Yale ERC 040 – 050 – 060 RA / ZA Lift Truck Service Repair and Maintenance Manual

Download Complete Service Repair Manual for Yale ERC 040 050 060 RA / ZA Lift Truck

This Factory Service Repair Manual offers all the service and repair information about Yale ERC 040 050 060 RA / ZA Lift Truck

The information on this manual covered everything you need to know when you want to repair or service Yale ERC 040 050 060 RA / ZA Lift Truck

MACHINE MODELS COVERED:

ERC 040 RA
ERC 040 ZA
ERC 050 RA
ERC 050 ZA
ERC 060 RA
ERC 060 ZA

Manual 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
HOW TO PUT A LIFT TRUCK ON BLOCKS

How To Raise The Drive Tires
How To Raise The Steering Tires
MAINTENANCE SCHEDULE
GENERAL LUBRICATION INSTRUCTIONS
EVERY 8 HOURS OR DAILY
HOW TO MAKE CHECKS WITH THE key swrrcH 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
KEY SWITCH ON
Gauges Horn and Fuses
Pedals And Control Levers
Lift System Operation
Sen/ice 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
Forks
Brake Fluid
Other Lubrication
Seat Brake
Electrical Inspection
Contactors
Motor Brushes
EVERY 2000 HOURS OR YEARLY

Wheel Bearings
Change the Hydraulic Oil and Filter
Change The Oil In The Differential
And Speed Reducer
Service Brakes
Service Brakes Cleaning
Lift Chains
Contactors
GENERAL PROCEDURES
HOW TO CHARGE THE BATTERY
HOW TO CHANGE THE BATTERY
CHECK FOR LEAKS IN THE LIFT
AND TILT SYSTEM
Check the Lift Cylinders for Leaks

Check the Tilt Cylinders for Leaks
LIFT CHAIN ADJUSTMENTS
HOW TO CHECK THE PMT CIRCUIT
WELDING REPAIRS
FRAME
OVERHEAD GUARD
Changes To The Overhead Guard
Removal
Installation
HYDRAULIC TANK
Inspection
COUNTERWEIGHT
Removal
Installation
TIRES AND WHEELS
Solid Tires (Press-on)
Install The Wheels
LABEL REPLACEMENT
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
GENERAL GUIDE TO TORQUE
VALUES (LBF-FT)
GENERAL GUIDE TO TORQUE VALUES
Section 3
ELECTRIC MOTOR MAINTENANCE
GENERAL
TRACTION MOTOR AND
HYDRAULIC PUMP MOTOR
Disassembly
Assembly
BRUSH AND COMMUTATOR INSPECTION

Normal Commutator Surface
Commutator Problems
BRUSH REPLACEMENT 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 Held Coil

Test For A Short-Circuit In A Held Coil
Test For A Short-Circuit Between The Field
And The Motor Case
Brush Holder Test
EV-100LX MOTOR CONTROLLER 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 (HYDRAULIC PUMP MOTOR)
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 (ITW 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 TX and TT)
Pump Control Card (label letter PX)

Tables for the Function Value Settings
TROUBLESHOOTING
REPAIRS
FUSES
CHECKING AN SCR
The SCR 1 Assembly
Thermal Protector
Replacing The SCR 1 Assembly
THE OFF CIRCUIT FOR SCR 1
Check The Reactor Assembly
Check Suppressors For SCR 2 And SCR 5
Check SCR 2 And SCR 5
REPLACING THE SCR 2 AND SCR 5
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
SCHEMATIC AND WIRING DIAGRAMS

Figure 3-55 Schematic Diagram
EV-100LX Motor Controller
Figure 3-56 GE Battery Indicator With Brush
Wear Indicator Display Lift Interrupt And With
SCR Control Of The Hydraulic Pump
Figure 3-57

Curtiss[ 933/4 Or 933/1
Battery Indicator With Lift Interrupt And
Without SCR Control Of The Hydraulic Pump
Figure 3-58 Wiring Diagram Curtiss[ 933/4
Or 933/1 Battery Indicator With Lift Interrupt
And Without SCR Control Of The
Hydraulic Pump
Figure 3-59

Wiring Diagram EV-100LX Mot
Controller
Figure 3-60 Battery Indicator
Without Lift Interrupt And Without
SCR Control Of The Hydraulic Pump
Figure 3-61 Traction Circuit With Regenerative
Braking Field Weakening And With SCR Control Of The Hydraulic Pump
Figure 3-62

Battery Discharge Indicator
With Lift Interrupt With Brush Wear Indicator
And With SCR Control Of The
Hydraulic Pump 3
Section 4
DRIVE UNIT ASSEMBLY GENERAL
DESCRIPTION
DRIVE UNIT ASSEMBLY REMOVAL
Traction Motor Removal
Traction Motor Installation
Drive Axle And Transmission Assembly
Removal
Drive Axle Disassembly
Transmission and Differential Disassembly
CLEANING
INSPECTION
TRANSMISSION AND DIFFERENTIAL
Input Gear Assembly installation
DIFFERENTIAL ASSEMBLY AND INSTALLATION
When A New Ring And Pinion Assembly Is Installed
Installation Of The Pinion Assembly
Assemble The Differential And Ring Gear
Drive Axle Assembly
DRIVE AXLE ASSEMBLY INSTALLATION

