Yale ERC 040 – 050 – 060 – 065 RG / ZG (E108) Lift Truck Service Repair and Maintenance Manual

Download Complete Service Repair Manual for Yale ERC 040 050 060 065 RG / ZG (E108) Lift Truck

This Factory Service Repair Manual offers all the service and repair information about Yale ERC 040 050 060 065 RG / ZG (E108) Lift Truck

The information on this manual covered everything you need to know when you want to repair or service Yale ERC 040 050 060 065 RG / ZG (E108) Lift Truck

MACHINE MODELS COVERED:

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

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
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

This manual can be used by anyone from a first time owner/amateur to a professional technicianEven the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings

Keep 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