Yale C807 ERC ERP 16-20 ATF Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
Yale C807 ERC ERP 16-20 ATF Workshop Manual – PDF DOWNLOAD
Part No. 5070385-01
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR:
When lifting parts or assemblies, make sure that all slings, chains, or cables are correctly fastened and that the load being lifted is balanced. Make sure that the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand. Use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See “How to Put the Lift Truck on Blocks” in the OPERATOR’S MANUAL or SECTION 2, GENERAL TRUCK AND LUBRICATION.
- Keep the unit and working area clean and in order. Use the correct tools for the job. Keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure that all nuts, bolts, circlips, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when making repairs or if the unit needs repairs. Make sure you follow the DANGER, WARNING, and CAUTION notes in the instructions.
- Wear a rubber apron, gloves, boots, and goggles or a face shield when doing maintenance on batteries. Batteries generate hydrogen gas when they are being charged. Keep open fire away from batteries. Do not check the electrolyte level with a match or a lighter. No smoking and do not create sparks. Make sure the area has ventilation. If the battery is charged in the lift truck, open the bonnet.
- Lift batteries correctly with a crane or equipment designed for the job. Always use a spreader bar designed and adjusted for the battery. Move batteries with a lift truck, or a conveyor or rollers designed for that purpose. If the battery does not have a cover, a rubber mat or insulating material must be put over the top of the battery to prevent a short circuit with other equipment.
Make sure the the lifting equipment has enough capacity for the job. Do not use chain or wire rope slings. Never put metal materials or tools on a battery. When maintenance on the battery or the battery charger is required, disconnect both the AC and DC power. If new battery connectors must be installed, make sure the positive and negative terminals and cables are kept separate and insulated from each other. Even a momentary short circuit can cause an explosion and damage the battery.
TABLE OF CONTENTS:
Yale C807 ERC ERP 16-20 ATF Workshop Manual – PDF DOWNLOAD
OPERATING INSTRUCTIONS
2 GENERAL TRUCK AND LUBRICATION
3 ELECTRICAL SYSTEM
4 DRIVE UNIT
5 BRAKE SYSTEM
6 TRAIL AXLE AND STEERING SYSTEM
7 HYDRAULIC SYSTEM
a MAST
9 BATTERY AND CHARGING SYSTEM
10 USER SUPPORT INFORMATION
11 ALPHABETICAL INDEX
INDEX:
GENERAL HYDRAULIC TANK 2-5
SAFETY AND INFORMATIONAL LABELS 1-2 Inspection 2-5
OPERATOR PRECAUTIONSRepairs Small Leaks 2-5
OPERATOR PRE-CHECKS AND INSPECTION 1-3 Repairs Large Leaks 2-5 OPERATING PROCEDURE 1-3 Cleaning SHUT DOWN PROCEDURE 1 -4 Steam Method of Cleaning 2 -6 FORK ADJUSTMENT 1-4 Chemical Solution Method of Cleaning Additional Preparations for Repair2 -6 SAFETY AND OPERATIONAL CHECK LIST 1-5
MODEL AND CONTROL INFORMATION 1-7 WELDING REPAIRS
TYRES AND WHEELS 2-6
instrument Panel A (STANDARD) ‘-lo HOW TO CHANGE THE WRES 2-7 Instrument Panel B (OPTIONAL)1-10 General 2-7
