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Original Illustrated Factory Workshop Manual for Yale Forklift Truck Type A814. 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: ERC 030 AG ERC 030 BG ERC 040 AG ERC 040 BG Format: PDF, 415 Pages Language: English Contents: Section 1 SUPPORT INFORMATION SERVICE PARTS ORDERING INSTRUCTIONS How To Order Service Parts When Ordering Parts SPECIAL TOOLS TECHNICAL SERVICE PUBLICATIONS OPERATOR TRAINING DAILY OPERATOR CHECK-OFF LISTS SERVICE TRAINING COURSES SERVICE TRAINING MATERIALS Section 2 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST GENERAL LIFT TRUCK MAINTENANCE AND LUBRICATION SCHEDULE HOW TO PUT A LIFT TRUCK ON BLOCKS How To Raise The Drive Wheels How To Raise The Steer Wheels MAINTENANCE SCHEDULE CAPACITIES MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY HOW TO MAKE CHECKS WITH THE KEY "OFF" Tires And Wheels Forks Forks, Adjustment Forks, Removal Forks, Installation Inspection Of Forks, Mast, And Lift Chains Safety Labels Operator Restraint System Battery Restraint System Battery Hydraulic System HOW TO MAKE CHECKS WITH THE KEY "ON" Gauges, Horn and Fuses Steering System Service Brakes Parking Brake Control Levers And Pedals Lift System Operation EVERY 250 HOURS OR SIX WEEKS Lower Spindle Bearings Steering Tie Rods EVERY 500 HOURS OR THREE MONTHS .... Hydraulic Tank Breather Differential And Speed Reducer Wheel Bolts Or Nuts Steering Axle Spindles Mast Lift Chains, Check for Wear Forks Brake Fluid Other Lubrication Seat Brake Electrical Inspection Contactors Motor Brushes EVERY 1000 HOURS OR SIX MONTHS . Lift Chains, Lubrication Check Upper And Lower Bearings, Integral Side-shift Carriage Fork Pins And Guides EVERY 2000 HOURS OR YEARLY Wheel Bearings Change the Filter For The Hydraulic Oil ... Change The Hydraulic Oil Change The Oil In The Differential And Speed Reducer Service Brakes Service Brakes, Cleaning Lift Chains King Pins And Rod Ends (Steering Cylinders) Contactors Replace Upper And Lower Bearings, Integral Side-shift Carriage Other Lubrication GENERAL PROCEDURES HOW TO CHARGE THE BATTERY HOW TO CHANGE THE BATTERY BATTERY SPECIFICATIONS CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM Check the Lift Cylinders for Leaks MAXIMUM CARRIAGE AND TILT CREEP RATES Check the Tilt Cylinders for Leaks LIFT CHAIN ADJUSTMENTS HOW TO CHECK THE PMT CIRCUIT WELDING REPAIRS FRAME Battery Restraint And Hood Seat Brake And Seat Assembly Overhead Guard Counterweight HYDRAULIC TANK Inspection WHEELS AND TIRES General HOW TO CHANGE A SOLID RUBBER TIRE Remove The Wheels From The Lift Truck Remove And Install The Tire On The Wheel PAINTING INSTRUCTIONS LABEL INSTRUCTIONS HOW TO PUT AN ELECTRIC SIT DOWN RIDER TRUCK IN STORAGE HOW TO PUT BATTERIES IN STORAGE HOW TO MOVE A DISABLED LIFT TRUCK How To Tow The Lift Truck SPECIFICATIONS TORQUE SPECIFICATIONS TORQUE VALUES FOR INCH FASTENERS TORQUE VALUES FOR METRIC FASTENERS Section 3 ELECTRIC MOTOR MAINTENANCE GENERAL TRACTION MOTOR AND HYDRAULIC PUMP MOTOR Disassembly Assembly BRUSH AND COMMUTATOR INSPECTION Normal Commutator Surface Commutator Problems BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS BRUSH INSTALLATION, TRACTION AND HYDRAULIC MOTORS TESTS FOR A DAMAGED FIELD AND ARMATURE Test For An Open Circuit In The