Yale g807 erp035vt lift truck service repair manual by 1630861

ERP030/040VT (G807) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ AC MOTOR REPAIR...................................................................................................... TRANSAXLE................................................................................................................... STEERING SYSTEM...................................................................................................... BRAKE SYSTEM............................................................................................................ HYDRAULIC SYSTEM.................................................................................................... HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVES............................................................................................. CYLINDER REPAIR (MAST S/N A270-72, A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515, D562-64, E509, E564).......................................................................................................................... WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE SUPERVISOR................................................................................. USER INTERFACE SERVICE TECHNICIAN................................................................. ELECTRICAL SYSTEM.................................................................................................. INDUSTRIAL BATTERY................................................................................................. MAST REPAIR (S/N C661, C662, C663, C665)............................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS..................................................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

PART NUMBER

YRM NUMBER

REV DATE

524295629 550025937 524327049 524295630 524295631 524295632 524295633 550073240 524319495

0100 YRM 1329 0100 YRM 1446 0620 YRM 1385 1300 YRM 1330 1600 YRM 1331 1800 YRM 1332 1900 YRM 1333 1900 YRM 1620 2000 YRM 1334

09/14 09/14 09/14 09/12 09/14 12/10 09/14 12/14 09/14

524319496 524223769 524319497 524319498 524320282 524158040 524333799 524150797 524320287 524306565 524319503 524319504

2100 YRM 1382 2200 YRM 1128 2200 YRM 1335 2200 YRM 1336 2200 YRM 1337 2240 YRM 0001 4000 YRM 1405 8000 YRM 0231 8000 YRM 1339 8000 YRM 1340 8000 YRM 1341 9000 YRM 1377

03/14 12/14 09/14 09/14 09/14 09/14 05/14 10/13 09/14 09/14 09/14 10/14

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 524320413 (12/14)

Maintenance

FRAME ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

PART NO. 524295629

0100 YRM 1329

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

•

• • • • • • • • • • • •

•

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death. When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. Keep the unit clean and the working area clean and orderly. Use the correct tools for the job. Keep the tools clean and in good condition. Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS Introduction ............................................................................................................................................................... 1 General .................................................................................................................................................................1 Description of Operation .......................................................................................................................................2 Discharging the Capacitors .................................................................................................................................. 3 Rapid Charge ....................................................................................................................................................... 3 Covers and Floor Plates ........................................................................................................................................... 4 Overhead Guard Replacement .................................................................................................................................6 Remove ................................................................................................................................................................ 6 Install .................................................................................................................................................................. 10 Hood and Seat Assembly ....................................................................................................................................... 12 Remove .............................................................................................................................................................. 15 Install .................................................................................................................................................................. 17 Ground Test ........................................................................................................................................................17 Counterweight Replacement .................................................................................................................................. 18 Remove .............................................................................................................................................................. 20 Install .................................................................................................................................................................. 23 Safety Labels .......................................................................................................................................................... 25 Painting Instructions ............................................................................................................................................... 30 Battery Specifications ............................................................................................................................................. 31 European Model Trucks ERP15-20VT (G807).................................................................................................... 31 US Model Trucks ERP030-040VT (G807)...........................................................................................................33 European Model Trucks ERP16-20VF (A955).................................................................................................... 34 US Model Trucks ERP30-40VF (A955)............................................................................................................... 35 This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

0100 YRM 1329

Introduction

Introduction GENERAL This section contains 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, side panels, and labels. Throughout this section, forward will refer to travel in the direction of the forks and left and right will be determined by an operator sitting in the seat facing forward. See Figure 1 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 2. for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

A. LEFT SIDE B. RIGHT SIDE

C. FORWARD TRAVEL

Figure 2. Truck Orientation for Lift Truck ERP16-20VF (ERP30-40VF) (A955)

A. LEFT SIDE C. FORWARD TRAVEL B. RIGHT SIDE Figure 1. Truck Orientation for Lift Truck ERP15-20VT (ERP030-040VT) (G807)

Introduction

0100 YRM 1329

DESCRIPTION OF OPERATION The frame is a welded assembly with mounts for the counterweight, overhead guard, mast, steering system, side panels, hydraulic system and transaxles. See Figure 3. The hood opens on hinges to provide access to the battery compartment. The weight of the battery is a major part of the counterweight system on this truck. A slot in the overhead guard permits removal of the battery without removing the overhead guard. Spacers may be added around the battery as required on some models.

The hydraulic pump and motor assembly and hydraulic tank are in the counterweight. The counterweight cover is removed for access. The AC drive motors and transaxles are located under the floor plates in the operator compartment. The floor plates are held in position by tabs and are to be removed to give access to components underneath. The hydraulic control valve is fastened to the front of the battery compartment and has covers to protect the control valve and control linkages.

Each lift truck has a cast-iron counterweight appropriately weighted for the indicated capacity on the nameplate.

NOTE: FRAME SHOWN FROM RIGHT SIDE AND REAR. Figure 3. Frame

0100 YRM 1329

DISCHARGING THE CAPACITORS WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery. Disconnect the battery and allow the capacitors to discharge before opening any compartment covers or inspecting or repairing the electrical system. DO NOT place tools on top of the battery. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage. Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so. Never wear any metallic items on your fingers, arms, or neck. Metal items can accidentally make an electrical connection and cause injury. Before performing any tests or adjustments, block the lift truck to prevent unexpected movement. The capacitor in the transistor controller(s) can hold an electrical charge for about 10 seconds after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected.

Covers and Floor Plates 3. Disconnect the battery by separating the connectors. 4. Block the drive wheels to prevent the lift truck from moving. 5. Make sure the Emergency-Disconnect switch HAS NOT been activated. If the EmergencyDisconnect switch is activated, rotate the switch to the right until it pops up. 6. Push horn button. Wait 30 seconds to be sure capacitors are fully discharged.

RAPID CHARGE The lift trucks covered in this manual may be equipped with a Rapid Charge System (see Figure 4). With a Rapid Charge System, the battery is charged during operator breaks or when the truck is not being used. The rapid charge system provides extended operation with a single battery. Some of the features of the Rapid Charge System include: •

Battery connector externally mounted for easy access

•

Vented side covers for improved battery cooling

•

Requires rapid charge vented battery and sealed battery fan box with thermostat

DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Make certain the Emergency-Disconnect switch has not been activated. This will isolate the controller and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors. 1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below.

1. RAPID CHARGE CONNECTOR 2. VENTED SIDE COVER Figure 4. Rapid Charge System

2. Turn the key or keyless switch to the OFF position.

Covers and Floor Plates

0100 YRM 1329

Covers and Floor Plates Various covers and floor plates provide access to components during service and securely cover areas during normal operation. Covers in the floor of the operator compartment allow access to the traction con-

trollers, AC drive motors, service and parking brakes. A cover on the top of the counterweight provides access to the hydraulic tank, hydraulic pump and motor assembly, and the hoist controller. See Figure 5.

0100 YRM 1329

Covers and Floor Plates

Figure 5. Covers and Floor Plates

Overhead Guard Replacement

0100 YRM 1329 Legend for Figure 5

NOTE: COUNTERWEIGHT FOR ERP15-20VT (ERP030-040VT) (G807) LIFT TRUCK SHOWN AS AN EXAMPLE ONLY. A. COUNTERWEIGHT COVER WITH RAPID CHARGE, LIFT TRUCKS MANUFACTURED AFTER JUNE, 2012 1. 2. 3. 4.

FLOOR PLATE MANUAL HYDRAULIC FLOOR PLATE BRAKE PEDAL FLOOR PLATE E-HYDRAULIC FLOOR MAT MANUAL HYDRAULIC

5. 6. 7. 8.

FLOOR MAT E-HYDRAULIC MANUAL HYDRAULIC COVERS HOSE COVER COUNTERWEIGHT COVER

Overhead Guard Replacement WARNING The overhead guard is part of the operator protection system. DO NOT operate the lift truck without the overhead guard correctly fastened to the lift truck. The overhead guard is designed to provide protection to the operator from falling objects and in the event of a tip over. A high visibility design allows for an unobstructed view while maintaining structural integrity. Removal of the battery is simplified by the slot in the overhead guard. This provides access to the battery with an overhead lifting device without removing the overhead guard.

