Yale Forklift A883 (ESC030-040FA) Service Manual - PDF

Yale Forklift A883 (ESC030-040FA) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A883 (ESC030-040FA) Service Manual – PDF DOWNLOAD

Language : English
Pages : 432
Downloadable : Yes
File Type : PDF

PART NO. 524150797

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A883 (ESC030-040FA) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-UK-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(03-2020)-UK-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524153627-8000YRM0991-(02-2010)-UK-EN 43
toc 43
Periodic Maintenance 43
Safety Precautions Maintenance and Repair 44
General 47
How to Move Disabled Lift Truck 47
How to Tow Lift Truck 47
How to Put Lift Truck on Blocks 48
How to Raise Load Wheels 48
How to Raise Steer Wheel 49
How to Clean a Lift Truck 49
Lift and Tilt System Leak Checks 50
Lift System 50
Tilt System 50
Safety Procedures When Working Near Mast 51
Check Operation 52
Gauges and Horn 52
Control Handle 52
Steering System 52
Maintenance Schedule 52
Maintenance Procedures Every 8 Hours or Daily 56
Before Operation Checks 56
Hydraulic System 57
Battery 57
Battery Restraint System 57
Mast, Forks, and Lift Chains 58
Tires and Wheels 59
Maintenance Procedures Every 350 Hours or 3 Months 60
Hydraulic System 60
Wheel Nut Torque 60
Transaxle 60
Lift System Operation 60
Mast 61
Lift Chains 61
Forks 62
Safety Labels 62
Other Lubrication 62
Electrical Inspection 63
Special Precautions 63
Contactors 64
Motor Brushes 64
Maintenance Procedures Every 2000 Hours or Yearly 64
Hydraulic System 64
Brakes 65
Transaxle 65
Battery Maintenance 65
How to Charge the Battery 65
How to Change the Battery 66
Lift Chain Adjustments 66
Forks 67
Remove 68
Inspect 68
Install 68
Wheels and Tires Maintenance 69
General 69
Wheels and Tires 69
Remove the Wheel From Lift Truck 69
Install the Tire on Wheel 69
Install the Wheel and Tire 69
tables 43
Table 1 Maintenance Schedule 53
Table 2 Transaxle Capacity 65
524153629-8000YRM0992-(06-2010)-UK-EN 73
toc 73
Diagrams 73
Safety Precautions Maintenance and Repair 74
524153630-0630YRM0993-(12-2001)-UK-EN 91
toc 91
Master Drive Unit 91
Safety Precautions Maintenance and Repair 92
General 95
Lubrication 95
Repair 95
Remove 95
Disassemble 96
Inspect 98
Assemble 99
Intermediate Shaft Installation 99
Axle Shaft Installation 99
Pinion Gear Installation 100
Final Assembly 102
Install 102
Tooth Contact Pattern Adjustment 103
Troubleshooting 104
tables 91
Table 1 Tooth Contact Pattern 103
524153631-0100YRM0994-(02-2002)-UK-EN 107
toc 107
Frame 107
Safety Precautions Maintenance and Repair 108
General 111
Frame 111
Size 111
Painting Instructions 111
Covers and Pads 112
Covers 112
Remove 112
Install 112
Pads 112
Remove 112
Install 113
Overhead Guard 114
Description 114
Remove 114
Repair 114
Install 114
Battery 116
Battery Sizes 116
Labels and Decals 117
Safety Labels 117
tables 107
Table 1 3000 lb Capacity, 43 9-inch Wheel Base 116
Table 2 3500 lb Capacity, 43 9-inch Wheel Base 116
Table 3 3500 lb Capacity, 46 4-inch Wheel Base 117
Table 4 4000 lb Capacity, 46 4-inch Wheel Base 117
524153632-2200YRM0995-(01-2007)-UK-EN 123
toc 123
Electrical System 123
Safety Precautions Maintenance and Repair 124
General 129
