Yale ERC/P16-20AAF (ERC030-040AF, ERC030-040AG/BG) [A814] ERC/P16-20AAF (ERC030-040AH) [B814] Service Manual PDF

Description

Yale ERC/P16-20AAF (ERC030-040AF, ERC030-040AG/BG) [A814] ERC/P16-20AAF (ERC030-040AH) [B814] Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale ERC/P16-20AAF (ERC030-040AF, ERC030-040AG/BG) [A814] ERC/P16-20AAF (ERC030-040AH) [B814] Service Manual – PDF DOWNLOAD

Language : English
Pages : 458
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale ERC/P16-20AAF (ERC030-040AF, ERC030-040AG/BG) [A814] ERC/P16-20AAF (ERC030-040AH) [B814] Service Manual – PDF DOWNLOAD

BRAKE SYSTEM-524179944(07-2005)-EN 1
toc 1
Brake System 1
Safety Precautions Maintenance and Repair 2
General 5
Description and Operation 5
Service Brakes 5
Master Cylinder 5
Parking Brake 6
Service Brakes Repair 7
Remove and Disassemble 7
Clean 10
Inspect 10
Assemble and Install 10
Master Cylinder Repair 13
Remove 13
Disassemble 14
Clean and Inspect 17
Assemble 17
Install 20
Parking Brake Repair 20
Remove and Dissemble 20
Assemble and Install 22
Parking Brake Switch Replacement 22
Brake System Air Removal 23
Service Brakes Adjustment 23
Brake Pedal Adjustment 24
Master Cylinder Adjustment 24
Parking Brake Adjustment 24
Parking Brake Switch Adjustment 25
Parking Brake Not Applied Switch Test 25
Seat Brake Assembly 25
Seat Brake, Adjust – Lift Truck Models ERC/P16-20AAF (ERC030-040 25
Brake Switch, Adjust – Lift Truck Models ERC/P16-20AAF (ERC030-0 25
Electric Seat Brake, Adjust for Lift Truck Model ERC/P16-20AAF ( 26
Electric Seat Brake With Handle for Lift Truck Model ERC/P16-20A 28
Remove 28
Clean 28
Inspect 28
Install 30
Solenoid Adjustment 30
Cable Adjustment 30
Torque Specifications 32
Troubleshooting 32
DRIVE AXLE-524179939(06-2004)-EN 39
toc 39
Drive Axle, Speed Reducer, and Differential 39
Safety Precautions Maintenance and Repair 40
General 43
Description 43
Drive Unit Assembly Repair 43
Remove Complete Drive Unit Assembly as a Unit 43
Traction Motor, Remove 44
Drive Unit and Speed Reducer, Remove 46
Drive Axle, Disassemble 47
Differential and Speed Reducer, Disassemble 47
Clean 50
Inspect 50
Assembly of Drive Unit 50
Find Correct Shim Set for Hypoid Gear 50
Pinion, Assemble and Install 51
Differential and Ring Gear, Assemble and Install 52
Input Gear for Speed Reducer, Assemble 56
Drive Axle and Hub Assembly, Assemble 57
Installation of Drive Unit 58
Drive Unit, Install 58
Traction Motor, Install 59
Torque Specifications 60
Troubleshooting 61
tables 39
Table 1 Shims Adjustment for Pinion 51
Table 2 Ring and Pinion Tooth Contact Adjustment 55
HYDRAULIC SYSTEM-524179945(03-2005)-EN 65
toc 65
Hydraulic System 65
Safety Precautions Maintenance and Repair 66
General 69
Description 69
Hydraulic System 69
Operation 73
Hydraulic System 73
Hydraulic Gear Pump 73
Steering Pump 73
Hydraulic Tank Repair 85
ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814), ERC/P16-20AAF (ERC03 85
ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216) Tank, R 86
ERC35-55HG (ERC70-120HH) (B839) Tank, Remove and Install 87
Inspect 88
Small Leaks, Repair 88
Large Leaks, Repair 88
Clean 88
Steam Method 88
Chemical Solution Method 89
Additional Methods for Tank Repair 89
ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814), ERC/P16-20AAF (ERC03 89
ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216) Tank, I 90
Filter Replacement 90
All Lift Trucks Except ERC35-55HG (ERC70-120HH) (B839) 90
Lift Truck Models ERC35-55HG (ERC70-120HH) (B839) 90
Hydraulic Pump Repair 91
ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) and ERC20-30AGF (ERC0 91
ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D216), ERC20-30A 92
Pump Seal, Replace and Pump Assemble 93
Assemble Pump on Motor 94
ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) and ERC20-30AGF (ERC0 96
ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D216), ERC20-30A 97
ERC35-55HG (ERC70-120HH) (B839) Hydraulic Pump, Remove 97
ERC35-55HG (ERC70-120HH) (B839) Hydraulic Pump, Disassemble 98
ERC35-55HG (ERC70-120HH) (B839) Hydraulic Pump, Inspect 98
ERC35-55HG (ERC70-120HH) (B839) Hydraulic Pump, Clean 98
ERC35-55HG (ERC70-120HH) (B839) Hydraulic Pump, Assemble 100
ERC35-55HG (ERC70-120HH) (B839) Hydraulic Pump and Motor Install 100
Main Control Valve Repair 102
Steering Pump Repair 102
ERC/P16-20AAF (ERC030-040AF, ERC030-040AG/BG) (A814) and ERC20-3 102
ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D216), ERC20-30A 103
Pump, Assemble and Install 105
Steering Control Unit Repair 106
Remove 106
Install 109
Steering Cylinder Repair 111
Main Control Valve Check and Adjust 111
Steering Relief Valve Check and Adjust 112
Specifications 112
Relief Valve Pressures* 112
Hydraulic Tank Capacity (dipstick full mark) 113
Hydraulic Pump Capacities – All Models Except ERC35-55HG (ERC70- 113
Hydraulic Pump Capacities – Models ERC35-55HG (ERC70-120HH) (B83 113
Troubleshooting 113
Steering 113
Steering Housing and Steering Control Unit 114
Hydraulic System 115
MAIN CONTROL VALVE-524179946(05-2004)-EN 121
toc 121
Main Control Valve 121
Safety Precautions Maintenance and Repair 122
General 125
Description 125
Operation 125
ERC/P16-20AAF (ERC030-040AF, AG/BG) [A814], ERC/P16-20AAF (ERC03 126
ERP20-30ALF [B216], and ERP20-30ALF (ERP040-060DH) [D216] 126
Lift Section 128
Tilt Section 128
Tilt Backward 128
Tilt Forward 128
Relief Valve 130
Main Control Valve Repair 131
Remove 131
Disassemble 131
Clean and Inspect 131
Assemble 135
Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814), ERC/P16-20A 135
Install [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216 136
Control Lever Linkage Repair 136
Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814),ERC/P16-20AAF 136
Disassemble [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814),ERC/P16- 136
Assemble and Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) 136
Control Valve Linkage Repair 138
Remove and Disassemble [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A81 138
Assemble and Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) 138
Control Lever Linkage Repair 139
Remove [ERP20-30ALF (B216), and ERP20-30ALF (ERP040-060DH) (D216 139
Disassemble [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) ( 139
Assemble and Install [ERP20-30ALF (B216) and ERP20-30ALF (ERP040 141
Pressure Relief Valve Check and Adjustment 142
Primary Relief Valve 142
Secondary Relief Valve 142
Troubleshooting 143
MAST DESCRIPTION-524158890(05-2004)-EN 149
toc 149
Mast 149
Safety Precautions Maintenance and Repair 150
General 153
Description and Operation 153
Carriages 153
Mast Mounts 155
Two-Stage Mast, Limited Free-Lift (LFL) 156
Description and Operation 156
Two-Stage Mast, Full Free-Lift (FFL) 158
Description and Operation 158
Three-Stage Mast, Full Free-Lift (FFL) 160
Description and Operation 160
Cylinder Cushion During Lifting Sequence 163
Cylinder Cushion During Lowering Sequence 164
MAST REPAIRS-524158891(05-2004)-EN 167
toc 167
Mast 167
Safety Precautions Maintenance and Repair 168
General 171
Safety Procedures When Working Near Mast 171
Forks Repair 173
Remove 173
Install 173
Carriages Repair 174
Standard Carriage, Remove 174
Hang-On Sideshift Carriage, Remove 175
Standard Carriage and Hang-On Sideshift Carriage, Repair 176
Standard Carriage, Install 176
Hang-On Sideshift Carriage, Install 177
Integral Sideshift Carriage 177
Remove 177
Clean and Inspect 179
Repair 179
Install 180
Mast Repair 180
Remove 180
Two-Stage LFL and Two-Stage FFL Masts, Disassemble 182
Three-Stage FFL Mast 189
Disassemble 189