REMOVE WARNING The overhead guard is heavy. Make sure the sling, chain, eye bolts, and crane or lifting device have the capacity to lift the overhead guard. 1. Remove hood and seat. See Hood and Seat Assembly section in this manual. 2. Remove rear capscrew, washers, and vibration mount top from rear leg and counterweight. See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

3. Repeat Step 2 for opposite rear leg.

4. Remove three capscrews from cowl and front leg. See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

5. Repeat Step 4 for opposite front leg. 6. Remove nut, washers, front capscrew, and vibration mount top from front leg and frame. See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

7. Repeat Step 6 for opposite front leg. 8. Use a lifting device to lift overhead guard until it is just higher than the counterweight. NOTE: Tag electrical wiring and note routing during removal to aid in installation. 9. Tag and disconnect electrical wiring for display. Remove display from display cover. NOTE: Note routing of electrical wires into, out of, or on the overhead guard during removal to aid in installation. NOTE: Tag electrical connectors during removal to aid in installation.

0100 YRM 1329

Overhead Guard Replacement

Figure 6. Overhead Guard for Lift Truck ERP15-20VT (ERP030-040VT) (G807)

Overhead Guard Replacement

0100 YRM 1329 Legend for Figure 6

1. 2. 3. 4. 5. 6. 7. 8. 9.

REAR CAPSCREW WASHER REAR LEG VIBRATION MOUNT TOP VIBRATION MOUNT BOTTOM COUNTERWEIGHT NUT FRONT CAPSCREW FRONT LEG

10. 11. 12. 13. 14. 15. 16. 17.

FRAME CAPSCREW OVERHEAD GUARD GRAB HANDLE COWL DISPLAY COVER RETAINING WASHER CLIP NUT

0100 YRM 1329

Overhead Guard Replacement

Figure 7. Overhead Guard for Lift Truck ERP16-20VF (ERP30-40VF) (A955)

Overhead Guard Replacement

0100 YRM 1329 Legend for Figure 7

1. 2. 3. 4. 5. 6. 7. 8. 9.

REAR CAPSCREW WASHER REAR LEG VIBRATION MOUNT TOP COUNTERWEIGHT NUT FRONT CAPSCREW FRONT LEG FRAME

NOTE: On lift truck models ERP030-040VT (G807) and ERP30-40VF (A955) equipped with inboard tail lights, the rear lights are mounted inboard of the overhead guard, reducing the risk of damage to the lights. A protection shield above the lights also provides protection from above. The overhead guard will include mounting features for both inboard and outboard lights. 10. Tag and disconnect electrical wires that go through the legs of overhead guard. Carefully remove the wiring if necessary. 11. Completely remove overhead guard from lift truck. 12. Remove two vibration mount bottoms from counterweight; remove two vibration mount bottoms and two retaining washers from frame. See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models

10. 11. 12. 13. 14. 15. 16. 17.

CAPSCREW GRAB HANDLE OVERHEAD GUARD COWL DISPLAY COVER VIBRATION MOUNT BOTTOM RETAINING WASHER CLIP NUT

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

15. Remove two capscrews, display cover, and two clip nuts from overhead guard. See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

INSTALL 1. Install grab handle and capscrews onto front leg. See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

NOTE: Perform the following step if grab handle is mounted onto rear leg.

13. Remove two capscrews and grab handle from front leg.

2. Install grab handle and two capscrews onto rear leg. Tighten capscrews to 6.5 N•m (57.5 lbf in)

•

See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

NOTE: Perform following step if grab handle is mounted onto rear leg. 14. Remove two capscrews and grab handle from rear leg. See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 6 for lift truck models •

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

3. Install two retaining washers and two vibration mount bottoms onto frame; install two vibration mount bottoms onto counterweight. See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

ERP16-20VF (ERP30-40VF) (A955)

0100 YRM 1329 4. Using a lifting device, position overhead guard just above mounting holes on counterweight and frame. 5. Route electrical wires through overhead guard legs as noted during removal.

Overhead Guard Replacement 11. Install three capscrews into cowl and front leg. See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

NOTE: Make sure electrical wires do not get pinched when overhead guard is lowered onto mounts.

12. Repeat Step 11 for opposite front leg.

6. Carefully lower overhead guard onto vibration mount bottoms on counterweight and frame.

13. Install two clip nuts, display cover and two capscrews onto overhead guard.

7. Install front capscrew, vibration mount top, washers, and nut into front leg and frame. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

8. Repeat Step 7 for opposite front leg. 9. Install vibration mount top, washers and rear capscrew into rear leg and counterweight. See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

See Figure 6 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 7 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

WARNING The ignition switch is a reed switch which uses an applied magnetic field. If a strong magnet is placed near the ignition switch, it may not function properly (such as not shutting off power). To ensure ignition switch functions properly, do not place a magnet near the ignition switch. 14. Install display into display cover. Connect electrical wiring to display as noted during removal. 15. Install hood and seat. See Hood and Seat Assembly Repair section in this manual.

10. Repeat Step 9 for opposite rear leg.

Hood and Seat Assembly

0100 YRM 1329

Hood and Seat Assembly The hood is the platform for the seat assembly and is located above the battery. It functions as a battery restraint that completely covers the battery compartment. See Figure 10. When correctly locked to the frame, it will hold the battery in the battery compartment if an accident causes the lift truck to tip over. The hood is a stamped steel cover. Two hinges at the back attach to the overhead guard. A latch assembly on the front bulkhead locks the hood closed during operation. A gas-controlled strut holds the hood in the open position. See Figure 10 for lift trucks manufactured before November, 2014 See Figure 11 for lift trucks manufactured after November, 2014 Opening the latch assembly unlocks the hood from the frame so the hood can be raised to access the battery. The latch assembly must be in good condition and properly secured before the lift truck can be operated. To raise the hood on a lift truck with manual hydraulics, the manual hydraulic lever and linkage assembly must be moved. Pull latch handle under manual hydraulic cover toward the seat, allowing the lever and linkage assembly to drop forward out of the way. See Figure 8. If the sliding latch assembly does not lock the hood in the closed position, the lever and linkage assembly will not lock into position and the lift truck will not operate. A large, red push-button switch is mounted on the lever and linkage assembly for manual hydraulics and in the armrest console for the electro-hydraulics. This switch is an emergency battery disconnect that allows the operator to quickly disconnect the battery while seated on the lift truck in case of an emergency. See Figure 8.

A. MANUAL HYDRAULIC LEVERS B. E-HYDRAULIC MINI-LEVERS 1. MANUAL HYDRAULIC LEVER LATCH HANDLE 2. EMERGENCY DISCONNECT SWITCH Figure 8. Emergency Disconnect Switch

0100 YRM 1329 The seat assembly slides on seat rails that are fastened to spacer plates (Figure 9) and hood by four capscrews. A lever at the left front side of the base controls the adjustment of the seat to the forward and backward positions. Optional seats are available in cloth or vinyl with features such as non-suspension, full suspension, and limited swivel. All seats have a seat switch installed in the bottom cushion that senses operator presence. When the operator is not on the seat, the seat switch opens and interrupts the controller stopping operation of the lift truck as follows: •

After 1.5 seconds, hydraulic functions will cease to operate.

•

The lift truck, through regenerative braking, will slowly come to a complete stop.

Hood and Seat Assembly Checks and adjustments for the operator restraint system are described in the Operating Manual or See Periodic Maintenance 8000YRM1339 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Periodic Maintenance 8000YRM1373 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

NOTE: The seat belt can be either black or red. The lift trucks covered in this Service Manual can be equipped with one of three seat belt configurations: •

Seat belt with no operational interlock.

•

Seat belt with operational interlock. Seat belt must be fastened for lift truck to start or travel.