Major Electrical System Features 130
Integrated System 130
CANbus Advantages 130
CANbus Communications 131
Steering 131
Traction 131
Master Control Unit 131
Multifunction Control Handle 131
Description/Features 131
Remove 132
Disassemble 132
Tools Required 132
Assemble 135
Install 135
Operator Input Devices 135
Multifunction Displays 135
Standard Display 135
Premium Display (Optional) 135
BDI 135
Setup 136
Setup Instructions 136
Curtis 1310 Master Control Unit 136
Normal Operation 141
Standard Display 141
Premium Display 141
Password Access 141
Startup Checklist 141
Truck Operation Mode 142
Diagnostics 142
Power-On Self-Test 142
Setup Menu Diagnostics 143
Standard Display 143
Premium Display 144
Checking Transistor Controller 145
Component Repair and Testing 145
Troubleshooting 145
Fault Codes and Display Messages 146
SEM Traction Motor Controller 156
Curtis 1243 Traction Controller 156
Hydraulic Pump Controller (Optional) 156
Adjusting the Curtis 1254 Pump Controller Parameters 157
Controller Removal 158
Install 158
Low-Voltage Protection Function 158
Checking Contactor Coils 158
Contactor and Electrical Panel Checks 159
Fuses 159
Contactors 160
General 160
Test 160
Tips 161
Disassemble and Assemble 161
Steer Position Sensor 163
General 163
Operation 163
Install 163
Position Steer Tire for Straight Travel 163
Adjust 164
Dash Display Method 164
Digital Voltmeter Method 164
Test 165
Causes of Motor Failure 166
Overload 166
Shock Loading 166
Short in Field Coils 166
Short Brushes 166
High or Low Commutator Bar 166
Open Circuit 166
Low Battery Voltage 166
Eccentricity of Commutator 166
Overspeeding 166
Drive Motor 166
Inspect 166
Preparation of Drive Motor Commutator 166
Drive Motor Brush and Brush Holder 167
Drive Motor Brush, Remove and Install (Motor Installed) 167
Drive Motor Brush Holder, Remove and Install (Motor Installed) 168
Drive Motor Disassembly and Assembly 168
Remove 168
Repair 169
Disassemble 169
Assemble 170
Install 170
Drive and Hydraulic Pump Motors 171
Routine Preventive Maintenance 171
Preventive Maintenance Checks 171
Cleanliness 171
Connections 171
Discoloration and Burn Marks 171
Brushes 172
Short in Armature 172
Commutator 172
Bearings 172
Hoist Pump Motor 172
Maintenance Instructions 172
Remove 172
Repair 172
Disassemble 174
Assemble 174
Install 174
Motor Tests 174
Excessive Current Draw 174
Measuring Current Draw 175
Excessive Resistance 175
Brush Springs 175
DC to DC Converter 175
tables 123
Table 1 Fault Codes and Display Messages 146
Table 2 1254 Hydraulic Pump Controller Parameter Settings 157
Table 3 Coil Resistance 160
Table 4 Potentiometer Specifications 165
524153633-1600YRM0996-(06-2015)-UK-EN 179
General 183
Description and Features 183
On-Demand Steering Circuit 183
Description 184
A883 184

B883 / C883
185
Steering Control Handle 186
Remove 186
Install 186
Steering Sensor 186
Test 186
Remove 186
Install 186
Steering Control Unit (SCU) 187
Description 187
Inspect 187
Remove 187
Repair 189
Replace 189
Steering Pump and Motor Assembly 190
Description 190
Inspect 190
Remove 190
Repair 191
Disassemble 191
Assemble 192
Install 193
Power Steering Pump 193
Description 193
Repair 193
Disassemble 193
Assemble 194
Steer Unit Actuator-Kordel™ 195
Description 195
Inspect 195
Steering Actuator 195
