Yale ESC020AB, ESC025AB, ESC030AB Forklift A824 Service Repair Manual

S.N: A824
Yale Model: ESC020AB, ESC025AB, ESC030AB
1 OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS – GENERAL
SERIAL NUMBER
MODEL CODE
TRUCK WEIGHT
CAPACITY RATING
SAFETYAND INFORMATIONAL LABELS
OPERATOR PRE-CHECKS AND INSPECTION
SHUTDOWN PROCEDURE
OPERATING PROCEDURE – GENERAL
SAFETYAND OPERATIONAL CHECK LIST
OPERATING CONTROLS – CONTROL HANDLE
LOWER BUTTON
HORN BUTTON
LIFT BUTTON
DIRECTIONAND SPEED CONTROL
BRAKING
PARKING BRAKE
BATTERY CONNECTOR
BATTERY INDICATOR AND HOURMETER
FAST SPEED CONTROL
TILT CONTROL
STEERING
DESIGNATED OPERATOR POSITION
OPERATING PROCEDURES
SAFE MAINTENANCE PROCEDURES
MOVINGA DISABLED LIFT TRUCK
HOW TO PUTA LIFT TRUCK ON BLOCKS
HOW TO RAISE DRIVE TIRE
HOW TO RAISE LOAD WHEELS
PRECAUTIONS FOR TRUCKS IN STORAGE
PRECAUTIONS FOR BATTERIES IN STORAGE
2 GENERAL TRUCK AND LUBRICATION SCHEDULE
GENERAL
BATTERY – REMOVAL AND INSTALLATION
DRIVE UNIT COMPARTMENT COVER
REMOVAL AND INSTALLATION
FRAME SEPARATION
FRAMEASSEMBLY
TIRES AND WHEELS
LOAD WHEELS
CASTER WHEELS
SOLID TIRES
REMOVE TIRE FROM WHEEL
INSTALL THE TIRE ON WHEEL
YALE WARRANTY INFORMATION
LUBRICATION INSTRUCTIONS – MPC-AD
EVERY 8 HOURS
EVERY 350 HOURS
EVERY 2000 HOURS
LUBRICATION INSTRUCTIONS – MPC-LD
EVERY 350 HOURS
EVERY 2000 HOURS
LUBRICATION INSTRUCTIONS – MTR 700
EVERY 350 HOURS
EVERY 2000 HOURS
RECOMMENDED SCHEDULE OF MAINTENANCE
HYDRAULIC OILS
GEAR OILS
GREASE
FASTENERS – INTRODUCTION
THREADS, NOMENCLATURE
STRENGTH IDENTIFICATION
GENERAL GUIDE TO TORQUE VALUES
CONVERSION TABLE FOR METRICAND ENGLISH UNITS
3 ELECTRICAL SYSTEM
ELECTRICAL SYSTEM – GENERAL
ELECTRICAL SYSTEM – CHECKS
TRANSISTOR MOTOR CONTROLLER
GENERAL
CONTROL
PLUGGING
STATIC-RETURN-TO-OFF (SRO)
THERMAL PROTECTION
LOW VOLTAGE PROTECTION
CURRENT LIMIT
MOTOR CONTROLLER REPLACEMENT
TROUBLESHOOTING
FAULT PROCEDURES
ADJUSTMENTS
PLUGGING ADJUSTMENT
ACCELERATION ADJUSTMENT
CURRENT LIMITADJUSTMENT
ACCELERATOR POTENTIOMETER ADJUSTMENT
ELECTRONIC LOGIC MODULE (ELM)
GENERAL
ELM OPERATION
TESTING THE ELM
CONTACTORS
TESTING CONTACTORS
CONTACTOR REPLACEMENT
CONTACTOR COMPONENT REPLACEMENT
FUSES
BRAKE SWITCH
REMOVAL AND INSTALLATION
HEIGHT LIMIT SWITCH
STEERING HANDLE SWITCHES
REMOVAL
INSTALLATION
MOTOR MAINTENANCE – GENERAL
BRUSHAND COMMUTATOR INSPECTION
NORMAL COMMUTATOR SERVICE
COMMUTATOR PROBLEMS
BRUSH REPLACEMENT, DRIVEAND
HYDRAULIC MOTORS
DRIVE MOTOR – BRUSH REPLACEMENT
HYDRAULIC PUMP MOTOR – BRUSH REPLACEMENT
DRIVE MOTOR
REMOVAL
INSTALLATION
HYDRAULIC PUMP MOTOR
REMOVAL
INSTALLATION
DRIVEAND HYDRAULIC MOTORS
DISASSEMBLY
ASSEMBLY
COMMUTATOR REPAIRS
TESTS
