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YALE (A807) ERP16-20ATF, ERC16-20ATF FORKLIFT Service Repair Manual Instant Download

(David StevensonNMIAqT) #1

OPERATING INSTRUCTIONS


HOW TO PUTA LIFT TRUCK ON BLOCKS 1-


HOW TO TOW THE LIFT TRUCK 1-


HOW TO TOW THE LIFT TRUCK 1-


MOVING A DISABLED LIFT TRUCK 1-


MOVING A DISABLED LIFT TRUCK 1-


SAFE MAINTENANCE PROCEDURES 1-


SAFE MAINTENANCE PROCEDURES 1-


              - Section 1 Section


  • GENERAL HYDRAULIC TANK 2-

  • SAFETY AND INFORMATIONAL LABELS 1-2 Inspection 2-

  • OPERATOR PRECAUTIONS Repairs. Small Leaks 2-

  • OPERATOR PRE-CHECKS AND INSPECTION 1-3 Repairs. Large Leaks 2-

  • SHUT DOWN PROCEDURE 1-4 Steam Method of Cleaning 2- OPERATING PROCEDURE 1-3 Cleaning

    • SAFETY AND OPERATIONAL CHECK LIST 1-5 Additional Preparations for Repair 2- FORK ADJUSTMENT 1-4 Chemical Solution Method of Cleaning

    • MODEL AND CONTROL INFORMATION 1-

      • TYRES AND WHEELS 2- WELDING REPAIRS

      • instrument Panel A (STANDARD) '-lo HOW TO CHANGE THE WRES 2-

      • Instrument Panel B (OPTIONAL) 1-10 General 2-

      • instrument Panel (OPTIONAL) '-lo PNEUMATIC TYRES 2-

      • Temperature Indicator Lamp 1-



    • SAFE MAINTENANCE PROCEDURES 1-

    • MOVING A DISABLED LIFT TRUCK 1-

    • HOW TO TOW THE LIFT TRUCK 1-

    • HOW TO PUT A LIFT TRUCK ON BLOCKS 1-1

    • HOW TO RAISE THE STEERING TYRE 1-

    • HOW TO RAISE THE DRIVE TYRES 1-

    • PRECAUTIONS FOR TRUCKS IN STORAGE 1-

    • IN STORAGE 1- PRECAUTIONS FOR BATTERIES

      • Section



    • GENERAL 2-

    • FRAME 2-

    • FLOOR PLATE 2-

      • REAR COMPARTMENT COVER 2-



    • FRONT COVER 2-

    • STEERING COLUMN COVER 2-

      • Remove the Wheel from the Lift Truck 2.

