Yale Forklift A888 (ERP10-15RCF) Service Manual - PDF

Yale Forklift A888 (ERP10-15RCF) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A888 (ERP10-15RCF) Service Manual – PDF DOWNLOAD

Language : English
Pages : 450
Downloadable : Yes
File Type : PDF

PART NO. 524150790

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A888 (ERP10-15RCF) Service Manual – PDF DOWNLOAD

524150790-2100YRM0103-(03-2007)-UK-EN 1
toc 1
Tilt Cylinders 1
Safety Precautions Maintenance and Repair 2
General 5
Description 5
Tilt Cylinder Repair 5
Remove 5
Disassemble 5
Clean 5
Assemble 6
Tilt Cylinders With O-Ring or Single-Lip Seals 6
Tilt Cylinders 7
Install 8
Tilt Cylinder Leak Check 10
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 11
Torque Specifications 11
Piston Rod Nut 11
Retainer 11
Troubleshooting 12
tables 1
Table 1 Movement Rates (Maximum) for Tilt Cylinders 10
524150797-8000YRM0231-(03-2020)-UK-EN 17
General 21
Threaded Fasteners 21
Nomenclature, Threads 21
Strength Identification 22
Cotter (Split) Pins 23
Fastener Torque Tables 28
Conversion Table 30
524156985-2200YRM1014-(11-2001)-UK-EN 37
toc 37
Sevcon Traction and Pump Controllers 37
Safety Precautions Maintenance and Repair 38
Sevcon PCpak 43
Introduction 43
System Requirements 43
Traction Controller Safety 43
Traction Controller Introduction 44
Traction Controller Installation 44
Mounting 44
Traction Controller Calibration 46
Adjustments 46
Status and Test Information 47
Traction Controller Configuration 48
System Configuration 48
System Voltage 48
System I/O Configuration 48
System/Motor Setup 50
Armature Field Map 50
Armature and Field Current Limit 51
Contactor Chopping 52
Accelerator Full/Zero Setting 52
Performance 52
Acceleration Delay 52
Deceleration Delay 52
Control Mode 53
Plugging 53
Types of Braking 53
Braking Levels 53
Footbraking 53
Footbrake Pot 53
Footbrake Priority 54
Creep Speed 54
Maximum Speed 55
Traction Controller Commissioning 55
Checklist 55
Traction Controller Features 57
Accelerator Characteristics 57
Features 58
Standard Controller Features 58
Power Steer 58
High Speed Switch and Anti-Tie Down 59
Seat Switch 60
Traction Drive Hours Meter 60
Personality Checksum 60
Reverse Buzzer 60
Traction Controller Safety Features 60
Start Up Sequence 60
SRO (Static Return to Off) 60
Belly Switch (not used) 60
Anti-Rollback 61
Anti-Rolloff 61
Fail-Safe 61
Traction Controller Protection 61
Controller Protection Features 61
Temperature Monitoring 61
Maximum Temperature Logging 62
Timed Current Cutback 62
Safe Operating Area (SOA) 63
Under-Voltage and Over-Voltage Protection 63
Traction Controller Diagnostics 64
Fault Codes 64
Fault Code Clearance 66
Software Version and Serial Number Indication 66
Pump Controller Safety 66
Pump Controller Introduction 67
Pump Controller Installation 67
Mounting 67
MillipaK Pump Power Wiring 68
Pump Controller Calibration 69
Adjustments 69
Status and Test Information 70
Pump Controller Configuration 70
System Configuration 70
System Voltage 70
System I/O Configuration 70
Current Limit 72
Accelerator Full/Zero Setting 72
Performance 72
Lift and Power Steer Ramps 73
Creep Speed 73
Maximum Speed 73
Pump Controller Commissioning 74
Under-Voltage Protection 74
Commissioning Checklist 74
Personalities Record 74
Pump Controller Features 76
Features 76
Standard Controller Features 76
Lift Switch Inputs – Priority 76
Lift Switch Inputs – Additive 76
Compensation 76
Power Steer Input 77
Lift Inhibit Input 77
Cooling Fan 77
Pump Hours Meter 77
Personality Checksum 77
Pump Controller Safety Features 78
Fail-safe 78
Pump Controller Protection 78