Remove 195
Disassemble 197
Clean 197
Inspect 197
Assemble 199
Install 200
Steer Tire and Wheel 200
Remove 200
Install 201
Wheel Hub 201
Remove 201
Clean 201
Inspect 202
Install 202
Checks and Adjustments 202
Air in System 202
Operation Check 203
Steering Pressure 203
Troubleshooting 204
524153634-1800YRM0997-(12-2001)-UK-EN 209
toc 209
Electric Brake System 209
Safety Precautions Maintenance and Repair 210
General 213
Description and Operation 213
Electric Brake Repair 213
Inspect 213
Remove 214
Adjust 215
Install 215
Electric Brake Operational Check 216
Brake Pedal Assembly 216
Remove 216
Install 217
Repair 217
Bushings and Spring 217
Remove 217
Install 218
Brake Switch Assembly 218
Remove 218
Install 218
Adjust 218
Troubleshooting 218
524153635-1900YRM0998-(01-2017)-UK-EN 221
General 225
Hoses 225
Fittings 225
Discharging the Capacitors 226
Multifunction Control Handle 227
Description 227
Manual Lowering 228
How to Lower Mast Manually 228
Main Hydraulic Control Valve 228
Description 229
Check and Adjust 229
Check Manifold Pressures 229
Check Internal Counterbalance Valve 229
Remove (Control Valve) 230
Repair (Control Valve) 232
Disassemble 232
Clean 232
Assemble 232
Install (Control Valve) 233
Counterbalance Valve 234
Install 234
Bleed Procedure 235
Lift Pump and Motor 236
Description 236
Remove 236
Motor 236
Lift Pump 237
Install 237
Lift Pump 238
Motor 238
Lift Pump 238
Description 238
Disassemble 238
Assemble 240
Hydraulic Tank 240
Inspect 240
Remove 242
Clean 242
Steam Method 243
Trisodium Phosphate Method 243
Install 243
Troubleshooting 244
524153636-2100YRM0999-(09-2016)-UK-EN 249
General 253
Description 253
Tilt Cylinder Repair 253
Remove 253
Disassemble 253
Clean 253
Assemble 257
Install 257
Tilt Cylinder Leak Check 258
Mast Tilt Angle Adjustment 258
Troubleshooting 258
524153637-4000YRM1000-(12-2001)-UK-EN 263
toc 263
Mast 263
Safety Precautions Maintenance and Repair 264
General 267
Description and Operation 267
Carriages 267
Mast Mounts 269
Two-Stage Mast, Limited Free-Lift (LFL) 269
Description and Operation 269
Two-Stage Mast, Full Free-Lift (FFL) 271
Description and Operation 271
Three-Stage Mast, Full Free-Lift (FFL) 273
Description and Operation 273
Cylinder Cushion During Lifting Sequence 276
Cylinder Cushion During Lowering Sequence 277
524153638-4500YRM1001-(04-2005)-UK-EN 281
toc 281
Mast 281
Safety Precautions Maintenance and Repair 282
General 285
Safety Procedures When Working Near Mast 285
Fork Repair 287
Check 287
Remove 288
Install 288
Carriages Repair 289
Standard Carriage 289
Remove 289
Repair 290
Install 290
Integral Sideshift Carriage 290
Remove 290
Clean and Inspect 290
Repair 292
Install 292
Mast Repair 293
Remove 293
Two-Stage LFL and Two-Stage FFL Masts, Disassemble 294
Three-Stage FFL Mast 297
Disassemble 297
Mast and Chains, Clean and Inspect 299
Two-Stage LFL and Two-Stage FFL Mast, Assemble 300
Three-Stage FFL Mast, Assemble 301
Install 302
Lift Cylinders Repair 303
Free-Lift Cylinder, Remove 303
Lift Cylinders, Disassemble 304
Lift Cylinders, Assemble 304
Main Lift Cylinders, Install 305
Free-Lift Cylinder, Install 305
Header Hose Arrangement 305
Two-Stage LFL Mast, New Hose Install 305
Two-Stage LFL Mast, Adjust Hoses After Installation 309
