Yale d216 erp20alf (erp040 060dh) lift truck service repair manual

ERP20ALF, ERP25ALF, ERP30ALF (D216) (ERP040-060DH) (D216) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................

DC MOTOR MAINTENANCE..........................................................................................

AC MOTOR MAINTENANCE..........................................................................................

DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL.............................................

STEERING AXLE............................................................................................................

STEERING CONTROL UNIT..........................................................................................

STEERING SYSTEM......................................................................................................

BRAKE SYSTEM............................................................................................................

HYDRAULIC SYSTEM....................................................................................................

MAIN CONTROL VALVE................................................................................................

TILT CYLINDERS...........................................................................................................

ELECTRICAL SYSTEM..................................................................................................

AC MOTOR CONTROLLER DESC/CHKS/ADJ/TRBSHT/REP&THEORY OF OPERATION/DISPLAY PANEL.................................................................................

TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS PROGRAM.................................................................................................................

INDUSTRIAL BATTERY.................................................................................................

MAST - DESCRIPTION...................................................................................................

MAST - REPAIR..............................................................................................................

METRIC AND INCH (SAE) FASTENERS.......................................................................

DIAGRAMS.....................................................................................................................

PERIODIC MAINTENANCE............................................................................................

CAPACITIES AND SPECIFICATIONS...........................................................................

PART NO. 524183079 (09/14)

PART NUMBER

YRM NUMBER

REV DATE

524179935 524158039 524183080 524179938 524158752 524158753 524183081 524179943 524179945 524179946 524150790 524183082

0100 YRM 0582 0620 YRM 0294 0620 YRM 1053 1400 YRM 0575 1600 YRM 0316 1600 YRM 0720 1600 YRM 1054 1800 YRM 0566 1900 YRM 0559 2000 YRM 0562 2100 YRM 0103 2200 YRM 1055

07/05 03/08 03/10 03/03 08/06 11/06 11/06 03/03 04/09 02/09 03/07 10/09

524183083

2200 YRM 1056

03/09

524183085 524158040 524158890 524158891 524150797 524183086 524183087 524183088

2200 YRM 1058 2240 YRM 0001 4000 YRM 0521 4000 YRM 0522 8000 YRM 0231 8000 YRM 1059 8000 YRM 1060 8000 YRM 1061

04/11 09/14 03/06 07/10 10/13 08/12 02/10 01/05

100 YRM 582

Description

General This section has a description and the service procedures for the parts of the frame. These parts include the frame, counterweight assembly, overhead guard, hood and seat assembly, access panels, and label positions. The procedure for removing the traction motor is also described in this section.

Description MAIN FRAME The main frame is a single weldment. See Figure 1.

The main frame has mounts for the following: • Counterweight • Overhead guard, • Battery restraint and hood • Tilt cylinders • Steering axle • Drive axle assembly • Cowl assembly • Floor pedals and floor plates • Side step and fender weldments • Hydraulic tank • Pump and motor assemblies (steer, lift, and traction motors) • Control valves, and the levers The hood is part of the operator and battery restraint system. The seat is part of the operator restraint system. The floor plates can be removed for access to the traction motor. The panels on the sides of the battery compartment can also be easily removed. The hydraulic tank, lift pump motor assembly, and the steering pump motor assembly are in a compartment between the battery and the counterweight. The SCR (silicon controlled rectifier) or transistor electronic controllers and contactors are in the top of the counterweight. The top cover of the counterweight can be removed for access to the controllers and contactors for early model ERP20-30ALF (B216) lift trucks. See Figure 2. The rear cover of the counterweight can be removed for access to the controllers and contactors for later model ERP20-30ALF (B216) trucks and ERP2030ALF (ERP040-060DH) (D216) trucks. See Figure 3.

There are two main frames for lift trucks made for use in North America and two main frames for lift trucks made for use in Europe. The frames are different because of the different battery compartment sizes. There are two battery compartment lengths. The battery compartment widths are also different for Europe and North

America. See Battery Specifications, at the back of this manual.

WARNING The battery must fit the battery compartment so that the battery restraint will operate correctly. A loose battery can cause serious injury and property damage if the lift truck overturns. Adjust the spacer plate to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

WARNING Maximum clearance between the battery and battery compartment width is 13 mm (0.5 in.). Maximum clearance between the battery and the spacer plate is also 13 mm (0.5 in.). The Battery Specifications chart shows the minimum size compartment allowed.

The weight of the battery is a large part of the counterweight system on an electric lift truck. Make sure that the battery is within the weight limits indicated on the nameplate. Each model of lift truck has a cast-iron counterweight that provides the additional weight necessary for the indicated capacity.

OTHER FRAME WELDMENTS These frame parts are the right-hand and left-hand side step and fender weldments, and the cowl weldment.

See Figure 1. Each part is a weldment fastened to the main frame to make the frame assembly. The cowl weldment is a mount for the front of the overhead guard (see Figure 2 and Figure 3), the steering column assembly (see Figure 4, Figure 5, and Figure 6), the release linkage of the parking brake, and the instrument panel with light switches. The display panels for these models of lift trucks are mounted into the instrument panel. See Figure 4, Figure 5, and Figure 6.

1

Description

1.

2.

3.

4.

100 YRM 582

COWL BATTERY SPACER PLATE BATTERY RETAINER ROD FRAME

5. SIDE STEP AND FENDER WELDMENT 6. ACCESS PANEL 7. FLOOR PLATES Figure 1. Lift Truck Main Frame

Legend for Figure 2 1. OVERHEAD GUARD 2. COVER OF ELECTRONICS COMPARTMENT 3. COUNTERWEIGHT

2

4.

