ERC35-55HG (A839) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ DC MOTOR MAINTENANCE.......................................................................................... DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL............................................. STEERING CONTROL UNIT.......................................................................................... STEERING AXLE............................................................................................................ STEERING SYSTEM...................................................................................................... BRAKE SYSTEM............................................................................................................ HYDRAULIC SYSTEM.................................................................................................... MAIN CONTROL VALVE................................................................................................ TILT CYLINDERS........................................................................................................... ELECTRICAL SYSTEM.................................................................................................. EV-100ZX SCR MOTOR CONTROLLER PARAMETER TABLES................................ TRANSISTOR MOTOR CONTROLLERS (SR AND SP) DESCRIPTION, CHECKS, ADJUSTMENTS, TROUBLESHOOTING, REPAIRS AND THEORY OF OPERATION.............................................................................................................. DISPLAY PANEL FOR SEM CONTROLS..................................................................... SR(SEM)/SP TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER (WINDOWS VERSION).............................................................................................. INDUSTRIAL BATTERY................................................................................................. MASTS............................................................................................................................ LIFT CYLINDER.............................................................................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS.....................................................................................................................
PART NUMBER
YRM NUMBER
REV DATE
524166809 524158039 524166834 524166835 524150783 524166836 524166837 524166838 524166839 524150790 524166840 524179949
0100 YRM 0284 0620 YRM 0294 1400 YRM 0413 1600 YRM 0257 1600 YRM 0326 1600 YRM 0485 1800 YRM 0338 1900 YRM 0286 2000 YRM 0077 2100 YRM 0103 2200 YRM 0560 2200 YRM 0595
03/03 03/08 11/06 05/02 03/07 07/03 05/09 07/02 02/09 03/07 07/05 07/03
524166843 524166844
2200 YRM 0808 2200 YRM 0942
06/05 08/07
524167640 524158040 524153920 524153919 524150797 524166846 524166847 524166848
2200 YRM 0947 2240 YRM 0001 4000 YRM 0736 4000 YRM 0741 8000 YRM 0231 8000 YRM 0915 8000 YRM 0916 8000 YRM 0917
08/07 09/14 07/10 03/05 10/13 07/02 12/03 01/04
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 524170489 (09/14)
100 YRM 284
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, hydraulic tank, access panels, and label positions. See Figure 1. The procedure for removing the traction motor is also described in this section.
Description The frame is a single weldment. The frame has mounts for the counterweight, overhead guard, tilt cylinders, steering axle, and drive axle assembly. See Figure 1. The hydraulic tank is part of the lift truck frame and is a welded steel unit. The lift trucks must have a hood over the battery or a covered battery if a hood is not installed. The floor plates can be removed for access to the hydraulic systems. A panel in the bottom of the battery compartment can be removed for access to the traction motor and the hydraulic pump motor. This panel also gives access to the power steering pump
1. OVERHEAD GUARD 2. COUNTERWEIGHT 3. STEERING AXLE AND WHEELS
4. 5. 6. 7.
motor. The SCR (silicon controlled rectifier) electronic controller and contactors are in the counterweight. A panel in the counterweight can be removed for access to the SCR controller and contactors. The ERC070-120HG models are made with two sizes of frames. A short frame (1018 mm battery compartment) is available for the ERC070-80HG and the ERC100HG models. A long frame (1183 mm battery compartment) is available for the ERC100-120HG models. The size of the battery compartment and battery size specifications are shown in Table 1.
FRAME DRIVE AXLE AND WHEELS MAST FORKS
8. CARRIAGE 9. LOAD BACKREST EXTENSION 10. ACCESS PANEL TO SCR ELECTRONIC CONTROLLER
Figure 1. Lift Truck Parts
1
Description
100 YRM 284 Table 1. Battery Specifications Minimum Compartment Size Length × Width
Battery Length Min./Max.
Weight Minimum
Maximum
Model
Volts
ERC070-080HG
36
841 × 987 mm (33.1 × 38.9 in.)
950/990 mm (37.4/39.0 in.)
1542 kg (3400 lb)
2400 kg (5292 lb)
ERC100HG (Short Frame)
36
841 × 987 mm (33.1 × 38.9 in.)
950/990 mm (37.4/39.0 in.)
1633 kg (3600 lb)
2400 kg (5292 lb)
ERC100HG (Long Frame)
36
694 × 1037 mm (27.3 × 40.8 in.)
