Yale ESC 030-040 FA A883, ESC 020-025-030 AB A824, ESC 030-050 ZA, ESC 030 EA Forklift Workshop Repair Service Manual PDF - MYALESCOPEK.zip

Yale Models ESC Service Maintenance Manual

A full workshop service and maintenance manual covering Yale Models ESC 030-040 FA, ESC 020-025-030 AB, ESC 030-050 ZA, and ESC 030 EA — everything needed to service, troubleshoot, repair, and maintain these units the way professional technicians do.

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