Two-Stage FFL Mast, New Hose Install 309
Two-Stage FFL Mast, Adjust Hoses After Installation 313
Three-Stage FFL Mast, New Hose Install 313
Three-Stage FFL Mast, Adjust Hoses After Install 323
Lift and Tilt System Leak Check 323
Lift Cylinders Leak Check 323
Tilt Cylinders Leak Check 323
Tilt Cylinders Adjustment 324
Lift Chain Adjustment 324
Mast Adjustment 325
Carriage Adjustment 327
Troubleshooting 327
524153639-8000YRM1002-(02-2007)-UK-EN 331
toc 331
Capacities and Specifications 331
Safety Precautions Maintenance and Repair 332
Lubrication Specifications 335
Battery Size Specifications 335
Fuses 336
Hydraulic System 337
Mast Speeds 337
19cc Pump One-Speed Contactor 337
19cc Pump Transistor Control 338
Mast Tilt Performance 338
Motors (Voltage 36) 338
Tire Sizes 339
Torque Specifications 339
Frame 339
Transaxle 339
Wheels 339
Steering System 339
Hydraulic System 339
Mast/Tilt/Attachment Systems 340
Control Settings 340
524158039-0620YRM0294-(09-2016)-UK-EN 343
General 347
Brush and Commutator Inspection 348
Hydraulic Pump Motor and Traction Motor 348
Steering Pump Motor 351
Normal Commutator Surface 351
Commutator Problems 351
Brush Replacement 356
Stoning the Commutator 359
Motors Repair 360
Disassemble 361
Traction Motor and Hydraulic Pump Motor 361
Steering Pump Motor 362
Assemble 366
Traction Motor and Hydraulic Pump Motor 366
Steering Pump Motor 368
Brush Alignment, Traction and Hydraulic Motors 370
Tests for Damaged Field and Armature 371
Test for an Open Circuit in One Armature Winding 371
Test for Short Circuit in One Armature Winding 371
Test for Short Circuit to Armature Shaft 372
Test for Open Circuit in Field Coil 372
Test for Short Circuit in Field Coil 373
Test for Short Circuit Between Field and Motor Case 373
Brush Holder Test 373
Troubleshooting 374
524158040-2240YRM0001-(01-2023)-UK-EN 379
General 385
Battery Type 385
Lead-Acid Batteries 385
Lithium-Ion Batteries 386
Specific Gravity 386
Chemical Reaction in a Cell 386
Electrical Terms 388
Battery Selection 389
Battery Voltage 390
Battery as a Counterweight 390
Battery Ratings 390
Kilowatt-Hours 390
Battery Maintenance 391
Safety Procedures 391
Maintenance Records 391
New Battery 391
Cleaning Battery 392
Adding Water to Battery 394
Hydrometer 394
Battery Temperature 395
Charging Battery 396
Types of Battery Charges 397
Methods of Charging 398
Troubleshooting Charger 399
Knowing When Battery Is Fully Charged 399
Where to Charge Batteries 399
Equipment Needed 399
Battery Connectors 400
Battery Care 400
Troubleshooting 402
524158040-2240YRM0001-(03-2020)-UK-EN 407
General 411
Battery Type 411
Lead-Acid Batteries 411
Lithium-Ion Batteries 412
Specific Gravity 412
Chemical Reaction in a Cell 412
Electrical Terms 414
Battery Selection 414
Battery Voltage 415
Battery as a Counterweight 416
Battery Ratings 416
Kilowatt-Hours 416
Battery Maintenance 416
Safety Procedures 416
Maintenance Records 417
New Battery 417
Cleaning Battery 417
Adding Water to Battery 419
Hydrometer 420
Battery Temperature 421
Charging Battery 422
Types of Battery Charges 422
Methods of Charging 424
Troubleshooting Charger 424
Knowing When Battery Is Fully Charged 425
Where to Charge Batteries 425
Equipment Needed 425
Battery Connectors 426
Battery Care 426
Troubleshooting 42+8