•

Seat belt with sequencing interlock. Operator must be in the seat, and the seat belt must be fastened, before lift truck will operate. This seat belt is used with the Optional Operator Presence System.

See the Operating Manual for more information on these seat belt types.

1. HOOD 2. SEAT ASSEMBLY 3. SEAT SPACER PLATES Figure 9. Seat Spacer Location

The hood, seat belt, hip restraint brackets, seat, and seat mount are all parts of the operator restraint system.

Hood and Seat Assembly

0100 YRM 1329

A. LOCKED POSITION

B. OPEN (RELEASE) POSITION

1. SEAT 2. HOOD

3. SEAT SWITCH CONNECTOR 4. LATCH ASSEMBLY

Figure 10. Hood and Seat Assembly, Lift Trucks Manufactured Before November, 2014

0100 YRM 1329 To raise the hood and seat assembly, move the seat to the rear of the hood. For lift trucks equipped with Rapid/Fast Charging, slide the seat all the way forward. If necessary, move the armrest all the way back if lift truck is equipped with E-Hydraulic control levers. Move the steering column to the most forward position. If lift truck is equipped with manual hydraulics, release and move the hydraulic lever and linkage assembly forward. See Figure 8. Open the latch mechanism and raise the hood. See Figure 10 for lift trucks manufactured before November, 2014 See Figure 11 for lift trucks manufactured after November, 2014

REMOVE 1. Disconnect battery connector.

Hood and Seat Assembly NOTE: Tag electrical connectors during removal to aid in installation. 2. Tag and disconnect the electrical connectors to the emergency battery disconnect and the seat switch. 3. Disconnect seat harness and remove from hood. NOTE: The seat assembly does not have to be removed from the hood for the hood to be removed from the lift truck. Perform Step 4 if removing seat assembly. 4. To remove seat assembly, disconnect electrical connectors if not already done, remove four screws, washers, spacers if required, and seat assembly from hood. 5. Raise hood. 6. Remove gas spring. See Figure 12.

A. OPEN (RELEASE) POSITION 1. SEAT 2. HOOD

3. SEAT SWITCH CONNECTOR 4. LATCH ASSEMBLY Figure 11. Hood and Seat Assembly, Lift Trucks Manufactured After November, 2014

Hood and Seat Assembly

0100 YRM 1329

7. Lower hood. 8. Remove two captive screws, tow pin, and counterweight cover from counterweight. 9. Remove two nuts securing hood mounting bolts. See Figure 12.

1. 2. 3. 4. 5.

HOOD GAS SPRING NUT WASHER HOOD MOUNTING BOLT

10. Remove washers and hood mounting bolts from hood hinges and hood mounting brackets. See Figure 12. 11. Release latch and lift hood out of lift truck.

6. 7. 8. 9.

HOOD HINGE OVERHEAD GUARD REAR LEG HOOD MOUNTING BRACKET CAPSCREW

Figure 12. Hood Mounting

0100 YRM 1329 12. If necessary, hood mounting brackets can be removed from overhead guard rear legs by removing the nuts and capscrews. See Figure 12.

INSTALL 1. Install hood mounting brackets, capscrews, and nuts onto overhead guard rear legs, if removed. Do not fully tighten capscrews at this time. See Figure 12. 2. Lower hood into position. 3. Install hood mounting bolts and washers onto hood hinges and hood mounting brackets. See Figure 12. 4. Install nuts onto hood mounting bolts. See Figure 12.

Hood and Seat Assembly

GROUND TEST NOTE: If the static discharge ground connection is not secured properly it could lead to the possible failure of the traction and/or pump motor controllers. 1. To ensure proper installation of seat assembly and associated bracketing, perform continuity test. 2. Using an ohm meter, place a test lead at the armrest mounting bolt and another at the truck frame. The resistance needs to read 5 Ohms or less. See Figure 13. 3. If the resistance is greater than 5 Ohms, double check installation of seat assembly, both ends of seat wiring harness, and wiring harness ground strap.

5. Allow hood to engage latch and adjust hood for adequate latch engagement with the hood striker. Adequate engagement is when the latch completely clears the 90 degree bend of the hood striker. 6. Tighten capscrews on hood mounting brackets. 7. Raise hood. 8. Install gas spring. See Figure 12. 9. Install seat, if removed, and route seat harness through hood and connect to seat. 10. Connect the electrical wiring harness to the seat switch. 11. Close the hood. Make certain that the latch is properly engaged. 12. Install counterweight cover, captive screws, and tow pin onto counterweight. 13. Move manual hydraulic lever and linkage assembly back to upright position and lock in place.

1. ARMREST BOLT 2. FRAME Figure 13. Ground Test

14. Connect the battery connector.

Counterweight Replacement

0100 YRM 1329

Counterweight Replacement WARNING DO NOT operate the lift truck if the capscrews for the counterweight are not installed. The counterweight is a structural member of the truck chassis. The counterweight cannot be removed without first supporting the frame. If the capscrews are not properly installed the counterweight will not support the lift truck. A one-piece, cast iron counterweight is used to offset the weight of the load and support the rear suspension of the lift truck, see figures indicated below. The weight of the counterweight is shown in the tables below. See Figure 14 and Table 1 for lift truck models •

ERP15-20VT (G807) manufactured before November, 2014

•

ERP030-040VT (G807)

See Figure 15 and Table 1 for lift truck models •

ERP15-20VT (G807) manufactured after November, 2014

Figure 14. Counterweight for Lift Truck ERP15-20VT (G807) Manufactured Before November, 2014 and ERP030-040VT(G807)

See Figure 16 and Table 2 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

A compartment space, accessed by removal of the counterweight cover, has been designed to house the hydraulic tank, hydraulic pump and motor, hoist controller, and electrical connections. A battery platform is used to support the battery on the lift truck frame. The battery platform also serves as part of the counterweight system and requires the use of an overhead lifting device for removal or installation. Be sure to replace the same battery platform, or one of equal weight, if the platform must be removed.

Figure 15. Counterweight for Lift Truck ERP15-20VT (G807) Manufactured After November, 2014

0100 YRM 1329

Counterweight Replacement

Figure 16. Counterweight for Lift Truck ERP16-20VF (ERP30-40VF) (A955) Table 1. Counterweights for Lift Truck ERP15-20VT (ERP030-040VT) (G807) Model

mm (in)*

Weight

+ 13.8 kg (30 lb) 13.8 kg (30 lb)

ERP15-20VT (ERP030-04VT)

546 mm (21.5 in.)

690 kg (1521 lb)

ERP15-20VT (ERP030-04VT)

642 mm (25.3 in.)

690 kg (1521 lb)

ERP15-20VT (ERP030-04VT)

750 mm (29.5 in.)

690 kg (1521 lb)

*Approximate battery compartment lengths.

Table 2. Counterweights for Lift Truck ERP16-20VF (ERP30-40VF) (A955) Model

mm (in)*

Weight

+ 20 kg (44 lb) 0 kg (0 lb)

ERP16-20VF (ERP30-40VF)

546 mm (21.5 in.)

670 kg (1477 lb)

ERP16-20VF (ERP30-40VF)

642 mm (25.3 in.)

670 kg (1477 lb)

ERP16-20VF (ERP30-40VF)

750 mm (29.5 in.)

670 kg (1477 lb)

*Approximate battery compartment lengths.

Counterweight Replacement

REMOVE 1. Remove battery.

0100 YRM 1329 See Figure 18 for lift truck models •

See Periodic Maintenance 8000YRM1339 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Periodic Maintenance 8000YRM1373 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

2. Remove overhead guard. See Overhead Guard Replacement section in this manual. 3. Remove hydraulic pump and motor and hydraulic tank from counterweight. See Hydraulic System 1900YRM1333. 4. Remove controller from counterweight. See Electrical System 2200YRM1337. 5. Remove steer axle, including wheels and tires. See Steering System 1600YRM1331 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Steering System 1600YRM1363 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955).