Controller Protection Features 78
Temperature Monitoring 78
Maximum Temperature Logging 78
Timed Current Cutback 79
Safe Operating Area (SOA) 79
Pump Controller Diagnostics 80
Diagnostics 80
Fault Clearance 80
Using Status and Test Menus 80
Software Version and Serial Number Indication 81
Pump Controller Specifications 82
Power Configurations 82
EMC Standards 82
Socket B Protection 82
Contactor Drive Ratings 82
Analogue Input Impedance 82
Digital Input Impedance 82
Ordering Information 83
EMC Guidelines 83
Power Cables 83
Signal Cables 83
Controller 83
tables 37
Table 1 Adjustment Menus 46
Table 2 Status and Test Information Menus 47
Table 3 Description of each Digital I/O Configuration 48
Table 4 Digital Functions 49
Table 5 Pin Allocations 50
Table 6 Analogue Functions 50
Table 7 Personality Record 55
Table 8 Internal Power Steer Triggers 58
Table 9 Timed Current Limit Cutback Levels 62
Table 10 Under- and Over-Voltage Cutback Levels 63
Table 11 Flash Fault Descriptions 64
Table 12 Fault Codes and Descriptions 64
Table 13 Software Version Format 66
Table 14 Serial Number Format 66
Table 15 Analogue Function 72
Table 16 Personality Record 74
524158040-2240YRM0001-(03-2020)-UK-EN 87
General 91
Battery Type 91
Lead-Acid Batteries 91
Lithium-Ion Batteries 92
Specific Gravity 92
Chemical Reaction in a Cell 92
Electrical Terms 94
Battery Selection 94
Battery Voltage 95
Battery as a Counterweight 96
Battery Ratings 96
Kilowatt-Hours 96
Battery Maintenance 96
Safety Procedures 96
Maintenance Records 97
New Battery 97
Cleaning Battery 97
Adding Water to Battery 99
Hydrometer 100
Battery Temperature 101
Charging Battery 102
Types of Battery Charges 102
Methods of Charging 104
Troubleshooting Charger 104
Knowing When Battery Is Fully Charged 105
Where to Charge Batteries 105
Equipment Needed 105
Battery Connectors 106
Battery Care 106
Troubleshooting 108
524166836-1600YRM0485-(07-2003)-UK-EN 113
toc 113
Steering System for Electric Lift Trucks 113
Safety Precautions Maintenance and Repair 114
General 117
Description 119
Steering Wheel and Column Assembly Repair 120
Assembly Components, Remove 120
Assembly Components, Install 124
Power Steering Motor and Pump 125
Description 125
Remove and Disassemble, Models ERC 20-30AGF (ERC040-065RF/ZF, RG 126
Remove and Disassemble, Models ERC35-55HG (ERC70-120HD, ERC70-12 127
Remove and Disassemble, Models ERP20-30ALF 130
Remove and Disassemble, Models ERC/P16-20AAF (ERC040-065AF, AG/B 130
Assemble and Install, All Models With A Vertical Mount Except ER 131
Assemble and Install, Models ERP20-30ALF 131
Assemble and Install, Models ERC/P16-20AAF (ERC030-040AF, AG/BG) 132
Power Steering Pump, Repair 132
Seal, Replace 133
Hydraulic Steering Motor 134
Steering System Air Removal 134
Steering Pressure Check 134
Optical Encoder and Activator Circuits Check 135
Troubleshooting 137
524175461-0100YRM0793-(09-2002)-UK-EN 141
toc 141
Frame 141
Safety Precautions Maintenance and Repair 142
General 145
Description 145
Overhead Guard Repair 146
Remove 146
Install 146
Hood and Seat Assembly Repair 146
Remove 148
Install 148
Counterweight Repair 148
Remove 148
Install 149
Hydraulic Tank Repair 150
Inspect 150
Small Leaks, Repair 150
Large Leaks, Repair 150
Clean 150
Steam Method 150
Chemical Solution Method 151
Additional Preparations for Repair 151
Safety Labels 151
Battery Specifications 154
tables 141
Table 1 Weight of Counterweights 149
524175462-0630YRM0794-(09-2002)-UK-EN 157
toc 157
Master Drive Unit (ZF) 157
Safety Precautions Maintenance and Repair 158
General 161
Description 161
Top Section Housing 161
