Yale e108 erc20 30agf lift truck service repair manual

ERC20-30AGF (E108) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................

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

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

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

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

STEERING HOUSING AND CONTROL UNIT (EARLY MODELS)................................

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

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

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

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

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

INSTRUMENT CLUSTER...............................................................................................

EV-100ZX SCR MOTOR CONTROLLER DESC/ADJ/TRBL/REPAIR AND THEORY..

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

EV-100ZX SCR MOTOR CONTROLLER PARAMETER TABLES................................

TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER............................

SR/SP TRANSISTOR MOTOR CONTROLLERS DESCRIPTION, CHECKS AND ADJUSTMENTS, TROUBLESHOOTING, REPAIRS, AND THEORY OF OPERATON...............................................................................................................

DISPLAY PANEL FOR SEM CONTROLS (DOS VERSION).........................................

SR/SP TRANSISTOR MOTOR CONTROLLER PARAMETER TABLES FOR FOURWHEEL ELECTRIC RIDER LIFT TRUCKS...............................................................

DISPLAY PANEL FOR SEM CONTROLS.....................................................................

SR(SEM)/SP TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER (WINDOWS VERSION)..............................................................................................

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

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

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

FOUR STAGE MAST......................................................................................................

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

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

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

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

DIAGRAMS (SEM)..........................................................................................................

PART NUMBER

YRM NUMBER

REV DATE

524179934 524158039 524179937 524158906 524166836 524179941 524158753 524179942 524179945 524179946 524150790 524158757 524179947 524166840 524179949 524270787

0100 YRM 0558 0620 YRM 0294 1400 YRM 0285 1600 YRM 0258 1600 YRM 0485 1600 YRM 0512 1600 YRM 0720 1800 YRM 0574 1900 YRM 0559 2000 YRM 0562 2100 YRM 0103 2200 YRM 0514 2200 YRM 0557 2200 YRM 0560 2200 YRM 0595 2200 YRM 0597

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

524179951 524166842

2200 YRM 0724 2200 YRM 0725

04/05 07/02

524179952 524166844

2200 YRM 0739 2200 YRM 0942

04/05 08/07

524167640 524158040 524158890 524158891 524179953 524150797 524179954 524179957 524179958 524179956

2200 YRM 0947 2240 YRM 0001 4000 YRM 0521 4000 YRM 0522 4000 YRM 0563 8000 YRM 0231 8000 YRM 0551 8000 YRM 0552 8000 YRM 0561 8000 YRM 0742

08/07 09/14 03/06 07/10 04/05 10/13 07/03 07/03 07/03 06/04

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.

PART NO. 524179916 (09/14)

100 YRM 558

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 • Seat plate (with optional seat brake) • 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 levers The hood is part of the operator and battery restraint system. The seat is also part of the operator restraint system. The floor plates are removed for access to the steering motor. A panel in the bottom of the battery compartment is removed for access to the traction motor and the hydraulic pump motor. The electronic controller and contactors are attached to the frame. A panel in the counterweight is removed for access to the controller and contactors. See Figure 16. For the location of the Master Controller and Electro-Hydraulics Valve Driver Module, see the section Electro-hydraulic Control Valve 2000 YRM 1224.

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.

The lift trucks are equipped with an adjustable spacer plate in the battery compartment. See Figure 2. Adjust the spacer plate to control the movement of the battery in the forward and backward directions. Tighten the jam nuts on the adjustment capscrew to prevent the adjustment from changing.

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. A slot in the overhead guard permits removal of the battery without removing the overhead guard.

1

Description

100 YRM 558

Figure 1. Lift Truck Frame

2

100 YRM 558

Description Legend for Figure 1

NOTE: OPTIONAL SIDE PANELS FOR BATTERY COMPARTMENT NOT SHOWN. 1.

2.

3.

4.

COWL BATTERY COMPARTMENT ACCESS COVERS BATTERY SPACER PLATE* BATTERY SPACER PLATE**

5.

6.

7.

8.

SIDE STEP AND FENDER WELDMENT FRAME FLOOR MATS FLOOR PLATES (COVERS)

* BATTERY SPACER PLATE USED ON NEWER LIFT TRUCK MODELS ** BATTERY SPACER PLATE USED ON OLDER LIFT TRUCK MODELS

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, the steering column assembly, the release linkage of the parking brake, and the instrument panel with light switches. The display panel is on the right side of the steering column and attached to the instrument panel for lift truck models with SEM (Separately Excited Motor), SCR (Silicon Controlled Rectifier), and AC (Alternating Current) electronic controllers and contactors. See Figure 3, Figure 4, Figure 5, Figure 6, and Figure 7.

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

The overhead guard is a weldment that fastens to the main frame and cowl to help protect the operator from falling objects. See Figure 5, Figure 6, Figure 7, or Figure 9.

1. BATTERY COMPARTMENT 2. BATTERY 3. BULKHEAD

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

Figure 2. Battery Spacer Plate

3

Description

A. STANDARD SEM DISPLAY PANEL

100 YRM 558

B. PREMIUM SEM DISPLAY PANEL Figure 3. SEM Display Panel

NOTE: FOR LIFT TRUCK MODELS WITH AC ELECTRONIC CONTROLLERS AND CONTACTORS, BOTH THE STANDARD AND PREMIUM DISPLAY PANELS LOOK IDENTICAL. THE ONLY DIFFERENCE IS IN THE DISPLAY SOFTWARE AND THE RESULTING FUNCTIONALITY. Figure 4. AC Display Panel

4

100 YRM 558

Overhead Guard Replacement

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

1. Remove the battery from the truck. See How to Change Battery in your vehicle’s Periodic Maintenance or Operating Manual.

2. Access to the capscrews that hold the rear legs of the overhead guard to the frame is from the battery compartment. Remove the capscrews, washers, and nuts that fasten each leg. See Figure 5, Figure 6, Figure 7, Figure 8, and Figure 9.

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.

Tighten capscrews to 55 N•m (41 lbf ft). Install the capscrews, washers, and nuts that hold the rear legs to the frame. For lift truck models ERC20-30AGF (ERC040-065RF/ZF, ERC040-065RG/ZG) (E108), tighten the capscrews to 68 N•m (50 lbf ft). For lift truck models ERC20-30AGF (ERC040-065GH) (A908), tighten the capscrews to 90 N•m (66 lbf ft). Install the battery. See How to Change Battery in your vehicle’s Periodic Maintenance or Operating Manual.

