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100% found this document useful (1 vote)
412 views406 pagesYale Erc RF-ZF
Uploaded by
Edinson Ospino BeleñoCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 406
Yale.
SERVICE MAINTENANCE MANUAL
For Models
ERC 040 - 065 RF/ZF
For Service & Parts-Contact
‘Authorized Dealer
Yale Materits Handing Corp. Publication ITD 1586
1400 Suan Di Yale Materials
Caller No. 1201 Handling Corporation
Greemie, NC 27884-2011 December 1994 Yale
Industrial Trucks
MODEL NOMENCLATURE
POWER
E- Electric
NOTE
‘The lift truck model and serial number are indicated
TYPE ‘on the Capacity Plate. The serial number is also
. stamped into the front crossmember of the frame to-
R- Sit Down Rider ward the right-hand sice.
TIRES
P— Pneumatic
C- Solid
RATED CAPACITY
(040 - 4000 Ib
(050 - 5000 Ib
(060 - 6000 Ib
(065 - 6500 Ib
‘SPECIAL DESIGNATION
(As Assigned)
DESIGN SERIES
A-B-C Etc,
rr
[e[R]c]o[4]o [RF [n/3 [6 [s[v]o[s]3]
ZIFl] | LI I
MAST OVERALL HEIGHT
(In Inches)
MAST TYPE
V Simplex
plex
~ilaex
CONTROL
S-SCR
MFG. SOURCE Industrial Trucks
SECTIONS
[1 [| GENERALINFORMATION
GENERAL LIFT TRUCK INFORMATION i
AND LUBRICATION SCHEDULE
DRIVE UNIT ASSEMBLY |
8
7 POWER STEERING SYSTEM
8 HYDRAULIC SYSTEM
MAST
| [=
a| [=
10 | BATTERY AND CHARGER SYSTEM
INDEX
‘This Workshop Manualis divided into 10 majorsections which are
listed on this page. Quick reference to these sections can be
‘made by placing the right thumb on the tab of the desired section,
bbending the book back and thumbing the pages to the
corresponding tab. SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
When lifting parts or assemblies, make sure that all
slings, chains or cables are correctly fastened and
thatthe load being ltedis balanced. Make sure that
the crane, cables and chains have the capacity to
Support the weight of the load.
Do not lift heavy parts by hand. Use a lifting
‘mechanism.
Wear safety glasses.
DISCONNECT THE BATTERY CONNECTOR
before doing any maintenance or repair on electric
lift trucks.
‘Always use correct blocks to prevent the unit from
rolling or falting. See “How To Put The Lift Truck On.
Blocks" in the OPERATOR'S MANUAL or
SECTION 2, GENERAL LIFT TRUCK
INFORMATION AND LUBRICATIONSCHEDULE.
Keep the unit and working area clean and in order.
Use the correct tools for the job.
Keep the tools clean and in good condition.
Always use YALE APPROVED parts when
making repairs. Replacement parts must meet or
exceed the specifications of the original equipment
manufacturer.
Make sure that all nuts, bolts, snap rings and other
fastening devices are removed before using forceto
remove parts.
‘Always fasten a DO NOT OPERATE sign to the
controls of the unit when making repairs or ithe unit
needs repairs.
‘Make sure you follow the DANGER, WARNING and
CAUTION notes in the instructions.
Wear a rubber apron, gloves, boots, and goggles or
‘face shield when doing maintenance on batteries.
Batteries generate hydrogen gas when they are
being charged. Keeps open fire away from
batteries. Do not check the electrolyte level with a
‘match or a lighter. No smoking and do not create
‘sparks. Make sure the area has ventilation.
Lift batteries correctly with a crane or equipment
designed for the job. Always use a spreader bar
Industrial Trucks
designed and and adjusted for the battery. Move
batteries with a lift truck or a conveyor or rollers
designed for that purpose. If the battery does not
have a cover, a rubber mat or insulating material
must be put over the top of the battery to prevent a
short-circuit with other equipment. Make the the
lifting equipment has enough capacity for the job.
Do not use chain or wire rope slings.
'* Never put metal materials or tools on a battery.
‘* Disconnect the battery from the lift truck before
doing maintenance or repairs.
© When maintenance on the battery or the battery
charger is required, disconnect both the AC and DC.
ower. If the battery connectors must be replaced,
make sure the positive and negative terminals and
cables are kept separate and insulated from each
other. Even a momentary short-circuit can cause
an explosion and damage the battery.
* Keep water readily available to flush spilled
electrolyte. Electrolyte in the eyes must be flushed
with waterimmediately and then quickly get medical
attention. Special showers and eye wash systems
are required in areas where battery maintenance is
done.
© Hfelectrolyte is spilled on a work surface or the floor,
flush the area with water, use a solution of soda
(Sodium bicarbonate) to make the acid neutral.
* Only trained persons are permitted to do
‘maintenance on batteries and battery chargers.
Make sure that the regulations by govemment
safety agencies, govemment insurers, private
insurers, and private organizations are followed
when doing maintenance on batteries.
NOTE: The following symbols and words indicate
safety information in this manual:
& DANGER
Indicates a condition that will cause Immediate
death or injury!
& warning
Indicates a condition that can cause death or injury!
A caution
Indicates a condition that can cause property dam-
age! Industrial Trucks
CONTENTS
Section 1 Hydraulic Tank Breather .. 245
SUPPORT INFORMATION 4 Differential And Speed Reducer . 215
SERVICE PARTS ORDERING eee eee
INSTRUCTIONS . 11 Steering Ade Spindles . 246
How To Order Service Parts. re Mast “ 2-46
When Ordering Pats 1 Lift Chains, Check for Wear . 2416
SPECIAL TOOLS .........-- Lot 247
TECHNICAL SERVICE PUBLICATIONS ..... 1-1 247
OPERATOR TRAINING : . ott 247
DAILY OPERATOR CHECK-OFF LISTS .... 1-1 247
‘SERVICE TRAINING COURSES inal 27
SERVICE TRAININGMATERIALS . 141 pices Crushes! 2-18
EVERY 2000 HOURS OR YEARLY ......... 2-21
GENERAL LirtTavoy uanTENANCe AND ea tol ae
LUBRICATION SCHEDULE a4 Change the Fr For The Hyrule OH. 2-2
HOW TOPUT ALIFTTRUCK ON BLOCKS . 2-1 eee ees aa
Change The Oil In The Differential And
How To Raise The Drive Wheels ... a4 Speed Reducer -
How To Raise The Steer Wheels . 22 Sane oe
MAINTENANCE SCHEDULE . 238 Service Brakes, Cleaning ..
EVERY 8 HOURS OR DAILY 240 LitChains
HOW TO MAKE CHECKS WITH Contactors sess veseee-
THE KEY SWITCH “OFF” . 2-10 GENERALPROCEDURES ............:. 2-28
ote ‘System... orig HOWTO CHARGE THE BATTERY. 2-23
pale : oto BATTERY SPECIFICATIONS . 2-24
Forte, Adjustment 2-19 _ HOWTOCHANGE THE BATTERY... 2-24
eee 2-11 QHECKFORLEAKS INTHE LIFT AND Tt
eens ant Check the Lit Cyinders for Leaks «...... 2-26
Inspection Of Fors, Mast, And Lit Chains 2-11
ae 2 ‘Check the Tit Cylinders for Leaks 2-26
carne aaran Saal peg METCHAIN ADJUSTMENTS ....... 2-26
Battery Restraint System... 211g HOWTOCHECK THE PMT CIRCUIT . 227
Safety Labels ns 2-13 WELDING REPAIRS 227
HOW TO MAKE CHECKS WITH THE KEY SWITCH La 2-27
‘On’. 244 Battory Restraint And Hood ........ 2-28
Gauges, Hom and Fuses . 2-14 Seat Brake And Seat Assembly... 2-28
Control Levers And Pedals 244 Overhead Guard oes eesecseseevees | 229
Lift System Operation 244 Changes To The Overhead Guard - 2-29
Service Brakes. 245 Removal ceeseeseesee 2229
Parking Brake . 245 Counterweight . 2-29
Steering System vo BAS Removal . 2-80
EVERY 350 HOURSOR TWO MONTHS... 2-15 Installation 2-31 HYDRAULIC TANK 2-31
Inspection .......+.+ : 2-31
WHEELS AND TIRES «0.020. -.-.-s-se0e 2-31
How To Change A Solid Rubber Tire
(Press-on) 2-32
Install The Steer Wheels. 2-32
Install The Drive Wheels. 2-32
PAINTING INSTRUCTIONS 2-32
LABEL INSTRUCTIONS ........- 2-33
HOW TO PUT AN ELECTRIC SIT DOWN RIDER
‘TRUCK IN STORAGE . 2-35
HOW TO PUT BATTERIES INSTORAGE 2-35
HOWTO MOVE ADISABLEDLIFT TRUCK . 2-35
How To Tow The Lift Truck. 2-96
‘SPECIFICATIONS .. 2-36
‘TORQUE SPECIFICATIONS 2-37
‘TORQUE VALUES FOR INCH FASTENERS. 2-38
‘TORQUE VALUES FOR METRIC
FASTENERS ... . 289
Section 3
ELECTRIC MOTOR MAINTENANCE,
GENERAL . a4
TRACTION MOTOR ANO HYDRAULIC PUMP
MOTOR....... : 34
Disassembly .. aH
Assembly . oe aH
BRUSH AND COMMUTATORINSPECTION. 9-3
‘Normal Commutator Surface .
Commutator Problems...