5.

6.

7.

TOW PIN AND HANDLE CAPSCREW LOCKWASHER WASHER

8.

9.

10.

11.

HANDLE SCREW NUT FOAM TAPE

100 YRM 582

Description

Figure 2. Overhead Guard and Counterweight Early Model ERP20-30ALF (B216) Trucks

3

Description

100 YRM 582

OVERHEAD GUARD WARNING Do not operate the lift truck without the overhead guard and cowl correctly fastened to the lift truck.

falling objects. For early model ERP20-30ALF (B216), see Figure 2. For later model ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216) trucks, see Figure 3. A slot in the overhead guard permits removal of the battery without removing the overhead guard.

The overhead guard is a weldment that fastens to the main frame and cowl to help protect the operator from Legend for Figure 3 A. OVERHEAD GUARD USED ON LATER MODEL ERP20-30ALF (B216) TRUCKS B. OVERHEAD GUARD USED ON ERP20-30ALF (ERP040-060DH) (D216) TRUCKS 1.

2.

3.

4.

5.

6.

7.

8.

9.

4

OVERHEAD GUARD HANDLE ROLLING THREAD SCREW NUT WASHER CAPSCREW COVER TOW PIN TAPE

10.

11.

12.

13.

14.

15.

16.

17.

COVER SOCKET CAPSCREW LOCKWASHER COUNTERWEIGHT FOAM TAPE SPACER BRACKET SELF RETAINING NUT

100 YRM 582

Description

Figure 3. Overhead Guard and Counterweight Later Model ERP20-30ALF (B216) Trucks and ERP20-30ALF (ERP040-060DH) (D216) Trucks

5

Description

100 YRM 582

A. CURTIS METER B. GE METER (OPTIONAL) C. STEERING CONTROL UNIT USED ON EARLY MODEL LIFT TRUCKS

D. STEERING CONTROL UNIT USED ON LATER MODEL LIFT TRUCKS

1.

2.

3.

4.

5.

6.

7.

8. OPTIONAL BASIC DISPLAY PANEL 9. STANDARD DISPLAY PANEL (WITH CURTIS OR GE METER) 10. PREMIUM DISPLAY PANEL 11. HORN BUTTON 12. STEERING COLUMN 13. STEERING COLUMN NUT

STEERING WHEEL STEERING CONTROL UNIT LATCH MECHANISM COLUMN COVER COLUMN FRAME HORN SWITCH CONNECTOR ON-DEMAND STEERING COMPONENTS (NOT ALL UNITS)

Figure 4. Steering Column and Instrument Panel Early Model ERP20-30ALF (B216) Lift Trucks

6

100 YRM 582

1.

2.

3.

4.

5.

6.

7.

STEERING WHEEL SHIFT LEVER MECHANISM COLUMN COVER STEERING CONTROL UNIT COLUMN FRAME ON-DEMAND STEERING COMPONENTS DISPLAY PANEL (PREMIUM DISPLAY PANEL SHOWN)

Description

8.

9.

10.

11.

12.

LATCH MECHANISM HORN SWITCH CONNECTOR HORN BUTTON STEERING COLUMN STEERING COLUMN NUT

Figure 5. Steering Column and Display Panel, Later Model ERP20-30ALF (B216) Trucks

7

Description

100 YRM 582

Figure 6. Steering Column and Display Panel, ERP20-30ALF (ERP040-060DH) (D216) Trucks

8

100 YRM 582

Description Legend for Figure 6

1.

2.

3.

4.

5.

6.

7.

8.

ON-DEMAND STEERING COMPONENTS SHIFT LEVER MECHANISM STEERING WHEEL DISPLAY PANEL COLUMN COVER COLUMN FRAME STEERING CONTROL UNIT COWL WELDMENT

BATTERY AND OPERATOR RESTRAINT, HOOD, AND SEAT ASSEMBLY Battery Restraint WARNING The hood and battery restraint, as well as the latch for the hand lever assembly, must operate correctly before a lift truck is operated. These parts are part of the battery restraint system. The battery restraint system must operate correctly to help provide reasonable protection to the operator if the lift truck tips over.

9.

10.

11.

12.

13.

14.

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DASH COLUMN MOUNT LATCH MECHANISM HORN SWITCH CONNECTOR HORN BUTTON STEERING COLUMN STEERING COLUMN NUT

movement of the battery. See Figure 8. The adjustable spacer plate is used inside the battery compartment.

See Figure 8. The spacer plate must be adjusted for a maximum clearance of 13 mm (0.5 in.) with the battery against the rear bulkhead. There must be some clearance to allow battery removal. See the section Periodic Maintenance 8000 YRM 552 for both early and later model ERP20-30ALF (B216) trucks and Periodic Maintenance 8000 YRM 1060, for ERP20-30ALF (ERP040-060DH) (D216) models, to remove the battery and adjust the spacer plate.

A battery restraint system is installed as a safety device.

See Figure 7. The function on the battery restraint system is to hold the battery in the battery compartment in case of a tip over. Part of the battery restraint system is a battery restraint rod at the rear of the battery compartment. See Figure 7. This restraint rod extends over the rear edge of the battery case to help hold the battery within the battery compartment during a tip over. A handle is used to move the restraint rod. The handle of the battery restraint must be in the DOWN position to close the hood. The handle can be moved to the DOWN position only after the restraint rod is extended over the battery. The restraint rod can only be retracted when the hood is in the UP position.