5

Overhead Guard Replacement

100 YRM 558

Figure 5. Overhead Guard, Steering Column, and Display Panel, Truck Models ERC20-30AGF (ERC040-065RF/ZF) (E108)

6

100 YRM 558

Overhead Guard Replacement Legend for Figure 5

NOTE: DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH SCR ELECTRONIC CONTROLLERS AND CONTACTORS. A. STEERING CONTROL UNIT USED ON EARLY MODEL LIFT TRUCKS B. STEERING CONTROL UNIT USED ON LATER MODEL LIFT TRUCKS 1. OVERHEAD GUARD 2. STEERING WHEEL 3. ON-DEMAND STEERING COMPONENTS (NOT ALL UNITS) 4. HORN SWITCH CONNECTOR 5. COLUMN COVER 6. COLUMN FRAME 7. STEERING CONTROL UNIT 8. LATCH MECHANISM 9. OPTIONAL PREMIUM DISPLAY PANEL

10.

11.

12.

13.

14.

15.

16.

17.

18.

REGULAR DISPLAY PANEL* CAPSCREW WASHER NUT SCREW OVERHEAD GUARD HANDLE HORN SWITCH CONNECTOR STEERING COLUMN STEERING COLUMN NUT

*CURTIS METER SHOWN. PANEL AVAILABLE WITH OPTIONAL GENERAL ELECTRICâ„¢ METER.

7

Overhead Guard Replacement

100 YRM 558

Figure 6. Overhead Guard, Steering Column, and Display Panel, Truck Models ERC20-30AGF (ERC040-065RG/ZG) (E108)

8

100 YRM 558

Overhead Guard Replacement Legend for Figure 6

NOTE: DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH SEM ELECTRONIC CONTROLLERS AND CONTACTORS. 1.

2.

3.

4.

5.

6.

7.

8.

STEERING WHEEL SHIFT LEVER MECHANISM COLUMN COVER LATCH MECHANISM STEERING CONTROL UNIT COLUMN FRAME ON-DEMAND STEERING COMPONENTS DISPLAY PANEL (PREMIUM DISPLAY PANEL SHOWN) 9. OVERHEAD GUARD

10.

11.

12.

13.

14.

15.

16.

17.

18.

CAPSCREW WASHER NUT SCREW OVERHEAD GUARD HANDLE HORN SWITCH CONNECTOR HORN BUTTON STEERING COLUMN STEERING COLUMN NUT

9

Overhead Guard Replacement

100 YRM 558

Figure 7. Overhead Guard, Steering Column, and Display Panel, Truck Models ERC20-30AGF (ERC040-065GH) (A908)

10

100 YRM 558

Overhead Guard Replacement Legend for Figure 7

NOTE: DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH AC ELECTRONIC CONTROLLERS AND CONTACTORS. NOTE: OVERHEAD GUARD FOR LIFT TRUCK MODELS ERC040-065GH (A908) SHOWN. SEE FIGURE 8 FOR OVERHEAD GUARD USED ON ERC20-30AGF (A908) MODELS. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

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

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

LATCH MECHANISM CAPSCREW WASHER NUT SCREW OVERHEAD GUARD HANDLE HORN SWITCH CONNECTOR HORN BUTTON STEERING COLUMN STEERING COLUMN NUT Legend for Figure 8

1.

2.

3.

4.

5.

6.

7.

8.

OVERHEAD GUARD PLUG NUT LOCKWASHER CAPSCREW WASHER HANDLE SCREW

Figure 8. Overhead Guard, Lift Truck Models ERC20-30AGF (A908)

11

Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 558

1.

2.

3.

4.

FRONT LEG, OVERHEAD GUARD SETSCREW ATTACHMENT PLATE REAR LEG, OVERHEAD GUARD

5. COUNTERWEIGHT 6. TOW PIN 7. BOLT

Figure 9. Overhead Guard and Counterweight

Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement BATTERY RESTRAINT SYSTEM WARNING On units with a shorter frame, the gas spring for the hood can raise the hood at a rapid rate and cause an injury. Do NOT bend over hood when raising hood.

A battery restraint system is installed as a safety device. See Figure 10. The function of the battery restraint system, when correctly locked in the down position, is to hold the battery in the battery compartment if an accident causes the lift truck to tip over. The battery restraint is a steel weldment that is connected to the

12

frame with a hinge. A sliding latch mechanism (see Figure 10.) locks the battery restraint in the down position for operation. The latch, at the top center of the counterweight, unlocks the battery restraint from the frame, so that the battery restraint can be raised to the up position for access to the battery. The battery restraint is also the support for the hood. A gas spring helps lift the hood assembly. A rod is used to hold the hood in the up position on units with a longer frame. The operator must hold the hood assembly with one hand. Use the other hand to move the rod to the storage position.

Lower the hood and battery restraint assembly to the operating position. Make sure that the battery restraint is correctly locked to the frame for operation of the lift truck.

100 YRM 558 Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement

1.

2.

3.

4.

5.

6.

HOOD SEAT LATCH ASSEMBLY BATTERY RESTRAINT AND HOOD FRAME GAS SPRING HINGE

7.

8.

9.

10.

11.

12.

STOP ROD RELEASE LABEL FOR STOP ROD COUNTERWEIGHT LATCH HANDLE LIFT HANDLE LATCH WARNING LABEL

Figure 10. Hood, Latch, and Battery Restraint System

WARNING Correct operation of the battery restraint system requires that the battery does not move more than 13 mm (0.5 in.) horizontally. Make sure that the battery spacer plate is correctly adjusted.

WARNING The battery restraint and its latch mechanisms must operate correctly before a lift truck is operated.

To operate correctly, the battery restraint must be locked in the down position. The battery compartment has an adjustable spacer plate, which is used to prevent forward and backward movement of the battery. Adjust the spacer plate to prevent movement in any one horizontal direction of 13 mm (0.5 in.) maximum. See Figure 2.

Raise the seat. Use the knob for the latch to release the battery restraint. See Figure 10. Use the handle on the hood to raise the battery restraint and hood. Make sure that the battery cannot move more than a total of 13 mm (0.5 in.) in any one horizontal direction. Make sure the spacer plate is correctly adjusted to prevent movement.

Push the hood and the battery restraint down until the

latch locks. Make sure the battery restraint is locked securely. Lift on the handle to make sure it is latched and will not move.

HOOD The hood must be locked in the down position during operation. The battery must have the spacer plate correctly adjusted to prevent forward or backmaximum. ward movement of 13 mm (0.5 in.)

On lift trucks ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108), if the unit has a seat brake, raise the seat and seat plate assembly. Use the latch handle at the rear of the hood (see Figure 11) to release the hood frame and battery restraint. Raise the latch handle and slide the handle toward the right side of the truck. A spring moves the handle back to the left.

Use the lift handle by the seat to raise the hood. See Figure 11. A gas spring and stop rod will hold the assembly in the up position. Make sure that the battery cannot move more than a total of 13 mm (0.5 in.) in any one horizontal direction. If necessary, adjust the battery spacer plate as shown in Figure 2.

13

Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 558 in.) clearance. The Battery Specifications, at the back of this manual, shows the minimum sizes of the battery compartment.