instrument Panel (OPTIONAL) ‘-lo PNEUMATIC TYRES 2-7
Temperature Indicator Lamp 1-11
SAFE MAINTENANCE PROCEDURES 1-11
MOVING A DISABLED LIFT TRUCK 1-12
HOW TO TOW THE LIFT TRUCK 1-12
HOW TO PUT A LIFT TRUCK ON BLOCKS 1-1 2
HOW TO RAISE THE STEERING TYRE1-13
HOW TO RAISE THE DRIVE TYRES 1-13
PRECAUTIONS FOR TRUCKS IN STORAGE 1-13
PRECAUTIONS FOR BATTERIES
IN STORAGE 1-14
Section 2
GENERAL 2-1
FRAME 2-1
FLOOR PLATE2-1
REAR COMPARTMENT COVER 2-1
FRONT COVER 2-2
STEERING COLUMN COVER 2-2
Remove the Wheel from the Lift Truck 27
Remove the Tyre from the Wheel 2-8
Install the Tyre on the Wheel2-8
Add Air to the Tyres 2-9
Remove the Wheel from the Lift Truck2-10
Remove the Tyre from the Wheel 2-10 2-11
SOLID TYRES 2-12
PNEUMATIC SHAPED SOLID TYRES 2-10
Install the Tyre on the Wheel
Remove the One Piece Wheel and Tyre 2-12
Install the Tyre on the One Piece Wheel 2-12
Install the Wheels on the Lift Truck 2-12
LABEL REPLACEMENT2-13
YALE WARRANTY INFORMATION2-14
RECOMMENDED SCHEDULE
OF MAINTENANCE 2-14
LUBRICATION INSTRUCTIONS 2-15
EVERY 8 HOURS2-15
EVERY 350 HOURS 2-15
EVERY 2000 HOURS 2-15
HYDRAULIC OILS2-21
GEAR OILS2-22
GREASE 2-23
FREEZER APPLICATIONS 2-24
HYDRAULIC CONTROL VALVE COVERS 2-2
BATTERY COVER 2-2
Open2-2
Close2-2
Removal 2-2
Installation 2-2
BATTERY REMOVAL AND INSTALLATION 2-3
BATTERY PLATFORM 2-3
Modifications 2-24
Complete Truck 2-24
Control ComDartment 2-24
OVERHEAD GUARD 2-4 Electrical System 2-24
Removal 2-4 Battery Compartment 2-24
Installation 2-4 Ignition Switch2-24
Removal 2-5 Accelerator Pedal 2-24
Installation 2-5 Drive Hydraulic and Steering Motors 2-24
COUNTERWEIGHT2-4 Steering Linkage and Pivot Points 2-24
Section 2
Brake Lines and Linkage 2-24
Tilt Cylinders 2-24
Upright and Carriage2-24
MAINTENANCE 2-24
Complete Truck 2-24
Electrical System 2-25
Ignition Switch2-25
Control Compartment 2-24
Battery Compartment 2-25
Steering Linkage and Pivot Points 2-25
Accelerator Pedal 2-25
Drive, Hydraulic and Steering Motors 2-25
Brake Lines and Linkage 2-25
Section 3
General 3-20
Connect Disconnect and
Check the Hand Set3-20
Check and Adjust Functions 3-20
FUNCTION DESCRIPTIONS3-21
Traction Control Cards 3-21
PUMP CONTROL CARD (LABEL LETTER PX) 3-23
TABLES FOR FUNCTION VALUE SETTINGS 3-24
TROUBLESHOOTING 3-26
CONTACTORS 3-59
TESTING CONTACTORS 3-59
Removal3-60
Installation 3-60
TMM1 CARD 3-62
Tilt Cylinders 2-25
Upright and Carriage2-25
Removal3-63
Installation 3-63
Hydraulic System 2-25 CIRCUIT PROTECTION 3-63
Current Limit 3-63
Threads Nomenclature 2-26 Thermal Protection 3-63
Strength Identification 2-26 Suppressors (Filter Blocks) 3-63
FASTENERS – IN T R 0D U C T I 0N 2 -26
Section 3 FUSES 3-64
ELECTRICAL SYSTEM -G EN ERAL 3- 1
EV-1 OOLX MOTOR CONTROLLER 3-2
EV-100 DESCRIPTION AND OPERATION 3-2
The Silicon Controlled Rectifier 3-2
A Motor Circuit that Operates with Pulses 3-2
Traction Circuit 3-4
Hydraulic Pump Motor 3-4
The SCR 1 “OFF” Circuit 3-4
INDUCTION CURRENT FROM THE MOTOR 3-6
THE CONTROL CARD 3-7
Pulse Monitor Trip 3-8
SRO Circuit3-8
Control Card Adjustments 3-8
Accelerator Control 3-1 1
CONTROL CARD 3-1 1
Status Codes 3-1 1
SEQUENCE OF OPERATION3-12