NOTE: Perform Step 6 through Step 10 for lift truck models ERP15-20VT (ERP030-040VT) (G807). 6. Remove nuts, capscrews, washers, and steer plate from counterweight. See Figure 17 for lift truck models

•

ERP15-20VT (G807) manufactured before November, 2014

•

ERP030-040VT (G807)

ERP15-20VT (G807) manufactured after November, 2014

WARNING The counterweight is very heavy. Make sure the chains, eyebolts, and overhead lifting device have the capacity to lift the counterweight. 7. Insert eye bolts into counterweight. See Figure 19. Attach lifting device to eye bolts to hold counterweight. NOTE: Ensure frame is supported, as specified in Steering System 1600YRM1331 prior to removal. 8. Remove upper capscrews and washers from frame and counterweight. 9. Remove lower capscrews and washers from frame and counterweight. See Figure 17 for lift truck models •

ERP15-20VT (G807) manufactured before November, 2014

•

ERP030-040VT (G807)

See Figure 18 for lift truck models •

ERP15-20VT (G807) manufactured after November, 2014

10. Using lifting device, lift counterweight away from lift truck frame. NOTE: Perform Step 11 through Step 15 for lift truck ERP16-20VF (ERP30-40VF) (A955). NOTE: Ensure frame is supported, as specified in Steering System 1600YRM1363 prior to removal. 11. Remove two capscrews from top of rear bulkhead and counterweight. See Figure 20.

0100 YRM 1329

1. 2. 3. 4.

STEER PLATE COUNTERWEIGHT CAPSCREW NUT

Counterweight Replacement

5. 6. 7. 8.

WASHER UPPER CAPSCREW LOWER CAPSCREW FRAME

Figure 17. Frame and Counterweight for Lift Trucks ERP15-20VT (G807) Manufactured Before November, 2014 and ERP030-040VT (G807)

Counterweight Replacement

1. 2. 3. 4.

STEER PLATE COUNTERWEIGHT CAPSCREW NUT

0100 YRM 1329

5. 6. 7. 8.

WASHER UPPER CAPSCREW LOWER CAPSCREW FRAME

Figure 18. Frame and Counterweight for Lift Trucks ERP15-20VT (G807) Manufactured After November, 2014

0100 YRM 1329

Counterweight Replacement

INSTALL WARNING The counterweight is very heavy. Make sure the chains, eyebolts, and overhead lifting device have the capacity to lift the counterweight. NOTE: Perform Step 1 through Step 5 for lift truck models ERP15-20VT (ERP030-040VT) (G807). 1. Using a lifting device, lower counterweight into position on lift truck. 2. Install washers and lower capscrews into frame and counterweight. Tighten capscrews to 250 N•m (184 lbf ft). See Figure 17 for lift truck models

NOTE: COUNTERWEIGHT FOR LIFT TRUCKS ERP15-20VT (G807) MANUFACTURED BEFORE NOVEMBER, 2014 AND ERP030-040VT (G807) SHOWN. HOLES FOR EYEBOLTS FOR COUNTERWEIGHT USED ON LIFT TRUCKS ERP15-20VT (G807) MANUFACTURED AFTER NOVEMBER, 2014 ARE IN SAME LOCATIONS. 1. COUNTERWEIGHT 2. EYE BOLT Figure 19. Counterweight Lift for Lift Truck ERP15-20VT (ERP030-040VT) (G807) 12. Remove two capscrews from rear bulkhead and spacer plates. Remove rear bulkhead. See Figure 20.

WARNING The counterweight is very heavy. Make sure the slings and overhead lifting device have the capacity to lift the counterweight. 13. Wrap two slings through slots in top of counterweight. Attach slings to lifting device. See Figure 21. 14. Remove lower capscrews, nuts, and washers from frame and counterweight. See Figure 20.

•

ERP15-20VT (G807) manufactured before November, 2014

•

ERP030-040VT (G807)

See Figure 18 for lift truck models •

ERP15-20VT (G807) manufactured after November, 2014

3. Install washers and upper capscrews into frame and counterweight. Tighten capscrews to 755 N•m (557 lbf ft). 4. Remove lifting device and eye bolts from counterweight. See Figure 19. 5. Install steer plate, washers, capscrews, and nuts onto counterweight. Tighten capscrews to 300 N•m (221 lbf ft). See Figure 17 for lift truck models •

ERP15-20VT (G807) manufactured before November, 2014

•

ERP030-040VT (G807)

See Figure 18 for lift truck models •

ERP15-20VT (G807) manufactured after November, 2014

NOTE: Perform Step 6 through Step 11 for lift truck models ERP16-20VF (ERP30-40VF) (A955). 6. Using a lifting device, lower counterweight into position on lift truck frame.

15. Remove upper capscrews and washers from frame and counterweight. See Figure 20. Using lifting device, lift counterweight away from frame. 23

Counterweight Replacement

0100 YRM 1329

7. Install washers and upper capscrews into frame and counterweight. See Figure 20. Tighten capscrews to 755 N•m (557 lbf ft). 8. Install washers, lower capscrews, and nuts into frame and counterweight. See Figure 20. Tighten capscrews to 250 N•m (184 lbf ft). 9. Detach both slings and remove from counterweight. See Figure 21. 10. Place rear bulkhead in position and install two capscrews into rear bulkhead and spacer plates. See Figure 20.

12. Install steer axle, with wheels and tires, onto counterweight. See Steering System 1600YRM1331 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Steering System 1600YRM1363 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

13. Install controller into counterweight. See Electrical System 2200YRM1337.

11. Install two capscrews into top of rear bulkhead and counterweight. See Figure 20.

NOTE: MAJOR COMPONENTS NOT SHOWN FOR CLARITY. 1. REAR BULKHEAD 2. CAPSCREW 3. SPACER PLATE

4. FRAME 5. COUNTERWEIGHT 6. LOWER CAPSCREW

7. NUT 8. WASHER 9. UPPER CAPSCREW

Figure 20. Frame and Counterweight for Lift Truck ERP16-20VF (ERP30-40VF) (A955)

0100 YRM 1329

Safety Labels Legend for Figure 21 1. COUNTERWEIGHT 2. SLING 14. Install hydraulic tank and hydraulic pump and motor into counterweight. See Hydraulic System 1900YRM1333. 15. Install overhead guard. See Overhead Guard Replacement section in this manual. 16. Install battery. See Periodic Maintenance 8000YRM1339 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Periodic Maintenance 8000YRM1373 for lift truck models •

ERP16-20VF (ERP30-40VF) (A955)

Figure 21. Counterweight Lift for Lift Truck ERP16-20VF (ERP30-40VF) (A955)

Safety Labels WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read. DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped and the nameplate must show the new capacity rating. Contact your Yale lift truck dealer for a replacement nameplate. If a label must be replaced, use the following procedure to install a new label.

WARNING Always use solvents and paints in an area with adequate ventilation. DO NOT use solvents or paints near heat, fire, or electrical equipment that can create sparks. Follow the manufacturer's instructions and cautions. 1. Clean the painted surface. Use household cleaning products to clean new paint and clean old paint with cleaning solvent. DO NOT use solvent on new paint. Make sure the surface is dry and is clean of dirt, oil, and grease. 2. Remove the paper from the back of the label and hold the label by the edges. Do not touch the adhesive surface.

See Figure 22 for lift truck models •

ERP15-20VT (ERP030-040VT) (G807)

See Figure 23 for lift truck models •

CAUTION The label cannot be moved after it touches the surface.

ERP16-20VF (ERP30-40VF) (A955)

Safety Labels 3. Carefully hold the label in the correct position above the surface and carefully apply to the correct location. Make sure that all air is removed from under the label by smoothing any wrinkles or

0100 YRM 1329 bubbles with your fingers working from the center out. Check that the corners and edges are tight against the surface.