WARNING The battery must fit the battery compartment so that the battery restraint will operate correctly. A loose battery can cause serious injury and property damage if the lift truck overturns. The battery must not be able to move more than 13 mm (0.5 in.) forward, backward, or side to side.

An adjustable spacer plate is used at the front of the battery compartment to prevent forward and backward

A. RETRACTED 1.

2.

3.

4.

5.

B. EXTENDED

BATTERY RESTRAINT WARNING LABEL HOOD BATTERY RESTRAINT HANDLE BATTERY STEEL WELDMENT Figure 7. Battery Restraint Rod

9

Description

100 YRM 582

Hood WARNING The gas springs for the hood can raise the hood at a rapid rate and cause an injury. DO NOT get over hood when raising hood.

WARNING The batteries for these lift trucks must fit the battery compartment width with a maximum of 13 mm (0.5 in.) clearance. The Battery Specifications at the back of this manual, shows the minimum sizes of the battery compartments.

1. BATTERY COMPARTMENT 2. BATTERY 3. BULKHEAD

4. SPACER PLATE 5. ADJUSTMENT CAPSCREW 6. JAM NUTS

Figure 8. Battery Spacer Plate

Another important part of the battery restraint system is the steel weldment that is also the hood frame. See Figure 7. This hood frame is connected to the lift truck frame with hinges at the rear of the hood (see Figure 13). The front of the hood and frame is locked in the closed position by the assembly for the hydraulic hand levers. A latch releases the assembly to tilt forward and allow the hood to raise. See Figure 9. Gas springs help lift the hood assembly. The seat and other parts of the operator restraint system fasten to the hood assembly.

A. CLOSED OVER HOOD

B. OPEN

1. HAND LEVER ASSEMBLY 2. HOOD 3. SEAT

4. LATCH HANDLE 5. LATCH

Figure 9. Hood and Hand Lever Assembly with Latch

10

100 YRM 582

Overhead Guard Replacement

Operator Restraint System and Seat Assembly The operator restraint system has the seat, hip restraints, and the seat belt. The system helps the operator stay within the lift truck in case of a tip over.

See Figure 10.

Make sure that the seat is not loose on the rails. Make sure the seat rails are not loose. The seat rails must lock securely in position, but move freely when unlocked.

The seat rails must be securely attached to the mounting surface.

Legend for Figure 10 1.

2.

3.

4.

5.

SEAT HIP RESTRAINT SEAT BELT AND MOUNT SEAT RAILS CAPSCREW

Figure 10. Seat Assembly and Operator Restraint

Overhead Guard Replacement REMOVE WARNING Do not weld, drill, grind, or cut the overhead guard for mounts of lights or accessories. The strength of the overhead guard can be reduced.

1. Remove the battery as described in the section Periodic Maintenance 8000 YRM 552 for both early and later ERP20-30ALF (B216) model lift trucks and Periodic Maintenance 8000 YRM 1060 for ERP20-30ALF (ERP040-060DH) (D216) lift truck models.

2. Access to the capscrews that hold the rear legs of the overhead guard to the frame is from the battery compartment. See Figure 11 and Figure 12. Remove the capscrews, washers, and nuts that fasten each leg.

3. Remove the capscrews, washers, and nuts that hold each front leg of the overhead guard to the cowl. Disconnect any electric wires from under the cowl that go through the front legs of the overhead

guard. When the overhead guard is lifted from the frame, make sure these electric wires move through the holes in the frame at the front and rear so that they are not damaged.

4. Use a lifting device or another person to help lift the overhead guard from the lift truck.

INSTALL Put the overhead guard on the lift truck. Install any electric wires from the overhead guard legs through the holes in the frame. Install the capscrews, washers, and nuts that hold each front leg to the frame. See Figure 11 and Figure 12. Tighten the capscrews to 102 N•m (75 lbf ft). Install the capscrews, washers, and nuts that hold the rear legs to the frame. Tighten the capscrews to 102 N•m (75 lbf ft). Install the battery as described in the section Periodic Maintenance 8000 YRM 552 for both early and later ERP20-30ALF (B216) model lift trucks and Periodic Maintenance 8000 YRM 1060 for ERP20-30ALF (ERP040-060DH) (D216) lift truck models.

11

Overhead Guard Replacement

100 YRM 582

Figure 11. Overhead Guard and Counterweight Early Model ERP20-30ALF (B216) Trucks

12

100 YRM 582

Overhead Guard Replacement Legend for Figure 11

1.

2.

3.

4.

5.

6.

OVERHEAD GUARD COVER OF ELECTRONICS COMPARTMENT COUNTERWEIGHT TOW PIN AND HANDLE CAPSCREW LOCKWASHER

7.

8.

9.

10.

11.

12.

WASHER HANDLE SCREW NUT NUT FOAM TAPE

13

Overhead Guard Replacement

100 YRM 582

Figure 12. Overhead Guard and Counterweight Later Model ERP20-30ALF (B216) Trucks and ERP20-30ALF (ERP040-060DH) (D216) Trucks

14

100 YRM 582

Hood, Seat Assembly and Operator Restraint Replacement Legend for Figure 12

A. OVERHEAD GUARD USED ON LATER MODEL ERP20-30ALF (B216) TRUCKS B. OVERHEAD GUARD USED ON ERP20-30ALF (ERP040-060DH) (D216) TRUCKS 1.

2.

3.

4.

5.

6.

7.

8.

9.

OVERHEAD GUARD HANDLE ROLLING THREAD SCREW NUT WASHER CAPSCREW COVER TOW PIN TAPE

10.

11.

12.

13.

14.

15.

16.

17.

