Yale e216 erp20alf lift truck (europe) service repair manual

ERP20-30ALF (E216) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................

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

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

DRIVE AXLE WET BRAKE............................................................................................

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

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

BRAKE PEDAL AND LINKAGE.....................................................................................

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

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

MAIN CONTROL VALVE E-CONTROLS.......................................................................

CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)..........................................................................................................................

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 REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........

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

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

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

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

PART NO. 524309197 (09/14)

PART NUMBER

YRM NUMBER

REV DATE

524256685 524158039 524183080 524256686 524158753 524183081 524264587 524179945 524179946 524256687

0100 YRM 1222 0620 YRM 0294 0620 YRM 1053 1400 YRM 1223 1600 YRM 0720 1600 YRM 1054 1800 YRM 1253 1900 YRM 0559 2000 YRM 0562 2000 YRM 1224

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

524223768 524183082

2100 YRM 1139 2200 YRM 1055

02/14 10/09

524183083

2200 YRM 1056

03/09

524183085 524158040 524158890

2200 YRM 1058 2240 YRM 0001 4000 YRM 0521

04/11 09/14 03/06

524223776 524150797 524256688 524309198 524256690

4000 YRM 1148 8000 YRM 0231 8000 YRM 1225 8000 YRM 1226 8000 YRM 1227

02/14 10/13 05/06 08/08 05/06

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Frame

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................

Description ..........................................................................................................................................................

Main Frame .....................................................................................................................................................

Other Frame Weldments .................................................................................................................................

Overhead Guard .............................................................................................................................................

Battery Restraint, Hood, and Seat Assembly..................................................................................................

Hood With Manual Hydraulic Levers ...............................................................................................................

Hood With E-Hydraulics ..................................................................................................................................

Operator Restraint System and Seat Assembly..............................................................................................

Operator Restraint System .........................................................................................................................

Emergency Locking Retractor (ELR) ......................................................................................................

Hood and Seat Latches ..............................................................................................................................

Overhead Guard Replacement............................................................................................................................

Remove ...........................................................................................................................................................

Install...............................................................................................................................................................

Hood, Seat Assembly, and Operator Restraint Replacement..............................................................................

Hood and Seat Assembly................................................................................................................................

Remove.......................................................................................................................................................

Install ..........................................................................................................................................................

Counterweight Replacement ...............................................................................................................................

Remove ...........................................................................................................................................................

Install...............................................................................................................................................................

Hydraulic Tank Replacement...............................................................................................................................

Remove ...........................................................................................................................................................

Inspect.............................................................................................................................................................

Clean...............................................................................................................................................................

Steam Method ............................................................................................................................................

Chemical Solution Method ..........................................................................................................................

Additional Preparations for Tank Repair..........................................................................................................

Small Leaks, Repair ........................................................................................................................................

Large Leaks, Repair ........................................................................................................................................

Preparations for Usage After Repair ...............................................................................................................

Install...............................................................................................................................................................

Painting Instructions ............................................................................................................................................

Safety Label Replacement ..................................................................................................................................

Battery Specifications..........................................................................................................................................

ERP20-32ALF (ERP040-065DH) (E216) Model Trucks ..................................................................................

1 1 1 1 1 5 6 7 8 8 8 9 9 9 9 11 11 11 13 17 17 17 18 18 18 19 19 19 20 20 20 20 20 21 23 25 25

This section is for the following models: ERP20-32ALF (ERP040-065DH) [E216]

Š2006 Yale Materials Handling Corp.

i

100 YRM 1222

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.

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 hydraulic tank, lift pump motor assembly, and the steering pump motor assembly are in a compartment between the battery and the counterweight. The top cover between the counterweight and hood can be removed for access to the master controller. The rear cover of the counterweight can be removed for access to the controllers and contactors. See Figure 2.

the battery is within the weight limits indicated on the nameplate. Each model of lift truck has a cast iron counterweight that provides additional weight necessary for the indicated capacity.