DAMAGED FIELD AND ARMATURE
SHORT CIRCUIT INAN ARMATURE WINDING
SHORT CIRCUIT IN THE ARMATURE
OPEN CIRCUIT INA FIELD COIL
SHORT CIRCUIT INA FIELD COIL
SHORT CIRCUIT BETWEEN FIELD AND MOTOR CASE
BRUSH HOLDER
WIRING DIAGRAMS
MPC 60/80 AD (524 136016)
MPC 60/80 LD (524138833)
MTR-700 (524138756)
4 DRIVE UNIT
DRIVE UNIT – GENERAL
DRIVE MOTOR ASSEMBLY
UPPER HOUSING
LOWER HOUSING
DRIVE WHEEL
REMOVAL
INSTALLATION
UPPER HOUSING
REMOVAL
INSTALLATION
LOWER HOUSING
DISASSEMBLY
ASSEMBLY
DRIVE UNIT
REMOVAL
INSTALLATION
BEVEL PINIONAND GEAR ADJUSTMENT
TOOTH CONTACT PATTERN
5 BRAKE SYSTEM
BRAKE SYSTEM – GENERAL
BRAKE SHOE AND LINING ASSEMBLY
REMOVAL
INSTALLATION
BRAKE LINKAGE
REMOVAL
INSTALLATION
ADJUSTMENTS
BRAKEADJUSTMENT
BRAKE HANDLEADJUSTMENT
BRAKE SWITCHADJUSTMENT
6 STEER HANDLE
STEER HANDLE – GENERAL
STEER HANDLE HEAD
REMOVAL
INSTALLATION
STEER HANDLE
REMOVAL
INSTALLATION
STEER HANDLE – TOWER
REMOVAL
INSTALLATION
7 LIFT LINKAGE AND LOAD WHEEL
LIFT LINKAGE AND LOAD WHEELS – GENERAL
LOAD WHEELS
REMOVAL
INSTALLATION
LIFT LINKAGEAND LOAD WHEEL ASSEMBLY – MPC-AD
REMOVAL
INSTALLATION
LIFT LINKAGE AND LOAD WHEEL ASSEMBLY – MPC-LD
REMOVAL
INSTALLATION
PULL ROD – MPC-AD
REMOVAL
INSTALLATION
PULL ROD – MPC-LD
REMOVAL
INSTALLATION
ROCKER ARM – MPC-AD
REMOVAL
INSTALLATION
ROCKER ARM – MPC-LD
REMOVAL
INSTALLATION
UPPER LINK – MPC-AD
REMOVAL
INSTALLATION
UPPER LINK – MPC-LD
REMOVAL
INSTALLATION
ADJUSTMENTS – MPC-AD
FORK HEIGHT
ADJUSTMENTS – MPC-LD
FORK HEIGHT
CASTER WHEELS
REMOVAL
INSTALLATION
8 HYDRAULIC SYSTEM
HYDRAULIC SYSTEM – GENERAL
SYSTEM OPERATION
LIFTING A LOAD
LOWERING A LOAD
HYDRAULIC LINES
HYDRAULIC OIL
CLEANLINESS
SOUND LEVEL
HYDRAULIC UNIT
REMOVAL
INSTALLATION
HYDRAULIC PUMP
REMOVAL
INSTALLATION
HYDRAULIC PUMP RESERVOIR
REMOVAL
INSTALLATION
HYDRAULIC CYLINDER
REMOVAL
INSTALLATION
REPACKING
RELIEF VALVE ADJUSTMENT
TROUBLESHOOTING – LIFT ASSEMBLIES
TROUBLESHOOTING – HYDRAULIC CYLINDERS
TROUBLESHOOTING – HYDRAULIC PUMP
9 BATTERY AND CHARGING SYSTEM
BATTERYAND CHARGING SYSTEM-GENERAL
SAFETY TIPS FOR HANDLING INDUSTRIAL TRUCK BATTERIES
LEAD-ACID BATTERIES
SPECIFIC GRAVITY
CHEMICAL REACTION
HOW TO SELECT THE BATTERY
VOLTAGE OFA BATTERY
BATTERY RATINGS
KILOWATT HOURS
THE BATTERYAS A COUNTERWEIGHT
BATTERY MAINTENANCE
MAINTENANCE RECORDS
CLEANING THE BATTERY
ADDING WATER
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
BATTERY CHARGING AREA
EQUIPMENT NEEDED
TROUBLESHOOTING-BATTERY
10 USER SUPPORT INFORMATION
SERVICE PARTS ORDERING INSTRUCTIONS
TECHNICAL PUBLICATIONS
PARTS MANUALS
OPERATING MANUAL
OPERATOR TRAINING
SERVICE TRAINING COURSES
SERVICE TRAINING MATERIALS
11 ALPHABETICAL INDEX