Transmission Housing 161
Repair 162
Remove 162
Disassemble 163
Top Section Housing 163
Transmission Housing 163
Assemble 167
Installing Spiral Bevel Pinion Shaft 167
Measuring Bearing Movement in Bevel Pinion Shaft 169
Assembly of Helical Gear 170
Assembling Crown Gear and Wheel Shaft 170
Assembling Transmission Housing Cover 172
Assembling Input Motor Pinion Gear 172
Inspecting Top Section Housing 172
Measuring Pivoting Bearing Movement 173
Installing Top Section Housing 173
Install 173
Tooth Contact Pattern Adjustment 174
Changing Transmission Oil 175
Troubleshooting 176
tables 157
Table 1 Tooth Contact Pattern 174
524175463-0630YRM0795-(09-2002)-UK-EN 181
toc 181
Master Drive Unit (Kordel) 181
Safety Precautions Maintenance and Repair 182
General 185
Description 185
Upper Section 185
Lower Section 187
Drive Unit Repair 187
Remove 187
Disassemble 188
Assemble 189
General 189
Assemble Component Subassemblies 189
Assemble Components Into Lower Section 191
Assemble Upper and Lower Sections 192
Install 192
Check and Change Transmission Oil 193
Tooth Contact Pattern Adjustment 194
Troubleshooting 195
tables 181
Table 1 Tooth Contact Pattern 194
524175464-1600YRM0796-(09-2002)-UK-EN 199
toc 199
Steering System 199
Safety Precautions Maintenance and Repair 200
General 203
Description 203
Steering Wheel and Column Assembly 204
Steering Control Unit Repair 208
Remove 208
Install 208
Hydraulic Steering Motor Repair 209
Description 209
Remove 209
Disassemble 209
Clean and Inspect 211
Assemble 211
Install 211
Direction Control Lever Repair 212
Remove 212
Assemble 212
Install 213
Power Steering Adjustments 213
Air in Steering System 213
Steering Pressure 213
Steering Chain, Adjust 214
Troubleshooting 214
524175465-1600YRM0797-(09-2002)-UK-EN 219
toc 219
Steering Control Unit 219
Safety Precautions Maintenance and Repair 220
General 223
Description 223
Operation 223
Steering Wheel and Column Assembly Repair 225
Steering Column Assembly Repair 226
Remove and Disassemble 226
Assemble and Install 226
Steering Control Unit, Disassemble 227
Steering Control Unit, Clean 229
Steering Control Unit, Assemble 230
System Air Removal 233
Troubleshooting 234
524175466-1800YRM0803-(09-2002)-UK-EN 239
toc 239
Brake System 239
Safety Precautions Maintenance and Repair 240
General 243
Description and Operation 243
Master Cylinder Repair 245
Remove and Disassemble 245
Clean and Inspect 246
Assemble and Install 246
Service and Parking Brakes Repair 246
Remove and Disassemble 246
Clean 247
Inspect 248
Assemble and Install 248
Brake System Air Removal 249
Service Brakes Adjustment 250
Brake Pedal Adjustment 250
Parking Brake Adjustment 250
Troubleshooting 251
524175467-1900YRM0802-(02-2009)-UK-EN 257
toc 257
Hydraulic System 257
Safety Precautions Maintenance and Repair 258
General 261
Description 261
Control Valve Repair 264
Description 264
Operation 264
Lift 264
Tilt and Auxiliary 264
Relief Valve 264
Check Valves 270
Description 270
Clean and Inspect 270
Repairs 270
Remove 270
Disassemble – Control Valve Without OPS Solenoids 270
Disassemble – Control Valve With OPS Solenoids 271
Inlet Section 272
Lift Section 272
Tilt Section 272
Auxiliary Section 273
Relief Valve Repair – Control Valve Without OPS Solenoids 273
Relief Valve Repair – Control Valve With OPS Solenoids 274
Clean and Inspect 274
Assemble – Control Valve Without OPS Solenoids 275
Assemble – Control Valve With OPS Solenoids 276
Inlet Section 276
Lift/Lower Section 276
Tilt Section 276
Auxiliary Section 276
Control Valve 276
Install 276
Checks 277
Relief Valve Check 277
Adjust 277