1115/1150 mm (43.9/45.3 in.)
1814 kg (4000 lb)
2700 kg (5954 lb)
ERC120HG
36
993 × 1146 mm (39.3 × 45.1 in.)
1115/1150 mm (43.9/45.3 in.)
1919 kg (4231 lb)
2700 kg (5954 lb)
ERC070-080HG
48
841 × 987 mm (33.1 × 38.9 in.)
950/990 mm (37.4/39.0 in.)
1542 kg (3400 lb)
2400 kg (5292 lb)
ERC100HG (Short Frame)
48
841 × 987 mm (33.1 × 38.9 in.)
950/990 mm (37.4/39.0 in.)
1633 kg (3600 lb)
2400 kg (5292 lb)
ERC100HG (Long Frame)
48
694 × 1037 mm (27.3 × 40.8 in.)
1115/1150 mm (43.9/45.3 in.)
1814 kg (4000 lb)
2700 kg (5954 lb)
ERC120HG
48
993 × 1146 mm (39.3 × 45.1 in.)
1115/1150 mm (43.9/45.3 in.)
1919 kg (4231 lb)
2700 kg (5954 lb)
Battery Width Batteries Without Cover: 950 to 1117 mm (37.4 to 44.0 in.) Batteries With Cover: 950 to 1143 mm (37.4 to 45.0 in.) NOTE: Maximum tolerances are +0 and 13 mm (+0 and 0.5 in.) for the size of the battery compartment. The battery specification chart shows the maximum size tolerances that will permit the battery to still fit into a battery compartment. The lift trucks are equipped with adjustable spacers in the battery compartment. See Figure 2. Add or remove shims from under the front spacer bar to control the movement of the battery in the forward and backward directions. Install an equal number of shims at each capscrew. Install the additional shims under the nuts of the capscrews (outside battery compartment). The spacers on each side of the battery can be adjusted to control the movement of the battery from side to side. Access to the nuts for the spacers for the sides of the battery is under the frame near the steer tires on all
2
units. Tighten all capscrews. It can be necessary to install the side spacers facing the opposite direction for some batteries. If the spacers cannot be adjusted for a battery that is specified for this lift truck, see your Yale lift truck dealer for the correct spacers. NOTE: Maximum tolerances are +0 and 13 mm (+0 and 0.5 in.) for the size of the battery compartment. The battery specification chart shows the maximum size tolerances that will permit a battery to still fit into a battery compartment.
100 YRM 284
Description
A. FRONT SPACER 1. BATTERY COMPARTMENT 2. BATTERY 3. BULKHEAD
4. SPACER BAR 5. SHIM 6. STORE ADDITIONAL SHIMS IN FRONT OF BULKHEAD Figure 2. Battery Compartment Shims
WARNING The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use spacers to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction.
The weight of the battery is a large part of the counterweight system on an electric lift truck. Make sure that the battery is within the weight limits indicated on the nameplate. Each model of lift truck has a cast-iron counterweight that provides the additional weight necessary for the indicated capacity. A slot in the overhead guard permits removal of the battery without removing the overhead guard.
3
Overhead Guard Repair
100 YRM 284
Overhead Guard Repair REMOVE
lifted from the frame, make sure these electric wires move through the holes in the frame so they are not damaged.
WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.
4. Use lifting device or another person to help lift overhead guard from lift truck.
1. Remove battery as described in the section Periodic Maintenance for your lift truck.
INSTALL
2. Access to capscrews that hold rear supports of overhead guard to counterweight is from the battery compartment. Remove capscrews. 3. Remove two capscrews that hold each front support of overhead guard to cowl. Disconnect any electric wires from under cowl that go through supports of overhead guard. When overhead guard is
Put overhead guard on lift truck. Install any electric wires from overhead guard supports through holes in cowl. Install four capscrews, washers, and nuts that hold front supports to cowl. Tighten capscrews to correct torque. Install capscrews and washers that hold rear supports to counterweight. Tighten capscrews to correct torque. The correct torque values are shown in Figure 3. Install battery.
Figure 3. Frame, Overhead Guard, and Counterweight
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100 YRM 284
Battery Restraint and Seat Assembly Repair Legend for Figure 3 Torque Values
Model
Overhead Guard
ERC070-120HG 1. 2. 3. 4.