      • Remove the Tyre from the Wheel 2-

      • Install the Tyre on the Wheel 2-

      • Add Air to the Tyres 2-

      • Remove the Wheel from the Lift Truck 2-

      • Remove the Tyre from the Wheel 2-

        • 2-



      • SOLID TYRES 2-

      • PNEUMATIC SHAPED SOLID TYRES 2-

        • Remove the One Piece Wheel and Tyre 2- Install the Tyre on the Wheel

        • Install the Tyre on the One Piece Wheel 2-

        • Install the Wheels on the Lift Truck 2-



      • LABEL REPLACEMENT 2-

      • YALE WARRANTY INFORMATION 2-

      • OF MAINTENANCE 2- RECOMMENDED SCHEDULE

        • LUBRICATION INSTRUCTIONS 2-

        • EVERY 8 HOURS 2-

        • EVERY 350 HOURS 2-

        • EVERY 2000 HOURS 2-

        • HYDRAULIC OILS 2-

        • GEAR OILS 2-

        • GREASE 2-

        • FREEZER APPLICATIONS 2-



      • HYDRAULIC CONTROL VALVE COVERS 2-

      • BATTERY COVER 2-

        • Open 2-

        • Close 2-

          • Removal 2-

          • Installation 2-





      • BATTERY REMOVAL AND INSTALLATION 2-

      • BATTERY PLATFORM 2-

        • Modifications 2-

        • Complete Truck 2-

        • Control ComDartment 2-



      • OVERHEAD GUARD 2-4 Electrical System 2-

        • Removal 2-4 Battery Compartment 2-

        • Installation 2-4 Ignition Switch 2-

        • Removal 2-5 Accelerator Pedal 2-

        • Installation 2-5 Drive. Hydraulic and Steering Motors 2-



      • COUNTERWEIGHT 2-4 Steering Linkage and Pivot Points 2-

        • Section

        • Brake Lines and Linkage 2-



      • Tilt Cylinders 2-

        • Upright and Carriage 2-





    • MAINTENANCE 2-

      • Complete Truck 2-

      • Electrical System 2-

      • Ignition Switch 2-

      • Control Compartment 2-

      • Battery Compartment 2-

        • Steering Linkage and Pivot Points 2-



      • Accelerator Pedal 2-

        • Drive, Hydraulic and Steering Motors 2-

        • Brake Lines and Linkage 2-

          • Section

          • General 3-

          • Check the Hand Set 3- Connect. Disconnect. and

          • Check and Adjust Functions 3-

          • FUNCTION DESCRIPTIONS 3-

            • Traction Control Cards 3-



          • PUMP CONTROL CARD (LABEL LETTER PX) 3-

          • TABLES FOR FUNCTION VALUE SETTINGS 3-

          • TROUBLESHOOTING 3-

            • CONTACTORS 3-



          • TESTING CONTACTORS 3-

            • Removal 3-

            • Installation 3-

            • TMM1 CARD 3-







      • Tilt Cylinders 2-

        • Upright and Carriage 2-

          • Removal 3-

          • Installation 3-



        • Hydraulic System 2-25 CIRCUIT PROTECTION 3-

          • Current Limit 3-





      • Threads. Nomenclature 2-26 Thermal Protection 3-

      • Strength Identification 2-26 Suppressors (Filter Blocks) 3-



    • FAST EN E R S - I N T R 0 D U CT I 0 N 2 -

      • Section 3 FUSES 3-



    • ELECTRICAL SYSTEM -G EN ERAL 3-

    • EV-1 OOLX MOTOR CONTROLLER 3-

    • EV-100 DESCRIPTION AND OPERATION 3-

      • The Silicon Controlled Rectifier 3-

      • A Motor Circuit that Operates with Pulses 3-

      • Traction Circuit 3-

        • Hydraulic Pump Motor 3-



      • The SCR 1 "OFF" Circuit 3-



    • INDUCTION CURRENT FROM THE MOTOR 3-



  • THE CONTROL CARD 3-

    • Pulse Monitor Trip 3-

    • SRO Circuit 3-

    • Control Card Adjustments 3-

    • Accelerator Control 3-1

    • CONTROL CARD 3-1

      • Status Codes 3-1



    • SEQUENCE OF OPERATION 3-

    • SCR CONTROL 3-1

    • CONTROL CARD CONNECTIONS 3-

    • HAND SET 3-

    • CONTROL CARD 3-1 CHECKS AND ADJUSTMENTS,

      • Function Codes 3-1

      • Bench Tests 3-1

      • Tests-Control Card Installed in a Lift Truck 3-1



    • FU N CT I 0 N SETT I N G S 3-

      • PRINTED CIRCUIT BOARDS 3-

        • Steering Angle Control Board 3-

          • Operation 3-



        • Testing 3-

        • Operation 3-

        • Testing 3-

        • Lift Pump Control Board 3-

          • Bypassing the Lift Pump Control Board 3-





      • ACCELE RAT0 R 3-

        • Removal 3-

        • Installation 3-

        • POWER STEERING 3-

        • KEY SWITCH 3-

        • INSTRUMENT PAN EL 3-

          • Standard Instrument Panel 3-



        • MOTOR MAINTENANCE - GENERAL 3-

        • BRUSH AND COMMUTATOR INSPECTION 3-

        • NORMAL COMMUTATOR SERVICE 3-

        • COMMUTATOR PROBLEMS 3-



      • HYDRAULIC PUMP MOTORS 3- BRUSH REPLACEMENT, DRIVE AND

        • Traction Motor Removal 3-

        • Hydraulic Pump Motor Installation 3-

        • Power Steering Pump Motor 3-

          • 3-



        • Traction Motor 3-

        • Traction Motor Installation 3-



      • Section

      • Lift Pump and Motor Removal 3-

      • Lift Pump and Motor Installation 3-

      • Power Steering Pump and Motor Removal 3-

      • Power Steering Pump and Motor Installation 3-

      • Disassembly 3-

      • Assembly 3-





  • TRACTION MOTOR REPAIR 3-

    • COMMUTATOR REPAIRS 3-



  • TESTS 3-

    • Damaged Field and Armature 3-

      • Short-Circuit in an Armature Winding 3-

      • Short-Circuit in the Armature 3-

      • Open Circuit in a Field Coil 3-

      • Short-circuit in a Field Coil 3-

      • Short-circuit Between Field and Motor Case 3-

      • Brush Holder 3-





  • WIRING DIAGRAMS AND SCHEMATICS 3-

    • Section

    • TRANSAXLE-GENERAL 4-

    • TRANSAXLE SPEC1 FlCATl ONS $4-

    • REMOVAL 4-

    • INSTALLATION 4-

    • D I SASSE M B LY 4.



