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ERP15-20VT
Repair Manual
32 pgs6.65 Mb2

Yale ERP15-20VT Repair Manual

ERP15-20VT (G807)
SERVICE MANUAL CONTENTS
PART
SECTION
FRAME............................................................................................................................ 524295629 0100 YRM 1329 09/14
CYLINDER REPAIR (MAST S/N A270-72, A551, A555, A559, A626, A627, A751-52,
B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515, D562-64, E509,
E564).......................................................................................................................... 524319496 2100 YRM 1382 03/14
NUMBER
YRM
NUMBER
REV
DATE
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 524320408 (12/14)
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure 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. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• 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 all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.
Transaxle Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Discharging the Capacitors ............................................................................................................................. 2
Special Tools................................................................................................................................................... 2
Transaxle Assembly............................................................................................................................................. 3
Remove Transaxle From Frame...................................................................................................................... 3
Remove the Parking Brake and Traction Motor............................................................................................... 4
Install Parking Brake and Traction Motor......................................................................................................... 4
Install Transaxle to Frame ............................................................................................................................... 5
Maintenance and Repair ..................................................................................................................................... 6
Speed Sensor Repair...................................................................................................................................... 6
Trunnion Cap Repair ....................................................................................................................................... 6
Fluid Level Check............................................................................................................................................ 8
Fluid Change................................................................................................................................................... 8
Breather Repair............................................................................................................................................... 9
Stud Repair ..................................................................................................................................................... 10
Brake Cylinder Repair ..................................................................................................................................... 11
Input Seal Repair ............................................................................................................................................ 13
Cover to Housing Seal .................................................................................................................................... 13
During the Transaxle Warranty Period ........................................................................................................ 13
After the Transaxle Warranty Period ........................................................................................................... 14
Removing the Cover............................................................................................................................... 14
Installing the Cover................................................................................................................................. 15
Wet Brakes...................................................................................................................................................... 16
This section is for the following models:
ERP15-20VT (ERP030-040VT) [G807];
ERP16-20VF (ERP30-40VF) [A955]
©2012 Yale Materials Handling Corp. i
1300 YRM 1330 General
General
CAUTION
DO NOT remove the cover from the transaxle hous­ing during the warranty period. Removing the cover from the housing will void the transaxle warranty. The transaxle warranty period may vary from truck hours or other warranties. Contact Yale Company Contact Management if you have questions about warranty status.
CAUTION
Use only transmission fluid from approved ven­dors. Using fluid from unapproved vendors will void the warranty. Contact Yale Company Contact Management if you have questions about warranty status.
A. LEFT SIDE B. RIGHT SIDE
C. FORWARD
TRAVEL
This section contains the removal, repair, inspection, and installation instructions for the transaxle assem­bliesusedonthesemodels.
WARNING
DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dan­gerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is neces­sary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery.
Throughout this section, forward will refer to travel in the direction of the forks and left and right will be deter­mined by sitting in the seat facing forward. See Figure 1 or Figure 2.
Figure 1. Truck Orientation (Three-Wheel Trucks)
A. LEFT SIDE B. RIGHT SIDE
Figure 2. Truck Orientation (Four-Wheel Trucks)
C. FORWARD
TRAVEL
1
General 1300 YRM 1330
DISCHARGING THE CAPACITORS
WARNING
DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dan­gerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is neces­sary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery.
Disconnect the battery and allow the capacitors to discharge before opening any compartment cov­ers or inspecting or repairing the electrical system. DO NOT place tools on top of the battery. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage.
Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so. Never wear any metallic items on your fingers, arms, or neck. Metal items can accidentally make an electri­cal connection and cause injury.
4. Blockdrivewheelstopreventlifttruckfrommoving.
5. Make sure Emergency Disconnect Switch HAS
NOT been activated. If Emergency Disconnect Switch is activated, rotate switch to the right until it pops up.