Armature Test For A Short-Circuit In An Armature Winding Test For A Short-Circuit In The Armature Test For An Open Circuit In A Field Coil Test For A Short-Circuit In A Field Coil Test For A Short-Circuit Between The Field And The Motor Case Brush Holder Test TRANSISTOR MOTOR CONTROLLERS (SR AND SP) DESCRIPTION Model Number Data For Transistor Motor Controllers (SR and SP) MOTOR CONTROLLER, CHECKS AND ADJUSTMENTS CHECKS AND ADJUSTMENTS USING A HAND SET General Connect Hand Set Check Or Delete Stored Status Codes Returning The Lift Truck To Normal Operation Checks And Adjustments On The Work Bench How To Check And Adjust The Registers ADJUSTMENTS - FUNCTION PARAMETERS General Function Numbers When The Hand Set Is Connected To A Motor Controller In The Lift Truck FUNCTION NUMBER DESCRIPTIONS TRACTION MOTOR CONTROLLER (LABEL LETTER - SR) FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY PUMP MOTOR CONTROLLER (LABEL LETTER - SP) FUNCTIONS WITH PREMIUM DISPLAY PANEL ONLY TROUBLESHOOTING - STATUS CODE CHARTS TROUBLESHOOTING General Status Codes SEM DISPLAY PANEL, GENERAL SEM DISPLAY PANEL FEATURES Descriptions Of Common Features Additional Features Of Premium Display Panel Descriptions Of Additional Features (Available With The Premium Display) SEM DISPLAY PANEL INDICATORS LCD "Screen" (Standard Display Panel) .. Battery State-Of-Charge (BDI) All Indicator Symbols Hourmeter Indicator Symbol Wrench Indicator Symbol Battery Indicator Symbol Brake Fluid Too Low Symbol Parking Brake Symbol Fasten Seat Belt Symbol ADDITIONAL COMPONENTS OF THE PREMIUM DISPLAY PANEL Alpha Numerical "Screen" "STAR" Push Button Push Buttons #1 Through #5 ADJUSTMENTS WITH A COMPUTER Computer System Connect A PC To The SEM Display Panel . . ITW SWITCHES SOFTWARE PROGRAM (For SEM Display Panel) Description Where To Get Help Hardware and Software Requirements. How To Start The ITW SWITCHES Program Menus Create A Setup File REPLACEMENT Removal And Replacement SR (SEM) AND SP TRANSISTOR MOTOR CONTROLLER, PARAMETER TABLES Function Numbers MOTOR CONTROLLER CHECKS AND ADJUSTMENTS PARAMETER TABLES REPAIRS GENERAL MAINTENANCE INSTRUCTIONS Special Precautions FUSES SEM DISPLAY PANEL REMOVAL Removal And Replacement REPLACE MOTOR CONTROLLER (SR or SP) CONTACTORS Contactor Repair CONTACTOR DRIVER MODULE Replace Contactor Driver MOTOR CONTROLLER PLUG BRUSH WEAR INDICATORS OTHER CONTROL COMPONENTS (INPUT DEVICES) Key Switch Start Switch Brake Light Switch Seat Switch Switch For Optional Seat Brake Parking Brake Switch Direction Control Switches Of Direction Control Lever Direction Switches Of Foot Direction Control Brake Fluid Switch Rocker Switches For Lights Position Sensor For Accelerator Or Foot Direction Control Pedal On-Demand Steering Components Lights And Reverse Alarm Horn And Horn Button Hydraulic Pump Switches Thermal Sensors Brush Wear Sensors REPLACE MOTOR CONTROLLER CHECKS AND ADJUSTMENTS Motor Controllers Control And Power Fuses Adjust The Start Switch Adjust The Brake Light Switch Check The Seat Switch Adjust The Switch For Optional Seat Brake Adjust The Parking Brake Switch Direction Switches (Steering Column) Direction Switches (Foot Direction Control Pedal) Hydraulic Pump Switches Adjust The Accelerator Or Foot Direction Control Pedal Adjust The Position Sensor For