OTHER FRAME WELDMENTS These frame parts are the right-side and left-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 parking brake release linkage, and the dash panel with light switches. The display panel is mounted into the dash panel. See Figure 3.

OVERHEAD GUARD WARNING Do not operate the lift truck without the overhead guard and cowl 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. A slot in the overhead guard permits removal of the battery without removing the overhead guard. See Figure 2.

The weight of the battery is a large part of the counterweight system on an electric lift truck. Make sure that

1

Description

1.

2.

3.

4.

COWL BATTERY SPACER PLATE BATTERY RETAINER ROD FRAME

100 YRM 1222

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

2

100 YRM 1222

1.

2.

3.

4.

5.

6.

7.

8.

9.

Description

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

10.

11.

12.

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15.

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REAR COVER SOCKET CAPSCREW LOCKWASHER COUNTERWEIGHT SEAL SPACER BRACKET SELF RETAINING NUT HOLE PLUG

Figure 2. Overhead Guard and Counterweight

3

Description

100 YRM 1222

Figure 3. Steering Column and Display Panel

4

100 YRM 1222

Description Legend for Figure 3

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 RESTRAINT, HOOD, AND SEAT ASSEMBLY 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.

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DASH PANEL COLUMN MOUNT LATCH MECHANISM HORN SWITCH CONNECTOR HORN BUTTON STEERING COLUMN STEERING COLUMN NUT STATIC STRAP

movement of the battery. The adjustable spacer plate is used inside the battery compartment. The spacer plate must be adjusted for a maximum clearance of 13 mm (0.5 in.) with the battery against the rear bulkhead. See Figure 5. There must be some clearance to allow battery removal. See the section Periodic Maintenance 8000 YRM 1226 to remove the battery and adjust the spacer plate.

A battery restraint system is installed as a safety device. 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 at the rear of the battery compartment. See Figure 4. This restraint rod extends over the rear edge of the battery case to help hold the battery within the battery compartment during 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. EXTENDED B. RETRACTED 1.

2.

3.

4.

BATTERY RESTRAINT WARNING LABEL HOOD BATTERY RESTRAINT HANDLE BATTERY Figure 4. Battery Restraint Rod

5

Description

100 YRM 1222

HOOD WITH MANUAL HYDRAULIC LEVERS 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 in.) clearance. The Battery Specifications, at the back of this manual, shows the minimum sizes of the battery compartment.

Before raising the hood, move the steering column to the forward position and slide the seat all the way back.

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4.

5.

6.

BATTERY COMPARTMENT BATTERY BULKHEAD SPACER PLATE ADJUSTMENT CAPSCREW JAM NUT Figure 5. Battery Spacer Plate

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. See Figure 15. 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 6. 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 6. Latch and Cover With Manual Hydraulic Levers

6

100 YRM 1222

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 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. See Figure 14. Gas springs help lift the hood assembly. The seat and other parts of the operator restraint system fasten to the hood assembly.

Description 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 8.

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 8. Use handle on the hood to place hood in the raised position.

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.

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 7.

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

6.

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PIN SCREW CAPSCREW NUT LOCKWASHER WASHER LATCH HANDLE

Figure 8. Latch and Cover With E-Hydraulics 1. ARMREST ADJUSTMENT HANDLE Figure 7. Armrest Latch Location

7

Description

100 YRM 1222

OPERATOR RESTRAINT SYSTEM AND SEAT ASSEMBLY Operator Restraint System The seat belt, hip restraint, seat, hood, and hood latch are all part of the operator restraint system. See Figure 9. Each item must be checked to make sure it is fastened correctly, functions correctly, and is in good condition. The system helps the operator stay within the lift truck in case of a tip over.

Make sure that the seat is not loose on the rails. Make sure that 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.

Emergency Locking Retractor (ELR) 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.

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OPERATOR WEIGHT ADJUSTMENT FORWARD BACKWARD ADJUSTMENT SEAT BELT HIP RESTRAINT SEAT SEAT RAIL Figure 9. Hood and Seat Check

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 9.