6. Press horn button. Wait 30 seconds to be sure
capacitors are fully discharged.
SPECIAL TOOLS
Special tools are necessary to properly perform some repairs. These tools are available from your Yale dealer. Warranty will not cover damage resulting from work done using improper tools. Refer to Table 1.
Table 1. Yale Special Tools
Input Seal Driver
Ya l e P a r t N o .
582000161
Before performing any tests or adjustments, block the lift truck to prevent unexpected movement.
The capacitor in the transistor controller(s) can hold an electrical charge for about 10 seconds after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected.
DO NOT short across the motor controller terminals with a screwdriver or jumper wire.
Make certain the Emergency Disconnect Switch has not been activated. This will isolate the con­troller and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors.
1. Ensure capacitors are discharged by performing
Step 2 through Step 6 below.
2. Tu r n k ey o r k e yl es s sw it ch t o OFF position.
3. Disconnect battery by separating connectors.
Breather Set Tool
Ya l e P a r t N o .
582000187
Wheel Stud Tool
Ya l e P a r t N o .
582000162
2
1300 YRM 1330 Transaxle Assembly
Transaxle Assembly
REMOVE TRANSAXLE FROM FRAME
WARNING
The lift truck of maintenan of the batter will cause la Position add lift truck is over.
1. Remove mast
See Mast Rep Masts 4000 Y
els
• ERP15-20VT
• ERP16-20VF
See Mast Rep Masts 4000 Y
lift truck m
• ERP15-20VT
• ERP16-20VF
2. Tu r n k ey s wi
tery.
3. Position li
suspended o
must be put on blocks for some types
ce and transaxle repair. The removal
y, mast, transaxle, or the counterweight
rge changes in the center of gravity.
itional blocks under theframe when the
on blocks, so the lift truck cannot tip
assembly.
air, 2- and 3-Stage High Visibility
RM 1386 for European lift truck mod-
(G807) (A955)
air, 2-, 3-, And 4-Stage Heavy Duty
RM 1405 for European and American
odels
(ERP030-040VT) (G807) (ERP30-40VF) (A955)
tch to OFF position and disconnect bat-
ft truck frame on blocks so drive tires are
ff the floor.
8. Tag and disconnect power cables from traction mo-
tor studs.
9. Disconnect traction motor temperature sensor at
traction motor.
10. Disconnect service brake line from port on
transaxle. Cap brake line andplug port on transaxle to reduce the possibility of contamination entering brake system.
11. Loosen, but do not remove, five mounting cap-
screws and nuts that hold transaxle assembly on lift truck.
WARNING
The transaxle and traction motor assemblies are heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the transaxle and traction motor.
12. Position a floor jack under transaxle assembly.
Make sure assembly is properly balanced on floor jack so it will not fall once mounting capscrews have been removed.
CAUTION
Check that cables, hoses, and wires do not interfere with the removal of the transaxle assembly.
See Period truck mode
• ERP15-20V
See Period truck mode
• ERP16-20V
4. Remove driv
assembly.
5. Disconnec
main wirin
6. Disconnec
wiring har
7. Disconnec
brakes.
t transaxle speed sensor connector from
g harness.
t parking brake connector from main
ness.
t manual override cable from parking
ic Maintenance 8000 YRM 1339 for lift
ls
T (ERP030-040VT) (G807)
ic Maintenance 8000 YRM 1373 for lift
ls
F (ERP30-40VF) (A955)
e tire lug nuts and drive tire and wheel
13. Remove five capscrews and washers holding
transaxle on lift truck frame. Carefully lower transaxle assembly from lift truck frame using floor jack.
WARNING
The transaxle and traction motor assemblies are heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the transaxle and traction motor.
14. Transfer transaxle assembly from floor jack to a
clean workbench using an appropriate sling and overhead lifting device.
3
Transaxle Assembly 1300 YRM 1330
REMOVE THE PARKING BRAKE AND TRACTION MOTOR
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.
