Yale Forklift A944 (AER020AA) Service Manual – PDF DOWNLOAD

Description

Yale Forklift A944 (AER020AA) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A944 (AER020AA) Service Manual – PDF DOWNLOAD

Language : English
Pages : 390
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A944 (AER020AA) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(03-2020)-US-EN 1
General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
550121615-0100YRM1906-(03-2016)-US-EN 21
General 27
Description 27
Features 28
Working Near Power Lines 28
Special Precautions 28
Discharging the Capacitors 29
Welding 30
Service Doors, Covers, and Mounting Brackets 30
Service Doors 31
Remove 31
Install 32
Service Door Handles 32
Remove 32
Install 32
Battery Cover 33
Remove 33
Install 33
Mast Cylinder Cover 34
Remove 34
Install 34
Caster Wheel Covers 34
Remove 34
Install 34
Controller Panel Mounting Bracket 34
Remove 34
Install 34
Lower Controls Panel Mounting Bracket 35
Remove 35
Install 36
Hydraulic System Mounting Bracket 36
Remove 36
Install 36
Caster Wheels 38
Remove 38
Install 38
Battery Compartment 39
Painting Instructions 40
Label Replacement 41
550121617-0630YRM1908-(08-2015)-US-EN 47
General 53
54
Working Near Power Lines 54
Special Precautions 55
Discharging the Capacitors 55
Master Drive Unit (Transmission) 58
Remove 58
Install 62
Steering System 63
Brake System 64
Description 64
Brake Check 66
Hold on Grade Test 66
Brake Coil Check 66
550121620-1900YRM1911-(04-2016)-US-EN 69
General 75
Special Precautions 76
Discharging the Capacitors 76
Description of Operation 78
Hydraulic Lines 79
Hydraulic Oil 79
Clean 79
Sound Level 80
Hydraulic Power Unit 80
Remove 81
Clean 82
Inspect 82
Install 83
Relief Valve Pressure Check 83
84
Pressure Check 84
Troubleshooting 86
Lift Assemblies 86
550121621-2100YRM1914-(08-2015)-US-EN 91
Special Precautions 97
Discharging the Capacitors 97
Lift Cylinder 99
Remove 99
Disassemble 101
Clean 102
Inspect 102
Assemble 102
Install 103
Seal Kit Installation 104
External Installation (Seal and Back-Up Ring) 104
Internal Installation (Piston Rod Assembly) 104
Torque Specifications 105
Main Lift Cylinder 105
550121622-0100YRM1915-(08-2015)-US-EN 109
General 115
Special Precautions 116
Discharging the Capacitors 116
Operator Compartment 118
Remove 118
Disassemble Operator Door 119
Clean and Inspect 121
Assemble Operator Door 121
Install 122
Operator Compartment Accessories 122
Mid-Mount Tray 122
Remove 122
Clean and Inspect 124
Install 124
550121623-4000YRM1916-(08-2015)-US-EN 129
General 135
Working Near Power Lines 136
Special Precautions 136
Discharging the Capacitors 136
Description 138
Mast Repair 139
Remove 140
Disassemble 142
Clean and Inspect 149
Assemble 149
Install 154
Mast Adjustments 154
Lateral Mast Adjustment 155
Vertical Mast Adjustment 157
550121625-2200YRM1913-(10-2017)-US-EN 161
General 165
Special Precautions 165
Discharging the Capacitors 166
Major Electrical System Features 167
Integrated System 167
CANbus Advantages 168
CANbus Communications 168
Steering 168
AC Controllers 168
Controller Inputs / Outputs 168
Upper Control Panel and Handle 169
Lower Control Panel 170
MDI-CAN Display 170
Key Switches (Upper and Lower) 170
Proximity Switches 171
Operator Gate Proximity Switch 171
Mast Proximity Switch 172
Object Detection Proximity Switch 173
AC Motor Controller 174
Components 174
General Maintenance Instructions 174
Special Precautions 174
Fuses 175
Main Contactor 175
Repair 176
Controller Pinout 177
Traction Controller Pinout 177
Combination Controller Pinout 178
Traction Controller, Replace 180
Combination Controller, Replace 181
Parameter Descriptions 182
Parameter Configuration 182
Traction 182
Battery Discharge Indicator (BDI) 182
Audible Alarm 183
Visible Alarm 183
Lift Lockout 183
Power Timeout 184
Object Detection 184
Top Speed LFT 184
Top Speed LWR 185
Mast Up Traction Inhibit 185