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

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FORWARD/BACKWARD ADJUSTMENT SWIVEL ADJUSTMENT OPERATOR WEIGHT ADJUSTMENT SEAT POSITION ADJUSTMENT (SEAT RAIL) SEAT BELT Figure 10. Swivel Seat Option

8

100 YRM 1222

Overhead Guard Replacement

Hood and Seat Latches Make sure the seat rails and latch striker are not loose.

The seat rails must lock tightly in position, but move freely when unlocked (see Figure 9 and Figure 10). The

seat rails must be correctly fastened to the hood and the fastened to the hinges on the frame. Try to lift the hood to make sure it is fastened correctly and will not move.

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 battery as described in the section Periodic Maintenance 8000 YRM 1226.

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. 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 1. Install the over head guard onto the lift using a lifting device or another person.

2. Install any electrical wires from the overhead guard legs through the holes in the frame. Make sure location of the wires is routed in the same location as was removed to assure that the wires do not get pinched.

3. Install the capscrews, washers, and nuts that hold each front leg to the frame. See Figure 11. Tighten the capscrews to 102 N•m (75 lbf ft).

4. Install the caspcrews, washers, and nuts that hold the rear legs to the frame. See Figure 11. Tighten the capscrews to 102 N•m (75 lbf ft).

5.

Install the battery as described in the section Periodic Maintenance 8000 YRM 1226.

9

Overhead Guard Replacement

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

100 YRM 1222

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11.

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15.

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REAR COVER SOCKET CAPSCREW LOCKWASHER COUNTERWEIGHT SEAL SPACER BRACKET SELF RETAINING NUT HOLE PLUG

Figure 11. Overhead Guard and Counterweight

10

100 YRM 1222

Hood, Seat Assembly, and Operator Restraint Replacement

Hood, Seat Assembly, and Operator Restraint Replacement HOOD AND SEAT ASSEMBLY Remove WARNING

hood. See Figure 6. Lift trucks equipped with E-hydraulic levers, pull back on the latch handle to remove cover to access the latch handle. Pull up on the latch handle to release the hood latch mechanism. See Figure 8.

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.

3. 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.

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. Perform only the steps necessary. If the hood and seat assembly will be removed as a unit, perform Step 1 through Step 5. To remove the seat assembly from the hood assembly, perform Step 1 through Step 4 and Step 6 through Step 8.

4. 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.

Remove the hood and seat assembly as follows (see Figure 12 and Figure 13).

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

NOTE: Before raising the hood, move the steering column to the forward position and slide the seat all the way to the rear. Lift trucks equipped with E-hydraulic control levers, move the armrest all the way to the rear.

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. Lift trucks equipped with manual hydraulic levers, unlatch the hand lever assembly and pull back from

5. 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 12 and Figure 13.

Carefully remove the hood assembly.

6. 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 12 and Figure 13.

7. 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.

8. 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.

11

Hood, Seat Assembly, and Operator Restraint Replacement

Figure 12. Hood Removal With Manual Hydraulics

12

100 YRM 1222

100 YRM 1222

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

A. TOP VIEW B. SIDE VIEW

C. HOOD IN OPEN POSITION

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HOOD HANDLE EMERGENCY STOP BUTTON HOOD SEAT SWITCH HARNESS GAS SPRING SEAT

Install NOTE: Install procedures apply for hoods with Manual and E-Hydraulics.

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 12 and Figure 13.

SEAT RAILS HOOD BRACKET SPRING CAPSCREW, WASHER, AND NUT WASHER, NUT, AND BOLT SIDE COVER OVERHEAD GUARD the hood and 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 12) and 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.

2. Carefully install the grommet over the wire connector See Figure 14 and Figure 15. Install the seat on

13

Hood, Seat Assembly, and Operator Restraint Replacement

100 YRM 1222

A. TOP VIEW

B. SIDE VIEW

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WASHER CAPSCREW NUT SPRING BRACKET PLATE-LEFT SIDE SHOWN BOLT GAS SPRING

STRAP CLAMP EMERGENCY STOP HOOD SEAT SWITCH HARNESS SEAT RAIL SEAT

Figure 13. Hood Removal With E-Hydraulics

14

100 YRM 1222

1.