Counterweight
Front
Rear
Upper
Lower
86 N•m (64 lbf ft)
86 N•m (64 lbf ft)
270 N•m (200 lbf ft)
66 N•m (49 lbf ft)
OVERHEAD GUARD (OHG) COUNTERWEIGHT (CWT) FRAME CAPSCREWS (4) OHG-FRONT
5. CAPSCREWS (2) OHG-UPPER 6. CAPSCREWS (2) CWT-UPPER 7. CAPSCREWS (2) CWT-LOWER
Battery Restraint and Seat Assembly Repair A battery restraint system is installed as a safety device. The function of the battery restraint system, when correctly locked in the down position, is to hold the battery in the battery compartment if an accident causes the lift truck to tip over. The battery restraint is a steel plate that is connected to the frame with a hinge. A sliding latch mechanism locks the battery restraint in the down position for operation. A knob near the hinge unlocks the battery restraint from the frame so the battery restraint can be raised to the up position for access to the battery. The battery restraint is also the support for the seat. A spring brace holds the seat and battery restraint in the up position. The operator must hold the seat assembly with one hand. Use the other hand on the knob to release the spring brace and lower the seat and battery restraint assembly to the operating position. Make sure that the battery restraint is correctly locked to the frame for operation of the lift truck. An additional battery retention bar is used where batteries can be longer. This bar has a hinge fastened to the counterweight and is part of the hood mechanism on lift truck with hoods. The bar is also installed on lift trucks without hoods. Spacers are used inside the battery compartment to prevent horizontal movement of the battery.
WARNING The battery restraint and its latch mechanisms must operate correctly before a lift truck is operated. Make sure the battery has a cover if the lift truck does not have a hood. To operate correctly, the battery restraint plate must be locked in the down position. The battery retention bar (and hood) must be lowered first; then the battery restraint plate is locked in the down position over the bar. The battery must have spacers to prevent movement in any one horizontal direction of 13 mm (0.5 in.) maximum. See Figure 4. Use the knob near the hinge to release the battery restraint plate. Use the handle on the restraint plate to raise the plate and seat. A spring brace will hold the assembly in the up position. If installed, raise the hood. Make sure that the battery cannot move more than a total of 13 mm (0.5 in.) in any one horizontal direction. Make sure the correct spacers are installed to prevent the movement. See your Yale lift truck dealer to replace damaged or missing spacers. If a smaller battery of the correct weight (see nameplate) is installed and the spacers cannot prevent movement, your Yale lift truck dealer has larger spacers. Push the seat and the battery restraint down until the latch locks. Make sure battery restraint is locked securely. Lift on battery restraint to make sure it is latched and will not move.
5
Battery Restraint and Seat Assembly Repair
100 YRM 284 Legend for Figure 4 1. 2. 3. 4. 5. 6. 7.
SEAT BATTERY RESTRAINT PLATE KNOB FOR LATCH MECHANISM HINGE LATCH SPRING BRACE BATTERY RETENTION BAR
SEAT BRAKE ASSEMBLY, ADJUST 1. Put a weight in the seat to release seat brake. Measure dimension X and Y. Add or remove shims under clamp so dimension Y is equal to dimension X within ±3 mm (0.12 in.). Use equal number shims under each clamp. See Figure 5. 2. Adjust setscrew at top of lever so bottom of lever equals dimension L from front plate of battery compartment. NOTE: This adjustment can be made with the spring assembly removed from the lift truck. 3. Adjust spring adjustment so length is dimension J. 4. On 280 mm (11 in.) diameter motor: Adjust lever to a level position using nut. On 330 mm (13 in.) diameter motor: Adjust lever to 25 ±2 mm (1 ±0.08 in.) using nut. Lock nut with jam nut. Make sure this adjustment does not apply the brake. See Table 2. 5. Adjust spring to dimension K. Lock nut with jam nut. This adjustment can be made with spring assembly removed from lift truck. 6. Adjust position of rod end so brake will start to apply when brake lever is raised 3 mm (0.12 in.) or less. Rotate brake drum by hand to feel brake start to apply. 7. Test operation of seat brake to make sure seat brake is actuated correctly. Make sure linkage is adjusted to correct measurements. If seat brake does not correctly actuate brake after adjustments have been made, adjust length of rod again and make sure dimension is correct. 8. The seat can be removed from the battery restraint plate. Remove four bolts. The battery restraint plate can be removed from the frame. Remove hinge pin that holds assembly to frame. Figure 4. Battery Restraint and Seat Assembly
6
100 YRM 284
Battery Restraint and Seat Assembly Repair Table 2. Seat Brake Adjustment
Motor Dia.
