Yale Models ESC Service Maintenance Manual
Yale Models ESC Service Maintenance Manual
Complete Service Maintenance Manual for Yale Models ESC 030-040 FA, ESC 020-025-030 AB, ESC 030-050 ZA, ESC 030 EA, with all the workshop information to maintain, diagnose, repair, and service like professional mechanics.
Yale Models ESC 030-040 FA, ESC 020-025-030 AB, ESC 030-050 ZA, ESC 030 EA technical service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Total Pages: 890 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Yale Models ESC 030-040 FA (A883) Service Maintenance Manual.pdf
Maintenance Manual Supplement for CURTIS MORTOR CONTROLLER
Yale Model ESC 020-030 AB (A824).pdf
Service Maintenance Manual for Yale Model ESC 020-025-030 AB.pdf
Service Maintenance Manual for Yale Model ESC 030-050 ZA.pdf
Service Maintenance Manual for Yale Model ESC 030 EA.pdf
MAIN SECTIONS
1 GENERAL INFORMATION
2 GENERAL LIFT TRUCK INFORMATION AND LUBRICATION SCHEDULE
3 ELECTRICAL SYSTEM
4 DRIVE AXLE
5 BRAKES
6 STEERING AXLE
7 POWER STEERING
8 HYDRAULIC SYSTEM
9 MAST
10 BATTERY
INDEX
Maintenance Manual Supplement for CURTIS MORTOR CONTROLLER Yale Model ESC 020-030 AB (A824)......2
Service Maintenance Manual for Yale Model ESC 020-025-030 AB......31
Service Maintenance Manual for Yale Model ESC 030 EA......139
Service Maintenance Manual for Yale Model ESC 030-040 FA (A883)......308
CAPACITIES AND SPECIFICATIONS......309
DC MOTOR MAINTENANCE......321
toc......321
DC Motor Maintenance......321
Safety Precautions Maintenance and Repair......322
General......325
Brush and Commutator Inspection......325
Hydraulic Pump Motor and Traction Motor......325
Steering Pump Motor......328
Normal Commutator Surface......328
Commutator Problems......328
Brush Replacement......332
Stoning the Commutator......334
Motors Repair......336
Disassemble......336
Traction Motor and Hydraulic Pump Motor......336
Steering Pump Motor......340
Assemble......340
Traction Motor and Hydraulic Pump Motor......340
Steering Pump Motor......341
Brush Alignment, Traction and Hydraulic Motors......344
Tests for Damaged Field and Armature......344
Test for an Open Circuit in Armature......344
Test for Short Circuit in One Armature Winding......345
Test for Short Circuit to Armature Shaft......345
Test for Open Circuit in Field Coil......345
Test for Short Circuit in Field Coil......345
Test for Short Circuit between Field and Motor Case......346
Brush Holder Test......346
Troubleshooting......346
tables......321
Table 1. Normal Commutator Surfaces......327
Table 2. Commutator Problems......328
Table 3. Brush Wear Replacement Guide......332
DIAGRAMS......351
toc......351
Diagrams......351
Safety Precautions Maintenance and Repair......352
ELECTRIC BRAKE SYSTEM......371
ELECTRICAL SYSTEMS......383
toc......383
Electrical System......383
Safety Precautions Maintenance and Repair......384
General......389
Major Electrical System Features......390
Integrated System......390
CAN Bus Advantages......390
CAN Bus Communications......391
Steering......391
Traction......391
Master Control Unit......391
Multifunction Control Handle......391
Operator Input Devices......391
Multifunction Displays......391
Standard Display......391
Premium Display (Optional)......391
BDI......391
Setup......392
Setup Instructions......392
Curtis 1310 Master Control Unit......392
Normal Operation......397
Standard Display......397
Premium Display......397
Password Access......397
Start-up Checklist......397
Truck Operation Mode......398
Diagnostics......398
Power-On Self-Test......398
Run-Time Diagnostic......398
Standard Display......399
Premium Display......400
Checking Transistor Controller......401
Component Repair and Testing......401
Troubleshooting......402
Fault Codes and Display Messages......403
SEM Traction Motor Controller......412
Curtis 1243 traction Controller......412
Hydraulic Pump Controller (Optional)......413
Adjusting the Curtis 1254 Pump Controller Parameters......413
Controller Removal......414
Install......414
Low-Voltage Protection Function......414
Checking Contactor Coils......414
Contactor and Electrical Panel Checks......415
Fuses......415
Contactors......416
General......416