COVER SOCKET CAPSCREW LOCKWASHER COUNTERWEIGHT FOAM TAPE SPACER BRACKET SELF RETAINING NUT

Hood, Seat Assembly and Operator Restraint Replacement HOOD AND SEAT ASSEMBLY Remove WARNING The gas spring for the hood can raise the hood at a rapid rate and cause an injury. DO NOT get over hood when raising hood.

NOTE: The hood and seat assembly can be removed as a unit or the seat assembly can be removed with the hood assembly installed on the truck frame. Do only the steps necessary. If the hood and seat assembly will be removed as a unit, do Step 1 through Step 4. To remove the seat assembly from the hood assembly, do Step 1 through Step 3 and Step 5 through Step 7.

Remove the hood and seat assembly as follows (see Figure 13): 1. Turn the key to the OFF position and remove the key.

WARNING Never put tools or other metal on the battery. Metal on the battery can cause a short circuit and possible damage or injury.

3. Disconnect the connector for the seat switch wires near the rear of the hood frame. If the hood will be removed, remove the Emergency Stop knob and the power disconnect assembly from the hood.

4. Fasten the hood assembly so that it cannot lower and carefully remove the gas springs from the hood.

Have an assistant help hold the hood assembly.

Remove the screws that fasten the hood assembly to the lift truck frame. See Figure 13 and Figure 14.

Carefully remove the hood assembly.

5. Push the connector of the seat switch wire through the grommet in the hood. It can be necessary to remove the grommet from the hole in the hood for enough clearance to get the connector through the grommet. Inspect seat switch and replace if worn or damaged. See Figure 13 6. Remove the screws that fasten the seat to the hood and hood frame. Close and latch the hood and put the seat on its side for access to the seat switch.

7. Use a flat blade screwdriver or other tool with a flat blade to carefully lift the switch free of the seat pan.

Slide the switch out of the seat cushion.

2. Open the hood and disconnect the battery connector. Install a cardboard or plywood cover on the top of the battery to prevent accidental short circuits.

15

Hood, Seat Assembly and Operator Restraint Replacement

Figure 13. Hood Remove

16

100 YRM 582

100 YRM 582

Hood, Seat Assembly and Operator Restraint Replacement Legend for Figure 13

A. TOP VIEW B. SIDE VIEW

C. HOOD IN OPEN POSITION

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

HOOD HANDLE EMERGENCY STOP BUTTON HOOD SEAT SWITCH GAS SPRING SEAT

Install NOTE: If just the seat assembly was removed, install seat assembly onto hood by performing Step 1, Step 2, Step 4, and Step 5. If the hood and seat assembly were removed, install hood and seat assembly by performing Step 3 through Step 5.

1. Carefully slide the seat switch into the cavity of the seat cushion until the end of the switch with the wires is aligned over the hole in the pan. Push on the switch until the clips of the switch are fastened to the seat. See Figure 13.

2. Carefully install the grommet over the wire connector (see Figure 14.) Install the seat on the hood and

SEAT RAILS HOOD BRACKET SPRING CAPSCREW, WASHER, AND NUT WASHER, NUT, AND BOLT BATTERY COVER OVERHEAD GUARD tighten the nuts. Install the grommet in the hole of the hood, connect the wire connector, and push the connector back inside the hood frame.

3. If the hood assembly was removed, have an assistant help align the hood assembly in the correct position. Install the screws that fasten the hood assembly to the lift truck frame. See Figure 13. Hold the hood assembly in the open position and carefully install the gas springs.

4. Install the power disconnect assembly on the hood.

Install the Emergency Stop knob.

5. Remove cardboard or plywood from top of battery.

17

Hood, Seat Assembly and Operator Restraint Replacement

1.

2.

3.

4.

5.

6.

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8.

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10.

HOOD STEEL WELDMENT PLATE WASHER LOCKWASHER NUT GAS SPRING FOAM TAPE SPACER BRACKET

11.

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16.

17.

18.

19.

20.

100 YRM 582

CAPSCREW TRIM COVER RIVET HANDLE STRAP CLAMP CLIP INSULATION BOLT GROMMET

Figure 14. Hood Assembly

18

100 YRM 582

Counterweight Replacement

OPERATOR RESTRAINT SYSTEM The parts of the operator restraint system are as follows: the seat belt, hip restraint brackets, seat and mounting, battery restraint (restraint rod and hood plate), and the assembly for the hydraulic hand levers and latch. See Figure 13 and Figure 15. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition.

The seat belt must latch securely. Make sure the seat belt extends and retracts smoothly and is not damaged or torn. If the seat belt cannot be pulled from the retractor assembly, the seat belt assembly must be replaced.

1.

2.

3.

4.

5.

SEAT HIP RESTRAINT SEAT BELT AND MOUNT SEAT RAILS CAPSCREW

Figure 15. Operator Restraint and Seat Assembly

Counterweight Replacement If the lift truck must be put on blocks for maintenance and repair, see the section Periodic Maintenance 8000 YRM 552 for early and later model ERP20-30ALF (B216) trucks and Periodic Maintenance 8000 YRM 1060 for ERP20-30ALF (ERP040-060DH) (D216) models, for the procedures of putting the lift truck on blocks.

WARNING

REMOVE NOTE: For early model ERP20-30ALF (B216) lift trucks, do Step 1 through Step 4 and Step 6 and Step 7. For later model ERP20-30ALF (B216) lift trucks and for ERP20-30ALF (ERP040-060DH) (D216) lift trucks, do Step 1 and Step 5 through Step 7.