280 mm (11 in.)
330 mm (13 in.)
Dimension
Seat Type
J
Standard
80 mm (3.2 in.)*
Suspension
75 mm (2.9 in.)
Standard
85 mm (3.3 in.)**
Suspension
80 mm (3.2 in.)
K
L
173 mm (6.7 in.)
65 mm (2.5 in.)
165 mm (6.5 in.)
55 mm (2.1 in.)
* 90 mm (3.5 in.), ** 80 mm (3.2 in.) on early models. Legend for Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
CLAMP LEVER SPRING ADJUSTMENT BEARING FRONT PLATE BATTERY COMPARTMENT SPRING ASSEMBLY MOTOR LEVER MOTOR LEVER SPRING JAM NUT JAM NUT ADJUSTMENT NUT ADJUSTMENT NUT JAM NUT SETSCREW MOTOR 280 mm (11 in.) MOTOR 330 mm (13 in.) BRAKE SEAT
Figure 5. Seat Brake Assembly
7
Counterweight Repair
100 YRM 284
Counterweight Repair If the lift truck must be put on blocks for maintenance and repair, see Periodic Maintenance 8000 YRM 915 section How to Put a Lift Truck on Blocks.
WARNING The counterweight is very heavy. Make sure that the crane and lifting devices have enough lifting capacity to safely lift the counterweight. The weights of the counterweights are shown in Table 3. The counterweight normally is not removed for most repairs. Replacement of some large parts of the SCR electronic controller is easier when the counterweight is removed. The counterweight is fastened to the frame with four capscrews. The weights for the counterweights are in Table 3. Table 3. Counterweights Weight*
ERC070HG
775 kg (1705 lb)
ERC080HG
1184 kg (2605 lb)
ERC100HG (Long Frame)
1184 kg (2605 lb)
ERC100HG (Short Frame)
1747 kg (3850 lb)
INSTALL
ERC120HG
1797 kg (3950 lb)
NOTE: The access panel to the electronic controller can be removed from the counterweight to make checks and adjustments on the controller. Make sure lugs are correctly engaged when access panel is installed again or panel will fall from counterweight during operation.
*Maximum weight
REMOVE 1. Remove battery. See the Periodic Maintenance 8000 YRM 915 section of this manual under How to Change the Battery. 2. Remove overhead guard as described in the paragraphs under Overhead Guard Repair, Remove. 3. ERC070-120HG models have a hole on top of the counterweight for a single eye bolt. Attach chain or sling to eyebolts. Use crane to hold the weight of the counterweight. See Figure 3 and Figure 6. 4. From inside the battery compartment, remove two capscrews that hold counterweight to frame. Remove two capscrews from tow pin area of counterweight. Use crane to lift counterweight away from frame. Make sure you do not damage the electronic controls.
8
NOTE: ERC120HG MODEL SHOWN.
Model
1. LIFTING EYEBOLT 2. CAPSCREWS
3. TOW PIN
Figure 6. Lift Counterweight
1. Use crane to lift counterweight into position. Make sure you do not damage electronic controller. Install two upper capscrews from inside battery compartment that hold counterweight to frame. Install two lower capscrews in tow pin area of counterweight. Tighten capscrews to correct torque. The correct torque values for capscrews are shown in Figure 3. 2. Disconnect sling or chain. Remove eyebolts from counterweight. 3. Install overhead guard as described in the paragraphs for the Overhead Guard Repair, Install. 4. Install battery. See Periodic Maintenance 8000 YRM 915 section How to Change the Battery.
100 YRM 284
Traction Motor Repair
Traction Motor Repair REMOVE This procedure will show the removal of the traction motor through the battery compartment. Some lift trucks have a seat brake that actuates the brake on the armature shaft of the traction motor. See Figure 7. The seat brake linkage must be disconnected at the front of the traction motor before the motor is removed.
