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Yale Electric Forklift Truck ERP030TFN, ERP035TFN, ERP040TFN Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Electric Forklift Truck.

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:
ERP030TFN
ERP035TFN
ERP040TFN

Format: PDF,350 Pages
Language: English

Contents:
1 OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS-GENERAL
SERIAL NUMBER
MODEL CODE
TRUCK WEIGHT
CAPACITY RATING
SAFETY AND INFORMATIONAL LABELS
OPERATOR PRECAUTIONS
OPERATOR PRE-CHECKS AND INSPECTION
OPERATING PROCEDURE
SHUT DOWN PROCEDURE
FORK ADJUSTMENT
SAFETY AND OPERATIONAL CHECK LIST
MODEL AND CONTROL INFORMATION
INSTRUMENT PANEL A (STANDARD)
INSTRUMENT PANEL B (OPTIONAL)
INSTRUMENT PANEL C (OPTIONAL)
TEMPERATURE INDICATOR LAMP
SAFE MAINTENANCE PROCEDURES
MOVING A DISABLED LIFT TRUCK
HOW TO TOW THE LIFT TRUCK
HOW TO PUTA LIFT TRUCK ON BLOCKS
HOW TO RAISE THE STEER TIRE
HOW TO RAISE THE DRIVE TIRES
PRECAUTIONS FOR TRUCKS IN STORAGE
PRECAUTIONS FOR BATTERIES IN STORAGE
2 GENERAL TRUCK AND LUBRICATION SCHEDULE
INTRODUCTION - GENERAL TRUCK
FRAME
FLOOR PLATE
REAR COMPARTMENT COVER
FRONT COVER
STEERING COLUMN COVER
HYDRAULIC CONTROL VALVE COVERS
BATTERY COVER
OPEN
CLOSE
REMOVAL
INSTALLATION
BATTERY REMOVAL AND INSTALLATION
BATTERY PLATFORM
OVERHEAD GUARD
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL
INSTALLATION
HYDRAULIC OIL TANK
INSPECTION
REPAIRS, SMALL LEAKS
REPAIRS, LARGE LEAKS
CLEANING
STEAM METHOD OF CLEANING
CHEMICAL SOLUTION METHOD OF CLEANING
ADDITIONAL PREPARATIONS FOR REPAIR
WELDING REPAIRS
TIRES AND WHEELS
PNEUMATIC TIRES
HOW TO CHANGE THE TIRES
REMOVE THE WHEEL FROM THE LIFT TRUCK
REMOVE THE TIRE FROM THE WHEEL
INSTALLING THE TIRE ON THE WHEEL
ADD AIR TO THE TIRES
PNEUMATIC SHAPED SOLID TIRES
REMOVE THE WHEEL FROM THE LIFT TRUCKSOLID TIRES
REMOVE THE ONE PIECE WHEEL AND TIRE
INSTALL THE TIRE ON THE ONE PIECE WHEEL
INSTALL THE WHEELS ON THE LIFT TRUCK
LABEL REPLACEMENT
YALE WARRANTY INFORMATION
RECOMMENDED SCHEDULE OF MAINTENANCE
LUBRICATION INSTRUCTIONS
EVERY 8 HOURS
EVERY 350 HOURS
EVERY 2000 HOURS
EVERY 4000 HOURS
HYDRAULIC OILS
GEAR OILS
ANTI-SEIZE LUBRICATING COMPOUND
GREASE
FASTENERS - INTRODUCTION
THREADS, NOMENCLATURE
STRENGTH IDENTIFICATION