SCR CONTROL 3-1 4
CONTROL CARD CONNECTIONS3-14
HAND SET 3-17
CHECKS AND ADJUSTMENTS,
CONTROL CARD3-1 8
Function Codes 3-1 8
Bench Tests 3-1 9
Tests-Control Card Installed in a Lift Truck 3-1 9
FU N CT I 0 N SETT I N G S3-20
PRINTED CIRCUIT BOARDS3-64
Steering Angle Control Board 3-64
Operation 3-64
Testing 3-65
Operation 3-69
Testing 3-70
Lift Pump Control Board 3-69
Bypassing the Lift Pump Control Board 3-71
ACCELE RAT0 R 3-72
Removal3-72
Installation 3-72
POWER STEERING 3-73
KEY SWITCH 3-73
INSTRUMENT PAN EL 3-73
Standard Instrument Panel3-74
MOTOR MAINTENANCE – GENERAL 3-75
BRUSH AND COMMUTATOR INSPECTION 3-75
NORMAL COMMUTATOR SERVICE 3-77
COMMUTATOR PROBLEMS3-78
BRUSH REPLACEMENT, DRIVE AND
HYDRAULIC PUMP MOTORS 3-80
Traction Motor Removal 3-82
Hydraulic Pump Motor Installation 3-83
Power Steering Pump Motor 3-83
3-83
Traction Motor3-83
Traction Motor Installation 3-83
MOTOR REMOVAL AND INSTALLATION
Section 3
Lift Pump and Motor Removal 3-84
Lift Pump and Motor Installation3-84
Power Steering Pump and Motor Removal 3-84
Power Steering Pump and Motor Installation 3-85
Disassembly 3-85
Assembly3-85
TRACTION MOTOR REPAIR3-85
COMMUTATOR REPAIRS 3-85
TESTS3-87
Damaged Field and Armature 3-87
Short-Circuit in an Armature Winding 3-88
Short-Circuit in the Armature 3-88
Open Circuit in a Field Coil3-88
Short-circuit in a Field Coil3-88
Short-circuit Between Field and Motor Case 3-88
Brush Holder 3-88
WIRING DIAGRAMS AND SCHEMATICS3-90
Section 4
TRANSAXLE-GENERAL 4- 1
TRANSAXLE SPEC1F lCATlO NS $ 41-
REMOVAL 4-1
INSTALLATION 4-3
D I SASSE M B LY 43
ASSEMBLY 43
TROUBLESHOOTING 46
Section 5
GENERAL 5 1
SPEC IF I CAT I ON S 5- 1
PARKING BRAKE ADJUSTMENT 5-1
SERVl CE BRAKE ADJUSTMENT 5- 1
REMOVAL- SERVICE BRAKE PADS 5- 1
INSTALLATION-SERVICE BRAKE PADS 5-1
REMOVAL-SERVICE BRAKE CALIPER 5-2
INSTALLATION-SERVICE BRAKE CALIPER 5-3
DISASSEMBLY-SERVICE BRAKE CALIPER 5-3
ASSEMBLY-SERVICE BRAKE CALIPER 5-3
REMOVAL-PARKING BRAKE CALIPER 5-3
INSTALLATION-PARKING BRAKE CALIPER 5-4
DISASSEMBLY-PARKING BRAKE CALIPER 5-6
ASSEMBLY-PARKING BRAKE CALIPER 5-6
MASTER CYLl NDER- REMOVAL 5 -6
MASTER CYLINDER-INSTALLATION 5-6
MASTER CYLINDER-DISASSEMBLY 5-6
MASTER CY LI N DE R – ASS EM BLY 57
PARKING BRAKE LEVER ASSEMBLYREMOVAL 5-7
Section 5
PARKING BRAKE LEVER ASSEMBLYINSTALLATION 5-7
TROUBLESHOOTING 5-9
Section 6
TRAIL AXLE 6-1
WHEEL ASSEMBLY6-1
Removal 6-1
Installation 6-1
Removal 6-1
Installation 6-1
Removal 6-3
Installation 6-3
POWER STEERING SYSTEM 6-4
General 6-4
Description6-4
WHEEL HUB 6-1
STEER AXLE ASSEMBLY:6-3
STEERING WHEEL AND COLUMN
ASSEMBLY 6-4
6-5
Installation 6-6
Cleaning 6-8
Disassembly 6-8
Assembly6-10
Installation 6-13
Removal6-14
Installation 6-14
Disassembly 6-14
Assembly6-14
Remove Air from the System 6-14
Check the Operation6-15
Steering Pressure 6-15
POWER STEERING CYLINDER 6-14
CHECKS AND ADJUSTMENTS 6-14
TROUBLESHOOTING 6-16
Section 7
GENERAL 7-1
HOIST SYSTEM 7-1
TILT SYSTEM7-1
AUXl Ll ARY FUNCTIONS 7-1
Third Function Location7-1
Fourth Function Location 7-1
HYDRAULIC OIL TANK 7-1
SPECIFICATIONS 7-2
Hydraulic Tank 7-2
Power Steering Pump 7-2
Hoist Pump7-2
Section 7
Strainers 7-2
