Yale Forklift A7S4 (ERP15UX, ERP18UX, ERP20UX, ERP25UX, ERP30UX, ERP35UX) Service Manual PDF

Yale Forklift A7S4 (ERP15UX, ERP18UX, ERP20UX, ERP25UX, ERP30UX, ERP35UX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A7S4 (ERP15UX, ERP18UX, ERP20UX, ERP25UX, ERP30UX, ERP35UX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 230
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A7S4 (ERP15UX, ERP18UX, ERP20UX, ERP25UX, ERP30UX, ERP35UX) Service Manual – PDF DOWNLOAD

Forklift Truck Main Parts 13
Battery 13
Overview 13
Battery Specification 13
Safety Instructions and Precautions 14
Lead-acid Battery 14
Lithium Battery 14
Battery Charging 15
Routine Lead-acid Battery Charging Steps 15
Notes When Lithim Battery Charging 15
Service of Battery 16
Lead-acid Battery 16
Lithium Battery 17
Common Failures and Disposal Methods of Battery 17
Main Technical Specification of Forklift Truck 19
Driving Motor and Driving System 23
Overview 23
Axle Box and Differential 23
Notes for Installation and Use 30
Front Tyre and Wheel Rim Models 30
Installation of Wheel Hub 30
Brake 31
Parking Brake 36
Clearance Self-Adjusting Mechanism 37
Brake Disassembly and Assembly, Adjustment Essentials 38
Disassembly of the Brake 38
Inspection of brake 40
Brake Assembly 41
Operation Steps for Brake Clearance Adjuster 42
Driving Motor 43
Specification of Driving Motor 43
Operating Environment Conditions 43
Pump Motor 44
Specification of Pump Motor 44
Operating Environment Conditions 44
Electrical System 45
Overview 45
Characteristics of AC Motor Controller 45
Electric System Schematic Diagram 47
Miscellaneous 48
Trouble shooting 50
Steering Device and Installation 86
Overview 86
Inspection of Steering System after Reassembly 86
Steering System Fault Diagnosis 87
Steering Axle and Installation 88
Overview of Steering Axle 88
Essentials of Adjustment and Maintenance 94
Steering Wheel Bearing Preload Adjustment 94
Parking Brake Operation 95
Overview 95
Operating Device of the Parking Brake 95
Brake Pedal Operation 96
Overview 96
Brake Pedal 96
Adjustment of Foot Pedal Brake 96
Adjustment of Brake Switch 97
Brake Master Cylinder 97
Brake Fault Diagnosis 99
Hydraulic Oil Tank and Installation 100
Overview 100
Hydraulic Oil Tank 100
Hydraulic System 101
Overview 101
Gear Pump 104
Maintenance of Gear Pump 104
Fault Diagnosis 107
Multi-Way Valve 107
Fault Diagnosis 114
Full Hydraulic Orbitrol 114
Speed Limit Valve 115
Hydraulic Pipeline 116
Lifting System 118
Safety Procedures when Working Near Mast 118
Overview 118
Inner and Outer Mast 118
Fork Carriage Assembly 119
Adjustment for Height of Fork Carriage 119
Roller Positions 120
Replacement of Fork Backrest 120
Lifting Cylinder 121
Working Status of Explosion Relieve Valve 124
Adjustment of Lifting Cylinder 125
Tilting Cylinder 125
Installation of Mast 129
Disassembly of Mast 131
Daily Checks and Maintenance 132
Periodic Maintenance Requirements 132
Periodic Maintenance Items 132
Periodic Maintenance 133
Tire 133
Front Wheel 133
Rear Wheel 133
Forks 133
Remove 133
Inspect 134
Install 136
Periodic Maintenance Tables 136
General (CATL-based Lithium-ion Battery) 144
Description of Batteries 144
Battery Types and Options 144
Battery Working Environment Temperature 145
Glossary and Abbreviations 145
Warnings and Cautions (CATL-based Lithium-ion Battery) 147
Safety 147
Hazardous Overview 147
Hazard Pictograms 147
Signal Word 147
Hazard Statements 147
Precautionary Statements 147
