Yale ERC040RF/ZF, ERC050RF/ZF, ERC060RF/ZF, ERC065RF/ZF Forklift Truck Service Maintenance Manual

Original Illustrated Factory Workshop Service Manual for Yale Forklift Truck Models ERC040RF, ERC040ZF, ERC050RF, ERC050ZF, ERC060RF, ERC060ZF, ERC065RF, ERC065ZF

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:
    ERC040RF
    ERC040ZF
    ERC050RF
    ERC050ZF
    ERC060RF
    ERC060ZF
    ERC065RF
    ERC065ZF

Format: PDF, 406 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
        DAILYOPERATOR CHECK-OFF LISTS
        SERVICE TRAINING COURSES
        SERVICE TRAINING MATERIALS
    2 GENERAL LIFT TRUCK INFORMATION AND LUBRICATION SCHEDULE
        GENERAL LIFT TRUCK MAINTENANCEAND
        LUBRICATIONSCHEDULE
        HOW TO PUTA LIFT TRUCK ONBLOCKS
        How To Raise The Drive Wheels
        How To Raise The Steer Wheels
        MAINTENANCESCHEDULE
        EVERY8 HOURS OR DAILY
        HOW TO MAKE CHECKS WITH THE KEYSWITCH ''''OFF ..
        Hydraulic System
        Battery
        Forks
        Forks, Adjustment
        Forks, Removal
        Forks, Installation
        Inspection Of Forks, Mast, And Lift Chains
        Tires And Wheels
        Operator Restraint System
        Battery Restraint System
        Safety Labels
        HOW TO MAKE CHECKS WITH THE KEYSWITCH ''''ON'''' ..
        Gauges, Horn and Fuses
        Control Levers And Pedals
        Lift System Operation
        Service Brakes
        Parking Brake
        Steering System
        EVERY350 HOURS OR TWO MONTHS
        Hydraulic Tank Breather
        DifferentialAnd Speed Reducer
        Wheel Nuts
        Steering Axle Spindles
        Mast
        Lift Chains, Check for Wear
        Forks
        Brake Fluid
        Other Lubrication
        ElectricalInspection
        Contactors
        Motor Brushes
        EVERY2000 HOURS OR YEARLY
        Wheel Bearings
        Change the Filter For The Hydraulic Oil
        Change the Hydraulic Oil
        Change The Oil In The DifferentialAnd Speed Reducer
        Service Brakes
        Service Brakes, Cleaning
        Lift Chains
        Contactors
        GENERAL PROCEDURES
        HOW TO CHARGE THE BATTERY
        BATTERY SPECIFICATIONS
        HOW TO CHANGE THE BATTERY
        CHECK FOR LEAKS IN THE LIFTAND TILT SYSTEM .
        Check the Lift Cylinders for Leaks
        Check the Tilt Cylinders for Leaks
        LIFT CHAINADJUSTMENTS
        HOW TO CHECK THE PMT CIRCUIT
        WELDING REPAIRS
        FRAME
        Battery Restraint And Hood
        Seat Brake And Seat Assembly
        Overhead Guard
        Changes To The Overhead Guard
        Counterweight
        HYDRAULIC TANK
        Inspection
        WHEELS AND TIRES
        How To Change A Solid Rubber Tire (Press-on)
        Install The Steer Wheels
        Install The Drive Wheels
        PAINTING INSTRUCTIONS
        LABEL INSTRUCTIONS
        HOW TO PUTAN ELECTRIC SIT DOWN RIDER TRUCK
        IN STORAGE
        HOW TO PUT BATTERIES IN STORAGE
        HOW TO MOVEA DISABLED LIFT TRUCK
        How To Tow The Lift Truck
        SPECIFICATIONS
        TORQUE SPECIFICATIONS
        TORQUE VALUES FOR INCH FASTENERS
        TORQUE VALUES FOR METRIC FASTENERS
    3 ELECTRICAL SYSTEM
        ELECTRIC MOTOR MAINTENANCE, GENERAL
        TRACTION MOTOR AND HYDRAULIC PUMP MOTOR
        Disassembly
        Assembly
        BRUSHAND COMMUTATOR INSPECTION
        Normal Commutator Surface
        Commutator Problems
        BRUSHALIGNMENT, TRACTION AND HYDRAULIC MOTORS
        BRUSHINSTALLATION, 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 ForA Short-Circuit In A Field Coil
        Test For A Short-Circuit Between The Field
        And The Motor Case
        Brush Holder Test
        EV-100ZXSCR MOTOR CONTROLLER
        ModelNumber Data For EV-100ZX Controller
        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 HandSet Is Connected To A
        Control Card Installed In A Lift Truck
        FUNCTIONNUMBER DESCRIPTIONS
        Traction Control Cards (Label letters - ZH And ZY).
        Pump Control Card (Label Letter ZP)
        REGISTER PARAMETERS
        TROUBLESHOOTING
        Status Codes
        REGISTER MAPS
        STANDARD DISPLAY PANEL
        PERFORMANCEDISPLAYPANEL
        STATUS CODE CHARTS
        REPAIRS
        Fuses
        Check An SCR
        Replace An SCR
        The SCR 1Assembly
        Thermal Protector
        InstallA New SCR 1Assembly
        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 D3And 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 FluidSwitch
            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 Indicators
        CHECKS AND ADJUSTMENTS
            Control Card
            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 OFOPERATION
        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 CardAdjustments (Traction Circuit)
            Accelerator Control
        SCR CONTROL (HYDRAULIC PUMP MOTOR)
        CONTACTORS
        CIRCUIT PROTECTION
            Traction Circuit Fuse
            Current Limit
            Thermal Protection
            Suppressors
        SEQUENCE OF OPERATION
        INPUTAND OUTPUT DEVICES FOR
        THE MOTOR CONTROLLERS
            Display Panels (Output Device)
            Regular Display Panel
            Performance Display Panel