Mast and Chains, Clean and Inspect 192
Two-Stage LFL and Two-Stage FFL Mast, Assemble 193
Three-Stage FFL Mast, Assemble 194
Install 195
Lift Cylinders Repair 197
Main Lift Cylinders, Remove 197
Free-Lift Cylinder, Remove 197
Lift Cylinders, Disassemble 198
Lift Cylinders, Assemble 199
Main Lift Cylinders, Install 201
Free-Lift Cylinder, Install 201
Header Hose Arrangements 202
Two-Stage LFL Mast, New Hose Install 202
Two-Stage LFL Mast, Adjust Hoses After Installation 207
Two-Stage FFL Mast, New Hose Install 207
Two-Stage FFL Mast, Adjust Hoses After Installation 212
Three-Stage FFL Mast, New Hose Install 212
Three-Stage FFL Mast, Adjust Hoses After Installation 224
Header Hose Arrangement 225
Two-Stage LFL Mast, New Hose Install 225
Two-Stage LFL Mast, Adjust Hoses After Installation 229
Two-Stage FFL Mast, New Hose Install 229
Two-Stage FFL Mast, Adjust Hoses After Installation 234
Three-Stage FFL Mast, New Hose Install 236
Three-Stage FFL Mast, Adjust Hoses After Install 244
Lift and Tilt System Leak Check 244
Lift Cylinders Leak Check 244
Tilt Cylinders Leak Check 244
Tilt Cylinders Adjustment 245
Lift Chains Adjustment 246
Mast Adjustment 248
Carriage Adjustment 250
Troubleshooting 250
tables 167
Table 1 Hook-Type Carriage Chain Adjustment 247
Table 2 Pin-Type Carriage Chain Adjustment 247
SR-SP MOTOR CONTROLLER524164220-2200YRM0779-(06-2005)-UK-EN 255
toc 255
SR/SP Transistor Motor Controller and Handset 255
Safety Precautions Maintenance and Repair 256
Introduction to SEM 259
Advantages of Transistorized SEM 259
Features of SEM 259
Solid-State Reversing 259
Performance and Efficiency 259
Field Weakening 259
Regenerative Braking 259
SR Transistor Traction Motor Controllers 260
Introduction 260
Proportional Operation for Dual-Motor Trucks 260
General 260
Operation 263
Controller Features 263
General 263
Creep Speed 263
Controlled Acceleration 264
Current Limit 264
Braking 264
Regenerative Braking to Zero Speed 264
Pedal Position Braking 264
Auto Regenerative Braking 264
Conventional Plug Braking 264
Auxiliary Speed Control 265
Field Weakening 265
Speed Limits 265
Ramp Operation 265
Ramp Start 265
Antirollback 265
Steer Pump Contactor Time Delay 265
On-Board Coil Drivers and Internal Coil Suppression 265
System Protective Override 265
SRO (Static Return to Off) 265
Accelerator Volts Hold Off 265
Pulse Monitor Trip (PMT) 266
Thermal Protector (TP) 266
Low Voltage 266
SP Lift Pump Controllers 266
Sensor Interface/Contactor Driver Module 270
Diagnostic Status Codes and Troubleshooting 270
General Maintenance Instructions 270
Special Precautions 270
Diagnostics 271
Systems Diagnostics 271
Status Codes 271
Standard Status Codes 271
Stored Status Codes 272
Other Features 272
Hourmeter Readings 272
Maintenance Alert and Speed Limit 272
Battery Discharge Indication (BDI) 272
Internal Resistance Compensation 272
Handset Programmable 272
RS 232 Communication Ports 272
Circuit Board Coil Driver Modules 272
Maintenance Management Capability 273
Interactive Instrument Panel Modes (Premium Only) 273
General Troubleshooting Instructions 275
Status Code Troubleshooting Tables 276
Description 276
SR/SP Handset Instructions 314
General Features 314
Connecting Handset 316
Startup Sequence 317
Setup Mode 318
Stored Status Code Mode 318
Clearing Stored Status Codes 319
Restarting Lift Truck 319
SR Traction Controller Function Descriptions 320
Premium Instrument Panel Interactive Modes 326
SP Pump Controller Function Descriptions 329
Premium Instrument Panel Interactive Modes 332
tables 255
Table 1 SR Traction Controller Connections/Descriptions 262
Table 2 SP Lift Pump Controller Connections/Descriptions/Status 267
Table 3 Instrument Panel Function Number Correlation 273
Table 4 Traction Function Settings Logic 274
Table 5 Lift Pump Function Settings Logic 275
