Yale Electric Forklift Truck: ERC060HC, ERC070HC, ERC080HC, ERC100HC, ERC120HC Workshop Service Manual

SERVICE MAINTENANCE MANUAL For Model ERC 060-120 HC For Service & Parts—Contact Authorized Dealer Yale Materials Handling Corp 1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011 1520 ® August 1992

Yale Industrial Trucks MODEL NOMENCLATURE - POWER E — Electric - TYPE R — Sit Down Rider TIRES C — Cushion RATED CAPACITY 060 — 6,000 Lbs. 070 — 7,000 Lbs. 080 — 8,000 Lbs. 100 — 10,000 Lbs. 120 — 12,000 Lbs. _ SPECIAL DESIGNATION (As Assigned) - DESIGN SERIES A — B - C Etc. H N 8 - MAST OVERALL HEIGHT (In Inches) - MAST TYPE V—Simplex F — Duplex E — Triplex - CONTROL S — SCR - VOLTAGE 36 - 48 - MFG. SOURCE B

Yale Industrial Trucks USER SUPPORT INFORMATION Your investment in a YALE Industrial Truck is important to you and to your YALE Dealer. You measure the return on that investment through the performance of these trucks and the drivers who operate and the mechanics who service them safely and efficiently. The following information and programs are intended to help you to achieve your investment objectives: SERVICE PARTS ORDERING INSTRUCTIONS HOW TO ORDER SERVICE PARTS In order to avoid delay, unnecessary correspondence and to have your orders filled correctly, promptly and at the least possible expense, the following is the recommended procedure to use when ordering replacement parts. WHEN ORDERING PARTS Contact your authorized YALE Industrial Truck Dealer providing the following information: 1 . Your Purchase order number. 2. Complete invoicing and shipping address. 3. Specify the method of shipment, otherwise the least expensive method will be used. 4. Correct part number(s) and descriptionÿ). Use your parts manual as a reference. 5. Model and serial number of the truck. TECHNICAL SERVICE PUBLICATIONS SERVICE PARTS MANUAL- PART NO. 1519 To assist every user to effectively maintain YALE Industrial Trucks in a safe and useful condition, a service parts manual is furnished with each truck. The replacement parts identification supplements this service maintenance manual which provides proper service and overhaul procedures. OPERATOR'S MANUAL — 1515(5189768-09) To provide instructions for safety operating and servicing YALE industrial Trucks, each truck is equipped with an operator's manual. It describes various operating techniques and safety warnings to the operator. It contains a guide to safe maintenance practices and recommended schedules for maintenance. If the operator's manual is missing from any YALE Industrial Truck, it should be replaced. Replacement copies are available for a nominal fee from your YALE Dealer. OPERATOR TRAINING YALE "Basic Operator Training" program helps industrial truck users increase materials handling productivity and safety through proper lift truck operation training and motivation. The YALE program is based upon real life experience — not theoretical concepts. We developed a "complete" program that is totally self-contained — incorporating the most modern instructional techniques, including elements of self-study, audio¬ visual support (both video and slides), and classroom study. SERVICE TRAINING COURSES User and YALE Dealer service technicians can improve their technical ability for maintaining and repairing YALE Industrial Trucks and reduce down-time and cost by participating in YALE sponsored Service Training courses. A variety of mechanical, electric and electronic subjects are offered at published tuition rates. Courses are available at user and Dealer facilities in addition to regularly scheduled courses which are conducted at YALE Corporate Headquarters in Remington, New Jersey. SERVICE TRAINING MATERIAL Your own service training efforts are supported through a complete line of YALE Service Training materials. An Index is available from your YALE Dealer which lists textbooks, audio¬ visual programs, films and their cost, which will provide your Trainer with everything necessary to conduct service training for your organization. For additional information or assistance in obtaining these user support publications and programs, contact your YALE Dealer or the YALE Materials Handling Corporation, 15 Junction Road, Flemington, New Jersey 08822-9499. C