BRUSH ALIGNMENT, TRACTION
‘AND HYDRAULIC MOTORS . 35
BRUSH INSTALLATION, TRACTION
‘AND HYDRAULIC MOTORS . 36
TESTS FOR A DAMAGED FIELD
AND ARMATURE 39
Test For An Open Circuit n The Armature 9-9
Test For A Short-Circuit In An Armature
Winding 3-9
Test For An Shot-Cicut nThe Armature 9-9
Test For An Open Circuit In A Field Coil 3-8
Test For A Short-Circuit nA Field Coil... 3-10
Test For A Short-Circuit Between The Field
‘And The Motor Case .. 3-10
Brush Holder Test 310
EV-1002X SCR MOTOR CONTROLLER... 9-11
Yale
Industrial Trucks
Model Number Data For EV-100ZX
Controller wees att
REGISTER PARAMETERS. 3418
General .. aoe cee 318
Function Numbers .. : - 318
CONTROL CARD, CHECKS
AND ADJUSTMENTS - 348
COMPUTER SYSTEM 3419
When A PC Is Connected To A Control
(Care Seen enema 2-20)
icin peneeeeneneeesercennears 3-29
‘Communications Program (MODEM) .... 3-30
Monitor Program . 3-31
HAND SET . 3-33
How To Check And Adjust The Registers . 3-83
How To Scroll Through The Fault Codes
‘And Clear Them .. 3-34
Checks And Adjustments On The
Work Bench ...... - 3-34
When The Hand Set Is Connected To A
Control Card installed In A Lift Truck 3-35
FUNCTION NUMBER DESCRIPTIONS . 3-36
Traction Control Cards
(Label letters - ZH And ZY) .. 3-37
Pump Control Card (Label Letter ZP) .... 3-42
REGISTER PARAMETERS.........2....26. 3-45
TROUBLESHOOTING + 3-57
‘Status Codes 3-58
REGISTER MAPS... 3-58
STANDARD DISPLAY PANEL .. 3-68
PERFORMANCE DISPLAY PANEL......... 3-70
STATUS CODE CHARTS .......-.000005. 3-73,
REPAIRS . 3-113
Fuses ......... a4
‘Check An SCR 315
Replace An SCR .. a5
The SCR 1 Assembly - 35
‘Thermal Protector . 3-115
Install A New SCR 1 Assembly . 316
‘THE “OFF” CIRCUIT FOR SCR 1 a6
‘Check The Reactor Assembly ... a6
‘Check Suppressors For SCR 2
And SCRS5 3116
Check SCR 2 And SCR 5 Si7
Replace SCR 2 And SCR . S17 Industrial Trucks
‘Check Capacitor C1
Check Diodes D3 And D4
Replace Diodes D3 and D4 .
Motor Current Sensor ..
CONTACTORS ......
Contactor Repair
CONTROL CARD
Control Card Plugs .
OTHER CONTROL COMPONENTS
(INPUT DEVICES) . =
Key Switch .
Start Switch
‘Seat Switch .
‘Switch For Optional Seat Brake .
Parking Brake Switch .
Direction Control Switches .
Brake Fluid Switch . .
Motor Temperature Switches ......
Rocker Switches For Lights .
‘Accelerator Position Sensor :
(On-Demand Steering Components
Hom And Hom Button.
Hydraulic Pump Switches
Replace A Display Panel .
Brush Wear Indicators .
CHECKS AND ADJUSTMENTS.
Control Card .
Adjustment Of Gris Meter In The Rega
Display Panel .
Contol And Power Fuses
Adjust The Start Switch ..
‘Adjusting Brake Light Switch
‘Check The Seat Switch .
‘Adjust The Switch For Optional Seat Brake
‘Adjust The Parking Brake Switch
Direction Switches .......
Hydraulic Pump Switches
‘Adjust The Accelerator Pedal .
‘Adjust The Accelerator Position Sensor
THEORY OF OPERATION ...
ELECTRONIC SPEED CONTROLS
‘The Silicon Controlled Rectifier (SCR)
3-417
. en7
S17
3-118
3-118
3-119
- 3-120
3-120
. 312
3-122
3-122
3-123
3-124
3-124
3125
3-125
3-125
3-125
ces B27
- 3127
- 3-129
3-130
3-131
3-132
3-133
3-134
3-134
3-134
3-134
3-135
3-136
3-136
3-136
3137
3137
34137
34137
3137
3-139
3-139
3-139
A.Motor Circuit That Operates
With Pulses
Traction Circuit .
Hydraulic Pump Motor.
The SCR 1 “OFF Circuit .
INDUCTION CURRENT FROM
‘THE MOTOR
Pulse Monitor Trip (PMT)
(Traction Circuit Only) .
‘SRO Circuit (Traction Circuit Only). .
Control Card Adjustments
(Traction Circuit) . :
‘Accelerator Control .
SCR CONTROL
(HYDRAULIC PUMP MOTOR)
CONTACTORS
CIRCUIT PROTECTION
‘Traction Circuit Fuse
Current Limit .
‘Thermal Protection ..
‘SEQUENCE OF OPERATION
INPUT AND OUTPUT DEVICES FOR
‘THE MOTOR CONTROLLERS ......
Display Panels (Output Device)
Regular Display Panel
Performance Display Panel ..
OTHER CONTROL COMPONENTS ..
SCHEMATICS ...... :
Section 4
DRIVE UNIT ASSEMBLY, GENERAL
DESCRIPTION ...
DRIVE UNIT ASSEMBLY, REMOVAL
‘Traction Motor, Removal
‘Traction Motor, Installation
Drive Axle And Speed Reducer Assomby,
Removal .
Drive Axle, Disassembly.
‘Speed Reducer and Differential,
Disassembly ....
CLEANING ...
INSPECTION .......
SPEED REDUCER AND DIFFERENTIAL
Input Gear Assembly, installation ...
3-140
3-143
3-143
3-143
- 3143,
3145
3147
. 3147
3-148
3-150
3-157
ot
A
ptt
ffser rss DIFFERENTIAL,
‘ASSEMBLY AND INSTALLATION
Installation Of The Pinion Assembly
‘Assemble The Differential And Ring Gear
Drive Axle, Assembly ..
DRIVE AXLE ASSEMBLY, INSTALLATION
TORQUE SPECIFICATIONS ... .
TROUBLESHOOTING ....
Section 5
BRAKE SYSTEM, GENERAL ..
DESCRIPTION AND OPERATION ......
Service Brakes ea
Master Cylinder
Parking Brake .
REMOVAL AND DISASSEMBLY OF THE
SERVICE BRAKES ........
CLEANING .
INSPECTION...
[ASSEMBLY AND INSTALLATION OF
‘THE SERVICE BRAKES .
REMOVAL AND DISASSEMBLY OF THE
PARKING BRAKE .....
ASSEMBLY AND INSTALLATION OF
THE PARKING BRAKE
MASTER CYLINDER ..
Removal .
Cleaning And inspection
Repair ......
Installation
CHECKS AND ADJUSTMENTS...
Remove The Air From The Brake System
‘Adjustments, Service Brakes .
Adjustment, Brake Pedal ..
‘Adjustment, Master Cylinder .
‘Adjustments, Parking Brake
Test The “Perkng Brake Not Applied”
Waming
Adjustments, Seat Brake...
TORQUE SPECIFICATIONS ........
‘TROUBLESHOOTING .
‘Section 6
‘STEERING AXLE ASSEMBLY, GENERAL ...
46
48
413
413
415
415
5-9
5-10
5-10
5-12
512
512
512
5-12
513
5-13
5-13
5-14
514
514
5-16
5-16
4
Industrial Trucks
DESCRIPTION . ot
‘STEERING AXLE ASSEMBLY 4
Removal e1
Installation 62
WHEELS... poeeereeee a C-2)
Removal and Disassembly 6-2
Cleaning ..... we 68
‘Assembly And installation ...... 68
SPINDLES, BEARINGS AND TIE RODS. 63
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, GENERAL... 7-1
‘STEERING WHEEL AND COLUMN
ASSEMBLY . 7-2
Removal OfThe Assembly Components. 7-2
Installation Of The Assembly Components 7-2
POWER STEERING MOTOR AND PUMP 7-4
Removal And Disassembly ............. 7-4
‘Assembly And Installation 7-6
STEERING CONTROL UNIT ad
Description . 7
Removal 8
Disassembly . 79
Cleaning . mH
‘Assembly . 71
Installation ..... 714
CHECKS AND ADJUSTMENTS ... TAS
Remove Air From The System TAS
Steering Relief Valve 715
‘CHECK OPTICAL ENCODER AND ACTIVATOR
CIRCUITS FOR “ON-DEMAND” STEERING 7-15
‘TROUBLESHOOTING ....... TAT Yale.
Section 8
HYDRAULIC SYSTEM, GENERAL ....
Description, Hydraulic System
Operation, Hydraulic System
Hydraulic (Lit) Pump .
Main Control Valve
Litt Section .....
Tilt Section
Roliet Valve .
REPAIRS, CONTROL LEVER LINKAGE
Removal .........eceeeeeeeeee
Disassembly ..
‘Assembly And Installation ... .
REPAIRS, CONTROL VALVE LINKAGE ....
Removal And Disassembly ..
‘Assembly And Installation ...
REPAIRS, MAIN CONTROL VALVE
Removal .
Disassembly :
‘Cleaning And Inspection ....
REPAIRS, LIFT PUMP cere
Removal .
New Seal Installation
Installation ...........
REPAIRS, HYDRAULIC TANK ....
Removal .
Inspection :
Repairs, Small Leaks
Repairs, Large Leaks
Cleaning .
Steam Method OF Clearing -
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 ......... 22-20-2000
a4
a4
84
8-3
8-3
8-5
8-5
8-6
8-7
8-7
8-8
8-9
a9
8-9
a9
810
810
en
a2
a2
a1
B13
e413
e413
B15
8416
e416
B16
816
e416
B46
817
817
847
8-18
818
8-418
8-18
8-19
8-20
8-21
‘TROUBLESHOOTING,
MAIN CONTROL VALVE...