0100 YRM 1329

Safety Labels

Figure 22. Label Locations for Lift Truck ERP15-20VT (ERP030-040VT) (G807)

Safety Labels

0100 YRM 1329 Legend for Figure 22

NOTE: NOT ALL LABELS USED ON ERP15-20VT (ERP030-040VT) (G807) LIFT TRUCK MODELS ARE SHOWN IN FIGURE 22. SEE PARTS MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON ERP15-20VT (ERP030-040VT) (G807) LIFT TRUCKS. 1. OVERHEAD GUARD IMPACT WARNING (INNER LEFT SIDE) 2. BATTERY SPACER 3. MAST WARNING 4. TILT COLUMN 5. PINCH POINT 6. OPERATOR WARNING 7. PINCH POINT 8. OPERATOR RESTRAINT 9. MAST WARNING 10. YALE

11. 12. 13. 14. 15. 16. 17. 18. 19.

CAPACITY PLATE AC LABEL COUNTERWEIGHT LABEL PATENTS AND TRADEMARKS "EE" UL LABEL (OPTIONAL) FREEZER (OPTIONAL) CAPACITY LABEL UL LABEL NO RIDER LABEL

0100 YRM 1329

Safety Labels

Figure 23. Label Locations for Lift Truck ERP16-20VF (ERP30-40VF) (A955)

Painting Instructions

0100 YRM 1329 Legend for Figure 23

NOTE: NOT ALL LABELS USED ON ERP16-20VF (ERP30-40VF) (A955) LIFT TRUCK MODELS ARE SHOWN IN FIGURE 23. SEE PARTS MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON ERP16-20VF (ERP30-40VF) (A955) LIFT TRUCKS. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

FREEZER "EE" UL LABEL (OPTIONAL) YALE - AC TECHNOLOGY PATENTS AND TRADEMARKS UL LABELS UL LABEL LIFTING EYE PINCH POINT BATTERY DISCONNECT OPERATOR WARNING LOCK/UNLOCK LABEL NO RIDER

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

BATTERY SPACER MAST WARNING YALE DECAL MAST WARNING PINCH POINT OPERATOR RESTRAINT TILT COLUMN BRAND LABEL NAMEPLATE CAPACITY PLATE COUNTERWEIGHT LABEL STABILITY SYSTEM LABEL*

*LABEL USED ONLY ON LIFT TRUCK MODELS ERP30-40VF (A955) MANUFACTURED AFTER JUNE, 2012.

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 paint and rust from the metal. All metal surfaces where the paint is completely removed, must be primed. Apply primer before applying the paint.

CAUTION DO NOT put tape on cylinder rods to protect from paint. Use a thick layer of multipurpose grease to protect cylinder rods. Cylinders can be damaged if operated with tape on the cylinder rod. 3. Protect all surfaces that will not be painted. DO NOT paint: Pedal Pads Lever Knobs Instrument Panel

Steering Wheel Labels and Information Plates Seat Assembly and Rails Information Case Tires Mast Chains and Hoses Battery Connector Key Switch Cylinder Rods All Plastic Covers

CAUTION DO NOT paint the pads, plastic covers or knobs, cables, labels, information plates, or controls. Paint can make some assemblies not operate correctly. NOTE: Use colors approved by Yale Material Handling Corporation. 4. Paint the surfaces. Use the correct paint from your dealer for YaleÂ® lift trucks. Follow the directions on the container.

0100 YRM 1329

Battery Specifications It is important that all safety labels are installed on the lift truck and can be read.

WARNING Make sure all labels are installed after painting is complete. Safety labels are installed on the lift truck to provide information about possible hazards.

5. Check that all labels are installed in the correct locations on the lift truck. See Safety Labels.

Battery Specifications ERP15-20VT (G807) EUROPEAN MODEL TRUCKS

Model/ Wheel Base ERP15-16VT 1290 mm (50.8 in.)

ERP16-20VT 1385 mm (54.5 in.)

Maximum Compartment Size Length × Width

546 x 991 mm (21.5 x 39 in.)

643 x 991 mm (25.3 x 39 in.)

Maximum Battery Size

Weight Maximum Battery Compartment Height

Length

Width

Minimum

Maximum

Standard Battery 537 mm (21.1 in.)

Standard Battery 980 mm (38.6 in.)

Standard Battery 800 kg (1765 lb)

Standard Battery 1100 kg (2425 lb)

Standard Battery 677 mm (26.7 in.)

DIN Battery 522 mm (20.6 in.)

DIN Battery 830 mm (32.7 in.)

DIN Battery 673 kg (1480 lb)

DIN Battery 743 kg (1640 lb)

DIN Battery 643 mm (25.3 in.)

Standard Battery 632 mm (24.9 in.)

Standard Battery 980 mm (38.6 in.)

Standard Battery 1000 kg (2205 lb)

Standard Battery 1200 kg (2646 lb)

Standard Battery 677 mm (26.7 in.)

DIN Battery 630 mm (24.8 in.)

DIN Battery 830 mm (32.7 in.)

DIN Battery 813 kg (1790 lb)

DIN Battery 899 kg (1980 lb)

DIN Battery 643 mm (25.3 in.)

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 front-to-back dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum. Battery width must fit within the battery compartment side-to-side 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.

Battery Specifications

Model/ Wheel Base ERP16-20VT 1495 mm (58.9 in.)

0100 YRM 1329

Maximum Compartment Size Length × Width

750 x 991 mm (29.5 x 39 in.)

Maximum Battery Size

Weight Maximum Battery Compartment Height

Length

Width

Minimum

Maximum

Standard Battery 742 mm (29.2 in.)

Standard Battery 980 mm (38.6 in.)

Standard Battery 1000 kg (2205 lb)

Standard Battery 1300 kg (2865 lb)

Standard Battery 677 mm (26.7 in.)

DIN Battery 738 mm (29.1 in.)

DIN Battery 830 mm (32.7 in.)

DIN Battery 962 kg (2120 lb)

DIN Battery 1064 kg (2350 lb)

DIN Battery 643 mm (25.3 in.)

0100 YRM 1329

Battery Specifications

ERP030-040VT (G807) US MODEL TRUCKS

Model/ Wheel Base

Maximum Compartment Size Length × Width

Battery Size Min/Max

Weight

Length

Width

Minimum

Maximum

Maximum Battery Compartment Height

ERP030VT 1290 mm (50.8 in.)

546 x 991 mm (21.5 x 39 in.)

508 to 532 mm (20 to 21.2 in.)

970 to 986 mm (38.2 to 38.8 in.)

771 kg (1700 lb)

998 kg (2200 lb)

587 mm (23.1 in.)

ERP035VT 1385 mm (54.5 in.)

642 x 991 mm (25.3 x 39 in.)

597 to 635 mm (23.5 to 25 in.)

975 to 986 mm (38.4 to 38.8 in.)

953 kg (2100 lb)

1089 kg (2400 lb)

587 mm (23.1 in.)

ERP040VT 1385 mm (54.5 in.)

642 x 991 mm (25.3 x 39 in.)

597 to 635 mm (23.5 to 25.0 in.)

975 to 986 mm (38.2 to 38.8 in.)

953 kg (2100 lb)

1089 kg (2400 lb)

587 mm (23.1 in.)

Battery Specifications

0100 YRM 1329

ERP16-20VF (A955) EUROPEAN MODEL TRUCKS

Model/ Wheel Base ERP16-18VF 1290 mm (50.8 in.)

ERP16-20VF 1431 mm (56.3 in.)

ERP16-20VF 1539 mm (60.6 in.)

Maximum Compartment Size Length × Width

546 x 991 mm (21.5 x 39 in.)

643 x 991 mm (25.3 x 39 in.)

750 x 991 mm (29.5 x 39 in.)

Maximum Battery Size

Weight Maximum Battery Compartment Height

Length

Width

Minimum

Maximum

Standard Battery 537 mm (21.1 in.)

Standard Battery 980 mm (38.6 in.)

Standard Battery 800 kg (1765 lb)

Standard Battery 1100 kg (2425 lb)

Standard Battery 677 mm (26.7 in.)

DIN Battery 522 mm (20.6 in.)

DIN Battery 830 mm (32.7 in.)

DIN Battery 673 kg (1480 lb)

DIN Battery 743 kg (1640 lb)

DIN Battery 643 mm (25.3 in.)

Standard Battery 632 mm (24.9 in.)

