Original Illustrated Factory Workshop Service Manual for Yale Electric Forklift Truck Type ESC-ZA.

Original factory manuals for Yale Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text

Covered models:
ESC030ZA
ESC035ZA
ESC040ZA
ESC050ZA

Format: PDF, 248 Pages
Language: English

Contents:
1 OPERATING INSTRUCTIONS
NAMEPLATE
SAFETYAND INFORMATION LABELS
GENERAL
OPERATOR PRE-CHECKS AND INSPECTION
OPERATING PRECAUTIONS
SAFETY AND OPERATIONAL CHECKS (PRIOR TO EACH SHIFT)
DESCRIPTION .
STARTING SEQUENCE
PERFORMANCE PROGRAMMING
LOW LEVEL PASSWORD
PROGRAM MENUITEMS
FWDSPEED & REVSPEED (3.0-7.0 MPH, DEFAULT+7)
DRIVEA/D (HARD, MEDIUM*, SOFT)
LIFTA/D (HARD, MEDIUM*, SOFT)
COASTDEC (SHORT, MEDIUM*, LONG)
TILT SPD (FAST, MEDIUM*, SLOW)
SIDESHFT (FAST, MEDIUM*, SLOW)
AUX SPD (FAST, MEDIUM*, SLOW) POS HOLD (DISABLE, ENABLE*)
DEFAULT (RESET Y)
STOPPING
PARKING
SAFE MAINTENANCE PROCEDURES
HOW TO PUTA LIFT TRUCK ON BLOCKS
HOW TO RAISE THE DRIVE TIRES
HOW TO RA HE STEER TIRE
PRECAUTIONS FOR TRUCKS IN STORAGE
PRECAUTIONS FOR BATTERIES IN STORAGE
2 GENERAL TRUCK AND LUBRICATION
GENERAL
DESCRIPTION
OVERHEAD GUARD
REMOVAL
INSTALLATION .
OVERHEAD GUARD REAR POST
REMOVAL
TALLATION
FRONT COVER
REMOVAL
INSTALLATION
TOP COVER
REMOVAL
INSTALLATION
CONTROL COVER
REMOVAL
INSTALLATION
OPERATOR COMPARTMENT PADS
REMOVAL
INSTALLATION
FLOOR MAT/BRAKE PEDAL PAD
REMOVAL
INSTALLATION
TIRES AND WHEELS
REMOVING TIRE AND WHEEL FROM TRUCK
REMOVING TIRE FROM WHEEL HUB
INSTALLING THE TIRE ON THE WHEEL HUB
INSTALLING THE TIRE AND WHEEL ON THE LIFT TRUCK
LABEL REPLACEMENT
PAINTING INSTRUCTIONS
CHANGING THE BATTERY
BATTERY SPECIFICATIONS - ESC-ZA
3 ELECTRICAL SYSTEM
GENERAL
THEORY OF OPERATION
POWER DISTRIBUTION
START-UP
STEERING CONTROL
DESCRIPTION
'NSTRUMENTS/CONTROLS
MULTI-FUNCTION CONTROLS
REPAIRS AND ADJUSTMENTS
CAPACITOR
DISCHARGE PROCEDURE
FUSES
REMOVAL AND INSTALLATION
CONTROL HANDLEASSEMBLY
REMOVAL
INSTALLATION
CONTROL HANDLE POTENTIOMETER
REMOVAL
INSTALLATION
HORNBUTTON
REMOVAL
INSTALLATION
SYSTEM CONTROLLER/OPERATOR DISPLAYASSEMBLY
REMOVAL
INSTALLATION
OPERATOR DISPLAY BOARD
REMOVAL
INSTALLATION
BATTERY-STATE-OF-CHARGE INDICATOR
KEY SWITCH
REMOVAL
INSTALLATION
AUXILIARY SELECTOR SWITCHAND LIGHT SWITCH
REMOVAL
INSTALLATION
HORN
REMOVAL
INSTALLATION
ACCELERATION CONTROL
CONTROLLER FAILURE CHECKLIST
TRACTION CONTROLLER .
REMOVAL .