  • ASSEMBLY 4.

    • TROUBLESHOOTING 4.

      • Section



    • GENERAL 5.

    • SPEC IF I CAT I ON S 5-

    • PARKING BRAKE ADJUSTMENT 5-

    • SERVl CE BRAKE ADJUSTMENT 5-

      • REMOVAL- SERVICE BRAKE PADS 5-

      • INSTALLATION-SERVICE BRAKE PADS 5-

      • REMOVAL-SERVICE BRAKE CALIPER 5-

      • INSTALLATION-SERVICE BRAKE CALIPER 5-

      • DISASSEMBLY-SERVICE BRAKE CALIPER 5-



    • ASSEMBLY-SERVICE BRAKE CALIPER 5-

      • REMOVAL-PARKING BRAKE CALIPER 5-

      • INSTALLATION-PARKING BRAKE CALIPER 5-

      • DISASSEMBLY-PARKING BRAKE CALIPER 5-



    • ASSEMBLY-PARKING BRAKE CALIPER 5-

    • MASTER CYLl NDER- REMOVAL 5-

      • MASTER CYLINDER-INSTALLATION 5-

      • MASTER CYLINDER-DISASSEMBLY 5-

      • MASTER CY LI N DE R - ASS EM BLY 5.

      • REMOVAL 5- PARKING BRAKE LEVER ASSEMBLY-

        • Section

        • INSTALLATION 5- PARKING BRAKE LEVER ASSEMBLY-

        • TROUBLESHOOTING 5-

          • Section



        • TRAIL AXLE 6-

        • WHEEL ASSEMBLY 6-

          • Removal 6-

          • Installation 6-

          • Removal 6-

          • Installation 6-

          • Removal 6-

          • Installation 6-

          • POWER STEERING SYSTEM 6-

            • General 6-

            • Description 6-





        • WHEEL HUB 6-

          • STEER AXLE ASSEMBLY : 6-

          • ASSEMBLY 6- STEERING WHEEL AND COLUMN

            • 6-

            • Installation 6-

            • Cleaning 6-

            • Disassembly 6-

            • Assembly 6-

            • Installation 6-

            • Removal 6-

            • Installation 6-

            • Disassembly 6-

            • Assembly 6-

              • Remove Air from the System 6-



            • Check the Operation 6-

            • Steering Pressure 6-



          • POWER STEERING CYLINDER 6-

          • CHECKS AND ADJUSTMENTS 6-

          • TROUBLESHOOTING 6-

            • Section



          • GENERAL 7-

          • HOIST SYSTEM 7-

          • TILT SYSTEM 7-

          • AUXl Ll ARY FUNCTIONS 7-

            • Third Function Location 7-

              • Fourth Function Location 7-



            • HYDRAULIC OIL TANK 7-

            • SPECIFICATIONS 7-

              • Hydraulic Tank 7-

              • Power Steering Pump 7-

              • Hoist Pump 7-







        • Section



      • Strainers 7-

      • Hydraulic Oil Filter 7-





  • HOIST PUMP 7-

    • Removal 7-

      • 7- Disassembly-Seal Replacement



    • POWER STEERING PUMP AND MOTOR 7.

      • Removal 7-

      • Installation 7-

      • Disassembly 7-

      • Assembly 7-





  • CONTROL VALVE 7-

    • Setti n g s 7-

    • Removal 7-

    • Installation 7-

    • Disassembly 7-1

    • Assembly 7-1

    • MAST TILT ADJUSTMENT 7-



  • CONTROL VALVE-EMERGENCY REPAIR 7-

  • TROUBLESHOOTING 7-

    • Section

    • MAST 8-

    • DESCRIPTION AND OPERATION 8-

      • Carriage 8-

      • Mast Mounts 8-

      • Description and Operation 8-





  • TWO STAGE MAST WITH FULL FREE LIFT 8-

    • Description 8-

    • Operation 8-

    • Description 8-

    • Operation 8-



  • TWO STAGE MAST WITH LIMITED FREE LIFT 8-

  • THREE STAGE MAST WITH FULL FREE LIFT 8-

  • NEAR THE MAST 8- SAFETY PROCEDURES WHEN WORKING

  • MAST REPLACEMENT 8-

  • MAST REPAIRS 8-

  • FORKS 8-

    • Removal 8-1

    • Installation 8-

    • Removal, Standard Carriage 8-1

    • Removal, Sideshift Carriage 8-1

    • Repairs 8-1

    • Installation, Standard Carriage 8-1



  • CARRIAGES 8-

    • Section

    • Installation. Sideshift Carriage 8-

    • MASTS 8-

      • Removal 8-

      • Mast with Limited or Full Free Lift 8- Disassembly Procedures for the Two Stage

