Yale Forklift ESC 030-040 FA (A883) Service Maintenance Manual – PDF DOWNLOAD

Description

Yale Forklift ESC 030-040 FA (A883) Service Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift ESC 030-040 FA (A883) Service Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 334
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift ESC 030-040 FA (A883) Service Maintenance Manual – PDF DOWNLOAD

toc 1
DC Motor Maintenance 1
Safety Precautions Maintenance and Repair 2
General 5
Brush and Commutator Inspection 5
Hydraulic Pump Motor and Traction Motor 5
Steering Pump Motor 8
Normal Commutator Surface 8
Commutator Problems 8
Brush Replacement 12
Stoning the Commutator 14
Motors Repair 16
Disassemble 16
Traction Motor and Hydraulic Pump Motor 16
Steering Pump Motor 20
Assemble 20
Traction Motor and Hydraulic Pump Motor 20
Steering Pump Motor 21
Brush Alignment, Traction and Hydraulic Motors 24
Tests for Damaged Field and Armature 24
Test for an Open Circuit in Armature 24
Test for Short Circuit in One Armature Winding 25
Test for Short Circuit to Armature Shaft 25
Test for Open Circuit in Field Coil 25
Test for Short Circuit in Field Coil 25
Test for Short Circuit between Field and Motor Case 26
Brush Holder Test 26
Troubleshooting 26
tables 1
Table 1 Normal Commutator Surfaces 7
Table 2 Commutator Problems 8
Table 3 Brush Wear Replacement Guide 12
toc 31
Diagrams 31
Safety Precautions Maintenance and Repair 32
toc 63
Electrical System 63
Safety Precautions Maintenance and Repair 64
General 69
Major Electrical System Features 70
Integrated System 70
CAN Bus Advantages 70
CAN Bus Communications 71
Steering 71
Traction 71
Master Control Unit 71
Multifunction Control Handle 71
Operator Input Devices 71
Multifunction Displays 71
Standard Display 71
Premium Display (Optional) 71
BDI 71
Setup 72
Setup Instructions 72
Curtis 1310 Master Control Unit 72
Normal Operation 77
Standard Display 77
Premium Display 77
Password Access 77
Start-up Checklist 77
Truck Operation Mode 78
Diagnostics 78
Power-On Self-Test 78
Run-Time Diagnostic 78
Standard Display 79
Premium Display 80
Checking Transistor Controller 81
Component Repair and Testing 81
Troubleshooting 82
Fault Codes and Display Messages 83
SEM Traction Motor Controller 92
Curtis 1243 traction Controller 92
Hydraulic Pump Controller (Optional) 93
Adjusting the Curtis 1254 Pump Controller Parameters 93
Controller Removal 94
Install 94
Low-Voltage Protection Function 94
Checking Contactor Coils 94
Contactor and Electrical Panel Checks 95
Fuses 95
Contactors 96
General 96
Test 96
Tips 97
Disassemble and Assemble 97
Steer Position Sensor 99
General 99
Operation 99
Install 99
Position Steer Tire for Straight Travel 99
Adjust 100
Dash Display Method 100
Digital Voltmeter Method 100
Test 101
Causes of Motor Failure 101
Overload 101
Shock Loading 101
Short in Field Coils 101
Short Brushes 101
High or Low Commutator Bar 101
Open Circuit 101
Low Battery Voltage 101
Eccentricity of Commutator 102
Overspeeding 102
Drive Motor 102
Inspect 102
Preparation of Drive Motor Commutator 102
Drive Motor Brush and Brush Holder 103
Drive Motor Brush, Remove and Install (Motor Installed) 103
Drive Motor Brush Holder, Remove and Install (Motor Installed) 103
Drive Motor Disassembly and Assembly 104
Remove 104
Repair 104
Disassemble 104
Assemble 104
Install 105
Drive and Hydraulic Pump Motors 106
Routine Preventive Maintenance 106
Preventive Maintenance Checks 106
Cleanliness 106
Connections 107
Discoloration and Burn Marks 107
Brushes 107
Short in Armature 107
Commutator 107
Bearings 107
Hoist Pump Motor 107
Maintenance Instructions 107
Remove 107
Repair 108
Disassemble 108
Assemble 108
Install 108
Motor Tests 110
Excessive Current Draw 110
Measuring Current Draw 110
Excessive Resistance 110
Brush Springs 110
DC to DC Converter 111
tables 63
Table 1 Fault Codes and Display Messages 83
Table 2 1254 Hydraulic Pump Controller Parameter Settings 93
Table 3 Coil Resistance 96
Table 4 Potentiometer Specifications 101
toc 115
Frame 115
Safety Precautions Maintenance and Repair 116
General 119
Frame 119
Size 119
Painting Instructions 119
Covers and Pads 120
Covers 120
Remove 120
Install 120
Pads 120
Remove 120
Install 121
Overhead Guard 122
Description 122
Remove 122
Repair 122
Install 122
Battery 124
Battery Sizes 124
Labels and Decals 125
Safety Labels 125
tables 115
Table 1 3000 lb Capacity, 43 9-inch Wheel Base 124
Table 2 3500 lb Capacity, 43 9-inch Wheel Base 124
Table 3 3500 lb Capacity, 46 4-inch Wheel Base 125
Table 4 4000 lb Capacity, 46 4-inch Wheel Base 125
toc 131
Hydraulic System 131