The counterweight is very heavy. Make sure that the crane and lifting devices have enough lifting capacity to safely lift the counterweight. The weights of the counterweights are shown in Table 1.

1. Remove the battery. See the section Periodic Maintenance 8000 YRM 552 for ERP20-30ALF (B216) models and Periodic Maintenance 8000 YRM 1060 for ERP20-30ALF (ERP040-060DH) (D216) models, for the procedures to remove the battery.

The counterweight normally is not removed for most repairs. The counterweight is fastened to the frame with four capscrews. The weights for the counterweights are shown in Table 1.

2. Remove the top cover of the counterweight (cover over electronics compartment). See Figure 11.

19

Counterweight Replacement

100 YRM 582 Table 1. Counterweights

Model

(mm*)

ERP20ALF and ERP25ALF (B216), ERP20ALF and ERP25ALF (ERP040DH and ERP050DH) (D216)

717 mm

ERP25ALF and ERP30ALF (B216), ERP25ALF and ERP30ALF (ERP50DH and ERP60DH) (D216)

861 mm

ERP30ALF (B216) and ERP30ALF (ERP060DH) (D216)

861 mm

Weight

+50 kg (110 lb) 0 kg (0 lb)

685 kg (1510 lb)

750 kg (1653 lb)

*Approximate battery compartment lengths.

WARNING Do not touch the terminals of capacitor C1 of the traction or lift motor SCR controllers. The charge on the capacitors can cause electrical shock and personal injury. Disconnect the battery and use an insulated screwdriver or jumper wire to make a short circuit across the capacitor terminals. The short circuit will discharge each capacitor and prevent electrical shocks.

1. COUNTERWEIGHT

3. Remove the three capscrews that fasten the motor controllers to the counterweight. See Figure 16.

Carefully lift the controller assembly up to a nearly vertical position. Use cord or wire fastened to the overhead guard to hold the controller assembly in this vertical position.

2. CAPSCREWS

Figure 16. Remove Motor Controllers, ERP30ALF (B216) Models Only

20

100 YRM 582 4. Install a lifting eye in the hole at the top rear of the counterweight. Use a lifting eye [shaft length approximately 200 mm (8 in.)] with a washer and nut. Fasten a sling or chain to the lifting eye. Make sure the chain or sling and crane has the capacity to lift the counterweight. See Table 1. Raise the crane to make sure the crane is the support for the weight of the counterweight.

5. Remove the top cover on the counterweight and the cover in the front part of the counterweight that covers the electronic control compartment. See Figure 12. Fasten a sling or chain around the counterweight. Make sure the chain or sling and crane has the capacity to lift the counterweight. See Table 1.

6. From inside the battery compartment near the bottom, remove the two top capscrews that hold the counterweight to the frame. Remove the capscrews, nuts, and washers that fasten the counterweight between the wheels under the tow pin. Use the crane to lift the counterweight away from the lift truck frame. On Later Model ERP20-30ALF (B216) Trucks and ERP20-30ALF (ERP040-060DH) (D216) Model Trucks, make sure that you do not damage the motor controller assembly.

7. Put the counterweight in a position so that it cannot fall and cause damage or in injury.

INSTALL, EARLY MODEL ERP20-30ALF (B216) LIFT TRUCKS 1. Use a crane and a lifting eye to lift the counterweight into position at the rear of the truck. Make sure that you do not damage the motor controller assembly during installation. See Figure 11. Install the two upper capscrews near the bottom of the battery compartment that hold the counterweight to the frame. Install the lower capscrews, washers, and nuts in the tow pin area of the counterweight.

Tighten the upper capscrews to 320 N•m (236 lbf ft).

Counterweight Replacement Tighten the lower (between wheels) capscrews and nuts to 66 N•m (49 lbf ft). If removed, tighten the cover capscrews to 52 N•m (38 lbf ft).

NOTE: The top cover of the counterweight can be removed from the counterweight to make checks and adjustments on the controller.

2. Disconnect the sling or chain. Remove the lifting eye from the counterweight and install the motor controller assembly (see Figure 16). Install the top cover on the counterweight.

3. Install the battery. See the section How to Change Battery in Periodic Maintenance 8000 YRM 552.

INSTALL, LATER MODEL ERP20-30ALF (B216) TRUCKS AND ERP20-30ALF (ERP040-060DH) (D216) MODEL TRUCKS 1. Use a crane and either a sling or chain to lift the counterweight into position at the rear of the truck.

See Figure 12. Install the two upper capscrews near the bottom of the battery compartment that hold the counterweight to the frame. Install the lower capscrews, washers, and nuts in the tow pin area of the counterweight. Tighten the upper capscrews to 320 N•m (236 lbf ft). Tighten the lower (between wheels) capscrews and nuts to 66 N•m (49 lbf ft). If removed, tighten the cover capscrews to 52 N•m (38 lbf ft).

2. Disconnect the sling or chain. Install the top cover and the electronic control compartment cover, on the front of the counterweight.

3. Install the battery.

See the section Periodic Maintenance 8000 YRM 552 for later model ERP20-30ALF (B216) trucks and Periodic Maintenance 8000 YRM 1060 for ERP20-30ALF (ERP040-060DH) (D216) models, for the procedures to install the battery.

21

Traction Motor Replacement

100 YRM 582

Traction Motor Replacement REMOVE This procedure will show the removal of the traction motor from the speed reducer with the drive train installed in the lift truck. See Figure 17, Figure 18, and Figure 19.

For repair procedures to the traction motor, see the section DC Motor Maintenance 620 YRM 294 for all lift truck models or the section AC Motor Repair 620 YRM 1053 for lift truck models ERP20-30ALF (ERP040060DH) (D216).