Another important part of the battery restraint system is the steel weldment that is also the hood frame. This hood frame is connected to the lift truck frame with hinges at the rear of the hood. Gas springs help lift the hood assembly. The seat and other parts of the operator restraint system fasten to the hood assembly.

NOTE: Before raising the hood, move the steering column to the forward position and slide the seat all the way back, and If necessary, move the armrest all the way back. See Figure 12.

1.

2.

3.

4.

5.

HINGE LIFT HANDLE HOOD LATCH HANDLE SEAT BRAKE PLATE

Figure 11. Hood and Seat Brake Plate Assembly, Lift Truck Models ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108) Release the stop rod by moving it to the right before lowering hood. See the label in Figure 10. Make sure the latch handle is fully to the right when closing the hood so that the latch can engage the latch piece. Make sure the hood is locked securely. Try to raise the hood using only the lift handle to make sure the hood is latched and will not move.

HOOD WITH E-HYDRAULICS WARNING The gas spring for the hood can raise the hood at a rapid rate and cause an injury. DO NOT lean 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

14

1. ARMREST ADJUSTMENT HANDLE Figure 12. Armrest Latch Location The latch that secures the cover for the hood release handle can be either a locking or non locking latch. If the latch is a locking latch, unlock latch with key first.

The cover, latch and hood release handle are located on the right side of the hood. See Figure 13.

Pull the latch handle, located on the top of the latch, to the up position and then pull on latch handle to move cover away from hood release handle. Pull hood release handle up to release hood latch mechanism. See Figure 13. Use handle on the hood to place hood in the raised position.

100 YRM 558 Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement Before lowering the hood, make sure the battery restraint rod is over the battery. Lower the hood and push hood release handle down to secure hood to frame.

Move cover over hood release handle and push latch handle down to secure cover to hood. If latch is a locking latch, lock latch with key.

OPERATOR RESTRAINT SYSTEM AND SEAT ASSEMBLY The seat belt, hip restraint brackets, seat and mounting, hood, and latches are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition. See Figure 14.

Automatic Locking Retractor (ALR) NOTE: ERC20-30AGF (ERC40-065RF/ZF, ERC40065RG/ZG) (E108) lift trucks produced before November 2005 are equipped with the ALR type seat belts.

The seat belt must fasten securely. Make sure the seat belt extends and retracts smoothly and is not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced. See Figure 14.

1. LATCH 2. COVER 3. HOOD RELEASE HANDLE 4. HOOD LATCH MECHANISM 5. COMPRESSION SPRING

6.

7.

8.

9.

10.

11.

12.

PIN SCREW CAPSCREW NUT LOCKWASHER WASHER LATCH HANDLE

Figure 13. Latch and Cover With E-Hydraulics

SEAT BRAKE On ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ ZG) (E108) units with a seat brake, there is a separate plate with a hinge fastened to the front of the battery compartment (see Figure 11.) The seat is fastened to this plate instead of the hood on these units. The linkage for the seat plate has a spring that holds the plate up and applies the brake on the rear of the traction motor. During operation of the lift truck, the seat brake will be applied to the traction motor if the seat brake switch, located under the seat, senses that the operator has left the seat and the parking brake has not been applied. On these units, push the seat and seat plate into position over the hood. See Figure 11 and Figure 14.

1. SEAT 2. HIP RESTRAINT 3. SEAT BELT AND MOUNT

4. HOOD 5. SEAT RAILS 6. SEAT PLATE (WITH SEAT BRAKE)*

*THE SEAT PLATE IS NOT USED ON ERC20-30AGF (ERC040-065GH) (A908) TRUCKS. Figure 14. Operator Restraint and Seat Assembly

15

Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 558

Emergency Locking Retractor (ELR) NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt.

When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator’s lower torso in the seat.

A seat belt that is damaged worn or does not operate properly will not give protection when it is needed. The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 15.

The following seat belt operation checks must be performed: • With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. If the seat belt does not pull out of the retractor assembly, the internal latch may be locked. Pull firmly on the seat belt and hold for a moment to remove slack from the belt in the retractor. Release the seat belt.

Seat belt will retract and the internal latch will unlock.

If the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly.

• With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly.

• With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with

16

the hood in the open position, replace the seat belt assembly.

Make sure the seat rails and latch striker 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. The hood must be fully closed. Lift the hood to make sure it is closed and will not move.

Adjust hood, hood latch, and latch striker when any of the parts of the operator restraint system are installed or replaced. See the section Hood Repair in this manual for the adjustment procedures for the hood.

1.

2.

3.

4.

5.

6.

OPERATOR WEIGHT ADJUSTMENT FORWARD/BACKWARD ADJUSTMENT SEAT BELT HIP RESTRAINT SEAT SEAT RAIL Figure 15. Hood and Seat Check

100 YRM 558

Counterweight Replacement

Counterweight Replacement If the lift truck must be put on blocks for maintenance or repair, see How to Put Lift Truck on Blocks in the Operating Manual or Periodic Maintenance section for your vehicle.

Table 1. Counterweights Model

(mm*)

ERC040-050RF/ ZF, RG/ZG (E108) and ERC040-050GH (A908)

700

578 kg (1274 lb)

ERC040-050RF/ ZF, RG/ZG (E108) and ERC040-050GH (A908)

786

794 kg (1750 lb)

ERC20-25AGF (E108) and ERC040-060RF/ ZF, RG/ZG (E108) and ERC20-25AGF (A908) and ERC040-060GH (A908)

847

942 kg (2076 lb)

ERC30AGF (E108) and ERC065RF/ZF, RG/ZG (E108) and ERC30AGF (A908) and ERC065GH (A908)

933

942 kg (2076 lb)

WARNING 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.

The counterweight normally is not removed for most repairs. Replacement of the SCR Electronic Controllers is easier with the counterweight removed. Replacement of the SEM, and AC Controllers is accomplished by removing the cover from the counterweight. See Figure 16. The counterweight is fastened to the frame with four capscrews. The weights for the counterweights are shown in Table 1.

1.

2.

3.

4.

5.

6.

7.

SEAL COUNTERWEIGHT TOW PIN ACCESS COVER UPPER CAPSCREW AND WASHER LOWER CAPSCREW AND WASHER COVER CAPSCREWS AND WASHERS

Weight

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

*Approximate battery compartment lengths.

REMOVE 1. Remove the battery from the truck. See How to Change Battery in your vehicle’s Periodic Maintenance or Operating Manual for the procedures.

Figure 16. Counterweight Assembly

17

Counterweight Replacement

100 YRM 558

2. Install the counterweight lifting tool to the counterweight with a 1 UNC Ă— 2 in. (50 mm) bolt. See Figure 17 and Figure 18. Connect a clevis to the counterweight lifting tool. The clevis must have a pin diameter of 16.0 to 19.0 mm (0.625 to 0.750 in.).