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WASHER CAPSCREW NUT SPRING BRACKET PLATE BACKING PLATE

Hood, Seat Assembly, and Operator Restraint Replacement

7.

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HANDLE HOOD EMERGENCY STOP CLIP RIVET STRAP CLAMP

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GAS SPRING BOLT FOAM TAPE INSULATION GROMMET

Figure 14. Hood Assembly With E-Hydraulics

15

Hood, Seat Assembly, and Operator Restraint Replacement

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HOOD FRAME BACKING PLATE WASHER LOCKWASHER NUT GAS SPRING FOAM TAPE SPACER

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100 YRM 1222

BRACKET CAPSCREW TRIM COVER RIVET HANDLE STRAP CLAMP CLIP GROMMET

Figure 15. Hood Assembly With Manual Hydraulics

16

100 YRM 1222

Counterweight Replacement

Counterweight Replacement If the lift truck must be put on blocks for maintenance and repair, see Periodic Maintenance 8000 YRM 1226 for procedures of putting the lift truck on blocks.

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

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

REMOVE 1. Remove the battery. See section Periodic Maintenance 8000 YRM 1226 for the procedures to remove the battery.

2. Remove the top cover between the counterweight and hood. The cover in the back part of the counterweight that covers the electronic control compartment. See Figure 11. 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.

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 frame. Make sure that you do not damage the motor controller assembly.

INSTALL 1. Use a crane and either a sling or chain, as during removal, to lift the counterweight into position at the rear of the truck. See Figure 11. Install the two upper capscrews near the bottom of the battery compartment that hold the counterweight to the frame.

Tighten capscrews to 320 N•m (236 lbf ft). Install the lower capscrews, washers, and nuts in the tow pin area of the counterweight. Tighten the lower capscrews (between wheels) and nuts to 66 N•m (49 lbf ft). If removed, tighten the cover capscrews to 75 N•m (56 lbf ft).

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

3. Install the battery. See the section Periodic Maintenance 8000 YRM 1226 for the procedures to install the battery.

3. From inside the battery compartment near the bottom, remove the two top capscrews that hold Table 1. Counterweights Model

(mm*)

ERP20ALF and ERP25ALF (ERP040DH and ERP050DH) (E216)

717 mm

ERP25ALF and ERP30ALF, ERP050DH and ERP60DH (E216)

861 mm

ERP32ALF and ERP065DH (E216)

861 mm

Weight

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

685 kg (1510 lb)

750 kg (1653 lb)

*Approximate battery compartment lengths.

17

Hydraulic Tank Replacement

100 YRM 1222

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

WARNING Do not attempt to drain or replace hydraulic oil, until hydraulic oil has cooled. The hydraulic oil is HOT at operating temperatures. Do not permit the HOT oil to contact skin and cause a burn.

WARNING Do not permit dirt to enter the hydraulic tank. Dirt can cause damage to the components of the hydraulic system.

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.

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 16. Install a container under the drain plug of the hydraulic tank with a capacity of 27.4 liter (7.25 gal).

4. Remove dipstick and fill cap.

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

6. Disconnect hydraulic lines and install plugs in all the hoses fastened to the hydraulic tank and hydraulic filter assembly.

7. Remove the screws from the bracket that fastens the hydraulic tank to lift truck frame. See Figure 16.

Remove the bracket assembly.

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

1. MOUNTING BRACKET 2. CAPSCREW 3. WASHER 4. NUT 5. STRAP CLAMP 6. CLAMP 7. PLUG 8. BREATHER 9. BREATHER HOSE

10. PIPE 11. DIPSTICK AND FILL CAP ASSEMBLY 12. PLATE 13. ADAPTER 14. HYDRAULIC FILTER ASSEMBLY 15. GAUGE

Figure 16. 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. • 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.

18

100 YRM 1222

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.

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.

Steam 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.