        OTHER CONTROL COMPONENTS
        SCHEMATICS
    4 DRIVE UNIT ASSEMBLY
        DRIVE UNITASSEMBLY, GENERAL
        DESCRIPTION
        DRIVEUNITASSEMBLY, 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 DifferentialAnd Ring Gear
            Drive Axle, Assembly .
        DRIVEAXLE ASSEMBLY INSTALLATION
        TORQUE SPECIFICATIONS
        TROUBLESHOOTING ....
    5 BRAKE SYSTEM
        BRAKESYSTEM, GENERAL
        DESCRIPTIONAND OPERATION
            Service Brakes
            Master Cylinder
            Parking Brake
        REMOVAL AND DISASSEMBLYOF THE SERVICEBRAKES .
        CLEANING
        INSPECTION
        ASSEMBLY AND INSTALLATION OF THE SERVICE BRAKES
        REMOVAL AND DISASSEMBLY OF THE PARKINGBRAKE . .
        ASSEMBLYAND INSTALLATION OF THE PARKING BRAKE ..
        MASTER CYLINDER
            Removal
            Cleaning And Inspection
            Repair
            Installation
        CHECKSAND ADJUSTMENTS
            Remove The Air From The Brake System
            Adjustments, Sen/ice Brakes
            Adjustment, Brake Pedal
            Adjustment, Master Cylinder
            Adjustments, Parking Brake
            Test The ''''Parking Brake Not Applied'''' Warning
            Adjustments, Seat Brake
        TORQUE SPECIFICATIONS
        TROUBLESHOOTING
    6 STEERING AXLE ASSEMBLY
        STEERING AXLE ASSEMBLY, GENERAL
        DESCRIPTION
        STEERING AXLE ASSEMBLY
            Removal
            Installation
        WHEELS
            Removaland Disassembly
            Cleaning
            Assembly And Installation
        SPINDLES, BEARINGS AND TIE RODS
            RemovalAnd Disassembly
            Cleaning
            Assembly And Installation
        STEERING CYLINDER
            RemovalAnd Disassembly
            Cleaning and Inspection
            Assembly and Installation
        TORQUE SPECIFICATIONS
        TROUBLESHOOTING
    7 POWER STEERING SYSTEM
        POWER STEERING SYSTEM, GENERAL
        STEERING WHEEL AND COLUMN ASSEMBLY
            Removal Of The Assembly Components .
            Installation Of The Assembly Components
        POWER STEERING MOTOR AND PUMP
            RemovalAnd 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
    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
            RemovalAnd Disassembly
            Assembly And Installation
        REPAIRS, MAINCONTROL VALVE
            Removal
            Disassembly
            CleaningAnd Inspection
            Assembly
            Installation
        REPAIRS, LIFTPUMP
            Removal
            New Seal Installation
            Installation
        REPAIRS, HYDRAULIC TANK
            Removal
            Inspection
            Repairs, Small Leaks
            Repairs, Large Leaks
            Cleaning
            Steam MethodOf Cleaning
            Chemical Solution MethodOf Cleaning
            Additional Preparations For Repair
            Installation
        CHECKSAND ADJUSTMENTS
            Main Control Valve
            Primary Relief Valve
            Secondary Relief Valve
        SPECIFICATIONS
        TROUBLESHOOTING, HYDRAULIC SYSTEM
        TROUBLESHOOTING, MAIN CONTROL VALVE
    9 MAST
        DESCRIPTION AND OPERATION
            Carriages
            Mast Mounts
        SIMPLEX MAST
            Description And Operation
        DUPLEX MAST
            Description
            Operation
        TRIPLEX MAST
            Description
            Operation
        QUADPLEXMAST
            Description
            Operation
        SAFETY PROCEDURES WHEN WORKING
        NEAR THE MAST
        REPAIRS
        FORKS
            Removal
            Installation
        CARRIAGES
            Removal, Standard Carriage
            Removal, Side-shift Carriage
            Repairs
            Installation, Standard Carriage
            Installation, Side-Shift Carriage
        MASTS
            Removal
            Disassembly Procedures For The Simplex
            Or Duplex Mast
            Disassembly Procedures For The
            Triplex Mast
            Disassembly Procedures For The
            QuadplexMast
            Cleaning and Inspection
            Assembly Of The Simplex
            And Duplex Mast
            Assembly Of The Triplex
            Assembly Of The Quadplex
            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 °
        TILT CYLINDERS
            Removal
            Disassembly
            Cleaning
            Assembly
            Installation
        HOSE TAKE UP ARRANGEMENTS
            New Hose Installation, Simplex Mast ..
            Adjustment Of Hoses After Installation,
            Simplex Mast
            New Hose Installation, Duplex
            Adjustment Of Hoses After Installation,
            Duplex
            New Hose Installation, Triplex
            Adjustment Of Hoses After Installation.
            Triplex
            Hose Take Up Installation, Quadplex ..
        CHECKS AND ADJUSTMENTS
        CHECK FOR LEAKS IN THE LIFT AND TILT
        SYSTEM
            Check The Lift Cylinders For Leaks ...
            Check The Tilt Cylinders For Leakage °
        ADJUST THE TILT CYLINDERS
        ADJUST THE LIFT CHAINS
        ADJUST THE MAST
        ADJUST THE CARRIAGE
        TROUBLESHOOTING
    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
    INDEX