Section 9
DESCRIPTION AND OPERATION .....
Carriages
Mast Mounts .
SIMPLEX MAST .
Desciiption And Operation
DUPLEX MAST ...
Description
TRIPLEX MAST
Description
Operation ....
QUADPLEX MAST
Description
‘SAFETY PROCEDURES WHEN WORKING
NEAR THE MAST
REPAIRS ....
FORKS ...
Removal
Installation
CARRIAGES .....
Removal, Standard Carriage
Removal, Side-shift Carriage .
Repairs zs -
Installation, Standard Carriage os
Installation, Side-Shift Carriage ......
MASTS
Removal
Disassembly Procedures For The sine
(Or Duplex Mast
Disassembly Procedures For The
Triplex Mast
Disassembly Procedures For The
‘Quadplex Mast .
Cleaning and inspection . .
Assembly Of The Simplex
‘And Duplex Mast .
‘Assembly Of The Triplex. .
Assembly Of The Quadplex
‘Mast Installation . .
8-22
oH
oH
ot
2
fesrree
a7
7
9-10
on
on
on
ot
on
on
o42
a2
413
13
a4
4
O45
417
o-19
9-22
9-24
9-25 LIFT CYLINDERS . 9-26
Removal Of The Main Lit Cylinders ..... 9-26
Removal Of The Free-Lift Cylinder 9-26
Disassembly OF A Lift Cylinder .. 9-26
Assembly Of A Lift Cylinder .
Inetallation Of The Main Lit Cylinders
Installation Of The Free-Lift Cylinder
TILT CYLINDERS
Removal
Disassembly
Cleaning . ween
Assembly
Installation .
HOSE TAKE UP ARRANGEMENTS .
‘New Hose Installation, Simplex Mast.
Adjustment Of Hoses After Installation,
Simplex Mast .
New Hose Installation, Duplex
‘Adjustment Of Hoses After Installation,
Duplex ....
New Hose Installation, Triplex .
Adjustment Of Hoses After installation.
Triplex...
Hose Take Up installation, Quadplex
CHECKS AND ADJUSTMENTS ......
CHECK FOR LEAKS IN THE LIFT AND TILT
SYSTEM.
CCheck The Lit Gyinders For Leaks ......
Check The Tilt Cylinders For Leakage ....
ADJUST THE TILT CYLINDERS ...
ADJUST THE LIFT CHAINS ...........-.
‘ADJUST THE MAST
‘ADJUST THE CARRIAGE .
931
9-31
Sifts nf; £2 88h geekee
51
51
ge
Industrial Trucks
‘TROUBLESHOOTING ...
Section 10
BATTERY AND CHARGER * SYSTEM,
GENERAL
LEAD-ACID BATTERIES
SPECIFICGRAVITY .....
‘THE CHEMICAL REACTION INA 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
HowTo Know When The Batlory ts
Fully Charged ..
WHERE TO CHARGE THE BATTERIES ....
Equipment Needed .
BATTERY CONNECTOR .
BATTERY CARE ...
9-53
10-1
10-1
10-1
10-2
10-3 [1 | GENERAL INFORMATION Industrial Trucks
CONTENTS,
SUPPORT INFORMATION .............-. . 4
SERVICE PARTS ORDERING INSTRUCTIONS
How To Order Service Parts .
When Ordering Parts ...
SPECIAL TOOLS ........-... :
TECHNICAL SERVICE PUBLICATIONS ....
OPERATOR TRAINING ...........
DAILY OPERATOR CHECK-OFF LISTS : oe
SERVICE TRAINING COURSES ............. TA
SERVICE TRAINING MATERIALS Industrial Trucks
‘SUPPORT INFORMATION
Your new Yale industrial Truckis important to you and to
your dealer for Yalelifttrucks. Youmieasure the retum on.
‘the investmentin yourlifttruckthrough the performance
of those lift trucks, the drivers who operate them and the
‘mechanics who service them safely and efficiently. The
{following information and programmes are made tohelp
fill your needs:
‘SERVICE PARTS ORDERING
INSTRUCTIONS
How To Order Service Parts
In order to prevent delay, and to have your orders filled
correctly, quickly and at the lowest cost, do the following
procedure to order realacement parts.
‘When Ordering Parts
Your authorized dealer for Yale lift trucks needs the fol-
lowing information:
1. Your Purchase Order number.
2. Complete addresses for sending the invoice and
parts.
3. Tellus how youwant your parts sent. we donot
{get this information, we will send the parts using
the lowest priced method.
4. Correct part numbers and descriptions. Use
your parts manual as a reference.
5. Model and serial number of the truck.
‘SPECIAL TOOLS
Yale makes a variety of special tools for servicing lift
trucks. They are available to users who do their own
maintenance. Your dealer for Yale lift trucks is ready to
help.
TECHNICAL SERVICE PUBLICATIONS
‘Tohelp you maintain your Yale Industrial Trucks in good
condition, additional service literature with more de-
tailed information is available. Included are Service
Parts Manuals with complete replacement parts ident-
fication and Service Maintenance Manuals which de-
sctibe service and overhaul procedures. Additional co-
pies of the Operator's Manual can also be obtained
from your dealer for Yale lft trucks.
GENERAL INFORMATION
OPERATOR TRAINING
‘The Yale “Basic Operator Training” program helps in-
dustrial truck users increase their materials handling
production and safety through correct lft tuck opera-
‘ion, training and motivation. The Yale program is based
‘upon real fe experience - not theoretical concepts. We
developed a ‘complete program tats totaly salt con-
incorporating the most modem instructional
tecigues, including elements of self-study, audio-
visual support (both video and slides), and classroom
study.
DAILY OPERATOR CHECK-OFF LISTS
According to OSHA requirements, lft truck operators
‘must examine their industrial trucks betore each shift of
‘operation. The OPERATOR'S DAILY CHECK LIST can
help operators comply with these OSHA regulations and
ive a fast easy inspection system that can be com-
pleted efficiently. A sample of the OPERATOR'S DAILY
CHECK LIST is shown on the following page.
SERVICE TRAINING COURSES:
Operators and Yale lift truck dealer service technicians
ccan improve their technical ability for maintaining and
repairing Yale Industrial Trucks and decrease repair
time and cost by taking the Yale Service Training
‘courses. Different types of mechanical, electric and
electronic subjects are available. Courses are available
atcustomer and Dealer locations in addition o regularly
scheduled courses which are held at Yale Corporate
Headquarters in Flemington, New Jersey.
SERVICE TRAINING MATERIALS
Your own service training is supported through a com-
plete ine of Yale Service Training materials. An index is
available from your dealer for Yale lift trucks which lists
‘textbooks, audio-visual programs and films. These ma-
terials will provide your Trainer with everything neces-
sary for training your group.
For additional information or help in getting these opera-
{or support publications and programs, see your dealer
{or Yale lft trucks or the.
Yale Materials Handling Corporation
15 Junction Road
Flemington, New Jersey 08822-9499 GENERAL INFORMATION
Industrial Trucks
Yale Electric Truck
Operator’s Daily Check List
Industrial Trucks
Record of Fluld Added
Date Operator Battery Water
Truck Number Mode! Number Hyérautic Oi!
Department Serial Number
shit rive Hour Holst Hour
Meter Reading ___________ Meter Reading
SAFETY AND OPERATIONAL CHECKS (Prior to each shift)
Have a qualified mechanic correct all problems.
‘OK. (-) | Need Maintenance
Leaks — Hydraulic Oil Battery
“Tires — Condition and Pressure
Forks, Top Clip Retaining Pin and Heel — Condition
Load Backrest Extension — Attached
‘Hydraulic Hoses. Mast Chains & Stops — Check Visually
r Guards — Attached.
‘Overhead Guard — Attached
Safety Warnings — Attached (Refer to Paris Manual For Location)
internal Checks:
Battery — Water/Electrolyte Level and Charge
draulic Fluid Level — Dipstick
Transmission Fiuid Level — Dipstick
‘Operator's Com; if
Operator's Manual In Container
‘Capacity Plate Attached — Information matches model, serial
number_and attachments
Battery Restraint System — Adjust and fasten.
‘Seat Balt, Buckle and Retractors — Functioning smoothh
Brake Fluid — Check Level
n Truck On) Unusual Noises Must Bo
immediately:
Accelerator Linkage — Functioning smoothly
Parking Brake — Functioning smoothly
‘Service Brake — Functioning smoothl
‘Steering Operation — Functioning smooth i
Drive Control — Forward/Reverse — Functioning smoothly
Tit Control — Forward and Back — Functioning emoothiy
Hoist and Lowering Control — Functioning smoothly.
‘Attachment Control — Operation
Hom — Functioning
[Lights — Functioning
Gauges:
Hour Meter — Functioning
Battery Discharge Indicator — Functioning
instrument Monitors — Functioning
NOTE: This daily check ist is available for the operator. Some items on this list may not be applicable to your truck. This
‘convenient checklists in tablet form and can be ordered through your dealer for Yale lift trucks. Form Number
944-6418-A,
roa 100 Yani Crrson Yo tte Ont Tanna Pope
1-2 Industrial Trucks
2 GENERAL LIFT TRUCK INFORMATION
AND LUBRICATION SCHEDULE CONTENTS
GENERAL LIFT TRUCK MAINTENANCE AND
LUBRICATION SCHEDULE .......2..-...202202002000+
HOW TO PUT A LIFT TRUCK ON BLOCKS
How To Raise The Drive Wheels... .
How To Raise The Steer Wheels ..