Fasten a chain or sling to the clevis. Make sure the chain or sling and crane has the capacity to lift the counterweight. See Table 1. Use the crane to hold the weight of the counterweight.

NOTE: THE MATERIAL IS ASTM A36 STEEL, 12.7 mm (0.50 in.) THICK. Figure 18. Counterweight Lifting Tool

INSTALL

1. LIFT CHAIN 2. LIFTING TOOL

3. CLEVIS 4. COUNTERWEIGHT

Figure 17. Lift the Counterweight 3. 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 from the tow pin area of the counterweight. Use the crane to lift the counterweight away from the frame. Make sure that you do not damage the electronic controller.

18

NOTE: The access panel to the electronic controller can be removed from the counterweight to make checks and adjustments on the controller. Before installing access panel, check the seal to make sure it fully seals the controls compartment and that there are no gaps between the seal, seal blocks, wire harness, battery bulkhead covers, or counterweight. Make sure the lugs are correctly engaged when the access panel is installed again, or the panel will fall from the counterweight during operation.

1. Use a crane and the lifting tool, during removal, to lift the counterweight into position. See Figure 16.

Make sure that you do not damage the electronic controller during installation. 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 380 N•m (280 lbf ft). Tighten

100 YRM 558

Traction Motor Replacement

the lower (tow pin) capscrews and nuts to 66 N•m (49 lbf ft). If removed, tighten the access cover capscrews to 52 N•m (38 lbf ft).

3. See How to Change Battery in your vehicle’s Periodic Maintenance or Operating Manual. Install the battery into the truck.

2. Disconnect the sling or chain. Remove the lifting tool from the counterweight.

Traction Motor Replacement REMOVE This procedure will show the removal of the traction motor through the battery compartment. Some lift trucks have a seat brake that actuates a brake on the armature shaft of the traction motor. See Figure 19 and Figure 20. On lift trucks ERC20-30AGF (ERC40-065RF/ ZF, ERC40-065RG/ZG) (E108), the seat brake linkage under the floor plate must be disconnected at the front of the traction motor before the motor is removed. On lift truck models ERC20-30AGF (ERC040-065GH) (A908) the guide pipe and electrical connections for the seat brake must be disconnected from the traction motor before motor is removed. See Figure 20.

1. GUIDE PIPE CONNECTION 2. ELECTRICAL CONNECTION 3. SEAT BRAKE 1.

2.

3.

4.

TRACTION MOTOR LEVER OF SEAT BRAKE LINKAGE NUT, CAPSCREW, WASHERS, AND BUSHING SPRING

Figure 20. Traction Motor With Seat Brake, Lift Trucks ERC20-30AGF (ERC040-065GH) (A908)

Figure 19. Traction Motor With Seat Brake, Lift Trucks ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108)

19

Traction Motor Replacement NOTE: The traction motor can be removed separately or as a unit with the drive train. These removal methods require removal from under the lift truck with the use of a floor jack. These methods are 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.

100 YRM 558 6. Remove the motor mount that holds the traction motor to the frame. Pull the traction motor from the speed reducer. See Figure 22.

1. See How to Change Battery in your vehicle’s Periodic Maintenance or Operating Manual. Remove the battery from the truck. Then remove the floor plates and the access panel in the bottom of the battery compartment.

NOTE: Replace the hydraulic tank breather with a plug to help prevent oil flow when disconnecting the tank-topump hydraulic line.

2. On lift trucks ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108), disconnect the ball of the ball joint from the lever of the seat brake linkage under the floor plate.

3. Disconnect the power cables from the traction motor. If installed, disconnect the wires for the brush wear indicators and the temperature sensor at the motor. Make an identification of which cable and wire is connected to each terminal.

4. Put the lift truck on blocks for easier access to the bottom bolts between the traction motor and the speed reducer. Remove the bolts that fasten the speed reducer and the motor.

5. Install a sling to hold the traction motor. See Figure 21. Use a wood block and a board under the sling as shown in the illustration to control the traction motor during removal and installation. Use the crane to hold the weight of the traction motor. See Figure 22.

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). Make sure that the sling cannot slide and permit the traction motor to fall.

20

NOTE: USE A WOOD BLOCK AND BOARD UNDER SLING FOR A LEVER. TRACTION MOTOR FOR MODELS ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108) SHOWN. TRACTION MOTOR FOR ERC20-30AGF (ERC040-065GH) (A908) IS SIMILAR. 1. SLING 2. BOARD AND BLOCK 3. TRACTION MOTOR Figure 21. Install Sling to Lift Traction Motor 7. Use the crane to move the traction motor to a space to make repairs.

If installed on lift truck models ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108), remove the bracket, lever, and spring for the seat brake. Remove the brake assembly from the traction motor as described in the section Brake System 1800 YRM 574.

100 YRM 558

Traction Motor Replacement motor to the speed reducer. Tighten the bolts to 38 N•m (28 lbf ft).

5. Remove the sling and install the traction motor mount. If equipped, install the ball of the ball joint on the lever for the seat brake.

6. Install the power cables and the access and floor plates. Tighten the power cable connectors to 21 to 25 N•m (15 to 18 lbf ft).

7. See How to Change Battery in your vehicle’s Periodic Maintenance or Operating Manual. Install the battery into the truck.

NOTE: TRACTION MOTOR FOR MODELS ERC2030AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108) SHOWN. TRACTION MOTOR FOR ERC20-30AGF (ERC040-065GH) (A908) IS SIMILAR. Figure 22. Use Crane to Lift Traction Motor

INSTALL 1. If the truck has a seat brake, install the brake assembly on the traction motor as described in the section Brake System 1800 YRM 574. For lift truck models ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108), install the bracket, lever, and spring for the brake. Install a sling to lift the traction motor. Use a wood block and a board under the sling to control the traction motor during installation. See Figure 22.

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

Align the traction motor with the speed reducer.

See Figure 23.

3. Use a board or pry bar as 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

NOTE: TRACTION MOTOR FOR MODELS ERC2030AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108) SHOWN. TRACTION MOTOR FOR ERC20-30AGF (ERC040-065GH) (A908) IS SIMILAR. 1. SLING 2. BOARD AND WOOD BLOCK 3. TRACTION MOTOR Figure 23. Align Traction Motor With Speed Reducer

21

Hydraulic Tank Repair

100 YRM 558

Hydraulic Tank Repair 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.

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

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

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. See Figure 24. 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.

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 the water out of the tank by removing the drain plug and letting the tank drain until there is no water in the oil.

22

A. HYDRAULIC BREATHER AND ADAPTER USED ON OLDER MODEL ERC20-30AGF (ERC040-065GH) (A908) LIFT TRUCKS. B. HYDRAULIC BREATHER AND ADAPTER USED ON NEWER MODEL ERC20-30AGF (ERC040-065GH) (A908) LIFT TRUCKS. 1.