Accelerator Or Foot Direction Control Pedal THEORY OF OPERATION GENERAL DESCRIPTION of SEM SYSTEM OPERATION OF SEM SYSTEM (SR MOTOR CONTROLLER) Reverse Circuit Performance and Efficiency Field Weakening Regenerative Braking INTRODUCTION General Creep Speed Controlled Acceleration Current Limit BRAKING Regenerative Braking to Zero Speed. Pedal Position Braking Auto Braking AUXILIARY SPEED CONTROL Field Weakening Speed Limits RAMP OPERATION Ramp Start Anti-Rollback STEER PUMP CONTACTOR TIME DELAY COIL DRIVERS AND INTERNAL COIL SUPPRESSION SYSTEM PROTECTIVE OVERRIDE SRO (Static Return to Off) Accelerator Volts Hold Off Pulse Monitor Trip (PMT) Thermal Protector (TP) Low Voltage SP PUMP MOTOR CONTROLLERS CONTACTOR DRIVER MODULE DIAGNOSTICS Systems Diagnostics Standard Status Codes Stored Status Codes Hourmeter Readings Maintenance Management Capability ... Section 4 DRIVE UNIT ASSEMBLY DESCRIPTION REMOVAL AND DISASSEMBLY OF DRIVE UNIT Removing Complete Drive Unit Assembly As A Unit Removing Traction Motor Removing Drive Unit And Speed Reducer Assembly Disassembly Of Drive Axle Disassembly Of Differential And Speed Reducer CLEANING INSPECTION General Inspection Of Gears, Bearings And Splines ASSEMBLY OF DRIVE UNIT Find The Correct Shim Set For The Hypoid Gear Set Assembly And Installation Of Pinion Assembly And Installation Of Differential And Ring Gear Assembly Of Input Gear For Speed Reducer Assembly Of Drive Axle And Hub Assembly INSTALLATION OF DRIVE UNIT Installing The Drive Unit Installing Traction Motor TORQUE SPECIFICATIONS TROUBLESHOOTING GUIDE Section 5 BRAKE SYSTEM DESCRIPTION AND OPERATION Service Brakes Master Cylinder Parking Brake SERVICE BRAKES Removal And Disassembly Cleaning Inspection Assembly And Installation MASTER CYLINDER Removal Cleaning And Inspection Repair Installation REMOVAL AND DISASSEMBLY OF THE PARKING BRAKE ASSEMBLY AND INSTALLATION OF THE PARKING BRAKE REPLACING THE PARKING BRAKE SWITCH CHECKS AND ADJUSTMENTS Remove The Air From The Brake System Adjustments, Service Brakes Adjust The Brake Pedal Adjust The Master Cylinder Adjust The Parking Brake Adjust The Parking Brake Switch Test The "Parking Brake Not Applied" Warning System Adjust The Seat Brake TORQUE SPECIFICATIONS TROUBLESHOOTING GUIDE Section 6 STEERING AXLE ASSEMBLY, GENERAL DESCRIPTION STEERING AXLE ASSEMBLY Removal Installation WHEELS Removal and Disassembly Cleaning Inspection Assembly And Installation SPINDLES, BEARINGS AND LINKS Removal And Disassembly Cleaning Assembly And Installation STEERING CYLINDER Removal And Disassembly Cleaning and Inspection Assembly and Installation TORQUE SPECIFICATIONS TROUBLESHOOTING Section 7 POWER STEERING SYSTEM STEERING WHEEL AND COLUMN ASSEMBLY Removal Of Components Installation Of Components POWER STEERING MOTOR AND PUMP Removal And Disassembly Assembly And Installation STEERING CONTROL UNIT Description Removal Disassembly Cleaning Assembly Installation CHECKS AND ADJUSTMENTS Remove Air From The System Steering Relief Valve CHECK OPTICAL ENCODER AND ACTIVATOR CIRCUITS FOR "ON-DEMAND" STEERING TROUBLESHOOTING GUIDE Section 8 HYDRAULIC SYSTEM, GENERAL Description, Hydraulic System Operation, Hydraulic System Hydraulic (Lift) Pump Main Control Valve Lift Section Tilt Section Relief Valve REPAIRS, CONTROL LEVER LINKAGE