MAINTENANCE SCHEDULE
EVERY 8 HOURS OR DAILY .........
HOW TO MAKE CHECKS WITH THE KEY SWITCH "OFF"...
Hydraulic System .
Forks eee
Forks, Adjustment .
Forks, Removal
Forks, Installation .
Inspection Of Forks, Mast, ‘And Lit Chains -
Tires And Wheels .........-.
Operator Restraint System .
Battery Restraint System
Safety Labels -
HOW TO MAKE CHECKS WITH THE KEY SWITCH ON".
Gauges, Horn and Fuses .
Control Levers And Pedals
Lift System Operation
Service Brakes
Parking Brake ..
Steering System ....
EVERY 350 HOURS OR TWO. MONTHS.
Hydraulic Tank Breather cree
Ditlerential And Speed Reducer
Wheel Nuts .......-..-
Steering Axle Spindles
Lift Chains, Check for Wear
Industrial Trucks
2-10
2-10
2-10
2-10
2-10
210
an
ant
ant
2-12
2413
2-13
213
214
214
2-14
214
215
215
215
215
215
215
2-16
2-16
216
2-16
217
247
217
2417
27
2-18 Industrial Trucks
EVERY 2000 HOURS OR YEARLY
Wheel Bearings
Change the Fiter For The Hycraulc Oi
‘Change the Hydraulic Oil
Change The Oil In The Diferental And Speed Reducer
Service Brakes -
Service Brakes, Cleaning .
Lift Chains ....
Contactors .......
GENERAL PROCEDURES
HOW TO CHARGE THE BATTERY...
BATTERY SPECIFICATIONS ..
HOW TO CHANGE THE BATTERY ......
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
Check the Lift Cylinders for Leaks
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 ; -
Changes To The Overhead Guard
Counterweight
HYDRAULIC TANK
Inspection ....
WHEELS AND TIRES -
How To Change A Solid Rubber Tie (Presson)
Install The Steer Wheels
Install The Drive Wheels
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
2-21
221
2-27
2-31 Industrial Trucks
GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
This section contains a MAINTENANCE SCHEDULE
and the instructions for maintenance and inspection.
This section also describes the removal and installation
of the overhead guard, counterweight and the battery.
‘The service intervals are given in both operating hours
recorded on the lift truck hour meter, and in calendar
time. Use the interval that occurs first. The recommen-
dation for he time intervals is for eight hours of operation
per day. The time intervals must be decreased from the
recommendations in the MAINTENANCE SCHEDULE
for the following conditions:
‘a. Ifthe lift truck is used more than eight hours per
day.
b. Ifthe lift truck must workin dirty operating condi-
tions.
‘Your dealer for YALE lift trucks has the facilities and
trained personnel to do the maintenance. A complete
[program of inspection, lubrication, and maintenance will
help your lift truck perform efficiently and operate over a
longer period of time.
Some users have service personnel to do the items
listed in the MAINTENANCE SCHEDULE. SERVICE
MAINTENANCE MANUALS are available from your
dealer for YALE lift trucks to help users who do their own
maintenance
A warnNine
Do not make repairs or adjustments unless specifi-
cally authorized to do so. Repairs and adjustments
must be done by trained service people.
Donot operate a lift truck that needs repairs. Report
the need for repairs immediately. If repair is neces-
‘sary, puta“DO NOT OPERATE” tag in the operator's
area. Remove the key from the key switch. Discon-
nect the battery connector.
Before doing maintenance, put the lft truck on a level
surface. Lower the carriage and forks, apply the parking
brake and tum the key to the OFF position. Disconnect
the battery connector.
A WARNING
Do not work under a raised carriage. Lower the car-
riage or use a chain to prevent the carriage and the
inner or intermediate. weldments from lowering
GENERAL LIFT TRUCK MAINTENANCE
‘AND LUBRICATION SCHEDULE
when doing maintenance. Make sure that the mov-
ing parts are attached to parts that can not move.
See the correct Lubrication List in this section forthe oils
and grease that are recommended for use on these lift
trucks.
HOW TO PUT A LIFT TRUCK ON BLOCKS,
& warnine
‘The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the fol-
lowing assemblies will cause large changes in the
center of gravity: mast, drive axle, battery and the
counterweight. When the lift truck is put on blocks,
Put additional blocks in the following positions to
maintain stability:
a. Before removing the mast and drive axle, put
blocks under the counterweight so that the
lift truck can not tip backward.
b, Before removing the battery and counter-
‘weight, put blocks under the mast assembly
so that the lift truck can not tip forward.
‘The surface must be solid, even, and level when the
lifttruckis put on blocks. Make sure that any blocks
used to support the lift truck are solid, one plece
units.
NOTE: Some lft trucks have lifting eyes. These lifting
eyes can be used to raise the lft truck so that blocks can
be instaled.
How To Raise The Drive Wheels
(See Figure 2-1.)
1. Put blocks on each side (front and back) of the steer
tires to prevent movement of the lift truck.
2. Put the mast in a vertical position. Put a block under
each outer mast channel,
3. Tiltthe mast fully forward until the drive tires are raised
from the surface.
4. Put additional blocks under the frame behind thedrive
tires.
5. Ifthe hydraulic system will not operate, use a hydrau-
lic Jack under the side of the frame and near the front of
the lift tuck. Make sure that the jack has a capacity
‘equal toat least half the weight of the lift truck. See the
Capacity Plate. GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
How To Raise The Steer Wheels
(See Figure 2-1,)
1. Apply the parking brake. Put blocks on both sides
(front and back) of the drivetires to prevent movement of
the lft truck.
‘STEERING TIRES
Figure 2-1. Put A Lift Truck On Blocks
Industrial Trucks
2. Use a hydraulic jack to raise the steer wheels. Make
‘sure thatthe jack has a capacity of atleast 2/3 of he total
‘weight ofthe lift truck as shown on the Capacity Plate.
3. Put the jack under the frame to raise the lft truck. Put
blocks under the frame and counterweight to support
‘the lft truck.
DRIVE TIRES GENERAL LIFT TRUCK MAINTENANCE
- ‘AND LUBRICATION SCHEDULE
oO
4 3 71 15 7
. WHEELS ANDTIRES 8. MAST SLIDINGSURFACES 14. WHEEL NUTS
. WHEEL BEARINGS ‘AND ROLLERS 15. ACCELERATOR PEDAL
MOTOR BRUSHES 9. LIFT CHAINS. 16. HYDRAULIC TANK BREATHER
|. SERVICE BRAKE 10. CARRIAGE 17. HYDRAULIC OIL FILTER,
. PARKING BRAKE 11. DIFFERENTIAL 18. DIPSTICK, AND FILL CAP
. MASTER CYLINDER —12. FORKS. 19. STEERING ROD ENDS
”. SERVICE BRAKES. 13. FORKGUIDES& LOCKS 20. CONTACTORS.
Figure 2-2. Maintenance And Lubrication Points
MAINTENANCE SCHEDULE
LEGEND
Every 8 Hours or Dally X— Indicates Visual inspection, Testing,
Every 350 Hours or 2 Months Adjusting as required
Every 2000 Hours or 1 Year IL. — Check indicator Light during operation”
O— Indicates Drain and Fill
F— Indicates Replacement
“Not all units have alll lights ea a
[SAFETY AND OPERATIONAL CHECKS (Before each shift)
[Only the 8 hour CHECKS are to be done by the operator.
Have a qualified mechanic correct all problems.
Leaks — Hydraulic Oi
Tires — Condition. See Note 7
Forks, Top Clip Retaining Pin and Heel — Condition
Toad Backrest Extension — Attached
Fiydraulic Hoses, Mast Chains and Stops — Check Visually
‘Safely Labels — Attached and can be read (See Parts Manual for location and
replacement part number) GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
Internal Checks:
Battery — Electrolyte Level and Charge
Hydraulic Tank Fluid Level — Dipstick
‘Speed Reducer and Differential — Check Fluid Level
‘Operator's Compartment:
(Operator's Manual in Case
(Capacity Plate Attached — Information matches model, serial number and
attachments.
Battery Restraint System — Lalched
[Accelerator Linkage — Operates Smoothly
Brake Fluid — Check Level
[Controis (Start Lift Truck) immediately Check Noises That Are Not Normal:
Parking Brake — Operates Correctly
‘Service Brake — Operates Smoothly and Correctly
‘Steering Operation — Operates Smoothly and Correctly
Drive Control — Forward/Reverse — Operates Correctly
Lift and Lowering Control — Operates Smoothly and Correctly
Tit Control — Operates Smoothly and Correctly Forward and Backward
[Attachment Controls — Operate Smoothly and Correctly
Battery Discharge Indicator — Operates
LUBRICATION CHECK: Use compressed air to clean. Inspect for damage.