Standard Battery 980 mm (38.6 in.)

Standard Battery 1000 kg (2205 lb)

Standard Battery 1200 kg (2646 lb)

Standard Battery 677 mm (26.7 in.)

DIN Battery 630 mm (24.8 in.)

DIN Battery 830 mm (32.7 in.)

DIN Battery 813 kg (1790 lb)

DIN Battery 899 kg (1980 lb)

DIN Battery 643 mm (25.3 in.)

Standard Battery 742 mm (29.2 in.)

Standard Battery 980 mm (38.6 in.)

Standard Battery 1000 kg (2205 lb)

Standard Battery 1300 kg (2865 lb)

Standard Battery 677 mm (26.7 in.)

DIN Battery 738 mm (29.1 in.)

DIN Battery 830 mm (32.7 in.)

DIN Battery 962 kg (2120 lb)

DIN Battery 1064 kg (2350 lb)

DIN Battery 643 mm (25.3 in.)

0100 YRM 1329

Battery Specifications

ERP30-40VF (A955) US MODEL TRUCKS Model/ Wheel Base

Maximum Compartment Size Length × Width

Battery Size Min/Max

Weight

Length

Width

Minimum

Maximum

Maximum Battery Compartment Height

ERP30VF 1290 mm (50.8 in.)

546 x 991 mm (21.5 x 39 in.)

508 to 532 mm (20 to 21.2 in.)

970 to 986 mm (38.2 to 38.8 in.)

771 kg (1700 lb)

998 kg (2200 lb)

587 mm (23.1 in.)

ERP35VF 1385 mm (54.5 in.)

642 x 991 mm (25.3 x 39 in.)

597 to 635 mm (23.5 to 25 in.)

975 to 986 mm (38.4 to 38.8 in.)

953 kg (2100 lb)

1089 kg (2400 lb)

587 mm (23.1 in.)

ERP40VF 1385 mm (54.5 in.)

642 x 991 mm (25.3 x 39 in.)

597 to 635 mm (23.5 to 25.0 in.)

975 to 986 mm (38.2 to 38.8 in.)

953 kg (2100 lb)

1089 kg (2400 lb)

587 mm (23.1 in.)

NOTES

Maintenance

TRANSAXLE ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

PART NO. 524295630

1300 YRM 1330

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

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

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Transaxle

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Discharging the Capacitors ............................................................................................................................. Special Tools ................................................................................................................................................... Transaxle Assembly............................................................................................................................................. Remove Transaxle From Frame ...................................................................................................................... Remove the Parking Brake and Traction Motor............................................................................................... Install Parking Brake and Traction Motor......................................................................................................... Install Transaxle to Frame ............................................................................................................................... Maintenance and Repair ..................................................................................................................................... Speed Sensor Repair...................................................................................................................................... Trunnion Cap Repair ....................................................................................................................................... Fluid Level Check............................................................................................................................................ Fluid Change................................................................................................................................................... Breather Repair............................................................................................................................................... Stud Repair ..................................................................................................................................................... Brake Cylinder Repair ..................................................................................................................................... Input Seal Repair ............................................................................................................................................ Cover to Housing Seal .................................................................................................................................... During the Transaxle Warranty Period ........................................................................................................ After the Transaxle Warranty Period ........................................................................................................... Removing the Cover ............................................................................................................................... Installing the Cover ................................................................................................................................. Wet Brakes......................................................................................................................................................

1 2 2 3 3 4 4 5 6 6 6 8 8 9 10 11 13 13 13 14 14 15 16

This section is for the following models: ERP15-20VT (ERP030-040VT) [G807]; ERP16-20VF (ERP30-40VF) [A955]

ÂŠ2012 Yale Materials Handling Corp.

1300 YRM 1330

General

General CAUTION DO NOT remove the cover from the transaxle housing during the warranty period. Removing the cover from the housing will void the transaxle warranty. The transaxle warranty period may vary from truck hours or other warranties. Contact Yale Company Contact Management if you have questions about warranty status.

CAUTION Use only transmission fluid from approved vendors. Using fluid from unapproved vendors will void the warranty. Contact Yale Company Contact Management if you have questions about warranty status. This section contains the removal, repair, inspection, and installation instructions for the transaxle assemblies used on these models.

A. LEFT SIDE B. RIGHT SIDE

C. FORWARD TRAVEL

Figure 1. Truck Orientation (Three-Wheel Trucks)

WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery. Throughout this section, forward will refer to travel in the direction of the forks and left and right will be determined by sitting in the seat facing forward. See Figure 1 or Figure 2.

A. LEFT SIDE B. RIGHT SIDE

C. FORWARD TRAVEL

Figure 2. Truck Orientation (Four-Wheel Trucks)

General

1300 YRM 1330 4. Block drive wheels to prevent lift truck from moving. 5. Make sure Emergency Disconnect Switch HAS NOT been activated. If Emergency Disconnect Switch is activated, rotate switch to the right until it pops up. 6. Press horn button. Wait 30 seconds to be sure capacitors are fully discharged.

SPECIAL TOOLS Special tools are necessary to properly perform some repairs. These tools are available from your Yale dealer. Warranty will not cover damage resulting from work done using improper tools. Refer to Table 1.

Table 1. Yale Special Tools

Input Seal Driver Yale Part No. 582000161

Before performing any tests or adjustments, block the lift truck to prevent unexpected movement. The capacitor in the transistor controller(s) can hold an electrical charge for about 10 seconds after the battery is disconnected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected.

Breather Set Tool Yale Part No. 582000187

DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Make certain the Emergency Disconnect Switch has not been activated. This will isolate the controller and prevent the capacitors from discharging properly. The proper way to disconnect the battery is by separating the battery connectors. 1. Ensure capacitors are discharged by performing Step 2 through Step 6 below. 2. Turn key or keyless switch to OFF position. 3. Disconnect battery by separating connectors.

Wheel Stud Tool Yale Part No. 582000162

1300 YRM 1330

Transaxle Assembly

Transaxle Assembly REMOVE TRANSAXLE FROM FRAME WARNING The lift truck must be put on blocks for some types of maintenance and transaxle repair. The removal of the battery, mast, transaxle, or the counterweight will cause large changes in the center of gravity. Position additional blocks under the frame when the lift truck is on blocks, so the lift truck cannot tip over. 1. Remove mast assembly. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck models • ERP15-20VT (G807) • ERP16-20VF (A955) See Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and American lift truck models • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) 2. Turn key switch to OFF position and disconnect battery.

8. Tag and disconnect power cables from traction motor studs. 9. Disconnect traction motor temperature sensor at traction motor. 10. Disconnect service brake line from port on transaxle. Cap brake line and plug port on transaxle to reduce the possibility of contamination entering brake system. 11. Loosen, but do not remove, five mounting capscrews and nuts that hold transaxle assembly on lift truck.

WARNING The transaxle and traction motor assemblies are heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the transaxle and traction motor. 12. Position a floor jack under transaxle assembly. Make sure assembly is properly balanced on floor jack so it will not fall once mounting capscrews have been removed.

CAUTION

3. Position lift truck frame on blocks so drive tires are suspended off the floor.

Check that cables, hoses, and wires do not interfere with the removal of the transaxle assembly.

See Periodic Maintenance 8000 YRM 1339 for lift truck models • ERP15-20VT (ERP030-040VT) (G807)

13. Remove five capscrews and washers holding transaxle on lift truck frame. Carefully lower transaxle assembly from lift truck frame using floor jack.

See Periodic Maintenance 8000 YRM 1373 for lift truck models • ERP16-20VF (ERP30-40VF) (A955) 4. Remove drive tire lug nuts and drive tire and wheel assembly. 5. Disconnect transaxle speed sensor connector from main wiring harness. 6. Disconnect parking brake connector from main wiring harness.

WARNING The transaxle and traction motor assemblies are heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the transaxle and traction motor. 14. Transfer transaxle assembly from floor jack to a clean workbench using an appropriate sling and overhead lifting device.