Test......416
Tips......417
Disassemble and Assemble......417
Steer Position Sensor......419
General......419
Operation......419
Install......419
Position Steer Tire for Straight Travel......419
Adjust......420
Dash Display Method......420
Digital Voltmeter Method......420
Test......421
Causes of Motor Failure......421
Overload......421
Shock Loading......421
Short in Field Coils......421
Short Brushes......421
High or Low Commutator Bar......421
Open Circuit......421
Low Battery Voltage......421
Eccentricity of Commutator......422
Overspeeding......422
Drive Motor......422
Inspect......422
Preparation of Drive Motor Commutator......422
Drive Motor Brush and Brush Holder......423
Drive Motor Brush, Remove and Install (Motor Installed)......423
Drive Motor Brush Holder, Remove and Install (Motor Installed)......423
Drive Motor Disassembly and Assembly......424
Remove......424
Repair......424
Disassemble......424
Assemble......424
Install......425
Drive and Hydraulic Pump Motors......426
Routine Preventive Maintenance......426
Preventive Maintenance Checks......426
Cleanliness......426
Connections......427
Discoloration and Burn Marks......427
Brushes......427
Short in Armature......427
Commutator......427
Bearings......427
Hoist Pump Motor......427
Maintenance Instructions......427
Remove......427
Repair......428
Disassemble......428
Assemble......428
Install......428
Motor Tests......430
Excessive Current Draw......430
Measuring Current Draw......430
Excessive Resistance......430
Brush Springs......430
DC to DC Converter......431
tables......383
Table 1. Fault Codes and Display Messages......403
Table 2. 1254 Hydraulic Pump Controller Parameter Settings......413
Table 3. Coil Resistance......416
Table 4. Potentiometer Specifications......421
FRAME......435
toc......435
Frame......435
Safety Precautions Maintenance and Repair......436
General......439
Frame......439
Size......439
Painting Instructions......439
Covers and Pads......440
Covers......440
Remove......440
Install......440
Pads......440
Remove......440
Install......441
Overhead Guard......442
Description......442
Remove......442
Repair......442
Install......442
Battery......444
Battery Sizes......444
Labels and Decals......445
Safety Labels......445
tables......435
Table 1. 3000 lb Capacity, 43.9-inch Wheel Base......444
Table 2. 3500 lb Capacity, 43.9-inch Wheel Base......444
Table 3. 3500 lb Capacity, 46.4-inch Wheel Base......445
Table 4. 4000 lb Capacity, 46.4-inch Wheel Base......445
HYDRAULIC SYSTEM......451
toc......451
Hydraulic System......451
Safety Precautions Maintenance and Repair......452
General......455
Multifunction Control Handle......455
Description......455
Manual Lowering......456
How to lower mast manually......456
Main Hydraulic Control Valve......457
Description......457
Check and Adjust......457
Manifold Pressures......457
Counter Balance Valve......458
Remove......458
Repair......459
Disassemble......459
Clean......460
Assemble......460
Install......460
Lift Pump and Motor......462
Description......462
Remove......462
Motor......462
Lift Pump......463
Install......463
Lift Pump......463
Motor......464
Lift Pump......464
Description......464
Disassemble......464
Assembly......465
Hydraulic Tank......466
Inspect......466
Remove......466
Clean......468
Steam Method......468
Trisodium Phosphate Method......469
Install......469
Troubleshooting......470
tables......451
Table 1. Pressure Settings......457
Table 2. Main Hydraulic Control Valve Cartridges......460
INDUSTRIAL BATTERY......475
toc......475
Industrial Battery......475
Safety Precautions Maintenance and Repair......476
General......479
Lead-Acid Batteries......479
Specific Gravity......480
Chemical Reaction in a Cell......480
Electrical Terms......481
Battery Selection......482
Battery Voltage......483
Battery as a Counterweight......483
Battery Ratings......483
Kilowatt-Hours......483
Battery Maintenance......484
Safety Procedures......484
Maintenance Records......484
New Battery......484
Cleaning Battery......485
Adding Water to Battery......486
Hydrometer......486
Battery Temperature......487
Charging Battery......488
Types of Battery Charges......489
Methods of Charging......490