1. Remove battery. Remove floor plates and access panel in bottom of battery compartment. 2. Disconnect seat brake linkage. Disconnect hydraulic line to main control valve so motor mount can be disconnected. Put caps on open hydraulic fittings. 3. Disconnect power cables from traction motor. Make an identification of which cable is connected to each terminal. 4. Put lift truck on blocks for easier access to bottom bolts between traction motor and speed reducer. Remove bolts between speed reducer and motor. 5. Install sling to hold traction motor. See Figure 8. Use wood block and board under sling as shown in the illustration to control traction motor during removal and installation. Use crane to hold weight of traction motor. See Figure 9.
A. TRACTION MOTOR B. TRACTION MOTOR WITH OPTIONAL SEAT BRAKE Figure 7. Traction Motor NOTE: The traction motor can also be removed from under the lift truck with the use of a floor jack, but is more difficult. The lift truck must be on blocks with clearance for the jack and traction motor if the traction motor is removed from under the lift truck. The hydraulic lines from the hydraulic tank must also be disconnected if the traction motor is removed from under the lift truck.
1. SLING 2. USE WOOD BLOCK AND BOARD UNDER SLING FOR A LEVER 3. TRACTION MOTOR Figure 8. Sling Installation to Lift Traction Motor
9
Hydraulic Tank Repair
100 YRM 284 2. Lower traction motor into position in lift truck. Align traction motor with speed reducer. See Figure 10. 3. Use board or prybar as necessary to push traction motor into speed reducer. 4. Align bolt holes in speed reducer and motor housing. Install bolts that hold traction motor to speed reducer. Tighten bolts to 38 N•m (28 lbf ft). 5. Remove sling and install traction motor mount. 6. Connect inlet hydraulic line to main control valve. Install power cables.
Figure 9. Use Crane to Lift Traction Motor NOTE: The traction motors are in different configurations for different applications of the lift trucks. Traction motors weigh approximately 90 to 140 kg (200 to 310 lb). Make sure the sling cannot slide and permit traction motor to fall. 6. Remove motor mount that holds traction motor to frame. Pull traction motor from speed reducer. 7. Use crane to move traction motor to a space to make repairs.
INSTALL 1. Install sling to lift traction motor. Use wood block and board under sling as shown in Figure 8 to control traction motor during installation.
1. SLING 2. BOARD
3. WOOD BLOCK
Figure 10. Align Traction Motor with Speed Reducer
Hydraulic Tank Repair INSPECT Make a visual inspection of all sides of the tank. Inspect welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors. The hydraulic tank is part of the frame weldment and cannot be removed from the lift truck. See Figure 11.
10
Repairs for leaks in the hydraulic tank can require special procedures described in the next paragraphs.
SMALL LEAKS, REPAIR Use the following procedure to seal small leaks: 1. Use steam to clean area around leak. Remove all paint and dirt around leak.
100 YRM 284
Hydraulic Tank Repair • Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, A6.0-65. • Safety In Welding and Cutting, American National Standard, ANSI Z 49.1 - 1973. When cleaning 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. 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 nozzle and tank. Connect ground wire to tank to prevent static electricity.
1. HYDRAULIC TANK 2. OUTER FRAME
3. INNER FRAME 4. SUCTION PIPE
Figure 11. Hydraulic Tank
WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion. 2. Apply Loctite® 290 to leak. Follow instructions of manufacturer.
Steam Method Use the following procedure to clean the tank with steam: 1. Remove all parts from tank. Install drain plug. 2. Fill tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water.
LARGE LEAKS, REPAIR
3. Mix solution in tank using air pressure. Make sure all surfaces on inside of tank are flushed with solution. Drain tank.
1. Use one of the procedures described under Clean in this section to clean and prepare the tank for repairs.
4. Put steam into tank until tank does not have odors and metal is hot. Steam vapors must come from all openings.
2. Use acceptable welding practices to repair tank. See the American National Standard Safety In Welding and Cutting ANSI Z 49.1 - 1973.
5. Flush inside of tank with boiling water. Make sure all loose material is removed from inside of tank.
CLEAN 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:
6. Make inspection of inside of 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 openings in tank. Wait 15 minutes, then remove 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.
11
Painting Instructions
100 YRM 284
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.
a light that is approved for locations with flammable vapors. 5. Check tank for flammable vapors using a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.
ADDITIONAL PREPARATIONS FOR REPAIR
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 tank with cleaning solution. Use compressed air to mix solution in tank.