Table 6 Speed/Torque Compensation 331
STEER CONTROL UNIT-524158753(07-2005)-EN 337
toc 337
Steering Housing and Control Unit 337
Safety Precautions Maintenance and Repair 338
General 341
Description 341
Operation 342
Steering Wheel and Column Assembly Repair 343
Assembly Components, Remove 343
Steering Control Unit, Disassemble 348
Steering Control Unit, Clean 348
Steering Control Unit, Assemble 348
Assembly Components, Install 350
System Air Removal 352
Troubleshooting 352
STEERING AXLE-524179940(06-2004)-EN 357
toc 357
Steering Axle 357
Safety Precautions Maintenance and Repair 358
General 361
Description 361
Steering Axle Assembly Repair 362
Remove 362
Install 362
Wheels and Hubs Repair 362
Remove and Disassemble 362
Clean 362
Assemble and Install 363
Spindles, Bearings, and Links Repair 364
Remove and Disassemble 364
Clean 364
Assemble and Install 364
Steering Cylinder Repair 366
Remove and Disassemble 366
Clean and Inspect 367
Assemble and Install 368
Torque Specifications 368
Troubleshooting 369
SX-SR MOTOR CONTROLLER 524164218-2200YRM0697-(08-2005)-UK-EN 373
toc 373
SX/SR Transistor Motor Controller and Handset 373
Safety Precautions Maintenance and Repair 374
Introduction to SEM 377
Advantages of Transistorized SEM 377
Features of SEM 378
Solid-State Reversing 378
Performance and Efficiency 378
Field Weakening 378
Regenerative Braking 378
SX Transistor Motor Controllers 379
Introduction 379
Proportional Operation for Dual-Motor Trucks 379
General 379
Operation 381
Controller Features 383
General 383
Creep Speed 383
Controlled Acceleration 383
Current Limit 383
Braking 383
Regenerative Braking to Zero Speed 383
Pedal Position Braking 384
Auto Braking 384
Conventional Plug Braking 384
Auxiliary Speed Control 384
Field Weakening 384
Speed Limits 384
Ramp Operation 384
Ramp Start 384
Antirollback 385
Steer Pump Contactor Time Delay 385
On-Board Coil Drivers and Internal Coil Suppression 385
System Protective Override 385
SRO (Static Return to Off) 385
Accelerator Volts Hold Off 385
Pulse Monitor Trip (PMT) 385
Thermal Protector (TP) 385
Low Voltage 385
SR Lift Pump Controllers 386
Sensor Interface/Contactor Driver Module 390
Diagnostic Status Codes and Troubleshooting 390
General Maintenance Instructions 390
Special Precautions 390
Diagnostics 391
Systems Diagnostics 391
Status Codes 391
Standard Status Codes 391
Stored Status Codes 391
Other Features 392
Hourmeter Readings 392
Maintenance Alert and Speed Limit 392
Battery Discharge Indication (BDI) 392
Internal Resistance Compensation 392
Handset Programmable 392
RS 232 Communication Ports 392
Circuit Board Coil Driver Modules 392
Maintenance Management Capability 392
Interactive Instrument Panel Modes 393
General Troubleshooting Instructions 395
Status Code Troubleshooting Tables 396
SX/SR Handset Instructions 432
General Features 432
Connecting the Handset 434
Startup Sequence 434
Setup Mode 435
Stored Status Code Mode 436
Clearing the Stored Status Codes 436
Restarting Lift Truck 436
SX Traction Controller Function Descriptions 437
Premium Instrument Panel Interactive Modes 444
SR Pump Controller Function Descriptions 446
Premium Instrument Panel Interactive Modes 449
tables 373
Table 1 SX Traction Controller Connections/Descriptions 380
Table 2 SR Lift Pump Controller Connections/Descriptions/Status 387
Table 3 Instrument Panel Function Number Correlation 393
Table 4 Traction Function Settings Logic 394
Table 5 Lift Pump Function Settings Logic 394
Table 6 Speed/Torque Compensation 448
Table 7 Traction Controller Settings – Standard With Auto Regen 451
Table 8 Traction Controller Settings – Standard Without Auto Re 452
Table 9 Traction Controller Settings – High Performance With Au 454
Table 10 Lift Pump Controller Settings 455

S.V 07/24