Troubleshooting Charger......490
Knowing When Battery Is Fully Charged......491
Where to Charge Batteries......491
Equipment Needed......491
Battery Connectors......491
Battery Care......492
tables......475
Table 1. Battery Capacity Terms......483
MAST DESCRIPTION......497
MAST REPAIRS......515
toc......515
Mast......515
Safety Precautions Maintenance and Repair......516
General......519
Safety Procedures When Working Near Mast......519
Fork Repair......521
Remove......521
Install......521
Carriages Repair......522
Standard Carriage......522
Remove......522
Repair......523
Install......523
Integral Sideshift Carriage......523
Remove......523
Clean and Inspect......523
Repair......525
Install......525
Mast Repair......526
Remove......526
Two-Stage LFL and Two-Stage FFL Masts, Disassemble......527
Three-Stage FFL Mast......530
Disassemble......530
Mast and Chains, Clean and Inspect......532
Two-Stage LFL and Two-Stage FFL Mast, Assemble......533
Three-Stage FFL Mast, Assemble......534
Install......535
Lift Cylinders Repair......536
Free-Lift Cylinder, Remove......536
Lift Cylinders, Disassemble......536
Lift Cylinders, Assemble......537
Main Lift Cylinders, Install......538
Free-Lift Cylinder, Install......538
Header Hose Arrangement ......538
Two-Stage LFL Mast, New Hose Install......538
Two-Stage LFL Mast, Adjust Hoses after Installation......540
Two-Stage FFL Mast, New Hose Install......542
Two-Stage FFL Mast, Adjust Hoses after Installation......546
Three-Stage FFL Mast, New Hose Install......546
Three-Stage FFL Mast, Adjust Hoses after Install......551
Lift and Tilt System Leak Check......555
Lift Cylinders Leak Check......555
Tilt Cylinders Leak Check......555
Tilt Cylinders Adjustment......556
Lift Chains Adjustment......556
Mast Adjustment......557
Carriage Adjustment......558
Troubleshooting......560
MASTER DRIVE UNIT......565
PERIODIC MAINTENANCE......581
toc......581
Periodic Maintenance......581
Safety Precautions Maintenance and Repair......582
General......585
How to Move Disabled Lift Truck......585
How to Tow Lift Truck......585
How to Put Lift Truck on Blocks......586
How to Raise Load Wheels......586
How to Raise Steer Wheel......587
Lift and Tilt System Leak Checks......587
Lift System......587
Tilt System......588
Safety Procedures When Working Near Mast......588
Check Operation......589
Gauges and Horn......589
Control Handle......589
Steering System......589
Maintenance Schedule......589
Maintenance Procedures Every 8 Hours or Daily......593
Before Operation Checks......593
Hydraulic System......593
Battery......593
Battery Restraint System......594
Tires and Wheels......594
Maintenance Procedures Every 350 Hours or 3 Months......595
Hydraulic Tank Breather......595
Wheel Nut Torque......595
Transaxle......595
Lift System Operation......595
Mast......595
Lift Chains......596
Forks......597
Safety Labels......597
Other Lubrication......597
Electrical Inspection......597
Special Precautions......597
Contactors......598
Motor Brushes......598
Maintenance Procedures Every 2000 Hours or Yearly......599
Hydraulic System......599
Change the Hydraulic Oil Filter......599
Check the Hydraulic Oil Strainer......599
Change the Hydraulic Oil......599
Brakes......599
Transaxle......599
Battery Maintenance......600
How to Charge the Battery......600
How to Change the Battery......601
Wheels and Tires Maintenance......601
General......601
Wheels and Tires......601
Remove the Wheel From Lift Truck......601
Install the Tire on Wheel......601
Install the Wheel and Tire......601
Mast and Lift Chains......602
Forks......602
Adjust......602
Remove......602
Inspect......603
Install......603
tables......581
Table 1. Maintenance Schedule......590
Table 2. Transaxle Capacity......599
STEERING SYSTEM......607
TILT CYLINDERS......631
toc......631
Tilt Cylinders......631
Safety Precautions Maintenance and Repair......632
General......635
Description......635
Tilt Cylinder Repair......635
Remove......635
Disassemble......635
Clean......635
Assemble......635
Install......637
Tilt Cylinder Leak Check......639
Mast Tilt Angle Adjustment......639
Troubleshooting......640
Service Maintenance Manual for Yale Model ESC 030-050 ZA......643