Hydraulic Oil Filter 7-2
HOIST PUMP 7-3
Removal 7-3
Installation
Disassembly-Seal Replacement
7-4
POWER STEERING PUMP AND MOTOR 75
Removal 7-5
Installation 7-5
Disassembly 7-6
Assembly 7-6
CONTROL VALVE 7-7
Setti n g s 7-7
Removal 7-7
Installation 7-8
Disassembly 7-1 0
Assembly7-1 0
MAST TILT ADJUSTMENT 7-12
CONTROL VALVE-EMERGENCY REPAIR 7-12
TROUBLESHOOTING 7-13
Section 8
MAST 8-1
DESCRIPTION AND OPERATION 8-1
Carriage 8-1
Mast Mounts 8-1
Description and Operation 8-3
TWO STAGE MAST WITH FULL FREE LIFT 8-5
Description8-5
Operation 8-5
Description8-7
Operation 8-7
TWO STAGE MAST WITH LIMITED FREE LIFT 8-3
THREE STAGE MAST WITH FULL FREE LIFT 8-7
SAFETY PROCEDURES WHEN WORKING
NEAR THE MAST 8-9
MAST REPLACEMENT 8-9
MAST REPAIRS 8-10
FORKS 8-10
Removal8-1 0
Installation 8-10
Removal, Standard Carriage 8-1 0
Removal, Sideshift Carriage 8-1 2
Repairs 8-1 2
Installation, Standard Carriage 8-1 2
CARRIAGES 8-10
Section 8
Installation Sideshift Carriage 8-12
MASTS 8-13
Removal8-13
Disassembly Procedures for the Two Stage
Mast with Limited or Full Free Lift 8-14
Disassembly Procedures for
the Three Stage Mast 8-17
Cleaning and Inspection 8-19
Assembly of the Two Stage Mast
with Limited and Full Free Lift 8-20
Assembly of the Three Stage Mast
with Full Free Lift 8-20
Mast Installation 8-21
Removal of the Main Lift Cylinders 8-21
Removal of the Free Lift Cylinder 8-22
Disassembly of a Lift Cylinder 8-22
8-22
Installation of the Main Lift Cylinders 8-24
Installation of the Free Lift Cylinder
Installation of Header Hoses for
Two Stage Mast with Limited Free Lift8-26
Installation of Header Hoses for
Two Stage Mast with Full Free Lift 8-27
Installation of Header Hoses for
Three Stage Mast with Full Free Lift 8-30
Removal8-33
Disassembly 8-33
Cleaning8-34
Assembly8-34
Installation 8-34
Check the Lift Cylinders for Leaks 8-34
Check the Tilt Cylinders for Leaks 8-34
Adjust the Tilt Cylinders 8-34
Adjust the Lift Chains8-35
Adjust the Mast8-36
Adjust the Carriage 8-36
LIFT CYLINDERS8-21
Assembly of a Lift Cylinder
HEADER HOSE ARRANGEMENTS 8-25
TILT CYLINDERS8-33
CHECKS AND ADJUSTMENTS 8-34
TROUBLESHOOTING 8-38
Section 9
BATTERY AND CHARGING SYSTEMGENERAL
9-1
SAFETY TIPS FOR HANDLING
INDUSTRIAL TRUCK BATTERIES 9-1
LEAD ACID BATTERIES 9-2
Specific Gravity 9-3
Chemical Reaction 9-3
Section 9
HOW TO SELECT THE BATTERY 9-4
Voltage of a Battery 9-4
Battery Ratings 9-4
Kilowatt Hours 9-4
THE BATTERY AS A COUNTERWEIGHT 95
THE NEW BATTERY 9-5
BAlTERY MAINTENANCE 9-5
Maintenance Records 9-5
Cleaning the Battery 9-6
Adding Water 9-6
Hydrometer9-7
Battery Temperature 9-7
Types of Battery Charges 9-8
Methods of Charging 9-8
CHARGING THE BATTERY 9-8
Troubleshooting the Charger9-9
Section 9
How to Know when the Battery
is Fully Charged 9-9
Battery Charging Area 99
Equipment Needed 9-9
TROUBLESHOOTING 9-10
Section 10
SERVICE PARTS
ORDERING INSTRUCTIONS10-1
HOW TO ORDER SERVICE PARTS 10-1
WHEN ORDERING PARTS 10-1
TECHNICAL PUBLICATIONS10-1
PARTS MANUAL 10-1
OPERATING MANUAL 10-1
OPERATOR TRAINING10-1
SERVICE TRAINING COURSES 10-1
SERVICE TRAINING MATERIALS 10-1
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