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

Hydraulic Tank Replacement 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.

Chemical Solution Method 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.

19

Hydraulic Tank Replacement 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.

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.

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

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

20

100 YRM 1222

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

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

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 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.

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

4. Connect the hoses to the hydraulic tank and hydraulic filter assembly. Install the bracket that fastens the hydraulic tank to truck frame. See Figure 16.

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

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

100 YRM 1222

Painting Instructions

Painting Instructions WARNING Always wear protection equipment like: Gloves, goggles, face shield, safety glasses, and a mask if an electric sander or spraying paint either aerosol can or spray gun is used.

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 17.

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 17.

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 18. New labels are available from your dealer for Yale lift trucks.

21

Painting Instructions

100 YRM 1222

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 17. Color Arrangement

22

100 YRM 1222

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 18.

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.

23

Safety Label Replacement

100 YRM 1222

Figure 18. Label Positions

24

100 YRM 1222

Battery Specifications Legend for Figure 18

NOTE: NOT ALL LABELS USED ON THESE LIFT TRUCK MODELS ARE SHOWN IN FIGURE 18. SEE THE PARTS MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON THESE LIFT TRUCKS. A. LABEL IS UNDER HOOD, NEAR CENTER 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

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 AUXILIARY FUNCTIONS LABEL

12.

13.

14.

15.

16.

17.

18.

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 20. AC POWER LABEL

*NORTH AMERICA ONLY

Battery Specifications ERP20-32ALF (ERP040-065DH) (E216) 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)

1625 kg (3582 lb)

ERP25-32ALF (ERP050-065DH)

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)

1965 kg (4332 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.

25

1400 YRM 1223

Description

General This section has the description and repair procedures for the differential, drive axle, traction motor, and the wet disc brakes.

Description The drive unit consists of following main components (see Figure 1): • The traction motor with hollow shaft.

• Mechanical differential assembly (located on left-hand side of traction motor shaft).

• The gearbox with intermediate flange, containing the wet disc brakes.

• Main housings, containing the pistons for the wet disc brakes and the parking brake levers.

• Speed sensor and reluctor wheel (located on traction motor shaft, see Figure 8).

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

WHEEL HUB GEARBOX (LH) INTERMEDIATE FLANGE (LH) MAIN HOUSING (LH) PARKING BRAKE LEVER TRACTION MOTOR

MAIN HOUSING (RH) INTERMEDIATE FLANGE (RH) GEARBOX (RH) SPEED SENSOR DIFFERENTIAL ASSEMBLY

Figure 1. Drive Unit 1

Description

1400 YRM 1223

The drive unit assembly is fastened to the frame of the lift truck by the frame mounts of the main housings. See Figure 2.

The traction motor is mounted in between the two main housings. The traction motor generates the power to the differential assembly. See Figure 4.

The mast is mounted on the J-hook mountings of the main housings of the drive unit. See Figure 3.

1. FRAME MOUNTS Figure 2. Drive Unit Frame Mounts

2

1400 YRM 1223

Description

1. J-HOOK MOUNTINGS Figure 3. Mast Mounting Hooks

1.

2.

3.

4.

5.

WHEEL HUB PLANETARY GEAR INPUT SHAFT (RH) DRIVE GEAR AXLE SHAFT

6.

7.

8.

9.

10.

TRACTION MOTOR SHAFT DIFFERENTIAL ASSEMBLY DRIVE GEAR INPUT SHAFT (LH) SUN PINION

11.

12.

13.

14.

15.

DRIVEN GEAR BRAKE DISC PACK DISC PUSHER PISTON PARK BRAKE LEVER

Figure 4. Drive Unit

3

Description

1400 YRM 1223

The differential then transfers the power through the axle shaft to the input shafts located in the intermediate flange assemblies. The input shaft drive gears transfer the power to the driven gears. The driven gears then transfer the power to the sun pinion. See Figure 5.

1.

2.

3.

4.

PLANETARY CARRIER PLANETARY GEARS RING GEAR WHEEL HUB Figure 6. Planetary Gears

1.