2.

3.

4.

5.

6.

7.

8.

BREATHER FILL/DIPSTICK MOUNT BRACKET ASSEMBLY HYDRAULIC TANK MAIN PUMP SUPPLY STEERING PUMP SUPPLY PORT DRAIN PLUG BREATHER ADAPTER Figure 24. Hydraulic Tank

100 YRM 558

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 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.

Steam Method 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.

Hydraulic Tank Repair 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.

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

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

23

Painting Instructions

100 YRM 558

ADDITIONAL PREPARATIONS FOR 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.

NOTE: Make sure to install the tank so that the fill neck is centered in the opening in the step of the frame. Make sure to install all plugs, hoses, and clamps to prevent leaks when oil is added to the tank.

SMALL LEAKS, REPAIR

1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.

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.

LARGE LEAKS, REPAIR 1. To clean and prepare the tank for repair, use one of the two cleaning procedures in the Clean section of this YRM. 2. Use acceptable welding practices to repair the tank. See the American National Standard Safety In Welding and Cutting, AWS Z49.1 - 1999.

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.

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

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

Use the following procedure to seal small 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

24

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 25.

CAUTION Do not paint the pads, plastic covers or knobs, cables, labels, 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 25.

100 YRM 558

Painting Instructions

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 safety labels are installed in the correct locations on the lift truck. See Figure 26. New labels are available from your dealer for Yale lift trucks.

NOTE: DO NOT PAINT THE FOLLOWING ITEMS: PEDAL PADS, LEVER KNOBS, INSTRUMENTS, STEERING WHEEL, SEAT ASSEMBLY, 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 LOAD BACKREST, FORKS AND WHEELS - PARCHMENT. USE COLORS APPROVED BY YALE. DO NOT PAINT ITEMS IN PREVIOUS NOTE. Figure 25. Color Arrangement

25

Safety Label Replacement

100 YRM 558

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.

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

26

NOTE: If the labels or information plates are missing or have damage, they must be replaced. See Figure 26.

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.

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.

100 YRM 558

Safety Label Replacement

NOTE: INSTALL NEW LABEL IN THE SAME LOCATION AS ORIGINAL. NOTE: NOT ALL LABELS USED ON THESE LIFT TRUCK MODELS ARE SHOWN IN FIGURE 26. SEE THE PARTS MANUAL FOR ALL LABELS USED AND THEIR POSITIONS. 1.

2.

3.

4.

5.

6.

7.

8.

OPERATOR WARNING PARK BRAKE WARNING NAMEPLATE PINCH POINT LABEL TILT COLUMN LABEL MAST WARNING TIPOVER WARNING NO ONE ON OR UNDER FORKS LABEL

9.

10.

11.

12.

13.

14.

15.

16.

NO RIDERS LABEL BATTERY DISCONNECT BATTERY SPACER PROP ROD UL INSPECTION PLATE HYDRAULIC FUNCTIONS LOAD BACKREST EXTENSION LABEL OVERHEAD GUARD

Figure 26. Label Positions

27

Battery Specifications

100 YRM 558

Battery Specifications Table 2. Lift Truck Models ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108)

Model

Min. Compartment Size Length × Width

Weight

Battery Size Min/Max Length

Width

Min

Max 1497 kg (3300 lb)

ERC40-50RF/ ZF, RG/ZG

695 × 987 mm (27.4 × 38.8 in.)

681/691 mm (26.8/27.2 in.)

1043 kg (2300 lb)

ERC40-50RF/ ZF, RG/ZG

781 × 987 mm (30.7 × 38.8 in.)

739/777 mm (29.1/30.6 in.)

1134 kg (2500 lb)

ERC20-25AGF (ERC40-60RF/ ZF, RG/ZG)

842 × 987 mm (33.1 × 38.8 in.)

ERC65RF/ZF, RG/ZG

928 × 987 mm (36.5 × 38.8 in.)

900/924 mm (35.4/36.4 in.)

1406 kg (3100 lb)

ERC30AGF

1010 × 987 mm (39.7 × 38.8 in.)

1001/1006 mm (39.4/39.6 in.)

1553 kg (3424 lb)

978/983 mm (38.5/38.7 in.)

800/838 mm (31.5/32.9 in.)

1317 kg (2903 lb)

1587 kg (3500 lb) 1771 kg (3904 lb) 1860 kg (4100 lb) 1998 kg (4405 lb)

612 mm (24.1 in.) = maximum height for all batteries. This dimension is 31.5 mm (1.24 in.) less with optional battery rollers.

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 and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

28

100 YRM 558

Battery Specifications Table 3. Lift Truck Models ERC20-30AGF (ERC040-065GH) (A908)

Model

Min. Compartment Size Length × Width

Weight

Battery Size Min/Max Length

Width

Min

Max 1497 kg (3300 lb)

ERC040050GH

695 × 987 mm (27.4 × 38.8 in.)

681/691 mm (26.8/27.2 in.)

1043 kg (2300 lb)

ERC040050GH

781 × 987 mm (30.7 × 38.8 in.)

739/777 mm (29.1/30.6 in.)

1134 kg (2500 lb)

ERC20-25AGF (ERC040060GH)

842 × 987 mm (33.1 × 38.8 in.)

ERC065GH

928 × 987 mm (36.5 × 38.8 in.)

900/924 mm (35.4/36.4 in.)

1406 kg (3100 lb)

ERC30AGF

1010 × 987 mm (39.7 × 38.8 in.)

1001/1006 mm (39.4/39.6 in.)

1553 kg (3424 lb)

978/983 mm (38.5/38.7 in.)

800/838 mm (31.5/32.9 in.)

1317 kg (2903 lb)

1587 kg (3500 lb) 1771 kg (3904 lb) 1860 kg (4100 lb) 1998 kg (4405 lb)

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 and side spacers to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.

29

620 YRM 294

Brush and Commutator Inspection

General This section describes disassembly and assembly, brush installation, inspection, and checks for malfunctions of DC motors. Inspect the commutator and brushes every 350 hours of operation. The commutator is the rotating electric connection between the armature and the electric power supplied by the battery. Brushes made of carbon compounds slide on the rotating commutator and are the path for electricity from the battery to the commutator and the armature.

The maintenance of the commutator and the brushes is important to the good operation of a DC motor.

Traction motors and hydraulic pump motors are similar in design. The hydraulic pump motors are smaller than the traction motors, but the disassembly and maintenance of these motors are similar. The cooling

fan in the traction motors is fastened to the armature and can be removed from the armature. The cooling fan can be removed during disassembly of the traction motor.

The cooling fan in the hydraulic pump motors can be a press fit on the armature shaft and is not easily removed during disassembly of the motor. The armature and cooling fan must be removed from the drive end of the motor during disassembly.