Relief Valve 277
Control Levers, Linkage, and Switches 277
Hydraulic Pump Repair 279
Description 279
Repairs 279
Remove 279
Seal, Replace 280
Install 281
Specifications 283
Relief Valves Pressures 283
Hydraulic System Capacity 283
Troubleshooting 283
Hydraulic Pump 283
Control Valve 284
524175469-2200YRM0144-(09-2002)-UK-EN 289
toc 289
Electrical Warning Devices 289
Safety Precautions Maintenance and Repair 290
General 293
Description 293
Operator-Controlled Horns 293
System Warning Lights, Buzzers, and Bells 293
Reverse Warning Horns 293
Warning Lights 294
Replacement 295
General 295
Horns or Bells, Replace 295
Horn Relay or Buzzer, Replace 295
Warning Lights/Bulbs, Replace 296
Light Assemblies, Replace 296
Flashing Units, Replace 296
524175470-2200YRM0806-(09-2002)-UK-EN 299
toc 299
Sevcon® SC2126 Motor Controller 299
Safety Precautions Maintenance and Repair 300
General 303
Lift Truck Control 303
Plugging 304
Contactors 304
Circuit Protection 305
Current Limit 305
Fuses 305
Controller Operation 306
General Operation 306
Operating Frequency 306
Temperature Monitoring 306
Safe Operating Area (SOA) 306
Undervoltage and Overvoltage Protection 306
Diagnostic LED 307
Fault Clearance 307
Software Version and Revision Indication 307
Setup Menu 307
Multi Languages 307
Power Circuit Descriptions 307
Traction Operation 308
Startup Sequence 308
Static Return to Off (SRO) 308
Seat Switch 308
Acceleration Delay 308
Deceleration Delay 308
Creep 308
Regenerative Braking 308
Plug Braking 309
Brake Constant Factor 309
Antirollback 309
Analog Inputs 309
Traction Accelerator 309
Digital Switch Inputs 310
Contactors 310
Contactor Chopping 310
Fail-Safe 310
Pump Operation 310
Pump Speeds and Priorities 311
Additive Speeds 311
Power Steer Speed 311
Pump Inhibit Input 311
Pump Speed Compensation 311
Calibration and Adjustments 312
Traction Personalities (Controller Adjustments) 312
Traction Status Information 314
Traction Test Information 314
BDI Adjustments 315
Fault Log 315
Setup Menu (Enables/Disables Features) 315
Pump Personalities (Controller Adjustments) 315
Pump Status Information 316
Pump Test Information 317
Pump Setup Menu 317
Traction and Pump Adjustment Descriptions 317
Setup Menu Descriptions 319
Controller Connections 320
Power Connections 320
Controller Connections 320
Contactor Connections 320
Contactor Types 320
Fuse Ratings 320
Back Panel Connectors 321
Connector A – 24 Pin 321
Connector B – 12 Pin 321
Connector C – 6 Pin 322
Controller Area Network (CAN) Overview 322
Diagnostics 322
Service and Fault Logs 324
Service Log 324
Fault Log 324
Technical Specifications 325
Environmental 325
Mechanical 325
Electrical 325
Voltage Specifications: 325
Current Specifications: 325
Miscellaneous Controller Specifications: 326
Contactor Repair 327
General 327
Remove Contactor Assembly 327
Contactor Contacts 327
Coil 329
Control Switches 330
Key Switch 330
Seat Switch 330
Start Switch 330
Brake Pedal Adjustment 330
Accelerator Pedal Adjustment 330
tables 299
Table 1 Over- and Undervoltage Protection 306
524175471-4000YRM0222-(09-2002)-UK-EN 335
toc 335
Vista® Masts 335
Safety Precautions Maintenance and Repair 336
General 339
Mast Weldments 339
Carriage 339
Mast Mounts 341
Vista® Two-Stage Mast 342
Description and Operation 342
Vista® Free-Lift Mast 344
Description 344
Operation 344
Vista® Three-Stage Mast 347
Description 347
Operation 347
524175472-4000YRM0374-(09-2002)-UK-EN 351
toc 351
Vista® Masts 351
Safety Precautions Maintenance and Repair 352
Safety Procedures When Working Near Mast 355
General 357
Forks 357
Carriage 358
Remove 358