Yale Industrial Trucks A Accelerator 3-58 Attachments 10-1 B Battery System 8-1 Charger 8-8 Compartment 2-4 Connector 1-5 Covers 2-21 Daily Report 8-5 Discharge Indicator 1-4, 3-60 Hydrometer 8-6 Inspection 8-4 Removal 8-4 Safety 8-1 Troubleshooting 8-10 Bleeding Brakes 5-3 Brakes, Adjusting (Service, Parking & Motor) 5-1 Bleeding 5-3 Master Cylinder 5-6 Parking 5-9 Service 5-4 Troubleshooting . ..... 5-1 1 Brushes, Motor 3-64 C Capacity Plate 1-1 Cell, Battery 8-1 Charging System, Battery 8-7 Commutator, Motor 3-64 Console Covers 2-22 Contactors 3-53 Control Unit (EV-200LX) 3-2 Control Valve, Hydraulic .7-8 Counterweight 2-22 Cowl Cover 2-23 D Daily Checklist 1-7 Daily Report, Battery 8-5 Decals, Safety 1-3 Diodes 3-45 Directional Contactors 3-53 Discharge Indicator, Battery 3-60 Drive Motor 3-61 Drive System 4-1 Drive Unit 4-1 E Electrical System 3-1 MAINTENANCE MANUAL INDEX F Failure Status Codes 3-14 Floor Plate 2-22 Fork Removal 1-2 Function Codes 3-10 G Gear Adjustment 4-1 1 Gear Oils 2-8 Grease Sources 2-9 H Handset 3-6, 3-9 Horn Button Assembly 6-7 Hoist Pump Drive Motors 3-69 Hydraulic Oils, Approved Listing 2-11 Hydraulic System 7-1 Control Valves 7-5 Motor 3-68 Sound Level (Noise) 7-4 Pump 7-7 Relief Valve 7-4 Reservoir (Tank) 7-3 Specifications 7-1 Troubleshooting 7-1 2 Tubing 7-12 Hydrometer (Battery) 8-6 I Instrument Panel 3-60 Intermediate Housing 4-6 K Key Switch 1-4, 3-60 L Lift Cylinder * Lift System * Load Backrest 2-10 Load Forks 2-1 0 Lube Chart 2-2 Lubrication Instructions . 2-1 M Maintenance Schedule 2-1 Mast Assembly * Master Brake Cylinder 5-6 Motor Brushes . 3-64 Commutator 3-64 Drive 3-65 Failure, Causes 3-62 Inspection 3-62 Power Steering 3-71 Tests . 3-62 'Refer to Mainenance Manual 1523 for Maintenance Information on Mast Assembly. D

Yale MAINTENANCE MANUAL Industrial Trucks INDEX N Noise, Hydraulic System 7-1 O Oil Filter 7-3 Oils, Gear 2-8 Hydraulic 2-1 1 Operational Checks (Daily) 1-6 Operator Inspections 1-6 Operator's Manual C, 1-5 Operator's Seat 2-22 Operator Training C Overhead Guard 1-2, 2-21 P Parking Brake 1-4, 5-7 Parts Ordering : C Plugging 3-4 Power Steering Motor 3-71 , 6-3 Preventative Maintenance 2-4 Pump, Hydraulic 7-7 Motor 3-68 Troubleshooting 7-12 R Relief Valve, Hydraulic 7-4 Power Steer Pump 6-17 Reservoir (Tank), Hydraulic 7-3, 7-10 Ring Gear & Pinion Adjustment 4-1 1 S Speed Control Circuit 3-1 Steering 1-4, 6-1 Axle 6-2 Motor 3-69 Pump 6-16 System . 6-1 Unit 6-7 Wheel 1-4 Switch Key 1 -4, 3-60 T Tank, Hydraulic 7-3 Test Procedures, Battery 8-1 Discharge Indicator 1-4, 3-60 Motors 6-10 Power Steer Motor 6-9 EV-100LX Control 3-1 Tires, Mounting 4-2 Torque Value Charts 2-17, 2-20 Training Materials C Trail Axled & Steering System 6-1 Troubleshooting, Battery 8-10 Battery Discharge Indicator 3-60 Brakes 5-1 1 Drive Unit 4-14 Hydraulic Pump 7-12 Truck Controls 1-4 S SCR Unit, EV-200LX 3-1 Test Specifications 3-44 Safety Checks 1-7 Safety & Operational Checklist 1-47 Schematics 3-73 Serial Number 1-1 Service Brake 5-1 Pedal Adjustment 5-8 Service Training Information C Sideshifter 10-1 Storage Precautions 1-10 V Valves, Hydraulic Control 7-5, 7-8 Relief 7-4 Voltage Regulation Circuit 3-4 W Wheel Asembly 4-1 , 6-1 Brakes 5-4 Cylinder 5-4 Wiring Diagrams and Schematics 3-73 E

Yale Industrial Trucks This Maintenance Manual divided into ten (1 0) major sections which are listed at the right side of this page. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab. SECTIONS 1 OPERATING INSTRUCTIONS 2 GENERAL TRUCK & LUBRICATION SCHEDULE 3 ELECTRICAL SYSTEM 4 DRIVE UNIT 5 BRAKE SYSTEM 6 TRAIL AXLE & STEERING SYSTEM | 7 HYDRAULIC SYSTEM | 8 MAST | 9 BATTERY & CHARGING SYSTEM | 10 ATTACHMENTS |

Yale Industrial Trucks SECTION 1 OPERATING INSTRUCTIONS 1

Yale Industrial Trucks OPERATING INSTRUCTIONS TABLE OF CONTENTS DESCRIPTION PAGE NUMBER GENERAL 1-1 INTRODUCTION 1-2 OPERATOR PRECHECKS AND INSPECTION. 1-6 SAFETY AND OPERATIONAL CHECKLIST. 1-7 CAUTION TO THE OPERATOR 1-8 HINTS FOR SAFE MAINTENANCE 1-8 PRECAUTIONS FOR TRUCKS IN STORAGE 1-10 BATTERIES 1-10 HOW TO PUT A LIFT TRUCK ON BLOCKS 1-11 HOW TO RAISE THE DRIVE TIRES 1-11

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Yale Electric Forklift Truck: ERC060HC, ERC070HC, ERC080HC, ERC100HC, ERC120HC Workshop Service Manual

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