NOTE: The traction motor can be removed separately or as a unit with the drive train. Removal with the drive train requires the use of a floor jack and is more difficult.

The lift truck must be on blocks with clearance for the jack and traction motor to be removed as a unit. The hydraulic lines from the hydraulic tank must also be disconnected if this method is used.

Remove the traction motor from the speed reducer and lift truck as follows (see Figure 17): 1. Put the lift truck on blocks for easier access to the bottom bolts between the traction motor and the speed reducer.

2. Disconnect the battery connector and remove the key from the key switch. Remove the floor plates.

NOTE: It is not necessary to disconnect the hydraulic line from the master cylinder to remove the traction motor. If the hydraulic line is not disconnected, it will not be necessary to remove air from the brake system after installation. The master cylinder has a cap that does not leak, so it is not necessary to remove the reservoir.

3. During the removal of the following items, make sure to install plugs in hydraulic lines that are disconnected. Install a tag on all wires or cables for correct connection during installation. Do not disassemble the pedal assemblies any more than necessary for clearance to remove the traction motor.

22

This will prevent having to make adjustments after installation. Remove the following components or fasten them in a position for clearance to remove the traction motor: • Horn • Foot Directional Control Pedal or Accelerator Pedal Assembly • Brake Pedal Assembly with Master Cylinder and Hydraulic Line • Parking Brake Pedal Assembly • Two Hydraulic Lines for Steering System that are Over Traction Motor • Power Cables and Sensor Wires of Traction Motor 4. Remove the bottom bolts that fasten the speed reducer and the motor. Make an alignment mark on the traction motor and the speed reducer case for correct installation.

5. Install a lifting eye in the hole in the top of the motor. The hole has M10 × 1.5 mm threads and is near the center of the motor on top. Connect a special lifting device or chain (for a crane) to the lifting eye to hold the traction motor. See Figure 18 or Figure 19. Use a special lifting device fastened to the overhead guard or use a crane to hold the weight of the traction motor.

NOTE: The traction motors are in different configurations for different applications of the lift trucks. Traction motors weigh approximately 90 to 140 kg (200 to 310 lb).

6. Remove all the other bolts that fasten the speed reducer and the motor. Pull the traction motor from the speed reducer. See Figure 18 or Figure 19.

7. Use the crane to move the traction motor to a space to make repairs.

100 YRM 582

Traction Motor Replacement

A. TOP VIEW, EARLY AND LATER MODEL ERP20-30ALF (B216) TRUCKS B. TOP VIEW, ERP20-30ALF (ERP040-060DH) (D216) MODELS

C. SIDE VIEW, EARLY AND LATER MODEL ERP20-30ALF (B216) TRUCKS D. SIDE VIEW, ERP20-30ALF (ERP040-060DH) (D216) MODELS

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TRANSMISSION AND DIFFERENTIAL TRACTION MOTOR CAPSCREW, NUT, AND WASHER TRACTION MOTOR MOUNTING PLATE (TO TRANSMISSION AND DIFFERENTIAL) 5. TRUCK FRAME

CAPSCREW, NUT, AND WASHER PIN CAPSCREW, WASHER, AND LOCK NUT DRIVE AXLE SPEED REDUCER

Figure 17. Remove and Install Traction Motor

23

Hydraulic Tank Repair

100 YRM 582 guard or a chain and crane to lift the motor. See Figure 18 or Figure 19.

2. Lower the traction motor into position in the lift truck.

Align the traction motor with the speed reducer.

See Figure 17. Align the alignment marks made during removal.

1. TRACTION MOTOR 2. LIFTING EYE

3. SLING

Figure 18. Lift Traction Motor From Truck, Early and Later Model ERP20-30ALF (B216) Trucks

NOTE: If a different traction motor is being installed, it can be necessary to adjust the capscrew that is between the housing for the speed reducer/differential and the bottom of the traction motor.

3. Use a board or pry bar if necessary to push the traction motor into the speed reducer.

4. Align the bolt holes in the speed reducer and the motor housing. Install the bolts that hold the traction motor to the speed reducer. Tighten the bolts to 38 N•m (28 lbf ft). See Figure 17.

5. Remove the lifting device and, if necessary, adjust the support capscrew. Loosen the jam nut and adjust the capscrew until the head just touches the traction motor. Turn the capscrew an additional 1/2 turn counterclockwise to push on the traction motor. Tighten the jam nut to 33 N•m (24 lbf ft) without moving the capscrew. Remove the lifting eye.

1. TRACTION MOTOR 2. LIFTING EYE

3. SLING

Figure 19. Lift Traction Motor From Truck, ERP20-30ALF (ERP040-060DH) (D216)

INSTALL 1. Install a lifting eye in the hole in the top of the motor.

Use a special lifting device fastened to the overhead

6. Install all power cables, wires, hydraulic lines, and pedal assemblies as removed. Fill the cavity of pivot for the parking and service brake pedals with multipurpose grease during installation. Remove the air from the brake system as described in the section the Brake System 1800 YRM 566.

7. Operate the steering system and check for leaks.

Repair any leaks. Install all panels, covers, and floor plates.

Hydraulic Tank Repair REMOVE 1. Turn the key to the OFF position and remove the key.

WARNING Never put tools or other metal on the battery. Metal on the battery can cause a short circuit and possible damage or injury.

2. Open the hood and install a cardboard or plywood cover on the top of the battery to prevent accidental short circuits.