Safety Precautions Maintenance and Repair 132
General 135
Multifunction Control Handle 135
Description 135
Manual Lowering 136
How to lower mast manually 136
Main Hydraulic Control Valve 137
Description 137
Check and Adjust 137
Manifold Pressures 137
Counter Balance Valve 138
Remove 138
Repair 139
Disassemble 139
Clean 140
Assemble 140
Install 140
Lift Pump and Motor 142
Description 142
Remove 142
Motor 142
Lift Pump 143
Install 143
Lift Pump 143
Motor 144
Lift Pump 144
Description 144
Disassemble 144
Assembly 145
Hydraulic Tank 146
Inspect 146
Remove 146
Clean 148
Steam Method 148
Trisodium Phosphate Method 149
Install 149
Troubleshooting 150
tables 131
Table 1 Pressure Settings 137
Table 2 Main Hydraulic Control Valve Cartridges 140
toc 155
Industrial Battery 155
Safety Precautions Maintenance and Repair 156
General 159
Lead-Acid Batteries 159
Specific Gravity 160
Chemical Reaction in a Cell 160
Electrical Terms 161
Battery Selection 162
Battery Voltage 163
Battery as a Counterweight 163
Battery Ratings 163
Kilowatt-Hours 163
Battery Maintenance 164
Safety Procedures 164
Maintenance Records 164
New Battery 164
Cleaning Battery 165
Adding Water to Battery 166
Hydrometer 166
Battery Temperature 167
Charging Battery 168
Types of Battery Charges 169
Methods of Charging 170
Troubleshooting Charger 170
Knowing When Battery Is Fully Charged 171
Where to Charge Batteries 171
Equipment Needed 171
Battery Connectors 171
Battery Care 172
tables 155
Table 1 Battery Capacity Terms 163
toc 195
Mast 195
Safety Precautions Maintenance and Repair 196
General 199
Safety Procedures When Working Near Mast 199
Fork Repair 201
Remove 201
Install 201
Carriages Repair 202
Standard Carriage 202
Remove 202
Repair 203
Install 203
Integral Sideshift Carriage 203
Remove 203
Clean and Inspect 203
Repair 205
Install 205
Mast Repair 206
Remove 206
Two-Stage LFL and Two-Stage FFL Masts, Disassemble 207
Three-Stage FFL Mast 210
Disassemble 210
Mast and Chains, Clean and Inspect 212
Two-Stage LFL and Two-Stage FFL Mast, Assemble 213
Three-Stage FFL Mast, Assemble 214
Install 215
Lift Cylinders Repair 216
Free-Lift Cylinder, Remove 216
Lift Cylinders, Disassemble 216
Lift Cylinders, Assemble 217
Main Lift Cylinders, Install 218
Free-Lift Cylinder, Install 218
Header Hose Arrangement 218
Two-Stage LFL Mast, New Hose Install 218
Two-Stage LFL Mast, Adjust Hoses after Installation 220
Two-Stage FFL Mast, New Hose Install 222
Two-Stage FFL Mast, Adjust Hoses after Installation 226
Three-Stage FFL Mast, New Hose Install 226
Three-Stage FFL Mast, Adjust Hoses after Install 231
Lift and Tilt System Leak Check 235
Lift Cylinders Leak Check 235
Tilt Cylinders Leak Check 235
Tilt Cylinders Adjustment 236
Lift Chains Adjustment 236
Mast Adjustment 237
Carriage Adjustment 238
Troubleshooting 240
toc 261
Periodic Maintenance 261
Safety Precautions Maintenance and Repair 262
General 265
How to Move Disabled Lift Truck 265
How to Tow Lift Truck 265
How to Put Lift Truck on Blocks 266
How to Raise Load Wheels 266
How to Raise Steer Wheel 267
Lift and Tilt System Leak Checks 267
Lift System 267
Tilt System 268
Safety Procedures When Working Near Mast 268
Check Operation 269
Gauges and Horn 269
Control Handle 269
Steering System 269
Maintenance Schedule 269
Maintenance Procedures Every 8 Hours or Daily 273
Before Operation Checks 273
Hydraulic System 273
Battery 273
Battery Restraint System 274
Tires and Wheels 274
Maintenance Procedures Every 350 Hours or 3 Months 275
Hydraulic Tank Breather 275
Wheel Nut Torque 275
Transaxle 275
Lift System Operation 275
Mast 275
Lift Chains 276
Forks 277
Safety Labels 277
Other Lubrication 277
Electrical Inspection 277
Special Precautions 277
Contactors 278
Motor Brushes 278
Maintenance Procedures Every 2000 Hours or Yearly 279
Hydraulic System 279
Change the Hydraulic Oil Filter 279
Check the Hydraulic Oil Strainer 279
Change the Hydraulic Oil 279
Brakes 279
Transaxle 279
Battery Maintenance 280
How to Charge the Battery 280
How to Change the Battery 281
Wheels and Tires Maintenance 281
General 281
Wheels and Tires 281
Remove the Wheel From Lift Truck 281
Install the Tire on Wheel 281
Install the Wheel and Tire 281
Mast and Lift Chains 282
Forks 282
Adjust 282
Remove 282
Inspect 283
Install 283
tables 261
Table 1 Maintenance Schedule 270
Table 2 Transaxle Capacity 279
toc 311
Tilt Cylinders 311
Safety Precautions Maintenance and Repair 312
General 315
Description 315
Tilt Cylinder Repair 315
Remove 315
Disassemble 315
Clean 315
Assemble 315
Install 317
Tilt Cylinder Leak Check 319
Mast Tilt Angle Adjustment 319
Troubleshooting 320

S.V 07/24