7. Disconnect manual override cable from parking brakes.

Transaxle Assembly

REMOVE THE PARKING BRAKE AND TRACTION MOTOR WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

1300 YRM 1330

WARNING The traction motor is heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the traction motor. 1. Position transaxle on blocks with studs down. Securely support in this position. 2. Install traction motor on transaxle:

WARNING

a. Install an eyebolt to traction motor shaft and attach an overhead lifting device of adequate capacity to eyebolt.

The traction motor is heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the traction motor.

b. Lightly lubricate inside lip of transaxle input shaft with multipurpose grease to ensure seal seats properly on traction motor shaft. It is not necessary to lubricate traction motor shaft as it is lubricated internally within the transaxle. See Figure 4.

1. Position transaxle on blocks with studs down. Securely support in this position. 2. Remove parking brake assembly from traction motor: a. Remove four capscrews, lockwashers, and washers holding brake assembly on traction motor. See Figure 3. b. Pry evenly on opposite sides to remove brake assembly from brake hub. Remove brake assembly by hand. c. Remove snap ring holding brake hub on traction motor shaft. Slide hub from shaft. Remove snap ring and woodruff key from beneath hub. 3. Remove traction motor from transaxle: a. Install an eyebolt to traction motor shaft and attach an overhead lifting device of adequate capacity to eyebolt. b. Remove four capscrews and washers mounting traction motor to transaxle. c. Lift traction motor from transaxle using overhead lifting device.

INSTALL PARKING BRAKE AND TRACTION MOTOR WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

1. 2. 3. 4.

CAPSCREW LOCKWASHER WASHER PARKING BRAKE ASSEMBLY 5. TRACTION MOTOR

6. 7. 8. 9. 10.

CAPSCREW WASHER MOTOR SHAFT TRANSAXLE INPUT SEAL

Figure 3. Traction Motor and Parking Brake

1300 YRM 1330

Transaxle Assembly

c. Lift traction motor and position it on transaxle using overhead lifting device. Guide traction motor shaft into transaxle through input seal. Align motor with transaxle. d. Install four capscrews and washers mounting traction motor on transaxle. Tighten capscrews to 48 N•m (35 lbf in). e. Remove eyebolt from traction motor shaft. 3. Install parking brake assembly to traction motor: a. Install lower snap ring and woodruff key on traction motor shaft. Align groove in hub with woodruff key and slide hub onto shaft. Install upper snap ring holding brake hub onto traction motor shaft. b. Position brake assembly onto brake hub. Align splines and seat brake on traction motor end head.

c. Install four capscrews, lockwashers, and washers to secure brake assembly. Tighten capscrews to 8 N•m (71 lbf in).

INSTALL TRANSAXLE TO FRAME 1. Check that dowels are installed in transaxle housing and are in good condition. Replace as necessary.

WARNING The transaxle and traction motor assembly are heavy. Be sure that all lifting devices are suitable and of adequate capacity to lift the transaxle and traction motor. 2. Move transaxle assembly onto a floor jack using an appropriate sling and lifting device. Make sure assembly is balanced and properly supported so it will not fall during installation. 3. Carefully position transaxle on frame using floor jack. Align transaxle mounting dowels with their mounting holes in frame. 4. Apply Loctite® 271 to five socket head capscrews and washers. Install capscrews with washers through transaxle and into mounting holes in frame. Tighten capscrews to 220 N•m (162 lbf ft). 5. Remove cap and plug from service brake line and service brake port. Install service brake line to service brake port. Tighten to 12 to 16 N•m (108 to 192 lbf in). 6. Connect power cables to traction motor studs as tagged during removal. Tighten to 8 N•m (71 lbf in). 7. Connect traction motor temperature sensor connectors to main wiring harness. 8. Connect parking brake connector to main wiring harness. 9. Connect manual override cable to parking brakes. 10. Connect transaxle speed sensor connector to main wiring harness.

1. 2. 3. 4.

CAPSCREW LOCKWASHER WASHER PARKING BRAKE ASSEMBLY 5. TRACTION MOTOR

6. 7. 8. 9. 10.

CAPSCREW WASHER MOTOR SHAFT TRANSAXLE INPUT SEAL

Figure 4. Traction Motor and Parking Brake

Maintenance and Repair

1300 YRM 1330

CAUTION Make sure the lift truck is blocked at the same height as with the drive tire installed to ensure the proper fluid level reading. 11. Bleed the service brakes. Refer Brake System 1800 YRM 1332 for procedures. 12. Check fluid level in transaxle. Fill as necessary. See Fluid Level Check. 13. Install drive tire and wheel assembly on wheel hub. Install lug nuts and tighten to 170 N•m (125 lbf ft). 14. Connect battery connector, turn key switch to ON position, and test lift truck for proper operation.

See Periodic Maintenance 8000 YRM 1373 for lift truck models • ERP16-20VF (ERP30-40VF) (A955) 16. Install mast on lift truck. See Mast Repair, 2- and 3-Stage High Visibility Masts 4000 YRM 1386 for European lift truck models • ERP15-20VT (G807) • ERP16-20VF (A955) See Mast Repair, 2-, 3-, And 4-Stage Heavy Duty Masts 4000 YRM 1405 for European and American lift truck models • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955)

15. Lower lift truck from the blocks. See Periodic Maintenance 8000 YRM 1339 for lift truck models • ERP15-20VT (ERP030-040VT) (G807)

Maintenance and Repair SPEED SENSOR REPAIR The speed sensor monitors the speed of the transaxle and relays the information to the controller. The speed sensor can be replaced with the transaxle installed to the lift truck. 1. Park lift truck on a level surface. Turn key switch to OFF position and unplug battery connector. 2. Discharge capacitors. See section Discharging the Capacitors. 3. Remove floor mat and floor plates from operator compartment to access top of transaxle(s). 4. Disconnect sensor wiring harness from main wiring harness.

CAUTION Use a brush to clean around the sensor before removing to avoid contaminating the transaxle. 5. Remove capscrew holding sensor to transaxle using a 5mm Allen wrench. See Figure 5. 6. Pull sensor out of transaxle. 7. Insert new sensor into transaxle.

8. Align screw holes and install capscrew. Tighten capscrew to 9.5 N•m (84.0 lbf in). 9. Connect sensor wiring harness to main wiring harness. 10. Replace floor plates and floor mat in operator compartment. 11. Connect battery, turn key to ON position and test lift truck for proper operation.

TRUNNION CAP REPAIR To repair the trunnion cap: 1. Remove load from forks and park lift truck on a level surface. Adjust mast to a vertical position, then turn key switch to OFF position and separate battery connectors. 2. Remove four capscrews holding trunnion cap on transaxle housing. Remove trunnion cap. See Figure 6. 3. Wipe away any dirt or grease near mounting holes. Clean holes with a proper sized tap and tap wrench as necessary.

1300 YRM 1330

Maintenance and Repair

4. Position new cap over mast pin and onto transaxle. 5. Apply Loctite® 242 to threads and install four capscrews and tighten alternately in small increments. Tighten capscrews to 24 N•m (216 lbf in). 6. Grease fitting in mast stub shaft to lubricate trunnion cap. 7. Connect battery, turn key to ON position and test lift truck for proper operation.

1. 2. 3. 4.

CAPSCREWS TRUNNION CAP THREADED MOUNTING HOLES TRANSAXLE HOUSING

Figure 6. Trunnion Cap

1. 2. 3. 4. 5. 6.

CAPSCREW SPEED SENSOR FILL PLUG TRANSAXLE COVER COVER CAPSCREWS DRAIN PLUG

Figure 5. Speed Sensor

Maintenance and Repair

FLUID LEVEL CHECK

1300 YRM 1330 6. Repeat for other transaxle. Check fluid level in each transaxle every 2000 hours or one year.

CAUTION Use only transmission fluid from approved vendors. Using fluid from unapproved vendors will void the warranty. Contact Yale Company Contact Management if you have questions about warranty status. Each transaxle has a separate fluid supply which must be checked every 2000 hours or 1 year or when other maintenance procedures require the fluid level to be checked. Make sure the transaxle is installed to the lift truck and the lift truck is positioned on a level surface when checking fluid levels for an accurate reading.