INSTALLATION
LIFT CONTROLLER
REMOVAL
INSTALLATION
BRAKE SWITCH
REMOVAL
INSTALLATION
ADJUSTMENT
STEER POSITIC POTENTIOMETER
REMOVAL
INSTALLATION
ADJUSTMENT
MAIN POWER CONTACTOR
REMOVAL
INSTALLATION
CONTACTOR TIPS
REMOVAL
INSTALLATION
BATTERY DISCONNECT LEVER
REMOVAL
INSTALLATION
ELECTRIC MOTOR MAINTENANCE, GENERAL
REPAIRS
DRIVE MOTOR AND HYDRAULIC PUMP MOTOR
DISASSEMBLY
ASSEMBLY
POWER STEERING PUMP MOTOR
DISASSEMBLY
ASSEMBLY
BRUSHAND COMMUTATOR INSPECTION
NORMAL COMMUTATOR SURFACE
COMMUTATOR PROBLEMS
DRIVE MOTOR BRUSHES
REMOVAL
INSTALLATION
LIFT PUMP MOTOR BRUSHES
REMOVAL
INSTALLATION
STONING THE COMMUTATOR
L CUTOUT (0-30, DEFAULT+20)
STEERING (STANDARD', REVERSE)
LANGUAGE (ENGLISH, ESPANOL, FRENCH, DEUTSCH)
BALARM (REVERSE', FORWARD, OFF, BOTH)
BA DUR (LONG', MEDIUM, SHORT)
SHCKSENS (0. 1-10.0 G OR OFF, DEFAULT+5.0)
IMPACT (RESET Y)
IDLETIME (5-60 MINOR OFF, DEFAULT+15)
PMI-TRACTION, LIFT, STEER(1 00-400 HRS, DEFAULT+350)
RESETPMI (RESET Y)
UNITS (ENGLISH', METRIC)
PASSWORD-HIGH LVL, LOW LVL, ELEC KEY
SOFTVER
DEFAULT (RESET Y)
DIAGNOSTIC MENU(DIAGNSTC)
DIAGNOSTIC INPUT TESTS
DIAGNOSTIC OUTPUT TESTS
OPERATIONAL FEEDBACK DEVICES
BATTERY-STATE-OF-CHARGE INDICATOR WITH LIFT INTERRUPT .
WHEEL POSITION INDICATOR ....
SPEED INDICATOR
OVERWEIGHTALERT ICON
LIFT LIMITALERT ICON (OPTIONAL)
SERVICEALERT ICON
DOTMATRIX DISPLAY
OPERATIONAL MODES
POWER-ON SELF TEST
RUNMODE
RESTRICTED MODE
SHUTDOWN MODE
WARNING MESSAGES/TROUBLESHOOTING
SYSTEM FAULT CODES/TROUBLESHOOTING
SCHEMATIC
WIRING DIAGRAM
ELECTRICAL SYSTEM LEGEND
4 DRIVE UNIT ASSEMBLY
DESCRIPTION
REPAIRS-DRIVE UNIT
REMOVAL
INSTALLATION
DRIVE MOTOR
BRUSH REMOVAL AND INSTALLATION
GEARBOX
ÿ,lCHANGE
DRIVE WHEEL ASSEMBLY
REMOVAL AND INSTALLATION
DRIVE WHEEL SEAL
REMOVAL
INSTALLATION
DRIVE WHEEL SPINDLE
REMOVAL
INSTALLATION
ENCODER ASSEMBLY
(SEE FIGURE 4-2)
REMOVAL
INSTALLATION
ENCODER BELTADJUSTMENT
DRIVE SHAFT INSERT
DRIVE UNITREBUILD
DISASSEMBLY
PINION GEAR TO MOTOR ASSEMBLY
GEAR HOUSING TO MOTOR ASSEMBLY
PROCEDURE!
GEAR HOUSING TO MOTOR ASSEMBLY
PROCEDURE II
GEAR HOUSING TO MOTOR ASSEMBLY
CARRIER TO GEAR HOUSING ASSEMBLY
CARRIER REBUILD
CARRIER DISASSEMBLY
CARRIER ASSEMBLY
5 BRAKE SYSTEM
GENERAL
DESCRIPTID OPERATION
THEORY OF OPERATION
DISC BRAKE UNIT-REPAIRS
REMOVAL
INSTALLATION
Lsi ivw C ACTUATOR ASSEMBLY
REMOVAL
INSTALLATION
MASTER CYLINDER
REMOVAL
INSTALLATION
CLEANING AND INSPECTION
DISASSEMBLY
ASSEMBLY
BRAKE PEDAL
REMOVAL
INSTALLATION
BLEEDING THE BRAKE SYSTEM
CHECKS AND ADJUSTMENTS
BRAKE PEDAL HEIGHT
BRAKE SWITCH
BRAKE PUSH ROD LENGTH
DISC BRAKE CLEARANCE
BRAKE PRESSURE
TROUBLESHOOTING
6 STEERING SYSTEM
GENERAL
DESCRIPTION
STEER PUMP & MOTOR ASSEMBLY-REPAIRS
REMOVAL
INSTALLATION
STEER PUMP
pr-ÿoVAL
INSTALLATION
STEER CONTROL VALVE
REMOVAL
INSTALLATION
HYDRAULIC MOTOR
REMOVAL
INSTALLATION
STEERING GEAR
REMOVAL .