Lubricate — All Fitings and Friction Surfaces
Mast Pivots (2 Fittings)
x
‘All Linkages (See NOTE 2)
Friction Surfaces of Camiage or Attachment
Clean and Lubricate Lift Chains
Giean and Fill Wheel Bearings with Grease
Hydraulic Oil Filter Element (1R” — Filter 1 100 Hours)
Hydraulic Tank Breather
Differential/Speed Reducer Gear Oil
HYDRAULIC SYSTEM CHECK
Tif Cylinders for Leaks
a4
a
x
x
x
Tit Cylinders for Leaks
Lift Pump for Noise and Operation [x] | GENERAL LIFT TRUCK MAINTENANCE
oe ‘AND LUBRICATION SCHEDULE
HYDRAULIC SYSTEM CHECK
Power Steering Pump for Noise and Operation
Hydraulic Control Valve for Leaks and Operation
All Hoses, Tubing and Fittings for Wear And Leaks
‘Attachment Operation
[Attachment Gylinders for Leaks
For General Leas
[aeacor 3
[MAST, CARRIAGE, AND ATTACHMENT CHECK
ce
>| | ><] ><} >f >] >|
‘Carriage Rollers
‘Chain Anchors, Adjustment
(Chain for Cracks and Wear
Forks — See Figure 2-4, and Figure 2-6. (see NOTES)
[Attachment — Sliding Surface Wear
[Attachment — Check Rotating Parts And The Torque On Bolts And Nuts
DRIVE ASSEMBLY
Brake Drums and Linings
(Wheel Nuts -~ Tighten to 237-305 N.m. (175-220 Ib; ft)
Wheel Bearings:
[STEERING
[Axle Bearings (See NOTE 4)
[Wheel Nuts — Tighten to 34 Nim (25 Iby ft) torque GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
ELECTRICAL SYSTEM A Cc E
(Glean all Controls (Never use steam To clean electrical paris)
Accelerator Switch and Potentiometer (Check Connections)
Traction Control Card Connections
Direction Switches (Check Connections)
Hydraulic Control Switches (Check Connections)
‘All Motors — Clean with a vacuum cleaner. I compressed air must be used, use
carefully and at a low pressure.
‘All Motors — Check Brushes and Springs
‘All Motors — Check Power Cable Connections:
Battery, Compartment and Connectors — Clean and make Neutral
Battery Condition — Structure and Electrical
‘All Wire Connections:
(Contactors — Contacts and Wire Connections
Replace the contact set for the hydraulic pump contactor every 1000 hours of oper:
tion. Replace other contactor sets when contact thickness is 30% of thickness when L a
new.)
| GENERAL CHECK: Cc E
All Bots, Nuts, Cotter Pins, etc.
[Overhead Guard and Load Backrest Extension — Cracks, Mounting, etc.
ROAD TEST AND LOAD TEST THE LIFT TRUCK — Do these tests daily and after
‘every maintenance inspection or repair. Do the tests in a clear area using a ca-
pacity load in the correct position on the forks. Drive carefully and observe all A
{traffic regulations and operating procedures. Report all functions or noises that
are not normal.
Brakes — Service and Parking, Seal (f equipped)
Flom, Lights:
[Traction System — Acceleration, Creep
Mast — Check for the correct sequence of channel operation. Do the checks with
‘and without a load.
Lifting — Full Lift (Do Not Titt Forward) and Lower.
Tit — With load lowered, tit fully Forward and Backward.
[Attachment — Operate all functions.
NOTE 1. TIRES — Condition can change STABILITY, OPERATOR SAFETY and LOAD CAPACITY that can be safely
handled.
NOTE 2. Lubricate hinges, levers, linkage pedals and other linkages with multi-purpose grease with 2-4% molybde-
‘num disulfide at “C” interval. Lubricate seat rails with a silicone spray at “E” interval.
NOTES. Have authorized personnel use Magnagio or equivalent Fatigue Crack Detectorto test forks. Referto Service
News Bulletin SE~643 for Procedure on Field Testing Load Forks. The Bulletin also has the minimum acceptable fork.
thickness due to wear.
NOTE 4. Lubricate lower spindle bearings at250 hours.For more information on Service Bulletins, contact your autho-
rized dealer for YALE lift trucks.
26 Yale GENERAL LIFT TRUCK MAINTENANCE
Industrial Trucks
‘AND LUBRICATION SCHEDULE
CAPACITIES
HYDRAULIC OIL (Total) 23.0 Tires (24.3 quarts)
DIFFERENTIALISPEED REDUCER ‘a tires (44 quarts)
[BRAKE FLUID I Oza Tires (05 pint)
HYDRAULIC OILS
Tee Fora Faia Rais ET
[antipateg Ambion Ar Temperature Range [F810 95°C (O70 #1007
(Actual Usable Operating Oil Temperature Range | 18° to 38°C (0° to +100" F)
|ASTM Viscosity Grade Number/index (Reference) | SAE J300/90 Minimum
Pour °C (°F) Maximum 29°C (-20°F)
Approved Sources
AMCO 200 Motor Oil SAE 10W
‘Ashland HD-10W
British Petroleum 'BP Vanellus M-10W
Chevron Oil Company Chevron Delo 100 Motor Oil 10W
Citgo (C300 Series Motor Oil Grade C310
Et HB I-B-10W
Exxon: HDX 10W
Fina Oi Company Delta Motor Oi 10W
Cult [Gulflube Motor Oi XHD 70W
‘Imperial Oil Ltd. Esso lube HD-10W
‘Mobil Oil Corporation Delvac 100 Aweiwa-10W
Fete OF-10W
| Sinclair Oil Corporation Super Tenol SAE 10W
Standard Oil Company of California RPM Delo 200 Motor oil 10W
‘Sun Oil Company ‘Sunftleet Mil-B-10W
| Texaco Inc. ‘Union Unitec Motor Oil-10W
Total HD1B SAE 10W
(Union Oil Company Union Unitec Motor Oil-10W
Field Personnel Note: The hydraulic ols, as listed here are approved by YALE MATERIALS HANDLING
CORP. These sources meet or exceed the specifications shown. The use of hydraulic oils other than those in
the list is not authorized.
+ For it trucks used in cold storage or arctic areas, see your YALE lift truck dealer.
27 GENERAL LIFT TRUCK MAINTENANCE Yale
AND LUBRICATION SCHEDULE
GEAR OIL
FOR USE IN THE DIFFERENTIAL AND SPEED REDUCER
Ultra Gear Lube Gear Oil
SAE 80W or SAE 90W EP
Approved Source
[Chevron Oi
GREASE
(For Masts)
"STANDARD FOR HIGH PRESSURE FITTINGS, PLAIN AND ANTI-FRICTION BEARINGS,
‘AND WHEEL BEARINGS.
High grade lithium soap, 2 to 4% micronized molybde-
‘num disulfide additive and high grade mineral oil
[Dropping Point Approx. [260°C (S00°F)
Base Oil Viscosity (SUS) (67/75 at 99°C (10°F)
[Nominal Operating Temperature Range 734°C t0 177°C (-30°F 10 350°F)
identification [Conta
f must be plainly marked with suppliers prod-
Exxon Corporation
‘Mobil Oil Corporation
‘Solene Lub. Inc.
‘Sun Petroleum Products
Field Personnel Note: The greases shown in this ist are approved by YALE MATERIALS HANDLING CORP.
‘These sources meet or exceed the specifications shown. The use of greases other than those in the list is not
authorized.
* For lift trucks used in cold storage or arctic areas, see your YALE lit truck dealer.
28 GENERAL LIFT TRUCK MAINTENANCE
- ‘AND LUBRICATION SCHEDULE
GREASE
(For Lift Truck)
"STANDARD FOR HIGH PRESSURE FITTINGS, PLAIN AND ANTI-FRICTION BEARINGS,
‘AND WHEEL BEARINGS.
‘num disulfide additive and high grade mineral oil
2
Dropping Point Approx. 340 (Minimum
‘At 38°C (100: 750 (Minimum)
At 99°C (210°F) 75 (Mirimum)
‘Approved Source
[American Oi Company Molyith Grease #2
[Ashland Oi, Inc. Special Moly Grease
BP Oil International Ltd. BP Energrease LMS 22 or Energrease L21M
Castrol ‘Spheerol LMM
[eioe | rer yr re
Elf
Exxon
Fina Oil Company Marson LM2
(Guilt [Guilflex Moly Grease
‘Mobil Oil Corporation Mobilgrease Special
yompany Lithall MDS Grease
‘Sinclair Oil Corporation Litholine EP Molylith Grease
Prestige Moly Grease M3
[Texaco ine. Molytex #2
FTotal, NV Total Multis MS
Field Personnel Note: The greases shown in this ist are approved by VALE MATERIALS HANDLING CORP.
[These sources meet or exceed the specifications shown. The use of greases other than those in the list is not
authorized.
For trucks used in cold storage or arctic areas, see your YALE lift tuck dealer. GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
EVERY 8 HOURS OR DAILY
Do all safety and operational checks as shown in the
MAINTENANCE SCHEDULE.
HOW TO MAKE CHECKS WITH THE KEY
‘SWITCH “OFF”
Put the lift truck on a level surface. Lower the carriage
land forks, apply the parking brake and tum the key
switch to OFF. Open the access panels and check for
leaks and conditions that arenotnormal. Clean any oilor
other spills. Make sure that lint, dust, paper, and other
‘materials are removed from the compartments.
Hydraulic System (See Figure 2-3.)
& warnine
At operating temperature the hydraulic oil is HOT.
Do not permit the oil to contact the skin and cause a
burn.
A caution
Do not permit dirt to enter the hydraulic system
when the oil levels checked or the filter is changed.
Never operate the hydraulic pump without oll in the
hydraulic system. The operation of the hydraulic
pump without oi will damage the pump.
Check the hydraulic oil evel when the oilis at operating
temperature, the carriage is lowered and the key switch
is OFF. Add hydraulicoil only asneeded. If more hydrau-
licoilis added than the “FULL level, the hydraulic oi will
leak from the breather during operation.
Inspect the hydraulic system for leaks and damaged or
loose components.
Figure 2-3. Check The Hydraulic Oil
210
Industria! Trucks
Battery
& warninc
‘The acid in the electrolyte can cause injury. If elec-
trolyte is spilled, use water to flush the area. Use a
solution of sodium bicarbonate (soda) to make the
acid neutral. Acid in the eyes must be flushed with
water immediately. Get medical attention.
Check the level of the electrolyte daily on a minimum of,
‘one cell. Add only distled water, as necessary to all
cells that do not have the correct electrolyte level. The
‘correct level is half-way between the top of the plates
and the bottom of the fil hole.