WARNING
The traction motor is heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the traction motor.
1. Position transaxle on blocks with studs down. Se-
curely support in this position.
2. Remove parking brake assembly from traction mo-
tor:
a. Remove four capscrews, lockwashers, and
washers holding brake assembly on traction motor. See Figure 3.
WARNING
The traction mo devices are sui the traction m
1. Position tran
curely suppor
2. Install tract
a. Install an eye
attach an over capacity to e
b. Lightly lubr
shaft with mu seats proper necessary to it is lubrica See Figure 4
otor.
ion motor on transaxle:
torisheavy.Besurethatalllifting
table and of adequate capacity to lift
saxle on blocks with studs down. Se-
t in this position.
bolt to traction motor shaft and
head lifting device of adequate
yebolt.
icate inside lip of transaxle input
ltipurpose grease to ensure seal
ly on traction motor shaft. It is not
lubricate traction motor shaft as
ted internally within the transaxle.
.
b. Pry evenly on opposite sides to remove brake
assembly from brake hub. Remove brake as­sembly by hand.
c. Remove snap ring holding brake hub on trac-
tion motor shaft. Slide hub from shaft. Remove snap ring and woodruff key from beneath hub.
3. Remove traction motor from transaxle:
a. Install an eyebolt to traction motor shaft and
attach an overhead lifting device of adequate capacity to eyebolt.
b. Remove four capscrews and washers mounting
traction motor to transaxle.
c. Lift traction motor from transaxle using over-
head lifting device.
INSTALL PARKING BRAKE AND TRACTION MOTOR
WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.
1. CAPSCREW
2. LOCKW
3. WASHER
4. PARKING BRAKE ASSEMB
5. TRACTION MOTOR
ASHER
LY
6. CAPSCREW
7. WASHE
8. MOTOR SHAFT
9. TRANSAXLE
10. INPUT S
Figure 3. Traction Motor and Parking Brake
R
EAL
4
1300 YRM 1330 Transaxle Assembly
c. Lift traction motor and position it on transaxle
using overhead lifting device. Guide traction motor shaft into transaxle through input seal. Align motor with transaxle.
d. Install four capscrews and washers mounting
traction motor on transaxle. Tighten capscrews to 48 N•m (35 lbf in).
e. Remove eyebolt from traction motor shaft.
3. Install parking brake assembly to traction motor:
a. Install lower snap ring and woodruff key on
traction motor shaft. Align groove in hub with woodruff key and slide hub onto shaft. Install upper snap ring holding brake hub onto trac­tion motor shaft.
b. Position brake assembly onto brake hub. Align
splines and seat brake on traction motor end head.
c. Install four capscrews, lockwashers, and wash-
ers to secure brake assembly. Tighten cap­screws to 8 N•m (71 lbf in).
INSTALL TRANSAXLE TO FRAME
1. Check that dowels are installed in transaxle housing
and are in good condition. Replace as necessary.
WARNING
The transaxle and traction motor assembly are heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the transaxle and traction motor.
2. Move transaxle assembly onto a floor jack using
an appropriate sling and lifting device. Make sure assembly is balanced and properly supported so it will not fall during installation.
3. Carefully position transaxle on frame using floor
jack. Align transaxle mounting dowels with their mounting holes in frame.
4. Apply Loctite® 271 to five socket head capscrews
and washers. Install capscrews with washers through transaxle and into mounting holes in frame. Tighten capscrews to 220 N•m (162 lbf ft).
1. CAPSCREW
2. LOCKWASHER
3. WASHER
4. PARKING BRAKE ASSEMBLY
5. TRACTION MOTOR
6. CAPSCREW
7. WASHER
8. MOTOR SHAFT
9. TRANSAXLE
10. INPUT SEAL
Figure 4. Traction Motor and Parking Brake
5. Remove cap and plug from service brake line and
service brake port. Install service brake line to ser­vice brake port. Tighten to 12 to 16 N•m (108 to 192 lbf in).