Other Hazards 147
Composition and Ingredient Information 147
Hazard Identification 149
Fire Fighting Measures 149
Hazard Analysis (electrical shock, fire, explode, population) 149
Material Preparation and Personnel Trainings 149
Fire Extinguisher Instruction 150
Unusual Fire and Explosion Hazards 150
Accidental Release Measures 150
Leak Emergency Measures 150
Handling and Storage 150
Handling 151
Storage 151
First Aid Measures 151
Handling and Storage 151
Exposure Controls and Personal Protection 151
Physical and Chemical Properties 152
Stability and Reactivity 152
Toxicological Information 152
Ecological information 152
Toxicological Information 153
Regulatory Information 153
USA 153
International 153
Air Transportation 153
Ocean Shipping 153
Land Transportation 153
Avoid Electrical Shock 153
Disposal Considerations 153
Transport Information 154
Transport Information 154
Charging and Labeling 156
Charging 156
Charging Voltages and Currents: 156
Labeling 156
Disposal 157
Component Description (CATL-based Lithium-ion Battery) 158
Key Components 158
Top Cover Components 158
Connection Points 160
Module Connection 160
Module Structure 161
Connection Ports 161
Charger Specification 162
Charger Selection 164
Software and User Interface (CATL-based Lithium-ion Battery) 166
Description of Software Tools for Technicians 166
Truck Instrument 166
Battery Displayer 169
Charger Displayer 173
BMS Interface 175
System Overview 175
Real-time Information 176
Parameter Calibration 177
Force Control 178
Firmware Upgrading 178
History Data 179
Real-time Information 180
Maintenance (CATL-based Lithium-ion Battery) 181
Battery Maintenance 181
Battery Repair (CATL-based Lithium-ion Battery) 182
Battery Disassembly 182
Module Replacement 183
Module Failure 183
Module Aging 184
Principles of Operation (CATL-based Lithium-ion Battery) 185
Functional Descriptions 185
Discharge Power-on Process 185
Discharge Power-off Process 185
Power Button Mode 185
BMS Sleep Mode 185
Fault Mode 185
Charging Mode 185
Charging Power-on Process 185
Charger Mode 185
Charging Power-off Process 186
Charger Mode 186
SOC Mode 186
Fault Mode 186
Power Button Mode 186
Module Heating Process 186
Signal Detection Process 187
Cell Voltage and Temperature 187
Total Circuit Current and Voltage 187
Contactor Adhesion 187
CAN Communication 187
Charging CAN 187
Discharging CAN 187
Battery Displayer (Optional) 187
Personal Computer 187
Child BMS (When Cell Quantity is over 48) 187
Other Functions 188
Alarm Buzzer 188
Key Switch (Optional) 188
MSD 188
Discharge Current Control 188
Charging Current Control 191
Schematics and Diagrams 193
System Electrical Schematic 193
Discharge Schematic Part (I) 193
Discharge Schematic Part (II) 194
Charging Schematic 195
Module Heating Schematic 196
Single Detection Schematic 197
CAN Communication Schematic 198
Other Functions Schematic 199
Main Wire Harness Connection 199
Link Wire and H Port Wire Connection 200
CAN Wire Connection 201
Power Cable Connection 202
Heating Cable Connection 203
CSC Wire Connection 204
Wire Sequence Detector 204
Troubleshooting (CATL-based Lithium-ion Battery) 206
Troubleshooting 206
Charging Alarm Codes and Solutions 206
Charger Faults and Solutions 209
Discharge Alarm Codes and Solutions 212
Battery System Alarm Codes and Solutions 215
Other Battery Faults and Solutions 217
Discharge Fault Threshold 219
Charging Fault Threshold 222
Other Fault Threshold 224
List of Wear Parts 225