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, A6.0-65. If these gases are not available, another method using water can be used as follows:
3. Drain tank. Flush inside of tank with hot (boiling) water. Make sure all cleaning compound is removed.
1. Fill 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.
4. Make an inspection of inside of tank. If tank is not clean, repeat Step 1 through Step 3. Make another inspection of tank. When making inspections, use
2. Use acceptable welding practices to repair tank. See the American National Standard "Safety in Welding and Cutting," ANSI Z 49.1 - 1973.
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 surface to be painted. Clean 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.
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 surfaces. Use correct paint from your dealer for Yale lift trucks. Follow directions on container. The correct arrangement of colors is shown in the note in Figure 12.
WARNING
2. Use sandpaper to remove top surface of paint and rust from metal. All metal surfaces where paint is completely removed must be painted. Use a primer. Apply primer before applying final coat of paint.
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.
3. Protect all surfaces that will not be painted. See the list of items in Figure 12.
5. Check that all safety labels are installed in correct locations on lift truck. New labels are available from your dealer for Yale lift trucks.
12
100 YRM 284
Safety Label Replacement
NOTE: USE COLORS APPROVED BY YALE. 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 = YELLOW, DARK AREAS = BLACK, AND LIGHT GRAY AREAS = PARCHMENT. Figure 12. Color Arrangement
Safety Label Replacement If the labels or information plates are missing or have damage, they must be replaced. See Figure 13.
WARNING Labels that have WARNINGS or CAUTIONS must be replaced if they are damaged. If an upright 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 YALE Dealer for a replacement nameplate. The nameplate information is a safety item and must be correct for the equipment and configuration of the lift truck.
1. Make sure surface is dry and has no oil or grease. Do not use solvent on new paint. Clean surface of old paint using a cleaning solvent. 2. Remove paper from back of label. Do not touch adhesive surface. 3. Carefully hold label in correct position above surface. The label cannot be moved after it touches the surface. Put label on surface. Make sure all air is removed from under label and corners and edges are tight.
NOTE: The nameplate is installed using rivets. The old rivets must be removed before installing a new nameplate.
13
Safety Label Replacement
100 YRM 284
Figure 13. Label Positions
14
100 YRM 284
Safety Label Replacement Legend for Figure 13
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
YALE LABEL MAST WARNING IMPACT RATING PLATE (OVERHEAD GUARD) OPERATOR WARNING OPERATOR RESTRAINT LIFT/TILT LABEL BATTERY RESTRAINT PINCH POINT BATTERY SPACER FREEZER LABEL CORROSION LABEL IDENTIFYING MARKER NFPA (TYPE EE) IDENTIFYING MARKER NFPA (TYPE ES)
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
BRAND LABEL NO RIDERS BATTERY DISCONNECT AUXILIARY FUNCTION PATENT TRADEMARK UL CLASSIFICATION PLATE (E) MAST WARNING PINCH POINT PARKING BRAKE WARNING CAPACITY PLATE NAMEPLATE PANEL PLUG FORWARD/REVERSE LABEL
15
620 YRM 294
Brush and Commutator Inspection
General This section describes disassembly and assembly, brush installation, inspection, and checks for malfunctions of DC motors. Inspect the commutator and brushes every 350 hours of operation. The commutator is the rotating electric connection between the armature and the electric power supplied by the battery. Brushes made of carbon compounds slide on the rotating commutator and are the path for electricity from the battery to the commutator and the armature. The maintenance of the commutator and the brushes is important to the good operation of a DC motor. Traction motors and hydraulic pump motors are similar in design. The hydraulic pump motors are smaller than the traction motors, but the disassembly and maintenance of these motors are similar. The cooling
fan in the traction motors is fastened to the armature and can be removed from the armature. The cooling fan can be removed during disassembly of the traction motor. The cooling fan in the hydraulic pump motors can be a press fit on the armature shaft and is not easily removed during disassembly of the motor. The armature and cooling fan must be removed from the drive end of the motor during disassembly. The assembly and disassembly of the motor used for the power steering pump is described in the Steering System section. This motor is a permanent magnet motor.
Brush and Commutator Inspection HYDRAULIC PUMP MOTOR AND TRACTION MOTOR NOTE: When inspecting brush conditions and motor commutator conditions for head damage or abnormal wear, the battery maintenance and condition should be eliminated as a cause first. See Industrial Battery 2240 YRM 1. NOTE: The brushes and commutator can be inspected, the brushes can be replaced, and Stoning the Commutator can be done with the motor installed in the truck.
in the Operating Manual or the Periodic Maintenance YRM section for your lift truck. NOTE: For some models of lift trucks, the battery does not need to be removed to access the electric motors. Other models will require the removal of the battery before gaining access to the electric motors. To remove the battery, either raise the hood panels or unfasten the floor plate, depending on which motor needs to be accessed.