      • the Three Stage Mast 8- Disassembly Procedures for

      • Cleaning and Inspection 8-

      • with Limited and Full Free Lift 8- Assembly of the Two Stage Mast

      • with Full Free Lift 8- Assembly of the Three Stage Mast

      • Mast Installation 8-

        • Removal of the Main Lift Cylinders 8-

        • Removal of the Free Lift Cylinder 8-



      • Disassembly of a Lift Cylinder 8-

        • 8-

        • Installation of the Main Lift Cylinders 8-



      • Two Stage Mast with Limited Free Lift 8- Installation of Header Hoses for

      • Two Stage Mast with Full Free Lift 8- Installation of Header Hoses for

      • Three Stage Mast with Full Free Lift 8- Installation of Header Hoses for

        • Removal 8-



      • Disassembly 8-

      • Cleaning 8-

      • Assembly 8-

        • Installation 8-



      • Check the Lift Cylinders for Leaks 8-

      • Check the Tilt Cylinders for Leaks 8-

      • Adjust the Tilt Cylinders 8-

      • Adjust the Lift Chains 8-

      • Adjust the Mast 8-

      • Adjust the Carriage 8-



    • LIFT CYLINDERS 8-

    • HEADER HOSE ARRANGEMENTS 8- Assembly of a Lift Cylinder

    • TILT CYLINDERS 8-

      • CHECKS AND ADJUSTMENTS 8-



    • TROUBLESHOOTING 8-

      • Section

      • GENERAL 9- BATTERY AND CHARGING SYSTEM-

      • INDUSTRIAL TRUCK BATTERIES 9- SAFETY TIPS FOR HANDLING

      • LEAD ACID BATTERIES 9-

        • Specific Gravity 9-

        • Chemical Reaction 9-





    • Section



  • HOW TO SELECT THE BATTERY 9-

    • Voltage of a Battery 9-

    • Battery Ratings 9-

    • Kilowatt Hours 9-



  • THE BATTERY AS A COUNTERWEIGHT 9.

  • THE NEW BATTERY 9-

  • BAlTERY MAINTENANCE 9-

    • Maintenance Records 9-

    • Cleaning the Battery 9-

    • Adding Water 9-

    • Hydrometer 9-

    • Battery Temperature 9-

    • Types of Battery Charges 9-

    • Methods of Charging 9-



  • CHARGING THE BATTERY 9-

    • Troubleshooting the Charger 9-

      • Section

      • is Fully Charged 9- How to Know when the Battery

      • Battery Charging Area 9.

      • Equipment Needed 9-

      • TROUBLESHOOTING 9-

        • Section



      • ORDERING INSTRUCTIONS 10- SERVICE PARTS

      • HOW TO ORDER SERVICE PARTS 10-

      • WHEN ORDERING PARTS 10-

      • TECHNICAL PUBLICATIONS 10-

        • PARTS MANUAL 10-

        • OPERATING MANUAL 10-

        • OPERATOR TRAINING 10-

        • SERVICE TRAINING COURSES 10-

        • SERVICE TRAINING MATERIALS 10-







  • FORKADJUSTMENT 1- CONTENTS

    • GENERAL 1-



  • HOW TO PUTA LIFT TRUCK ON BLOCKS 1-

  • HOW TO RAISE THE DRIVE TYRES 1-

  • HOW TO RAISE THE STEERING TYRE 1-

  • HOW TO TOW THE LIFT TRUCK 1-

  • MODEL AND CONTROL INFORMATION 1-

    • Instrument Panel A (STANDARD) 1-

    • Instrument Panel B (OPTIONAL) 1-


    • Instrument Panel C (OPTIONAL) 1-



    • MOVING A DISABLED LIFT TRUCK 1-

    • OPERATOR PRECAUTIONS 1-

    • OPERATING PROCEDURE 1-

    • OPERATOR PRE-CHECKS AND INSPECTION 1-

    • PRECAUTIONS FOR BATTERIES IN STORAGE 1-

    • PRECAUTIONS FOR TRUCKS IN STORAGE 1-

    • SAFENAND INFORMATIONAL LABELS 1-

    • SAFETYAND OPERATIONAL CHECK LIST 1-

    • SAFE MAINTENANCE PROCEDURES 1-

    • SHUT DOWN PROCEDURE 1-



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