‘Some water loss in the battery cells is normal. Always
check the electrolyte level after charging the battery.
‘Add distled water as necessary.
Forks
‘The identificationot a forks determined by how tis con-
ected to the cariage. These lft trucks have hook forks.
Forks, Adjustment
Hook forks are connected to the carriage by hooks and
lock pins. See Figure 2-4. These lock pins are installed
‘through the top fork hooks and fitinto slots in the top car-
riage bar. Adjust the forks as far apart as possible for
‘maximum support of the load. Raise the lock pin in each
{fork to slide the fork on the carriage bar. Make sure the
lock pin is engaged in the carriage bar to lock the fork in
Position after making adjustments.
1. FORK
2 HOOK
3. LOCK PINASSEMBLY ‘“#
4, CARRIAGE
Figure 2-4, Hook Fork Industrial Trucks
Forks, Removal
A warning
Do not try to move a fork without a lifting device.
Each fork can weigh 115 kg (250 Ib).
Slide a hook fork to the fork removal notch on the car-
riage. Lower the fork onto blocks so that the bottom of
the fork moves through the fork removal notch. Lower
the carriage further sothat the top hook of the forkis dis-
engaged from the top carriage bar. Move the carriage
away from the fork, or use a lifting device to move the
fork away from the cariage.
1. CARRIAGE BARS
2. HOOK FORK
3. FORK REMOVAL
NOTCH
4, BLOCKS:
Figure 2-5, Remove A Hook Fork
GENERAL LIFT TRUCK MAINTENANCE
‘AND LUBRICATION SCHEDULE
Forks, Installation
‘Move the fork and carriage so that the top hook on the
‘fork can engage the top carriage bar. Raise the carriage
to move the lower hook through the fork removal notch.
‘Slide the forkon the carriage so that both upper and low-
erhooks engage the carriage. Engage thelock pin with a
notch in the top carriage bar.
Inspection Of Forks, Mast, And Lift Chains
A warning
NEVER work under a raised carriage or forks that
can suddenly lower and cause injury and death.
Lower the carriage or use chains on the mast weld-
ments and carriage so that they can not move. Make
sure the moving parts are attached to a part that
does not move.
Do not try to correct fork tip alignment by bending
the forks or adding shims. Replace bent forks.
‘Never repair damaged forks by heating or welding.
Forks are made of special steel using special proce-
‘dures. Replace damaged forks.
1. Inspect the welds on the mast and carriage for cracks.
‘Make sure that the nuts and bolts are tight.
2. Inspectthe channel for excessive wear in the areas of
roller contact. Check the rollers for wear or damage.
3. Inspect the load backrest extension for cracks and
damage.
4. Inspect the forks for cracks and wear. Check that the
fork tips are aligned as shown in Figure 2-6.). Check
that the bottom of the fork is not wom (item 4,
Figure 2-6.).
5. Replace any damaged or broken parts that are used
to keep the forks locked in position.
ant GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
Industrial Trucks
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION “X")
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 83°
FORK TIP ALIGNMENT
LENGTH OF FORKS,
915 mm (36 in)
1220 mm (48 in)
1830 mm (72 in)
3% DIMENSION
27 mm (1.10 in)
‘37 mm (1.45 in)
55mm (2.1
Figure 2-6. Check The Forks
6. Inspect that the lift chains for the correct lubrication.
Use engine oil or a the lft chain and cable lubricant.
7. Inspect the lift chains for cracks or broken links and
pins. See Figure 2-7.
4. WORN PIN
2. CRACKS
3. EDGE WEAR
4. HOLE WEAR
5. LOOSE LEAVES
6. DAMAGED PIN
7. CORROSION
Figure 2-7. Check The Lift Chains
212
8. Inspect the chain anchors and pins for cracks and
damage.
9. Make sure the lift chains are adjusted so that they
hhave equal tension. Ifthe lft chains need repair or ad-
justment, it must be done by authorized personnel.
Tires And Wheels (See Figure 2-8.)
Inspect the tires for wire, rocks, glass, pieces of metal,
holes, cuts and other damage. Remove any object that
will cause damage. Check for loose or missing hard-
ware. Remove any wire strapping or other material that
is wrapped around the axle.
Make sure the wheel nuts are tight. Tighten the wheel
nuts in a cross pattem to the correct torque value shown
in the MAINTENANCE SCHEDULE table.
A caution
Check ail wheel nuts after 2 to 5 hours of operation:
when new lift trucks begin operation and on all lift
trucks when the drive wheels have been removed
and installed, Tighten the nuts in a cross pattern to
‘the correct torque shown in the MAINTENANCE
‘SCHEDULE. When the nuts stay tight for eight
hours, the interval for checking the torque can be
extended to 350 hours. 1. CHECK FOR DAMAGE AND REMOVE
NAILS, GLASS, METAL, AND OTHER,
OBJECTS
2, MAKE EDGES SMOOTH
Figure 2-8. Check The Tires.
Operator Restraint System
(See Figure 2-9. and Figure 2-10.)
CHECK THE INDICATOR LIGHT DURING OPERA-
TION. There is an indicator light on the display panel for
the seatbelt. The redlight is ON for approximately eight
to ten seconds when the key is first moved to the ON
position. The light can help the operator remember to
fasten the seat belt.
‘The seatbelt, hip restraint brackets, seat and mounting,
battery restraint (hood plate) and latch are all part of the
operator restraint system. Each item must be checked
to make sure itis attached securely, functions correctly
ands in good conditon.
‘The seat belt must latch securely. Make sure the seat
belt extends and retracts smoothly and is not damaged
‘nor tom. Ifthe seat belt can not be pulled from the retrac-
tor assembly, the seat belt must be replaced.
1. HIP RESTRAINT BRACKETS
. SEAT BELT.
3. HOOD LATCH (REAR CENTER OF HOOD)
Figure 2-9. Operator Restraint System
GENERAL LIFT TRUCK MAINTENANCE
‘AND LUBRICATION SCHEDULE
Make sure the seat rails are not loose. The seat rails
must lock securely in position, but move freely when un-
locked. The seat rails must be securely attached to the
‘mounting surtace.
Battery Restraint System (See Figure 2-10.)
‘The battery restraint and hood frame is a heavy steel
‘weldment that has a hinge at the front of the battery
‘compartment. An adjustable spacer plate is used inside
the battery compartment to prevent forward and back:
ward movement ofthe battery. The batteries for these lft
trucks must fit the battery compartment width with &
‘maximum of 13 mm (0.5 in) clearance.
‘The hood must be locked in the down position during op-
eration. The battery must have the spacer plate correct-
ly adjusted to prevent forward or backward movement of
13 mm (0.5 in) maximum. Ifthe unit has @ seat brake,
raise the seat and seat plate assembly. Use the latch
handle at the rear of the hood (see Figure 2-10.) to re-
lease the hood frame and battery restraint. Raise the
latch handle and side the handle toward the right side of
the truck. A spring moves the handle back tothe left. Use
the lft handle by the seat to raise the hood. A gas spring
will hold the assembly in the up position, Make sure that
the battery can not move more than a total of 13 mm (0.5
in) in any one horizontal direction. Release the stop rod
‘by moving it to the right before lowering the hood. See
the label in Figure 2-30. Make sure the latch handle is
fully to the right when closing the hood so that the latch
can engage the latch piece. Make sure the hood is
locked securely. Try to raise the hood using only the lft
handle to make sure the hood is latched and will not
move.
A warninc
‘The hood and battery restraint with its latch mecha-
nisms must operate correctly before a lift truck is
‘Operated.
Htnecessary, adjust the battery spacer plate as shown in
Figure 2-20.
Safety Labels
A WARNING
‘Safety labels are installed on the lift truck to give in-
formation about operation and possible hazards. It
isimportant that all safety labels are installed on the
lift truck and can be read.
Check that all safety labels are installed in the correct
location on the lif truck See the PARTS MANUAL for
the correct location of the safety labels.
2413 GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
5.GASSPRING 14
6. HINGE.
7. STOP ROD
3. LATCH ASSEMBLY
4. BATTERY RESTRAINT
AND HOOD FRAME
8. RELEASE LABEL FOR
‘STOP ROD
9, COUNTERWEIGHT
10. LATCH HANDLE,
11. LIFT HANDLE
12. LATCH WARNING LABEL
Figure 2-10. Battery Restraint
HOW TO MAKE CHECKS WITH THE KEY
SWITCH “ON”
A warninc
IFINSTALLED, FASTEN YOUR SEAT BELT! The seat
beltis installed to help the operator stay on the truck
if the lift truck tips over. IT CAN ONLY HELP IF ITIS-
FASTENED.
‘Make sure the area around the lift truck is clear before
moving the lift truck. Be careful when making the
checks. Proceed carefully.
Gauges, Horn and Fuses
1. Checkthe operation of the gauges and hom. The hom
will operate when the key is in the OFF position. On the
‘standard panel, the hourmeter will operate when the key
is in the ON position and the seat switch is closed. On
the premium panel, the hourmeter will operate when the
key isin the OFF position.
2. The battery indicator will operate when the key isin
the ON position. If the battery is replaced with a fully
charged battery, the battery indicator wil not indicate a
fully charged battery until the lft truck has operated for a
short period of time. A battery indicator without “ft inter-
‘upt’willonly indicate battery charge when the hydraulic
relief valve operates. Tit the mast backward until the hy-
draulic relief valve operates. The battery indicator will
then indicate correctly.
244
‘3. Most fuses are located in the electrical compartment.
Control Levers And Pedals
Check that the pedals and the control levers for the mast
and attachment operate as described in “Instruments
‘And Controls” inthe OPERATOR'S MANUAL.