The assembly and disassembly of the motor used for the power steering pump is described in the Steering System section. This motor is a permanent magnet motor.

Brush and Commutator Inspection HYDRAULIC PUMP MOTOR AND TRACTION MOTOR NOTE: When inspecting brush conditions and motor commutator conditions for head damage or abnormal wear, the battery maintenance and condition should be eliminated as a cause first. See Industrial Battery 2240 YRM 1.

NOTE: The brushes and commutator can be inspected, the brushes can be replaced, and Stoning the Commutator can be done with the motor installed in the truck.

in the Operating Manual or the Periodic Maintenance YRM section for your lift truck.

NOTE: For some models of lift trucks, the battery does not need to be removed to access the electric motors.

Other models will require the removal of the battery before gaining access to the electric motors. To remove the battery, either raise the hood panels or unfasten the floor plate, depending on which motor needs to be accessed.

NOTE: Inspect the brushes and commutator every 350 hours for best operation and to prevent motor damage.

The hydraulic pump motor normally has more start cycles than other motors, so it can have more wear and possible damage.

NOTE: The following procedure is for inspecting the brushes and commutator with the motor installed in the lift truck. The same inspections can be done with the motor removed. If the motor is removed, start at Step 3.

1. To rotate the commutator of the traction motor without moving the truck, the drive wheels must be raised. See Figure 1. Raise drive wheels so commutator of the traction motor can be rotated without moving lift truck. See How To Raise Drive Wheels

1. ARMATURE (DRIVE) SHAFT

2. COOLING FAN 3. BRUSH COVER

Figure 1. Traction Motor

1

Brush and Commutator Inspection 2. Remove battery. See How to Remove Battery in the Operating Manual or the Periodic Maintenance YRM section for your lift truck. Remove access plate to motors. If the battery in your lift truck does not need removal for access to the motors, go to Step 3.

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.

NOTE: Vacuum cleaning, when possible, is the recommendation of manufacturers of electric motors. The use of compressed air can send dirt particles into the bearings and other areas of the motor that can cause possible damage.

3. Remove brush covers at rear of motor. See Figure 2. Wear eye protection. Use a vacuum cleaner or compressed air to remove dirt and brush dust from commutator area.

620 YRM 294 the commutator and must not have cracks or defects. Some brushes have wear sensor wires attached, even if they are not connected to an indicator. Replace these brushes if brushes are worn enough to see sensor at commutator end of brush.

5. Inspect commutator surface. See Table 1 and Table 2. Carefully rotate armature. DO NOT damage commutator if you use a tool to rotate armature.

The commutator wears slowly in normal service.

The mica must be cut below the surface of the commutator bars after a long service period or after a commutator has been turned in a lathe.

A commutator that has been in service will have a smooth and polished surface with a darker brown color where it rotates under the brushes. A variation of color on the commutator surface between light brown and darker brown is normal. The surface condition is the lubrication between the commutator and the brushes. The brushes will wear rapidly if this surface condition does not develop during the first 6 to 10 hours of operation after a commutator with a new surface is installed. If the commutator has deep grooves, rough edges of the bars, or a few bars that are black or raised above the others, the motor must be removed for service.

6. Inspect white or gray insulation (mica) between commutator bars. The mica must not touch the brushes or the brushes will wear very rapidly.

Figure 2. Brush Cover Removal From Motor 4. Remove and inspect brushes for damage or uneven wear. Replace all brushes if any brush is worn or damaged. The brushes must be at least half their original length. Move brush springs away from top of each brush and pull brushes from their holders to inspect surface that rides on commutator. See Figure 3. That surface must have the same shape as

2

7. To replace a brush set, remove screw that holds brush wires to bus. Pull brush end of springs from brushes, and pull brushes from holders. Lift brush springs away from holders, and install new brushes so brush commutator surface fully touches commutator. Make sure the springs are pushing on each brush. Install and tighten screws for brush wires and bus connectors.

8. Carefully install brush covers so sparks are kept inside motor housing. Install battery as described in Operating Manual or the Periodic Maintenance YRM section for your lift truck.

620 YRM 294

Brush and Commutator Inspection Legend for Figure 3 1. BRUSH 2. BRUSH SPRING 3. MICA

Figure 3. Brush Removal and Inspection Table 1. Normal Commutator Surfaces A light brown surface of the commutator where it rotates on the brushes is a normal condition. The surface of the commutator must be smooth.

Variations between light brown and dark brown colors are also normal. The surface of the commutator must be smooth.

3

Brush and Commutator Inspection

620 YRM 294

Table 1. Normal Commutator Surfaces (Continued) A condition called slot bar marking is also normal if the commutator surface is smooth. The variable color occurs in a pattern according to the number of conductors per slot.

STEERING PUMP MOTOR NOTE: Some electrical trucks use a steering pump motor. Refer to your truck model’s service manual for instructions on removal and installation of steering pump motors.

1. Disconnect battery connector. Remove floor plate from lift truck for access to steering pump motor.

Open hood for access to motor. Remove screws that hold two brush cover plates to motor housing.

2. Inspect brushes and commutator as described in previous paragraphs for traction and hydraulic pump motors. The brush replacement procedure is also the same, although there are only two brushes for the steering pump motor. See Table 3.

4

A very dark surface is also a normal and an acceptable condition if the commutator surface is smooth.

3. Install brush covers and screws. Install floor plate or close hood and connect battery connector.

NORMAL COMMUTATOR SURFACE A commutator that has been in service will have a smooth and polished surface with a darker brown color where it rotates under the brushes. See Table 1. A variation of color on the commutator surface between light brown and darker brown is normal. This surface condition is the lubrication between the commutator and the brushes. The brushes will wear rapidly if this surface condition does not develop during the first 6 to 10 hours of operation after a commutator with a new surface is installed.

620 YRM 294

Brush and Commutator Inspection

COMMUTATOR PROBLEMS Commutator and motor problems and are shown in Table 2.

Table 2. Commutator Problems Problem

Possible Cause

Heavy streaks and fine grooves indicate the beginning of damage to the commutator.

• Operation of the motor in dirty and abrasive conditions.

• Continuous operation of a motor with a light load.

• Brush pressure is too low.

• Worn brushes.

Grooves and lines that have followed the heavy streaks and fine grooves shown above.

The armature must be removed from the motor so the commutator can be repaired. A commutator with this condition will cause the brushes to wear rapidly.

• Operation of the motor in dirty and abrasive conditions.

• Continuous operation of a motor with a light load.

• Brush pressure is too low.

• Worn brushes.

Illustration

5

Brush and Commutator Inspection

620 YRM 294

Table 2. Commutator Problems (Continued) Problem

Possible Cause

Grooves that are the width of the brushes.

• Operation of the motor in dirty and abrasive conditions.

• Wrong type of brushes for this motor and operation.