2.

3.

4.

5.

6.

DRIVE GEAR INTERMEDIATE FLANGE INPUT SHAFT AXLE SHAFT DRIVEN GEAR SUN PINION

Figure 5. Drive Gear, Driven Gear, and Sun Pinion The sun pinion then transfers the power to the planetary gears and planetary carrier which then engages the wheel hubs. See Figure 6.

The wet brake discs are mounted on the intermediate flanges. The piston, which is located in the main housing (one in each main housing), is activated when the brake pedal is applied. The piston presses against the disc pusher which compresses the brake friction discs and steel discs which causes the braking. See Figure 7.

4

1. INTERMEDIATE FLANGE 2. DISC PUSHER 3. BRAKE DISC PACK Figure 7. Brake Disc Pack

1400 YRM 1223

Wet Disc Brake Repair

The parking brake levers press against the back of the piston which forces the piston to press against the disc pusher to compress the brakes friction discs and steel discs to mechanically apply the parking brake.

The speed sensor is mounted on the main housing on the right-hand side of the drive unit. The reluctor wheel is mounted on the traction motor shaft on the right-hand side of the traction motor. The speed sensor is a hall effect sensor which reads the variation in its magnetic field when a tooth of the reluctor wheel passes the sensor. See Figure 8.

1. SPEED SENSOR 2. RELUCTOR WHEEL Figure 8. Speed Sensor and Reluctor Wheel

Wet Disc Brake Repair WET DISC BRAKES For replacement of the pistons and piston seals, refer to the section Main Housing Repair.

Remove STEP 1.

Remove the gearbox. Refer to the section Gearbox Replacement.

STEP 2.

Press down on the disc pusher device and remove the retaining rings from the studs.

5

Wet Disc Brake Repair

1400 YRM 1223

STEP 3.

Remove the disc pusher device from the studs.

1. DISC PUSHER DEVICE 2. STUDS STEP 4.

Remove the springs from the studs.

If necessary, remove the studs.

6

1400 YRM 1223

Wet Disc Brake Repair

1. STUDS 2. SPRINGS STEP 5.

Note the position of the notches on the steel discs for correct positioning during assembly.

Remove one steel disc.

1. STEEL DISC 2. NOTCH

7

Wet Disc Brake Repair

1400 YRM 1223

STEP 6.

Remove the one friction disc.

1. FRICTION DISC STEP 7.

Remove four springs/spacers.

1. SPRINGS/SPACERS

8

1400 YRM 1223

Wet Disc Brake Repair

STEP 8.

Repeat STEP 5 through STEP 7 until the last steel disc is removed.

STEP 9.

Remove the aluminum reaction disc.

Inspect 1. Inspect the brake friction discs and brake steel discs. The discs must be measured as a pack (6 steel discs and 5 friction discs) to determine if the discs need replaced. Replace discs as a pack when the thickness is less than 23 mm (0.91 in.).

A new disc pack will have a thickness of 23.95 to

24.45 mm (0.94 to 0.96 in.). When replacing the disc pack, all springs must also be replaced.

2. Inspect the aluminum reaction disc. Replace the aluminum reaction disc when the thickness is equal or less than 4.5 mm (0.18 in.). A new aluminum reaction disc will have a thickness of 4.95 to 5.05 mm (0.195 to 0.199 in.).

Install STEP 1.

If removed, install the four pins.

9

Wet Disc Brake Repair

1400 YRM 1223

STEP 2.

If removed, apply LoctiteŽ 242 to the studs and install the studs. Tighten the studs to 2 N•m (17.7 lbf in).

STEP 3.

Install the aluminum reaction disc.

NOTE: The first and last disc installed must be a smooth steel disc.

STEP 4.

Align the notch of the steel disc as noted during disassembly.

Install one steel disc.

1. NOTCH

10

1400 YRM 1223

Wet Disc Brake Repair

STEP 5.

Install one friction disc.

STEP 6.

Install four springs/spacers.

STEP 7.