INSTALLATION
STEER FORKASSEMBLY
REMOVAL
INSTALLATION
STEER WHEEL ASSEMBLY
REMOVAL
INSTALLATION
STEER POSITION POTENTIOMETER
REMOVAL
INSTALLATION
STEER POSITION POTENTIOMETER ADJUSTMENT
CHANGING STEER TIRES
STEERING PRESSUREADJUSTMENT
STEER PUMP MOTOR
BRUSH REMOVAL AND INSTALLATION
7 HYDRAULIC SYSTEM
GENERAL
DESCRIPTION
OPERATION
MULTI-FUNCTION CONTROL HANDLE
REPAIRS
LIFT PUMP & MOTOR / °
REMOVAL
INSTALLATION
LIFT PUMP
REMOVAL . ...... ....
INSTALLATION ... ..... .
LIFT PUMP MOTOR
BRUSH REMOVAL AND INSTALLATION
STEER PUMP & MOTOR ASSEMBLY
HYDRAULIC GEAR PUMPS
DESCRIPTION
FLOW CONTROL VALVE
RELIEF VALVE
REPAIRS
DISASSEMBLY
CLEANING
INSPECTION
ASSEMBLY
CHECKS .ND ADJUSTMENTS
CHECKING THE OUTPUT OF THE PUMP
CHECKING FOR AIR IN THE HYDRAULIC SYSTEM
SPECIFICATIONS .
HYDRAULIC VALVE CARTRIDGE
REMOVAL
INSTALLATION
PRESSURE RELIEF VALVE
REMOVAL
INSTALLATION
MANUAL LOWERING VALVE
REMOVAL
INSTALLATION
8 MAST
LIFT CHAINADJUSTMENT
SHEAVES
REMOVAL-FREE LIFT CYLINDER SHEAVES
INSTALLATION-FREE LIFT CYLINDER SHEAVES
REMOVAL-SECONDARY MAST SHEAVES
INSTALLATION-SECONDARY MASTSHEAVES
HYDRAULIC COMPÿ'ENTS
REMOVAL-MAIN HYDRAULIC MANIFOLD BLOCK
INSTALLATION-MAIN HYDRAULIC MANIFOLD BLOCK
REMOVAL-FREELIFT CYLINDER MANIFOLD BLOCK
INSTALLATION
REMOVAL-OPTIONAL AUXILIARY HOSE TAKE-UP
INSTALLATION-OPTIONAL AUXILIARY HOSE TAKE-UP
REMOVAL-STANDARD HOSEASSEMBLY
INSTALLATION-STANDARD HOSEASSEMBLY
TROUBLESHOOTING - LIFT CYLINDERS
TROUBLESHOOTING - MASTS
9 BATTERY AND CHARGING SYSTEMS
BATTERYAND CHARGING SYSTEM-GENERAL
SAFETY TIPS FOR HANDLING INDUSTRIAL TRUCK BATTERIES
BATTERY TROUBLESHOOTING
BATTERY TROUBLESHOOTING
LEAD-ACID BATTERIES
SPECIFIC GRAVIV
CHEMICAL REACTION
HOW TO SELECT THE BATTERY
VOLTAGE OFA BATTERY
BATTERY RATINGS
KILOWATT HOURS
THE BATTERYAS A COUNTERWEIGHT
THE NEW BATTERY
BATTERYMAINTENANCE
MAINTENANCE RECORDS
CLEANING THE BATTERY
ADDING WATER
HYDROMETER
BATTERY TEMPERATURE
CHARGING THE BATTERY
TYPES OF BATTERY CHARGES
METHODS OF CHARGING
TROUBLESHOOTING THE CHARGER
HOW 'O KNOW WHEN THE ATTERY IS FULLY CH, RGED
BATTERY CHARGING AREA
EQUIPMENT NEEDED
10 USER SUPPORT INFORMATION
11 ALPHABETICAL INDEX