• Brush pressure is too high.

A condition called copper drag occurs when copper from the commutator bar is pulled into the slot between the commutator bars. This condition will cause a short circuit between the commutator bars if it is not corrected.

The brushes will wear rapidly.

• Operation of the motor in dirty and abrasive conditions.

• Brush holder is not adjusted electrically correct for the motor.

• Wrong type of brushes for this motor and operation.

• Brush pressure is wrong (too high or too low).

Electrical burns on commutator bars on opposite sides of the commutator.

• Open armature winding.

• Motor has been stalled.

6

Illustration

620 YRM 294

Brush and Commutator Inspection

Table 2. Commutator Problems (Continued) Problem

Possible Cause

Copper wears rapidly at the edge of the commutator bars.

• Operation of the motor in dirty and abrasive conditions.

• Wrong type of brushes for this motor and operation.

1. Flashover causes burning of the ends of the commutator bar.

2. Open circuit in winding causes deep burning of adjacent commutator bars.

3. Overheating causes damage to varnish insulation.

• Motor has been too hot. Wrong lift truck for the application.

• Motor has been stalled.

• Open armature winding.

• Open field coil.

Brush and commutator damage occurs when the high commutator hits and forces the brush up.

Arcing and burns occur as the brush moves back down to the normal surface.

Check for loose or high commutator bars.

• Motor has been stalled.

(High commutator bars at each brush position can occur if the motor is stalled.)

• Motor has been too hot.

Illustration

1. High commutator bars at each brush position can occur if the motor is stalled.

2. Rapid brush wear from high commutator bars.

7

Brush Replacement

620 YRM 294

Brush Replacement The lead wire for some brushes is installed directly into the carbon compound of the brush. New brushes must be installed before the lead wire cuts a groove in the commutator. Install a new brush set when a brush is worn to a short length.

1. Motor brushes must be replaced before they are worn enough to damage the surface of the commutator. Move the brush spring and remove a brush from its brush holder. Install new brushes as a set if length of any brush is worn to a minimum length.

See Table 3. If the brush lead is fastened to the brush with a rivet, install a new set of brushes if it is worn to within 3 mm (0.118 in.) of the rivet. If a brush does not move easily in its holder, a new set of brushes must be installed.

Brushes are made to different specifications for motors used in different applications. Use only new brushes approved by Yale Company for that motor.

Table 3. Brush Wear Replacement Guide Brush Height

17 mm (0.67 in.)

22 mm (0.87 in.)

28 mm (1.10 in.)

30 mm (1.18 in.)

31 mm (1.22 in.)

32 mm (1.26 in.)

40 mm (1.57 in.)

Wear

8 mm (0.31 in.)

12 mm (0.47 in.)

14 mm (0.55 in.)

15 mm (0.59 in.)

16 mm (0.63 in.)

16 mm (0.63 in.)

16 mm (0.63 in.)

Worn Brush Height

9 mm (0.35 in.)

10 mm (0.39 in.)

14 mm (0.55 in.)

15 mm (0.59 in.)

15 mm (0.59 in.)

16 mm (0.63 in.)

20 mm (0.79 in.)

NOTE: For some models of lift trucks, the battery does not need to be removed to access the electric motors.

Other models will require the removal of the battery before gaining access to the electric motors.

2. Remove battery as necessary for your lift truck.

See How To Remove Battery in the Operating Manual or the YRM section Periodic Maintenance for your lift truck.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Verify the path of the compressed air is away from all personnel. Wear protective goggles of a face shield to prevent injury to the eyes.

3. Remove access plate to motors. Remove brush covers to motor. See Figure 2. Wear eye protection. Use a vacuum cleaner or compressed air to remove dirt and brush dust from commutator area.

4. Make a note of the arrangement and connections of the brush assembly. See Figure 4. The new brushes must be installed in the same positions from which the worn brushes were removed.

5. Loosen screw that fastens brush wire to its terminal.

Remove brush springs and brushes.

1.

2.

3.

4.

BRUSH BRUSH BRUSH BRUSH

HOLDER (4) MOUNTING PLATE SPRING (4) SET Figure 4. Brush Assembly

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620 YRM 294

Brush Replacement

6. Inspect brush holders for burns and damage. Make sure brush holders are fastened tightly to brush mounting plate at end of motor. Make sure new brushes will move freely and smoothly in brush holders. Check that brush mounting plate is holding brush holder so it does not move.

7. Connect new brush wire to its terminal mount.

NOTE: When new brushes must be installed, a recommendation is to also install new brush springs. Damage from heat can cause the brush springs to have the wrong spring pressure.

8. Check brush springs for damage from heat and corrosion. If brush springs are damaged, install new brush springs. Check brush springs for approximately equal pressure.

Brush springs normally have a spring pressure of approximately: 1.0 to 2.0 Newtons per each cm 2 (1.5 to 3.0 lbf per each in 2) when measured with a spring scale.

A brush for a traction motor has an area of approximately: 5.33 × 1.27 cm = 6.8 cm 2 (2.1 × 0.5 in. = 1.05 in 2).

Brush springs for the traction motor normally have a spring force of approximately: 9.1 to 11.3 Newtons (36 to 44 ozf) when measured with a spring scale as shown in Figure 5.

A brush for a hydraulic pump motor has an area of approximately: 4.42 × 0.95 cm = 4.21 cm 2 (1.74 × 0.375 in. = 0.653 in 2).

Brush springs for the hydraulic pump motor normally have a spring force of approximately: 5.2 to 7.4 Newtons (20 to 28 ozf) when measured with a spring scale as shown in Figure 5.

NOTE: SOME MOTORS HAVE SPRINGS AS SHOWN IN FIGURE 7 AND FIGURE 11. SOME SPRINGS ARE IN PAIRS AT EACH BRUSH HOLDER. 1. SPRING SCALE 2. BRUSH IN BRUSH HOLDER

3. COMMUTATOR 4. BRUSH SPRING

Figure 5. Brush Spring Pressure Check

WARNING Wear eye protection. Raise the drive wheels. Operate the motor at low speed. Protect your fingers.

You are doing work close to moving parts of the motor. Do not use a brush seater stone less than 60 mm (2.4 in.) in length.

NOTE: The brush springs used in motors made by Yale have a constant force design. The force of the brush spring against the brush stays almost constant as the brush wears and becomes shorter in its brush holder.

NOTE: New brushes made by the manufacturer are normally made to fit the surface of the commutator when they are installed. This contact surface must be checked when new brushes are installed. The contact

9

Stoning the Commutator

620 YRM 294

surface MUST be approximately 85 percent of the brush surface where it touches the commutator. A small contact surface can cause burns and a rough surface on the commutator. If the contact surface is less than approximately 86 percent, the new brushes must be made to fit the commutator better.