Thermal Cutback 185
Lower Control Panel Repair 185
Lower Control Panel 186
Control Panel Component Repair 186
Battery Charging Port, Replace 186
Lift and Lower Button, Replace 186
E-Stop, Replace 187
Display, Replace 187
Key Switch, Replace 188
Upper Control Panel and Handle Repair 188
Control Handle 189
Control Handle Removal 189
Control Handle Disassembly and Repair 189
Upper Control Panel 190
Upper Control Panel Disassembly and Repair 191
Traction/Lift Selection Switch and Traction Speed Switch, Replace 192
E-Stop Switch, Replace 192
Dash Display, Replace 192
AC Traction Motor Controller 193
Controller Removal 193
Install 193
Low-Voltage Protection Function 193
Contactor and Electrical Panel Checks 193
Fuses 194
Contactor 194
General 194
Test 194
Contactor Tips 195
Disassemble and Assemble 195
Alarms 196
Audible Alarm 196
Visible Alarm 197
Object Sensing System 198
Tilt Sensor 199
Remove 199
Install 200
Calibration 200
Tilt Sensor Check 200
Traction and Lift Pump Motors 200
Periodic Maintenance Checks 200
550121626-8000YRM1918-(03-2016)-US-EN 203
Introduction 209
General 209
Working Near Power Lines 210
Aerial Work Platform Service Doors 210
Remove 210
Install 210
How to Move a Disabled Lift 212
How to Tow the Lift 213
Lift and Carry the Aerial Work Platform 214
Special Precautions 214
Discharging the Capacitors 214
Welding 216
Safety Procedures When Working Near Mast 217
Maintenance Schedule 218
Maintenance Procedures Every 8 Hours or Daily 222
Checks With the Key Switch OFF 222
Safety Labels 222
Frame 223
Drive Tires and Casters 223
Checks With the Key Switch ON 223
Control Handle 223
Steering 224
Turning 224
Stopping 224
Gauges 224
Object Sensing System 225
Lifting Mechanism 225
Maintenance Procedures Every 250 Hours or Every 2 Months 225
Control Panel Inspection 225
Upper Control Panel and Handle 225
Lower Control Panel 225
Battery 226
Changing the Battery 227
Remove 227
Install 229
Electrical Wiring Connections 229
Inspection of
Lift Chains and Phasing Cable System 229
Mast Channel Cleaning 230
Brake Assembly 230
Regenerative Braking 230
Parking Brake 230
Audible Alarm 230
Visible Alarm 230
Hydraulic Oil Analysis 230
Maintenance Procedures Every 500 Hours or Three Months 230
Mast 231
Mast Sliding Surfaces 231
Lift Chain Lubrication 231
Slider Block 232
Chain Sheaves 233
Caster Wheels 233
Operator Compartment 233
Drive Tires 233
Maintenance Procedures Every 2000 Hours or Yearly 234
Hydraulic System 234
Oil Change 234
Relief Valve Check 234
Service Doors 234
Mast Hardware 235
Welding Repairs 235
Blocking the Mast 235
550121627-8000YRM1919-(09-2017)-US-EN 241
550121628-8000YRM1917-(08-2015)-US-EN 269
Truck Weight 275
Master Drive Unit (MDU) 275
Electrical Specifications 276
Hydraulic System 276
Batteries 276
Tire Specifications 278
Mast Speeds 278
Lubrication Specifications 279
Travel Speeds 279
Torque Specifications 280
Drive Unit 280
Electrical System 280
Hydraulic System 280
Wheels 280
Main Lift Cylinder 280
550121629-9000YRM2020-(09-2016)-US-EN 283
SECTION 9030 ELECTRICAL SYSTEM 287
Group 03 – General Maintenance and Diagnostic Data 289
Group 20 – Diagnostic Trouble Codes 301
550134194-2240YRM1963-(08-2015)-US-EN 365
General 371
Special Precautions 372
Discharging the Capacitors 372
Absorbed Glass Mat (AGM) Batteries 374
Specific Gravity 374
Chemical Reaction in a Cell 375
Electrical Terms 376
Battery Selection 377
Battery as a Counterweight 377
Battery Ratings 378
Kilowatt-Hours 378
Battery Maintenance 378
Safety Procedures 378
Maintenance Records 379
New Battery 379
Cleaning Battery 379
Battery Temperature 381
Charging Battery 382
Types of Battery Charges 383
Methods of Charging 384
AC Charge Port 384
Troubleshooting Charger 385
Knowing When Battery Is Fully Charged 385
Where to Charge Batteries 386
Battery Connectors 386
Battery Care 386

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