REMOVE THE TIRE FROM THE WHEEL
INSTALL THE TIRE ON THE WHEEL
3 ELECTRICAL SYSTEM
ELECTRICAL SYSTEM-GENERAL
EV-100LX MOTOR CONTROLLER
EV-100LX DESCRIPTID OPERATION
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
SEQUENCE OF OPERATION
CONTROL CARD
STATUS CODES
SCR CONTROL (HYDRAULIC PUMP MOTOR)
CONTROL CARD CONNECTIONS
HANDSET
CHECKS AND ADJUSTMENTS, CONTROL CARD
FUNCTION CODES
BENCH TESTS
TESTS-CONTROL CARD INSTALLED INA LIFT TRUCK
FUNCTION SETTINGS
GENERAL
CONNECT, DISCONNECT, AND CHECK THE HAND SET
CHECK AND ADJUST FUNCTIONS
FUNCTION DESCRIPTIONS
TRACTION CONTROL CARDS (LABEL LETTER DX OR DT)
TRACTION CONTROL CARDS (LABEL LETTER FX OR FT)
PUMP CONTROL CARD (LABEL LETTER PX)
TABLES FOR FUNCTION VALUE SETTINGS
TROUBLESHOOTING
TROUBLESHOOTING
CONTACTORS
TESTING CONTACTORS
REMOVAL
INSTALLATION
REMOVAL-"EE" CONTACTORS
INSTALLATION-'EE" CONTACTORS
DISASSEMBLY-EE" CONTACTORS
ASSEMBLY-EE" CONTACTORS
TMM 1 CARD
REMOVAL
INSTALLATION
CIRCUIT PROTECTION
CURRENT LIMIT
THERMAL PROTECTION
SUPPRESSORS (FILTER BLOCKS)
FUSES
PRINTED CIRCUIT BOARDS
STEERING ANGLE CONTROL BOARD
OPERATION
TESTING
LIFT PUMP CONTROL BOARD
OPERATION
TESTING
BY-PASSING THE LIFT PUMP CONTROL BOARD
ACCELERATOR
REMOVAL
INSTALLATION
ON-DEMAND POWER STEERING
KEY SWITCH
INSTRUMENT PANEL
STANDARD INSTRUMENT PANEL
INDICATOR LAMPS
OPTIONAL INSTRUMENT PANEL A
INDICATOR LAMPS
OPTIONAL INSTRUMENT PANEL B
INDICATOR LAMPS
MOTOR MAINTENANCE -GENERAL
BRUSH AND COMMUTATOR INSPECTION
NORMAL COMMUTATOR SERVICE
COMMUTATOR PROBLEMS
BRUSH REPLACEMENT, DRIVEAND
HYDRAULIC PUMP MOTORS
TRACTION MOTOR
HYDRAULIC PUMP MOTOR
POWER STEERING PUMP MOTOR
MOTOR REMOVAL AND INSTALLATION
TRACTION MOTOR REMOVAL
TRACTION MOTOR INSTALLATION
LIFT PUMP AND MOTOR REMOVAL
LIFT PUMP AND MOTOR INSTALLATION
POWER STEERING PUMPAND MOTOR REMOVAL
POWER STEERING PUMP AND MOTOR INSTALLATION
TRACTION MOTOR REPAIR
DISASSEMBLY
ASSEMBLY
COMMUTATOR REPAIRS
TESTS
DAMAGED FIELD AND ARMATURE
SHORT-CIRCUIT INAN ARMATURE WINDING
SHORT-CIRCUIT IN THE ARMATURE
OPEN CIRCUIT INA FIELD COIL
SHORT-CIRCUIT INA FIELD COIL
SHORT-CIRCUIT BETWEEN FIELD AND MOTOR CASE
BRUSH HOLDER
WIRING SCHEMATIC-CONTACTOR CONTROLLED LIFT PUMP.
WIRING SCHEMATIC-CONTACTOR
CONTROLLED LIFT PUMP (CONTINUED)
OPTIONS SCHEMATIC-CONTACTOR CONTROLLED LIFT PUMP .