9. If new brushes must be made to fit the surface of the commutator, see Stoning the Commutator.

Use a Brush Seater and Commutator Stone (No. 23-007M from the Ideal Company or an equivalent brush seater stone). Stoning the commutator

is most easily done when the motor rotates slowly.

When the motor rotates at higher speeds, the centrifugal force removes the abrasive particles from the commutator more quickly.

NOTE: To rotate the commutator of the traction motor without moving the truck, the drive wheels must be raised. See How to Raise Drive Wheels in the Operating Manual or the YRM section Periodic Maintenance for your lift truck.

Stoning the Commutator 1. If the commutator has grooves or other damage, the armature must be removed so the commutator can be repaired. Motors are normally repaired by service persons that have the special equipment required. Connect battery so the motor can be operated. See Figure 6. The battery must be removed for access to the motor. Use a jumper cable to connect battery to lift truck. Raise drive wheels. See How to Raise the Drive Wheels in the Operating Manual or the YRM section Periodic Maintenance for your lift truck.

2. Close seat switch and key switch so motor will operate.

NOTE: A brush seater stone can also be fastened to a wood stick with glue as shown in Figure 6. This arrangement makes it easier to apply a brush seater stone in small spaces.

3. Operate motor so commutator rotates slowly. Apply brush seater stone to moving commutator with light pressure. Move brush seater stone backward and forward across surface of commutator until marks on commutator are removed. Apply brush seater

10

stone to commutator before each set of brushes so the brush seater particles have an even distribution.

CAUTION Do not permit the brush seater stone to stay in contact with the commutator too long and cause more wear than necessary.

4. Turn key switch to OFF position and disconnect battery. Check all brush contact surfaces. The brushes fit correctly when 85 percent of the brush contact surface touches the commutator. This stoning procedure normally requires approximately 15 to 45 minutes.

5. When the brushes have the correct contact surface with the commutator, use a vacuum cleaner to remove abrasive dust from commutator area and motor.

6. When the installation and checks are complete, install brush cover. Make sure wires to brushes do not touch any part of motor case and cause a short circuit.

620 YRM 294

Stoning the Commutator Legend for Figure 6 1.

2.

3.

4.

RAISE DRIVE WHEELS JUMPER BATTERY BRUSH SEATER STONE

Figure 6. Stoning the Commutator

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Motors Repair

620 YRM 294

Motors Repair DISASSEMBLE See the Master Drive Unit section or the Frame section for your lift truck for instructions on the removal and installation of the traction motor.

plastic or rubber hammer as necessary to loosen end frame.

6. Remove drive end frame from armature.

If the brush holder (1) must be loosened or removed from the end frame for repairs, the brush holder must be installed again in the same position. See Figure 7. Make alignment marks between the brush holder and the end frame before the brush mounting plate (4) is released. The brush holder must be installed again in the same position.

See the Hydraulic System section for instructions to remove and install the hydraulic pump and motor.

See the Brush and Commutator Inspection and Brush Replacement in this section for more information on these components of the motor.

Traction Motor and Hydraulic Pump Motor

If a new brush holder must be installed, there will not be an alignment mark on the new brush holder.

Make an alignment mark on end frame with a reference point on brush holder that must be removed.

Install new brush holder so reference point and alignment mark are aligned. The new brush holder must be installed in the same position as the old holder so the timing will be correct.

NOTE: It is recommended that the bearings and the seal be replaced every 3,000 hours or 36 months, whichever comes first.

1. Clean outside surfaces of motor before disassembly. See Figure 8, Figure 9, and Figure 10. Put motor on its commutator (brush) end on a bench. On hydraulic motor assemblies, make index marks on pump and motor. Make index marks on end frames of motor and field frame so correct assembly is possible.

2. On hydraulic motor assemblies, remove two capscrews that fasten pump to pump motor. See Figure 11 or Figure 12. Remove pump. Put an index mark on armature shaft at the position of the coupler hub for correct assembly. Remove coupler hub from armature shaft by loosening setscrew and sliding hub off shaft and key. Do not lose key.

7. Remove screws that fasten brush holder assembly to commutator end frame.

8. Disassemble components of motor as necessary to make repairs.

3. Remove brush cover. Remove brushes and spring assemblies.

4. Remove hex head screws from commutator end of motor. Carefully slide end frame from motor and armature shaft. Do not damage parts. A puller is frequently necessary to separate end frame from field frame.

CAUTION The drive end frame and the armature are heavy components. Work carefully so the field coils, pole pieces, and armature are not damaged during disassembly and assembly.

1.

2.

3.

4.

BRUSH HOLDER BRUSH SPRING BRUSH BRUSH MOUNTING PLATE Figure 7. Brush Holder and Mounting Plate

5. Remove screws that fasten drive end frame to field frame. Remove end frame and armature. Use a

12

620 YRM 294

1.

2.

3.

4.

5.

6.

7.

8.

9.

Motors Repair

FIELD FRAME ASSEMBLY ARMATURE BRUSH SPRING (4) BRUSH (4) BEARING BEARING DRIVE END FRAME COMMUTATOR END FRAME SCREW (4)

10.

11.

12.

13.

14.

15.

16.

17.

18.

SCREW (4) WASHER (8) WASHER FAN COVER BRUSH COVER SCREW (4) WASHER (4) FAN HUB FAN

19.

20.

21.

22.

23.

24.

25.

26.

27.

SCREW (2) SNAP RING OIL SEAL BRUSH HOLDER SCREW (4) WASHER (4) BRUSH MOUNTING PLATE MOUNT PLATE SCREW (4)

Figure 8. Typical Traction Motor (Example 1)

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Motors Repair

620 YRM 294

Steering Pump Motor NOTE: Some lift trucks could be equipped with a Brushless DC Power Steering motor, which is non-repairable.

NOTE: Some electrical trucks use a steering pump motor. Refer to the service manual for your truck model for instructions on the removal and installation of steering pump motors.

1. See Power Steering Motor and Pump for the removal and installation procedures for the steering

1.

2.

3.

4.

5.

6.

7.

SNAP RING BEARING SEAL DRIVE END FRAME FAN COVER SNAP RING FAN

8.

9.

10.

11.

12.

13.

14.

pump motor. Make index marks on the steering pump and the drive end frame of the motor. Remove two capscrews that hold steering pump to motor. Remove pump and allow oil to drain from drive end frame.

2. Remove brush covers. See Figure 2. Remove two screws that hold brushes and terminal wires to brush holders. Pull brush springs out of the way and pull two brushes from holders.

KEY ARMATURE BEARING BRUSH COVER COMMUTATOR END FRAME TERMINAL BRUSH MOUNTING PLATE

15.

16.

17.

18.

19.

20.

Figure 9. Typical Traction Motor (Example 2)

14

BUS CONNECTOR WIRE BRUSH SPRING BRUSH BRUSH HOLDER FIELD FRAME

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