TORQUE SPECIFICATIONS
TROUBLESHOOTING
Section 5
BRAKE SYSTEM GENERAL
DESCRIPTION AND OPERATION
Service Brakes
Parking Brake
Seat Brake
REMOVAL AND DISASSEMBLY OF THE SERVICE BRAKES
CLEANING
INSPECTION
ASSEMBLY AND INSTALLATION
OF THE SERVICE BRAKES
PARKING BRAKE
CHECKS AND ADJUSTMENTS
Remove The Air From The Brake System
Adjustments Service Brakes
Adjustments Parking Brake
Adjustment Parking Brake Switch
Adjustment Brake Pedal
MASTER CYLINDER
Removal And Disassembly
Inspection
Assembly
SEAT BRAKE
Inspection
Removal
Installation
TORQUE SPECIFICATIONS
TROUBLESHOOTING
Section 6
STEERING AXLE ASSEMBLY GENERAL
DESCRIPTION
STEERING AXLE ASSEMBLY
Removal
Installation
WHEELS AND HUBS
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
Section 7
POWER STEERING SYSTEM GENERAL
STEERING WHEEL AND COLUMN ASSEMBLY
Removal Of The Assembly Components

Installation Of The Assembly Components
POWER STEERING MOTOR AND PUMP
Removal And Disassembly
Assembly And Installation
Repairs Power Steering Pump
Seal Replacement
STEERING CONTROL UNIT (ROSS HGF)
Control Valve Section
Metering Section
Disassembly And Inspection
Assembly
Installation
TROUBLESHOOTING (ROSS HGF)
STEERING CONTROL UNIT (DANFOSS)

Description
Removal
Disassembly
Cleaning
Assembly
Installation
TROUBLESHOOTING (DANFOSS)
CHECKS AND ADJUSTMENTS
Remove Air From The System
Steering Relief Valve
CHECK OPTICAL ENCODER AND ACTIVATOR
CIRCUITS
Section 8
HYDRAULIC SYSTEM GENERAL
Description Hydraulic System
Operation Hydraulic System
Hydraulic Pump
Main Control Valve
Lift Section
Tilt Section
Relief Valve
REPAIRS MAIN CONTROL VALVE
Removal and Disassembly
Cleaning and Inspection
Assembly
Installation
REPAIRS HYDRAULIC PUMP
Removal
Seal Replacement
Installation
CHECKS AND ADJUSTMENTS HYDRAULIC
SYSTEM
Main Control Valve Linkage and Switches
Main Control Valve Relief Valve
TILT CYLINDERS
Removal
Disassembly
Cleaning
Assembly
Installation
Check The Tilt Cylinders For Leakage
Adjust The Tilt Cylinder Stroke
And The Backward Tilt Angle
HYDRAULIC SPECIFICATIONS
TROUBLESHOOTING

HYDRAULIC SYSTEM
TROUBLESHOOTING MAIN CONTROL VALVE
TROUBLESHOOTING TILT CYLINDER
Section
SAFETY PROCEDURES WHEN WORKING NEAR
THE MAST
FOUR-STAGE MAST GENERAL
REPAIRS
Forks Removal
Forks Installation
CARRIAGE
Removal
Installation
MAST
Removal
Disassembly
Cleaning
Inspection of Forks Mast and Lift Chains
Assembly
Installation
LIFT CYLINDERS
Lowering Control Valve
Lift Cylinder Removal
Lift Cylinder Disassembly
Lift Cylinder Assembly
Main Lift Cylinders Installation
Free-Lift Cylinder Installation
CHECKS AND ADJUSTMENTS
Check For Leaks In The Lift System
Check the Lift Cylinders for Leaks
Adjust The Tilt Cylinder Stroke
And The Backward Tilt Angle
Lift Chain Adjustments
Mast Adjustments
Carriage Adjustments
TORQUE SPECIFICATIONS
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
BATTERY CONNECTOR
BATTERY CARE
Section 11
SIDE-SHIFT CARRIAGE
(SIMPLEX AND TRIPLEX MASTS)
Removal Side-Shift Carriage
Inspection
Repairs Side-Shift Cylinder
Installation Side-Shift Carriage
SIDE-SHIFT CARRIAGE
(FOUR-STAGE MAST ONLY)
Removal
Repairs
Installation
TORQUE SPECIFICATIONS
TROUBLESHOOTING

This manual can be used by anyone from a first time owner/amateur to a professional technician

Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawingsKeep this manual handy and use it often Performing routine preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs

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Language: English