CAUTION Clean around the fill and check plugs with solvent before removal to prevent contamination of the system.

CAUTION Blocking the lift truck higher or lower or at a different angle than it normally sits with the drive tire installed will result in an incorrect fluid level check. 1. Remove drive tire and block lift truck frame to position transaxle at the same height and position as with drive tire installed. See Periodic Maintenance 8000 YRM 1339 for lift truck models • ERP15-20VT (ERP030-040VT) (G807) See Periodic Maintenance 8000 YRM 1373 for lift truck models • ERP16-20VF (ERP30-40VF) (A955) 2. Remove check plug. Fluid should be level with bottom of check hole. 3. If necessary, remove fill plug and add fluid through fill hole until level with bottom of check hole. Each transaxle holds approximately 0.60 liter (0.63 qt) of transmission fluid. NOTE: New sealing rings must be installed with the drain, fill, and check plugs.

1. FILL PLUG 2. WHEEL HUB

3. DRAIN PLUG 4. CHECK PLUG

Figure 7. Transaxle Plug Locations

FLUID CHANGE CAUTION Use only transmission fluid from approved vendors. Using fluid from unapproved vendors will void the warranty. Contact Yale Company Contact Management if you have questions about warranty status. The fluid is not normally changed unless contamination is suspected or other maintenance procedures require draining the transaxle. If changing the fluid is necessary, refer to the following procedures.

WARNING The fluid is hot at normal operating temperatures. Be careful when draining the transaxles.

CAUTION Blocking the lift truck higher or lower or at a different angle than it normally sits with the drive tire installed will result in an incorrect fluid level check.

CAUTION

4. Replace check plug (and fill plug if removed) and tighten to 22 N•m (192 lbf in). See Figure 7.

Clean around the fill and check plugs with solvent before removal to prevent contamination of the system.

5. Reinstall drive tire and tighten lugs to 170 N•m (125 lbf ft). Remove truck from blocks.

NOTE: Install new sealing rings on the plugs anytime the drain, check, or fill plugs are removed.

1300 YRM 1330 NOTE: Operate the lift truck for 5 minutes or until the transaxle is warm to the touch. Transaxle fluid will drain easier and more thoroughly when it is warm. Each transaxle uses separate, self-contained fluid supplies. 1. Remove drive tire and block lift truck frame to position transaxle at the same height and position as with drive tire installed. See Periodic Maintenance 8000 YRM 1339 for lift truck models • ERP15-20VT (ERP030-040VT) (G807) See Periodic Maintenance 8000 YRM 1373 for lift truck models • ERP16-20VF (ERP30-40VF) (A955) 2. Turn key switch to OFF position and disconnect battery. Block thewheels to prevent unexpected movement. 3. Place a drip pan with at least a 3.0 liter (3.3 qt) capacity under transaxle.

CAUTION Clean around plugs with solvent before removal to prevent contamination of the transaxles. 4. Remove fill plug on transaxle. Inspect breather for proper operation. Clean or replace as necessary. See section Breather Repair. 5. Remove check plug. 6. Remove drain plug. Clean drain plug thoroughly, removing any metallic debris that has collected on drain plug magnet.

Maintenance and Repair (192 lbf in). Remove drip pan and dispose of waste fluid properly. NOTE: Use a funnel or a funnel with a tube attached to add fluid to the transaxle. Pour slowly. 8. Fill transaxle with fluid until level with bottom of check hole. Each transaxle should be filled with approximately 0.60 liter (0.63 qt) of fluid. 9. When fluid reaches bottom of check hole, install check plug and fill plug and tighten each to 22 N•m (192 lbf in).

BREATHER REPAIR The breather can be repaired with the transaxle installed to the lift truck and the drive tire removed. The breather equalizes air pressure inside the transaxle with the air pressure outside. If the breather is visibly damaged then the breather should be replaced. 1. Remove drive tire and block lift truck frame to position transaxle at the same height and position as with drive tire installed. See Periodic Maintenance 8000 YRM 1339 for lift truck models • ERP15-20VT (ERP030-040VT) (G807) See Periodic Maintenance 8000 YRM 1373 for lift truck models • ERP16-20VF (ERP30-40VF) (A955) 2. Remove breather cap by shearing of with a flat screwdriver. See Figure 8.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

CAUTION The drain plug must not be interchanged with the fill or check plugs. Use only an approved magnetic type drain plug to prevent damage to the transaxle. NOTE: It may take as long as 10 minutes for the transaxle to drain completely depending on temperature and contaminants. Allow the transaxle to drain completely before continuing.

Figure 8. Remove Breather Cap 7. After transaxle has drained completely, install drain plug into transaxle as removed. Tighten to 22 N•m

Maintenance and Repair 3. Remove spring by hand. A small breather ball is located under spring. Blow into breather at a slight angle with compressed air to force breather ball out. 4. Install a 6mm thread tap into breather using a tap wrench, and pull breather out of housing. See Figure 9.

1300 YRM 1330 7. Reinstall drive tire and tighten lugs to 170 N•m (125 lbf ft). Remove truck from blocks.

STUD REPAIR Stud repair can be performed with the transaxle installed to the lift truck or removed. 1. Remove drive tire and block lift truck frame to position transaxle at the same height and position as with drive tire installed. See Periodic Maintenance 8000 YRM 1339 for lift truck models • ERP15-20VT (ERP030-040VT) (G807) See Periodic Maintenance 8000 YRM 1373 for lift truck models • ERP16-20VF (ERP30-40VF) (A955) 2. Remove damaged stud using adjustable grip pliers. 3. If stud is sheared off:

Figure 9. Extracting the Breather 5. Position new breather into housing by hand.

a. Mark center of stud with a center punch and nylon faced hammer. b. Drill into center of stud with a 3mm drill bit. See Figure 11.

CAUTION A special tool is require to set the proper gap between housing and breather head. DO NOT drive the breather flush against the housing. 6. Drive breather into housing using Breather Set Tool (refer to section General, Special Tools) and a nylon faced hammer. See Figure 10.

Figure 11. Drilling the Stud c. Drill hole larger with a 7mm drill bit. d. Lightly tap an easy-out into hole in stud. Install tap wrench and unscrew stud from hub. See Figure 12.

Figure 10. Installing the Breather

1300 YRM 1330

Maintenance and Repair The service brake pedal in the operator compartment actuates the master cylinder sending pressurized fluid to the brake pistons in the transaxles through the service brake lines. 1. Remove transaxle from lift truck. Remove parking brake and traction motor from transaxle. See section Remove Transaxle From Frame. 2. Drain oil from transaxle. 3. Remove snap ring in brake cylinder. See Figure 14.

Figure 12. Removing the Stud 4. Run a thread tap (size M14 x 1.5) into stud hole to clean and repair any damaged threads. 5. Test threads with a thread plug gauge (size M14 x 1.5 - 6H). 6. If threads are within specification, install new stud using Stud Installation Tool (refer to section General, Special Tools). 7. Tighten studs to 80 Nâ&#x20AC;˘m (59 lbf ft). See Figure 13.

1. 2. 3. 4.

CYLINDRICAL PIN PISTON SEAL PISTON SPRING

5. O-RING 6. CAP 7. SNAP RING

Figure 14. Brake Piston Assembly

CAUTION Cover the cap with a cloth to control it in case it is ejected from the piston.

Figure 13. Stud Installation 8. Reinstall drive tire and tighten lugs to 170 Nâ&#x20AC;˘m (125 lbf ft). Remove truck from blocks.

BRAKE CYLINDER REPAIR

NOTE: Make note of the piston and cap orientation as well as the orientation of the seal on the piston before removal. 4. Direct pressurized air into service brake line port in cover to force cap out of cylinder. Recover spring from beneath cap. Remove seal from thecap and cut it in two to prevent accidental reuse. See Figure 15.

WARNING Always wear eye protection and use the proper tools when installing/removing snap rings.

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