Lift System Operation
A warninc
NEVER work under a raised carriage or forks. Lower
the carriage or use chains on the mast weldments
1nd carriage so that they can not move. Make sure
the moving parts are attached toa part that doesnot
move.
Donot try to locate hydraulic leaks by putting hands
on pressurized hydraulic components. Hydraulic oil
‘can be injected into the body by the pressure.
1. Check for leaks in the hydraulic system. Check the
condition of the hydraulic hoses and tubes.
2. Slowly raise and lower the mast several times without
a load. The mast components must raise and lower
‘smoothly in the correct sequence. The carriage raises
first, then the inner wekiment and intermediate weld-
ments,
NOTE: Some parts ofthe mast move atdifferentspeeds
during raising and lowering.
3. The inner and intermediate weldments and the car-
riage must lower completely. Industrial Trucks
4, Raise the forks one metre (three feet), with a capacity
load. The inner wekiment and carriage must raise
‘smoothly. Lower the forks. All moving components must
lower smoothly.
5. With the load lowered, tit the mast backward and for-
ward. The mast must ttt smoothly and both ttt cylinders.
‘must stop evenly.
6. Check that the controls for the attachment operate the
{functions of the attachment. See the symbols by each of,
the controls. Make sure all of the hydrauliclines are con-
nected correctly and do not leak.
Service Brakes
CHECK THE INDICATOR LIGHT DURING OPERA-
TION. Thereis an indicator light on the display panel for
the brake fluid level. The red light is ON when the key is
in the ON position and must go OFF after approximately
‘one second. the lightis ON after approximately onese-
‘cond, the fluidin the reservoir for the brake master cylin-
der is too low. Add brake fluid and check for leaks. The
reservoir is under the brake pedal and floor plate. Clean
the area around the fil cap so that no dirt enters the res-
ervoir.
‘Check the operation of the service brakes. Push on the
brake pedal. The brakes must be applied before the
‘pedal reaches the floor plate. The brake pedal muststop
firmly and must not move slowly down after the brakes
are applied. The brakes must apply equally to both drive
wheels with nonoticeable pullto either side. The service
brakes are automatically adjusted as the brakes are ap-
plied when the it truck changes directions.
A warning
Loss of fluid from the brake fluid reservoir indicates.
a leak. Repair the brake system before using the lift
truck. Replace the brake fluid in the system if there
Is dirt, water or oil in the system.
Parking Brake
CHECK THE INDICATOR LIGHT DURING OPERA.
TION. Theres an indicator light on the display panel for
the parking brake. The red lightis ON when the key is in
the ON position and must go OFF after approximately
‘onesecond. Ifthe lightis ON after approximately one se-
ccond, the operator is not on the seat or the key isin the
OFF position. An alarm will also make anoise. ALWAYS
apply the parking brake when leaving the seat.
‘Make sure the service brakes operate correctly before
‘checking the operation of the parking brake. Check the
‘operation of the parking brake. The parking brake, when
in good condition and correctly adjusted, will hold a lift
GENERAL LIFT TRUCK MAINTENANCE
‘AND LUBRICATION SCHEDULE
truckwith a capacity load on a 15% grade[1.5 metrerise
in 10 metres (1.5 ftrisein 10 ft). necessary, adjust the
parking brake by first making sure the lft truck cannot
‘move (block the tires). Release the parking brake and
remove the floor plates for access to the adjustment
knob at the bottom of the pedal linkage. Turn the knob
clockwise to increase the braking force.
‘Some lft trucks are equipped with an additional linkage
that automatically actuates a separate brake when the
operator leaves the seat (seat brake). When correctly
adjusted, this brake will also hold the lft truck with a ca-
pacity load on a 15% grade. If the brake does not hold
the lift truck on the grade, the seat brake must be ad-
justed by authorized service personnel according to the
procedure in SECTION 5.
Steering System
& warnina
Because the lift truck has hydraulic power steering,
the steering can be difficult when the power steer-
ing pump is not operating.
Make sure that the steering system operates smoothly
‘and gives good steering control
EVERY 350 HOURS OR TWO MONTHS,
Do ail safety and operational checks as shown in the
MAINTENANCE SCHEDULE.
Hydraulic Tank Breather
‘Check and clean the hydraulic tank breather. Clean the
breather when itis dirty and will not permit the easy pas-
‘sage of air. The breathers fastened to the truck frame to
the right of the control valve on a hose to the hydraulic,
tank.
Differential And Speed Reducer
(See Figure 2-11.)
A warnine
Do not work under a raised carriage. Lower the car-
riage or use a chain to prevent the carriage and the
inner or intermediate weldments from lowering
when doing maintenance. Make sure that the mov-
Ing parts are attached to parts that can not move.
Check the oil level at the fill plug. Add oil slowly at the
plug. See Figure 2-11. Fill unti oil just starts to flow out
‘the fll plug hole. Add oil only i the oil level is low. The oil,
‘must flow through the bearings to the speed reducer, so
filing slowly is necessary to indicate the correct level.
215 GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
1. DRAIN PLUG
(ON BOTTOM)
2. FILL PLUG.
3. DIP STICK
4, BREATHER
Figure 2-11. Differential
‘Wheel Nuts
Tighten wheel nuts as required. See Install The Wheels,
and SPECIFICATIONS.
Check the drive whee! nuts for the correct torque two to
five hours after a wheel has been installed. Tighten the
nuts. a cross pattem 237 to 305 N.m (1750225 Ibyft).
When the nuts stay tight for eight hours or more, the in-
terval for checking the torque can be extended to 350
hours,
Steering Axle Spindles
Use multi-purpose grease to lubricate the spindles in
the steering axle. There are grease fittings for the lower
bearings of the spindles on the bottom of the bearing
caps.
Mast
A warning
Parts of the lift mechanism can move and cause se-
rious injury. Do not allow anyone under a raised car-
riage or forks.
Before you reach into the lift mechanism:
* Make sure that all parts of the lift mechanism
are completely lowered.
* Tum the key switch to “OFF”. Remove the
key. Disconnect the battery.
© Ifthe lift mechanism cannot be lowered com-
pletely, use chains on the mast weldments:
and carriage so that they cannot move. Use a
chain to attach each moving part of the lift
216
Yale.
mechanism to a part that does not move. Op-
erate the lifvlower control to check that all
parts will not move, but do not allow the lift
chains to become loose.
Cleaning solvents can be flammable and toxic, and
‘can cause skin Irritation. When using cleaning sol
vents, always follow the recommendations of the
manufacturer.
A caution
DO NOT use steam or high-pressure water to clean
the load rollers or the lift chains. Steam and high-
pressure water can remove the lubrication from the
bearings in the load rollers. Water in the bearings of
the sheaves and the link pins of chains can also
shorten the service life of these parts.
1. Clean the mast assembly. Inspect the mast channels
inthe areas where the rollers travel. If there areloose or
displaced metal particles, remove the metal parties.
& warninc
‘Metal particles can fall Into the eyes during the op-
eration of the mast. Failure to remove this loose ma-
terial can cause eye injury.
Remove displaced metal particles with a grinder if
necessary. Always wear eye protection when using
a grinder.
2. Lubricate the sliding surfaces and the load roller sur-
faces along the full/ength ol the channels. Only apply lu-
bbricant to surfaces that are clean and dry.
NOTE: Some applications of the lift truck will require
more frequent cleaning and lubrication of the mast as-
‘sembly. DO NOT use a spray-on lubricant on the sur-
faces of the mast channels where the load rollers make
‘contact. The use of the correct lubricant is important!
Use multi-purpose grease with 2% to 4% molybdenum,
disulfide described in the specifications table for
“Grease”. The load rollers and sheaves have sealed
bearings that do not need additional lubrication.
3. Lubricate the pivots for the mast at the grease fittings
cn the pivots or the pivot pins. Use multi-purpose
grease.
4. Ita side-shift carriages installed, lubricate the tings
{or the rollers or the sliding surfaces with multi-purpose
grease.
Lift Chains, Check for Wear
(Gee Figure 2-12.)
lta section of chain is 3% longer than a similar section of
‘new chain, the chain is wom and a new chain must be
installed. if a chain scale is available, check the fit, Yale.
chains as shown in Figure 2-12. if a chain scale is not
available, measure 20 links of chain. Measure from the
center of apin tothe canter of another pin 20 links away.
Compare the length with the chartin Figure 2-12. Install
‘a new chain if the chain length of 20 links of the worn
section is more than the WEAR LIMIT.
WEAR LIMIT
The maximum
length of 20
Tinks.
‘mm (inch)
261.6 (10.)|
3270 (12.9)
392.4 (15.6)
5233 (20.6)
1. CHAIN WEAR SCALE ve
NOTE: The instructions for measuring chain
wear are shown on the Chain Wear Scale.
Figure 2-12. Check The Lift Chains.
A warning
Do not repair a wom or damaged lift chain. If a lift
chain is wom or damaged install anew lift chain. Ifa
Pair of lift chains is used in the mast, new lift chains.
must be installed for both lift chains.
Lubricate the lift chains with clean 30W engine oil.
NOTE: Lubrication and cleaning (see EVERY 2000
HOURS OR YEARLY) can be needed more frequently
GENERAL LIFT TRUCK MAINTENANCE
‘AND LUBRICATION SCHEDULE
in very dirty applications. Correct lubrication helps pro-
vide normal service life from these parts.
Forks (See Figure 2-6.)
& warning
Never repair damaged forks. Do not heat, weld, or
bend the forks. Forks are made of special steel us-
ing special methods. If the forks are worn damaged
or worn, install new forks.
1. Check the heel and attachment points ofthe forks with
‘ penetrant or magnetic particle inspection.