Removal Disassembly Assembly And Installation REPAIRS, CONTROL VALVE LINKAGE Removal And Disassembly Assembly And Installation REPAIRS, MAIN CONTROL VALVE Removal Disassembly Cleaning And Inspection Assembly Installation REPAIRS, LIFT PUMP Removal New Seal Installation Installation REPAIRS, HYDRAULIC TANK Removal Inspection Repairs, Small Leaks Repairs, Large Leaks Cleaning Steam Method Of Cleaning Chemical Solution Method Of Cleaning. Additional Preparations For Repair Installation CHECKS AND ADJUSTMENTS Main Control Valve Primary Relief Valve Secondary Relief Valve SPECIFICATIONS TROUBLESHOOTING, HYDRAULIC SYSTEM TROUBLESHOOTING, MAIN CONTROL VALVE Section 9 MAST DESCRIPTION AND OPERATION Carriages Mast Mounts TWO-STAGE LIMITED FREE-LIFT MAST. Description And Operation TWO-STAGE FULL FREE-LIFT MAST Description Operation THREE-STAGE FULL FREE-LIFT MAST Yale IndustrialTrucks Description Operation CYLINDER CUSHION DURING LIFTING SEQUENCE CYLINDER CUSHION DURING LOWERING SEQUENCE MAST REPAIRS SAFETY PROCEDURES WHEN WORKING NEAR THE MAST FORKS Removal Installation CARRIAGES Removal, Standard Carriage Removal, Hang-On Side-Shift Carriage. Repairs Installation, Standard Carriage Installation, Hang-On Side-Shift Carriage Removal, Integral Side-Shift Carriage Cleaning and Inspection, Integral Side-Shift Carriage Repairs, Integral Side-Shift Carriage Installation, Integral Side-Shift Carriage MASTS Removal Disassembly Procedures For The Two-Stage Limited Free-Lift Or Two-Stage Full Free-Lift Mast Disassembly Procedures For The Three-Stage Full Free-Lift Mast Cleaning and Inspection Assembly Of The Two-Stage Limited Free-Lift And Two-Stage Full Free-Lift Mast Assembly Of The Three-Stage Full Free-Lift Mast Installation LIFT CYLINDERS Removal Of The Main Lift Cylinders Removal Of The Free-Lift Cylinder Disassembly Of A Lift Cylinder Assembly Of A Lift Cylinder Installation Of The Main Lift Cylinders Installation Of The Free-Lift Cylinder HEADER HOSE ARRANGEMENTS New Hose Installation, Two-Stage Limited Free-Lift Mast Adjustment Of Hoses After Installation, Two-Stage Limited Free-Lift Mast New Hose Installation, Two-Stage Full Free-Lift Mast Adjustment Of Hoses After Installation, Two-Stage Full Free-Lift Mast New Hose Installation, Three-Stage Full Free Lift Mast Adjustment Of Hoses After Installation, Three-Stage Full Free-Lift Mast TILT CYLINDERS Removal Disassembly Cleaning Assembly Installation CHECKS AND ADJUSTMENTS Check For Leaks In The Lift And Tilt System Check The Lift Cylinders For Leaks Check The Tilt Cylinders For Leaks Adjust The Tilt Cylinders Adjust The Lift Chains Adjust The Mast Adjust The Carriage TROUBLESHOOTING Section 10 BATTERY AND CHARGER SYSTEM, GENERAL LEAD-ACID BATTERIES SPECIFIC GRAVITY THE CHEMICAL REACTION IN A CELL ELECTRICAL TERMS HOW TO SELECT THE BATTERY VOLTAGE OF A BATTERY THE BATTERY AS A COUNTERWEIGHT BATTERY RATINGS Kilowatt-Hours BATTERY MAINTENANCE Safety Procedures Maintenance Records The New Battery How To Clean The Battery How To Add Water The Hydrometer Battery Temperature CHARGING THE BATTERY Types Of Battery Charges Methods Of Charging Troubleshooting The Charger How To Know When The Battery Is Fully Charged WHERE TO CHARGE THE BATTERIES Equipment Needed HOW TO CHANGE THE BATTERY BATTERY CONNECTOR BATTERY CARE