7
     POWER STEERING SYSTEM
     STEERING WHEEL AND COLUMN
     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
     Description
     Operation
     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 GUIDE, HYDRAULIC SYSTEM
     TROUBLESHOOTING GUIDE, 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
     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-Stag Full Free-Lift Mast
     Cleaning and Inspection
     Assembly Of The Two-Stage Limited Free-Lif 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
     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