2, Measure the thickness of the forks at avertical section
where there is no wear. This is dimension X. Now mea-
‘sure the thickness at the heel (5) of the fork. Ifthe thick-
‘ness not more than 90% of dimension X, install anew
fork.
3. Use clean engine oil as necessary to lubricate the
‘guides and looks for the forks.
Brake Fluid
A warning
Loss of fluid from the master cylinder indicates a
leak. This condition can cause brake failure. The re-
sult can be material damage or personal injury. Re-
pair the brake system before the lift truck is used. If
there is dirt, water or oil in the brake system, the sys-
tem must be flushed and new brake fluid installed.
Check the brake fluid in the reservoir for the master oyl-
inder. Add brake fluid as necessary. Use the SAE
4J+1708 hydraulic brake fluid.
Other Lubrication
Lubricate hinges, pins, linkages, cables, pedals, and le-
vers as necessary. Use SAE 30 oil, multi-purpose
‘grease, oF silicone lubricant-spray as needed.
Electrical Inspection
& warninc
Disconnect the battery connector to prevent injury
from electric shock before you make any inspec-
tions or repairs.
Discharge the capacitors when you make any in-
‘spections or repairs inside of the electrical
compartment.
Additional information for the EV-100ZX motor control-
lersis available in SECTION 3, ELECTRICAL SYSTEM.
Contactors (See Figure 2-15.)
‘The contactor contacts are made of special silver alloy.
‘The contacts will look black and rough from normal op-
D7 GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
eration. This condition does not cause problems with the
operation of the lft truck. Cleaning is not necessary. DO
NOT USE A FILE ON THE CONTACTS. DO NOT LU-
BRICATE THE CONTACTS. Always install new con-
tacts in sets. Check for equal spring tension if the con-
tacts do not wear evenly. See the SECTION 3, ELEC-
TRICAL SYSTEM for installation and adjustment proce-
dures.
Motor Brushes
NOTE: The traction motor and the hydraulic pump motor
are below the battery compartment. Remove the battery
and the access panel to check the motors. The steering
[pump motor is on a vertical mount below the floor plate.
Remove the floor plates for access to the steering pump
‘motor.
1. Visually inspect the commutator and brushes every
350 hours. Make sure the surface of the commutator is
{good and that the motor operates normally. Wom motor
brushes must be replaced before they damage the sur-
face of the commutator.
Move the brush spring and remove a brush from the
brush holder. When the brush wears within approxi-
‘mately1.5 mm (0.060 in) of where the brush wire joins,
the brush, the brush must be replaced.
2. Some lft trucks are equipped with brush wear indica-
{ors on the traction and hydraulic motors. The brush
wear indicators give a signal on the LED display panel
‘on the instrument panel. The sensor wires for the brush
wear indicators are an insert in the brush material when
itis made. When the brush wears within 1.5 mm (0.060,
in) of the brush wire, the insulation between the sensor
wire and the brush material is destroyed. The connec-
tion between the brush and the sensor causes the LED
indicator to illuminate. The brush wear indicators will not
indicate a damaged commutator nor indicate a motor
maftunction. Visually inspect the commutator and
brushes on lift trucks with brush wear indicators also.
218
1. BRUSH HOLDER (4)
2. BRUSH YOKE.
3. BRUSH SPRING (4)
4, BRUSH SET
Figure 2-13. Brush Assembly
3. Inspect the brush holders for burns or damage. Make
‘sure the brush holder's fastened tightly to the mounts at
the end of the motor. Make sure the brushes will move
freely and smoothly in the brush holders.
4. Check the brush springs for damage from heat and
corrosion. Replace a damaged brush spring.
NOTE: When new brushes are installed, a recommen-
ation is to also install new brush springs. Brushes must
‘be installed as complete sets. Install all new brushes at
the same time.
See SECTIONS, ELECTRIC MOTOR MAINTENANCE,
{or additional information to inspect the commutator and
brushes. Yale GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
MOTOR CONTROLLER WITH REGENERATIVE
BRAKING, 1A BY-PASS, FIELD WEAKENING AND SCR
CONTROLLER FOR HYDRAULIC PUMP MOTOR,
1. CONTROL CARD, SCR CONTROL FOR HYDRAULIC PUMP MOTOR
2. CONTROL CARD, TRACTION, WITH REGENERATIVE BRAKING
3. CONTACTOR, POWER STEERING
4, CONTACTOR, 14
5. CONTACTOR, REGENERATIVE BRAKING
6. CONTACTOR, REVERSE DIRECTION
7. CONTACTOR, FORWARD DIRECTION
8. CONTACTOR, FIELD WEAKENING
Figure 2-14. Typical Configurations Of The EV-100ZX Motor Controller
219 GENERAL LIFT TRUCK MAINTENANCE
‘AND LUBRICATION SCHEDULE
MOTOR CONTROLLER WITH REGENERATIVE BRAKING,
1A BY-PASS, FIELD WEAKENING AND CONTACTOR:
‘CONTROL FOR HYDRAULIC PUMP MOTOR
1. CONTROL CARD, TRACTION, WITH REGENERATIVE BRAKING AND FIELD WEAKENING
2. CONTACTOR, POWER STEERING
3. CONTACTOR, 1A
4. CONTACTOR, REGENERATIVE BRAKING.
. CONTACTOR, REVERSE DIRECTION
6. CONTACTOR, FORWARD DIRECTION
7. CONTACTOR, FIELD WEAKENING
8 CONTACTOR, HYDRAULIC PUMP MOTOR
Figure 2-15. Typical Configurations Of The EV-100ZX Motor Controller Industrial Trucks
EVERY 2000 HOURS OR YEARLY
Do all safety and operational checks as shown in the
MAINTENANCE SCHEDULE.
Wheel Bearings
Steer Wheels, Lubrication — Remove the steer
wheels. Remove the bearings and seals. Remove the
‘old grease from the bearings and clean the parts with
‘solvent. Dry the bearings with compressed air. Lubricate
betweenthe rollers and cups with grease. Fillthe spaces
between the rollers completely with grease. Put a thin
layer of grease on the spindle and the finished surface
(on which the oil seal rides. Install the wheels and bear-
ings on the spindle.
Install the castle nut. Tighten the castle nut to 200 N.m
(150 tb) whilerotating the wheel. Loosenthe castienut
until the wheel tums freely. Tighten the nut to approxi-
‘mately 34 N.m (25 by) or until the first alignment posi-
tion after 34 N.m (25 Iby ft). Install the cotter pin in the
closest slot that aligns with the castle nut and spindle.
Install the cap for the bearings.
Drive Wheels, Lubrication — Also see SECTION 4,
DRIVE AXLE for the procedures to remove and install
the drive wheels. Remove the bearings and seals. Re-
move the old grease from the bearings and clean the
parts with solvent. Dry the bearings with compressed
air. Lubricate between the rollers and cups with grease.
Fill the spaces between the rollers completely with
grease. The wheel cavity between the inner bearing
‘cups and the oil seal mustbe filled with the same grease
toalevel with the inner diameter ofthe bearing cups. Put
athin ayer of grease on the spindle and the finished sur-
face on which the oil seal rides. Install the bearings and
seals in the wheel.
Install the wheel assemblies on the axle housings. Do
NOT damage the seals. Lubricate the outer bearing
‘cones with differentia oil and install them in the wheels.
Install the washer, lock plate and lock nut. Tighten the
‘nut to 200 N.m (150 It) while rotating the wheel. Loos-
‘en the nut until the wheel tums freely. Tighten the axle
nut to approximately 34 N.m (25 tly ft) or until the first
alignment position after 34 Nn (25 Ib ft). Bend the lock
plate over the nut. Put iquid sealant on the axle flanges:
and install the axle shafts. Install the capscrews and
tighten them to 90 N.m (66 Iby ft ) torque. Install the
wheels and wheel ruts. Tighten the wheel nuts in a
cross pattern to 237 to 305 N.m(175to225 Ib). Check
all wheel nuts after 2t0 5 hours of operation. When the
nuts stay tight for eight hours, the interval for checking
the torque can be extended to 350 hours.
GENERAL LIFT TRUCK MAINTENANCE
‘AND LUBRICATION SCHEDULE
Change the Filter For The Hydraulic Oil
(See Figure 2-16.)
NOTE: Change the oil fer for the hydraulic system after
the first 100 hours on new lft trucks.
1. Remove the floor plates. Clean the hydraulic filter and
hoses at the fer.
2. Loosen the hose clamp at the filter for the hose from.
the control valve. Lift he filter as high as possible and
remove the hose from the fiter. Tilt the filter up to let the
oil drain into the tank.
3. After the oil has drained, loosen the other hose clamp,
and remove the filter.
NOTE: The hydraulic ol fiter has a by-pass relief valve
thats part ofthe fier. Make sure the correet fier with a
by-pass relief valve is installed.
4. Install the new filter. Make sure the flow arrow points,
toward the hydraulic tank hose. Tighten the hose
1. BREATHER
2. MAINCONTROL VALVE 4. FILTER.
3. RELIEF VALVE,
Figure 2-16. Hydraulic Fitter
Change the Hydraulic Oit
1. Put the lift truck on a level surface. Lower the mast.
Put adrain pan with a 25 litre (26 q1) capacity under the
hydraulic tank. Disconnect the hydraulic hose from the
hydraulic tank to the steering pump and drain the ol into
the drain pan. (The quantity of olin the hydraulicsystem
is according to the size of the hydraulic cylinders in the
‘mast and any addtional hydraulic equipment.)
2, When the oil has drained, connect the hydraulic hose.
Fill the hydraulic tank with approximately 19 litre (20 qt)
of hydraulic oil after the fiter is installed. See the Hy-