Install 358
Mast 358
Remove 358
Disassemble 360
Two-Stage and Free-Lift Masts 360
Three-Stage Mast 361
Clean and Inspect 362
Assemble 364
Two-Stage and Free-Lift Mast 364
Two-Stage Mast 364
Free-Lift Mast 364
Three-Stage Mast 364
Install 365
Lift Cylinders 365
Lowering Control Valve 369
Lift Cylinder Removal Without Removing Mast 370
Disassemble 370
Main Lift Cylinders 370
Free-Lift Cylinder 370
Assemble 370
Main Lift Cylinders 370
Free-Lift Cylinders 371
Lift Cylinders Installation Into Masts 371
Main Lift Cylinders 371
Free-Lift Cylinder 371
Tilt Cylinder 372
Description 372
Remove 372
Disassemble 372
Clean 372
Assemble 372
Install 373
Sideshift Carriage 374
Remove (Early Models) 375
Remove (Late Models) 375
Repairs (Early Models) 375
Repairs (Late Models) 375
Install (Early Models) 375
Install (Late Models) 377
Lift and Tilt System Leaks Check 377
Lift Cylinders Leaks Check 377
Tilt Cylinder Leaks Check 378
Adjustment of Tilt Cylinder Stroke and Backward Tilt Angle 378
Lift Chain Adjustments 379
Mast Adjustments 380
Carriage Adjustment 382
Sideshift Cylinder Adjustment 382
Troubleshooting 382
524175473-8000YRM0798-(03-2010)-UK-EN 387
toc 387
Periodic Maintenance 387
Safety Precautions Maintenance and Repair 388
General 391
How to Move Disabled Lift Truck 391
How to Tow Lift Truck 391
How to Put Lift Truck on Blocks 392
How to Raise Load Wheels 392
How to Raise Steer Wheels 392
How to Clean a Lift Truck 393
Safety Procedures When Working Near Mast 394
Maintenance Schedule 396
Maintenance Procedures Every 8 Hours or Daily 398
Checks Before Operation 398
Hydraulic System 398
Battery 399
Battery Restraint System 399
Operator Restraint System 400
Mast, Forks, and Lift Chains 400
Lift Chain Adjustments 402
Tires and Wheels 403
Check Operation 403
Gauges and Horn 403
Control Levers and Pedals 403
Lift System Operation 403
Service Brakes 404
Parking Brake 404
Steering System 404
Maintenance Procedures Every 500 Hours or 3 Months 404
Hydraulic Tank Breather 404
Wheel Nut Torques 404
Master Drive Unit (MDU) 404
Mast 405
Lift Chains 405
Forks 406
Safety Labels 406
Brake Fluid 406
Other Lubrication 406
Electrical Inspection 407
Contactors 407
Motor Brushes 407
Maintenance Procedures Every 2000 Hours or Yearly 408
Hydraulic System 408
Change Hydraulic Oil Filter 408
Change Hydraulic Oil 408
Brake Shoes 408
Steering System 408
Master Drive Unit 408
Adjust Service Brakes 409
Adjust Parking Brake 409
Lift and Tilt System Leak Check 410
Lift System 410
Tilt System 411
Battery Maintenance 411
How to Charge Battery 411
How to Change Battery 412
Battery Size Specifications 413
Wheel and Tire Maintenance 413
General 413
How to Change Tires 413
Solid Rubber Tires on Pneumatic Wheels 413
Remove Wheels From Lift Truck 414
Remove Solid Rubber Tire From Pneumatic Wheel 414
Install Solid Rubber Tire on Pneumatic Wheel 415
Wheels, Install 416
tables 387
Table 1 Maintenance Schedule 396
Table 2 Battery Size Specifications – Type: Lead-Acid Battery 413
524175474-8000YRM0804-(09-2002)-UK-EN 419
toc 419
Capacities and Specifications 419
Safety Precautions Maintenance and Repair 420
Wheels and Tires 423
Hydraulic System 423
Motors (24 Volt) 423
Mast Creep Speeds 423
Mast Speeds 424
Battery Size Specifications 425
Torque Specifications 425
Frame 425
Master Drive Unit (MDU) (ZF Gotha) 425
Master Drive Unit (MDU) (Kordel) 425
Steering System 425
Brake System 425
Hydraulic System 426
Mast 426
Wheels 426
Sevcon SC2126 Motor Controller Adjustments 426
524175475-8000YRM0805-(02-2009)-UK-EN 429
toc 429
Diagrams 429
Safety Precautions Maintenance and Repair 430