24

3. Turn the steering wheel for a full left turn for access to the drain plug near the front of the right rear wheel. See Figure 20. Install a container under the drain plug of the hydraulic tank with a capacity of 27.4 liter (7.25 gal).

4. Remove the drain plug and let the oil drain from the hydraulic tank. Install and tighten the drain plug.

5. Remove and install plugs in all the hoses fastened to the hydraulic tank. Remove the breather/dipstick/ fill cap and install a plug in the opening of the fill tube.

100 YRM 582

Hydraulic Tank Repair

6. Remove the screws from the bracket that fastens the bracket holding the hydraulic tank in the truck frame. See mount bracket assembly of Figure 20.

Remove the bracket assembly.

• Safety In Welding and Cutting, American National Standard, AWS Z 49.1 - 1999.

7. Carefully lift the hydraulic tank up out of the frame.

Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion.

WARNING

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer.

Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.

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HYDRAULIC TANK FILTER MOUNT BRACKET ASSEMBLY FILL CAP/BREATHER/DIPSTICK RETURN TO TANK RETURN FROM SYSTEM DRAIN PLUG LIFT PUMP SUPPLY PORT STEERING PUMP SUPPLY PORT Figure 20. Hydraulic Tank Assembly

INSPECT WARNING Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside of a building, make sure there is enough ventilation. See the following manuals for additional information: • Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999.

The hydraulic tank is a separate sheet metal tank and can be removed from the lift truck if necessary to check for leaks or for replacement. Repairs for leaks in the hydraulic tank can require special procedures described in the next paragraphs. The most common cause of leaks is from rust caused by the moisture of condensation or a plugged hydraulic tank breather. Drain any water out of the tank by removing the drain plug and letting the tank drain until there is no water in the oil.

CLEAN WARNING When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.

WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion.

When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.

25

Hydraulic Tank Repair

100 YRM 582

Steam Method

Chemical Solution Method

When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control the pressure of the steam by a valve installed at the nozzle of the hose.

If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection between the nozzle and the tank. Connect a ground wire to the tank to prevent static electricity.

If the tank cannot be cleaned with steam, use the following procedure:

Use the following procedure to clean the tank with steam: 1. Remove all the parts from the tank. Install the drain plug.

2. Fill the tank 1/4 full with a solution of water and sodium bicarbonate (baking soda) or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

3. Mix the solution in the tank using air pressure.

Make sure all the surfaces on the inside of the tank are flushed with the solution. Drain the tank.

4. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors must come from all the openings.

5. Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank.

6. Make an inspection of the inside of the tank. If it is not clean, repeat Step 4 and Step 5 and make another inspection. When making inspections, use a light that is approved for locations with flammable vapors.

7. Put plugs in all the openings in the tank. Wait 15 minutes, then remove the inlet and outlet plugs.

Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.

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1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkali base. Follow the instructions given by the manufacturer.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel.

Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank.

3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning compound is removed.

4. Make an inspection of the inside of the tank. If the tank is not clean, repeat Step 1 through Step 3.

Make another inspection of the tank. When making inspections, use a light that is approved for locations with flammable vapors.

5. Check the tank for flammable vapors as described in the previous section Step 7. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.

ADDITIONAL PREPARATIONS FOR TANK REPAIR If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual Safe Practices For Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999. If these gases are not available, another method using water can be used as follows: 1. Fill the tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent.

2. Use acceptable welding practices to repair the tank. See the American National Standard "Safety in Welding and Cutting," AWS Z 49.1 - 1999.

100 YRM 582

Painting Instructions

SMALL LEAKS, REPAIR Use the following procedure to seal small leaks: 1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.

2. If there are no leaks coming from the tank, remove all the water from the tank.

INSTALL 1. Turn the key to the OFF position and remove the key.

WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion.

2. Apply LoctiteÂŽ 290 to the leak. Follow the instructions of the manufacturer.

WARNING Never put tools or other metal on the battery. Metal on the battery can cause a short circuit and possible damage or injury.

LARGE LEAKS, REPAIR

2. Open the hood and install a cardboard or plywood cover on the top of the battery to prevent accidental short circuits. See Figure 20.

1. Use one of the procedures described under Clean, Steam Method of cleaning tank or Chemical Solution Method of cleaning tank to clean and prepare the tank for repairs.

3. Carefully position the hydraulic tank over the correct position in the frame and install the hoses on the bottom of the tank. Lower the tank into the correct position in the frame.

2. Use acceptable welding practices to repair the tank. See the American National Standard Safety In Welding and Cutting AWS Z 49.1 - 1999.

4. Install the other hoses and if removed, the filter on the tank. Install the bracket that fastens the hydraulic tank in the truck frame. See mount bracket assembly of Figure 20.

PREPARATIONS FOR USAGE AFTER REPAIR 1. Add more water to the tank so that the water goes above the point of where the work was done. Check to see if there are any leaks coming from tank.

5. Fill the tank to the FULL mark on the dipstick and install the breather/dipstick/fill cap.

6. Operate the lift and steering systems and check for leaks.

Painting Instructions WARNING Always use solvents and paints in an area with ventilation. Do not use solvents or paints near heat, fire, or electrical equipment that can make sparks. Follow the manufacturer’s instructions and Cautions.

1. Remove all dirt from the surface to be painted.

Clean the area to be painted. Use a solvent for painted surfaces to remove grease and oil before sanding. Do not use solvent on new paint. Make sure all oil and grease is removed.

2. Use sandpaper to remove the top surface of the paint and rust from the metal. All metal surfaces where the paint is completely removed, must be

painted. Use a primer. Apply the primer before applying the final coat of paint.