WIRING DIAGRAM-CONTACTOR CONTROLLED LIFT PUMP
WIRING DIAGRAM-CONTACTOR CONTROLLED LIFT PUMP (CONTINUED)
OPTIONS DIAGRAM-CONTACTOR CONTROLLED LIFT PUMP
OPTIONS DIAGRAM-CONTACTOR CONTROLLED LIFT PUMP (CONTINUED)
WIRING SCHEMATIC-SCR CONTROLLED LIFT PUMP
WIRING SCHEMATIC-SCR CONTROLLED LIFT PUMP (CONTINUED)
OPTIONS SCHEMATIC-SCR CONTACTOR CONTROLLED LIFT PUMP
WIRING DIAGRAM-SCR CONTACTOR CONTROLLED LIFT PUMP
WIRING DIAGRAM-SCR CONTACTOR CONTROLLED LIFT PUMP (CONTINUED)
OPTIONS DIAGRAM-SCR CONTACTOR CONTROLLED LIFT PUMP
OPTIONS DIAGRAM-SCR CONTACTOR CONTROLLED LIFT PUMP (CONTINUED) 3-11
WIRING SCHEMATIC-OPTIONAL EQUIPMENT WIRING DIAGRAM-OPTIONAL EQUIPMENT
WIRING DIAGRAM-OPTIONAL EQUIPMENT (CONTINUED)
4 DRIVE UNIT
TRANSAXLE
GENERAL
LUBRICATION
REMOVAL
INSPECTION
INSTALLATION
S1 SERIES TRANSAXLE
DISASSEMBLY
ASSEMBLY
S2 SERIES TRANSAXLE
DISASSEMBLY
ASSEMBLY
GENERAL
RING GEAR INSTALLATION
INTERMEDIATE SHAFT INSTALLATION
AXLE SHAFT INSTALLATION
PINION GEAR INSTALLATION
FINAL ASSEMBLY
TROUBLESHOOTING
5 BRAKE SYSTEM
BRAKES - GENERAL
SPECIFICATIONS
PARK BRAKEADJUSTMENT
SERVICE BRAKEADJUSTMENT
SERVICE BRAKE PADS - REMOVAL
SERVICE BRAKE PADS - INSTALLATION
SERVICE BRAKE CALIPER - REMOVAL
SERVICE BRAKE CALIPER - INSTALLATION
SERVICE BRAKE CALIPER - DISASSEMBLY
SERVICE BRAKE CALIPER -ASSEMBLY
PARK BRAKE CALIPER - REMOVAL
PARK BRAKE CALIPER - INSTALLATION
PARK BRAKE CALIPER - DISASSEMBLY
PARK BRAKE CALIPER -ASSEMBLY
MASTER CYLINDER - REMOVAL
MASTER CYLINDER - INSTALLATION
MASTER CYLINDER - DISASSEMBLY
MASTER CYLINDER -ASSEMBLY
FOOT OPERATED PARK BRAKE LEVER ASSEMBLY
REMOVAL
INSTALLATION
ELECTRICALLY RELEASED PARK BRAKE
MECHANICAL OPERATION
REMOVAL
INSTALLATION
ELECTRICAL COMPONENTS - ELECTRICALLY RELEASED
PARK BRAKE
CONTROL BOX - REMOVAL
CONTROL BOX - INSTALLATION
TERMINAL BLOCK - REMOVAL ..
TERMINAL BLOCK - INSTALLATION
TROUBLESHOOTING
6 TRAIL AXLE AND STEERING SYSTEM
STEERING AXLE
WHEEL ASSEMBLY
REMOVAL
INSTALLATION
WHEEL HUB
REMOVAL
INSTALLATION
STEER AXLE ASSEMBLY
REMOVAL
INSTALLATION
POWER STEERING SYSTEM
GENERAL
DESCRIPTION
STEERING WHEEL AND COLUMN ASSEMBLY
REMOVAL
INSTALLATION
STEERING CONTROL UNIT
DISASSEMBLY
ASSEMBLY
INSTALLATION
POWER STEERING CYLINDER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CHECKS AND ADJUSTMENTS
REMOVEAIR FROM THE SYSTEM
CHECK THE OPERATION
STEERING PRESSURE
TROUBLESHOOTING
7 HYDRAULIC SYSTEM
HYDRAULIC SYSTEM -GENERAL
LIFT SYSTEM
TILT SYSTEM
AUXILIARY FUNCTIONS
THIRD FUNCTION LOCATION
FOURTH FUNCTION LOCATION
HYDRAULIC OIL TANK
SPECIFICATIONS
HYDRAULIC TANK
LIFT PUMP
POWER STEER PUMP
STRAINERS
HYDRAULIC OIL FILTER
LIFT PUMP
REMOVAL