6. Connect power cables to traction motor studs as
tagged during removal. Tighten to 8 N•m (71 lbf in).
7. Connect traction motor temperature sensor con-
nectors to main wiring harness.
8. Connect parking brake connector to main wiring
harness.
9. Connect manual override cable to parking brakes.
10. Connect transaxle speed sensor connector to main
wiring harness.
5
Maintenance and Repair 1300 YRM 1330
CAUTION
Make sure the lift truck is blocked at the same height as with the drive tire installed to ensure the proper fluid level reading.
11. Bleed the service brakes. Refer Brake System
1800 YRM 1332 for procedures.
12. Check fluid level in transaxle. Fill as necessary.
See Fluid Level Check.
13. Install drive tire and wheel assembly on wheel hub.
Install lug nuts and tighten to 170 N•m (125 lbf ft).
14. Connect battery connector, turn key switch to ON
position, and test lift truck for proper operation.
15. Lower lift truck from the blocks.
See Periodic Maintenance 8000 YRM 1339 for lift truck models
• ERP15-20VT (ERP030-040VT) (G807)
Maintenance and Repair
See Periodic Maintenance 8000 YRM 1373 for lift truck models
• ERP16-20VF (ERP30-40VF) (A955)
16. Install mast on lift truck.
See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck mod-
els
• ERP15-20VT (G807)
• ERP16-20VF (A955)
See Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and American
lift truck models
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
SPEED SENSOR REPAIR
The speed sensor monitors the speed of the transaxle and relays the information to the controller. The speed sensor can be replaced with the transaxle installed to the lift truck.
1. Park lift truck on a level surface. Turn key switch to OFF position and unplug battery connector.
2. Discharge capacitors. See section Discharging the
Capacitors.
3. Remove floor mat and floor plates from operator compartment to access top of transaxle(s).
4. Disconnect sensor wiring harness from main wiring harness.
CAUTION
Use a brush to clean around the sensor before re­moving to avoid contaminating the transaxle.
5. Remove capscrew holding sensor to transaxle us-
ing a 5mm Allen wrench. See Figure 5.
6. Pull sensor out of transaxle.
7. Insert new sensor into transaxle.
8. Align screw holes and install capscrew. Tighten
capscrew to 9.5 N•m (84.0 lbf in).
9. Connect sensor wiring harness to main wiring har-
ness.
10. Replace floor plates and floor mat in operator com-
partment.
11. Connect battery, turn key to ON position and test lift
truck for proper operation.
TRUNNION CAP REPAIR
To repair the trunnion cap:
1. Remove load from forks and park lift truck on a level
surface. Adjust mast to a vertical position, then turn key switch to OFF position and separate battery connectors.
2. Remove four capscrews holding trunnion cap on
transaxle housing. Remove trunnion cap. See Fig­ure 6.
3. Wipe away any dirt or grease near mounting holes.
Clean holes with a proper sized tap and tap wrench as necessary.
6
1300 YRM 1330 Maintenance and Repair
4. Position new cap over mast pin and onto transaxle.
5. Apply Loctite® 242 to threads and install four cap-
screws and tighten alternately in small increments. Tighten capscrews to 24 N•m (216 lbf in).
6. Grease fitting in mast stub shaft to lubricate trun-
nion cap.
7. Connect battery, turn key to ON position and test lift
truck for proper operation.
1. CAPSCREWS
2. TRUNNION CAP
3. THREADED MOUNTING HOLES
4. TRANSAXLE HOUSING
1. CAPSCR
2. SPEED SENSOR
3. FILL PLUG
4. TRANSAX
5. COVER CAPSCREWS
6. DRAIN PLUG
EW
LE COVER
Figure 5. Speed Sensor
Figure 6. Trunnion Cap
7
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