Repeat STEP 4 through STEP 6 until six steel discs and five frictions discs have been installed.

11

Wet Disc Brake Repair

1400 YRM 1223

STEP 8.

Install the springs onto the studs.

1. STUDS 2. SPRINGS STEP 9.

Install the disc pusher device onto the studs.

12

1400 YRM 1223

Wet Disc Brake Repair

1. DISC PUSHER DEVICE 2. STUDS STEP 10.

Press down on the disc pusher device and install the retaining rings into the seats on the studs.

STEP 11.

Install the gearbox. Refer to the section Gearbox Replacement.

13

Gearbox Replacement

1400 YRM 1223

Gearbox Replacement REMOVE Gearbox Removal WARNING When putting the lift truck on blocks, make sure the surface is solid, even, and level. Any blocks used to support the lift truck must be solid, one-piece units.

1. Put blocks on each side (front and back) of the steering tires to prevent movement of the lift truck.

10. Place a sling connected to an overhead lift around the gearbox and wheel hub assembly and apply light tension to the sling.

11. Remove the socket-head screws retaining the gearbox to the main housing. Note the positions of the short and long socket-head screws for when the gearbox is installed. See Figure 10.

12. Remove the gearbox and wheel hub assembly.

2. Raise the lift truck and put blocks under the frame so that the drive wheels do not touch the floor. Put blocks under the counterweight for stability.

3. Remove the mast assembly as described in the section Mast Repairs, 2, 3, and 4-Stage Masts 4000 YRM 1148.

4. Disconnect the battery connector.

5. Remove the wheel from the wheel hub of the gearbox being replaced.

6. Remove the gearbox oil fill plug. See Figure 9.

7. Remove the gearbox magnetic drain plug to drain the oil from the gearbox into a suitable container.

See Figure 9.

8. Remove the brake oil fill/breather plug from main housing. See Figure 9.

9. Remove the brake oil drain plug to drain the oil from the main housing into a suitable container. See Figure 9.

1.

2.

3.

4.

BRAKE OIL FILL/BREATHER PLUG GEARBOX OIL FILL PLUG GEARBOX OIL DRAIN PLUG (MAGNETIC) BRAKE OIL DRAIN PLUG Figure 9. Oil Refill and Drain Plugs

14

1400 YRM 1223

Gearbox Replacement Legend for Figure 10 1. M8 SOCKET-HEAD SCREWS, 3 EACH 2. M12 X 1.75 X 70 MM LONG SOCKET-HEAD SCREWS, 11 EACH 3. M12 X 1.75 X 40 MM SHORT SOCKET-HEAD SCREWS, 2 EACH

Figure 10. Gearbox Removal/Installation

Intermediate Flange Removal STEP 1.

Remove the brake discs and friction plates. Refer to the section Wet Disc Brake Repair.

STEP 2.

For the left-hand side gearbox only, remove the spacer from the input shaft.

15

Gearbox Replacement

1400 YRM 1223

STEP 3.

Remove the socket-head screws used to retain the intermediate flange to the gearbox housing.

Insert a prybar into the pry slots between the intermediate flange and the gearbox housing and pry upwards to break the seal between the flange and housing.

1. SOCKET-HEAD SCREWS 2. PRY SLOTS

16

1400 YRM 1223

Gearbox Replacement

STEP 4.

Remove the intermediate flange assembly from the gearbox housing.

DISASSEMBLE Due to the requirement of specialized tools and equipment (which most service departments do not

possess) to properly service this gearbox, it is highly recommended to replace rather than rebuild this assembly.

Intermediate Flange NOTE: If the inner ring for the needle bearing is being replaced, the needle bearing in the gearbox housing must be replaced.

STEP 1.

Using an appropriate puller, remove the needle bearing from the gearbox housing.

1. GEARBOX 2. NEEDLE BEARING

17

Gearbox Replacement

1400 YRM 1223

STEP 2.

Remove the snap ring retaining the input shaft into the intermediate flange.

1. SNAP RING 2. INPUT SHAFT

18

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