INSTALLATION
DISASSEMBLY - SEAL REPLACEMENT
ASSEMBLY
POWER STEERING PUMP AND MOTOR
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CONTROL VALVE
SETTINGS
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
MAST TILT ADJUSTMENT
CONTROL VALVE - EMERGENCY REPAIR
(PLUNGER AND PLUNGER HOUSING SECTION)
TROUBLESHOOTING
8 MAST
MAST-GENERAL
DESCRIPTION AND OPERATION
CARRIAGE
MAST MOUNTS
SIMPLEX MAST
DESCRIPTION
OPERATION
DUPLEX MAST
DESCRIPTION
OPERATION
TRIPLEX MAST
DESCRIPTION
OPERATION
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
MAST REPLACEMENT
MAST REPAIRS
FORKS
REMOVAL
INSTALLATION
CARRIAGES
REMOVAL, STANDARD CARRIAGE
REMOVAL, SIDESHIFT CARRIAGE
REPAIRS
INSTALLATION, STANDARD CARRIAGE
INSTALLATION, SIDESHIFT CARRIAGE
MAST REPAIRS
REMOVAL
DISASSEMBLY SIMPLEX AND DUPLEX MASTS
DISASSEMBLY TRIPLEX MAST
CLEANING AND INSPECTION
ASSEMBLY OF THE SIMPLEX AND DUPLEX MAST
ASSEMBLY OF THE TRIPLEX MAST
MAST INSTALLATION
LIFT CYLINDERS
REMOVAL OF THE MAIN LIFT CYLINDERS
REMOVAL OF THE FREE LIFT CYLINDER
DISASSEMBLY OFA LIFT CYLINDER
ASSEMBLY OFA LIFT CYLINDER
INSTALLATION OF THE MAIN LIFT CYLINDERS
INSTALLATION OF THE FREE LIFT CYLINDER
HOSE TAKE-UP ARRANGEMENTS
INSTALLATION OF HOSE TAKE-UP ARRANGEMENT
FOR SIMPLEX MAST
INSTALLATION OF HOSE TAKE-UP ARRANGEMENT
FOR DUPLEX MAST
INSTALLATION OF HOSE TAKE-UP ARRANGEMENT
FOR TRIPLEX MAST
TILT CYLINDERS
REMOVAL
DISASSEMBLY
CLEANING
ASSEMBLY
INSTALLATION
CHECKS AND ADJUSTMENTS
CHECK FOR LEAKS IN THE LIFTAND 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
QUAD MAST
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
DISASSEMBLY FREE LIFT CYLINDER
ASSEMBLY FREE LIFT CYLINDER
DISASSEMBLY MAIN CYLINDER
ASSEMBLY MAIN CYLINDER
CHAIN-CHECKS AND ADJUSTMENTS
MASTADJUSTMENTS
BLEEDING THE CYLINDERS
TROUBLESHOOTING
9 BATTERY AND CHARGING SYSTEM
BATTERYAND CHARGING SYSTEM-GENERAL
SAFETY TIPS FOR HANDLING
INDUSTRIAL TRUCK BATTERIES
TROUBLESHOOTING
TROUBLESHOOTING
LEAD-ACID BATTERIES
SPECIFIC GRAVITY
CHEMICAL REACTION
HOW TO SELECT THE BATTERY
VOLTAGE OFA BATTERY
BATTERY RATINGS
KILOWATT HOURS
THE BATTERY AS A COUNTERWEIGHT
THE NEW BATTERY
BATTERY MAINTENANCE
MAINTENANCE RECORDS
CLEANING THE BATTERY
ADDING WATER
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
BATTERY CHARGING AREA
EQUIPMENT NEEDED
10 USER SUPPORT SYSTEM
SERVICE PARTS ORDERING INSTRUCTIONS
HOW TO ORDER SERVICE PARTS
WHEN ORDERING PARTS
TECHNICAL PUBLICATIONS
PARTS MANUAL
OPERATING MANUAL-1 565 (5189768-11)
OPERATOR TRAINING
SERVICE TRAINING COURSES
SERVICE TRAINING MATERIALS
11 ALPHABETICAL INDEX
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