3. Protect all surfaces that will not be painted. See the list of items in Figure 21.

CAUTION Do not paint the pads, plastic covers or knobs, cables, labels, and information plates or controls.

Paint can make some assemblies not operate correctly.

4. Paint the surfaces. Use the correct paint from your dealer for Yale lift trucks. Follow the directions on the container. The correct arrangement of colors is shown in Figure 21.

27

Painting Instructions

100 YRM 582

WARNING Make sure all labels are installed after painting is complete. Safety labels are installed on the lift truck to give information about possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

5. Check that all labels are installed in the correct locations on the lift truck. See Figure 22. New labels are available from your dealer for Yale lift trucks.

NOTE: USE COLORS APPROVED BY YALE CORPORATION. DO NOT PAINT THE FOLLOWING ITEMS: PEDAL PADS, LEVER KNOBS, INSTRUMENTS, STEERING WHEEL, SEAT ASSEMBLY AND SEAT RAILS, INFORMATION CASE AND COVER, TIRES, MAST CHAINS AND HOSES, ALL LABELS AND INFORMATION PLATES, BATTERY CONNECTOR, PARKING BRAKE HANDLE, KEY SWITCH, CYLINDER RODS, ALL PLASTIC COVERS, AND STEERING COLUMN COVER. NOTE: LIGHT AREAS = GOLD; DARK AREAS = BLACK; AND PARCHMENT = LOAD BACKREST, FORKS, AND WHEELS. Figure 21. Color Arrangement

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100 YRM 582

Safety Label Replacement

Safety Label Replacement WARNING Labels that have WARNINGS or CAUTIONS must be replaced if they are damaged. If a mast of a different size or an accessory carriage is installed, the capacity rating can change. Changes in the kind of drive tires can change the capacity rating. See a dealer for YALE lift trucks for a replacement nameplate. The nameplate information is a safety item and must be correct for the equipment and configuration of the lift truck.

NOTE: If the labels or information plates are missing or have damage, they must be replaced.

1. Before installing a new label, make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint using a cleaning solvent. See Figure 22.

2. Remove the paper from the back of the label. Do not touch the adhesive surface.

3. Carefully hold the label in the correct position above the surface. The label cannot be moved after it touches the surface. Put the label on the surface.

Make sure all air is removed from under the label and the corners and edges are tight.

NOTE: The nameplate is installed using rivets. The old rivets must be removed before installing a new nameplate.

29

Safety Label Replacement

100 YRM 582

A. LABEL IS UNDER HOOD, NEAR CENTER 1.

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MAST WARNING LABEL TIP OVER (OPERATOR RESTRAINT) OVERHEAD GUARD TEST PLATE (LEFT SIDE)* OPERATOR WARNING LABEL (RIGHT SIDE) PARK BRAKE WARNING PATENT PLATE U.L. INSPECTION PLATE* BATTERY SPACER EMERGENCY BATTERY DISCONNECT LIFT AND TILT LABEL

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AUXILIARY FUNCTIONS LABEL YALE LOGO FIRE SAFETY LABEL* NO RIDERS PINCH POINT NO ONE ON OR UNDER FORKS NAMEPLATE WARNING LABEL FOR RESTRAINT ROD (UNDERSIDE OF HOOD) 19. BLACK YALE LETTERS

*NORTH AMERICA ONLY Figure 22. Label Positions

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100 YRM 582

Battery Specifications

Battery Specifications EARLY AND LATER ERP20-30ALF (B216) MODEL TRUCKS Minimum Compartment Size Length × Width

Length

Width

ERP20-25ALF* 72/80V

712 × 1032 mm (28.0 × 40.6 in.)

1025/1028 mm (37.3/40.8 in.)

708/711 mm (27.9/28.0 in.)

1558 kg (3435 lb)

ERP25-30ALF 72/80V

856 × 1032 mm (33.7 × 40.6 in.)

1025/1028 mm (37.3/40.8 in.)

852/855 mm (33.5/33.7 in.)

1863 kg (4108 lb)

Model

Battery Size Min/Max Weight

*Short Wheelbase 784 mm (30.9 in.) = maximum height for all batteries.

NOTE: Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column shows the size range that will permit the battery to still fit into a battery compartment.

NOTE: Battery compartment length is front-to-back. Width is side to side. The "length" dimension of the battery must fit within the battery compartment side-to-side dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum. Battery width must fit within the battery compartment front-to-back dimension.

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

ERP20-30ALF (ERP040-060DH) (D216) MODEL TRUCKS Minimum Compartment Size Length × Width

Length

Width

Minimum

Maximum

ERP20-25ALF (ERP040-050DH)

712 × 1032 mm (28.0 × 40.6 in.)

1025/1028 mm (40.4/40.5 in.)

708/711 mm (27.9/28.0 in.)

1470 kg (3241 lb)

1879 kg (4143 lb)

ERP25-30ALF (ERP050-060DH)

856 × 1032 mm (33.7 × 40.6 in.)

1025/1028 mm (40.4/40.5 in.)

852/855 mm (33.5/33.7 in.)

1770 kg (3902 lb)

2233 kg (4923 lb)

Model

Weight

Battery Size Min/Max

NOTE: Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column shows the size range that will permit the battery to still fit into a battery compartment.

NOTE: Battery compartment length is front-to-back. Width is side to side. The "length" dimension of the battery must fit within the battery compartment side-to-side dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum. Battery width must fit within the battery compartment front-to-back dimension.

WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use only batteries with the correct length shown in this table. Adjust the spacer plate to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

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