NOTE: Inspect the brushes and commutator every 350 hours for best operation and to prevent motor damage. The hydraulic pump motor normally has more start cycles than other motors, so it can have more wear and possible damage. NOTE: The following procedure is for inspecting the brushes and commutator with the motor installed in the lift truck. The same inspections can be done with the motor removed. If the motor is removed, start at Step 3. 1. To rotate the commutator of the traction motor without moving the truck, the drive wheels must be raised. See Figure 1. Raise drive wheels so commutator of the traction motor can be rotated without moving lift truck. See How To Raise Drive Wheels
1. ARMATURE (DRIVE) SHAFT
2. COOLING FAN 3. BRUSH COVER
Figure 1. Traction Motor
1
Brush and Commutator Inspection 2. Remove battery. See How to Remove Battery in the Operating Manual or the Periodic Maintenance YRM section for your lift truck. Remove access plate to motors. If the battery in your lift truck does not need removal for access to the motors, go to Step 3.
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. NOTE: Vacuum cleaning, when possible, is the recommendation of manufacturers of electric motors. The use of compressed air can send dirt particles into the bearings and other areas of the motor that can cause possible damage. 3. Remove brush covers at rear of motor. See Figure 2. Wear eye protection. Use a vacuum cleaner or compressed air to remove dirt and brush dust from commutator area.
620 YRM 294 the commutator and must not have cracks or defects. Some brushes have wear sensor wires attached, even if they are not connected to an indicator. Replace these brushes if brushes are worn enough to see sensor at commutator end of brush. 5. Inspect commutator surface. See Table 1 and Table 2. Carefully rotate armature. DO NOT damage commutator if you use a tool to rotate armature. The commutator wears slowly in normal service. The mica must be cut below the surface of the commutator bars after a long service period or after a commutator has been turned in a lathe. A commutator that has been in service will have a smooth and polished surface with a darker brown color where it rotates under the brushes. A variation of color on the commutator surface between light brown and darker brown is normal. The surface condition is the lubrication between the commutator and the brushes. The brushes will wear rapidly if this surface condition does not develop during the first 6 to 10 hours of operation after a commutator with a new surface is installed. If the commutator has deep grooves, rough edges of the bars, or a few bars that are black or raised above the others, the motor must be removed for service. 6. Inspect white or gray insulation (mica) between commutator bars. The mica must not touch the brushes or the brushes will wear very rapidly.
Figure 2. Brush Cover Removal From Motor 4. Remove and inspect brushes for damage or uneven wear. Replace all brushes if any brush is worn or damaged. The brushes must be at least half their original length. Move brush springs away from top of each brush and pull brushes from their holders to inspect surface that rides on commutator. See Figure 3. That surface must have the same shape as
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7. To replace a brush set, remove screw that holds brush wires to bus. Pull brush end of springs from brushes, and pull brushes from holders. Lift brush springs away from holders, and install new brushes so brush commutator surface fully touches commutator. Make sure the springs are pushing on each brush. Install and tighten screws for brush wires and bus connectors. 8. Carefully install brush covers so sparks are kept inside motor housing. Install battery as described in Operating Manual or the Periodic Maintenance YRM section for your lift truck.
620 YRM 294
Brush and Commutator Inspection Legend for Figure 3 1. BRUSH 2. BRUSH SPRING 3. MICA
Figure 3. Brush Removal and Inspection Table 1. Normal Commutator Surfaces A light brown surface of the commutator where it rotates on the brushes is a normal condition. The surface of the commutator must be smooth.
Variations between light brown and dark brown colors are also normal. The surface of the commutator must be smooth.
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Brush and Commutator Inspection
620 YRM 294
Table 1. Normal Commutator Surfaces (Continued) A condition called slot bar marking is also normal if the commutator surface is smooth. The variable color occurs in a pattern according to the number of conductors per slot.
STEERING PUMP MOTOR NOTE: Some electrical trucks use a steering pump motor. Refer to your truck model’s service manual for instructions on removal and installation of steering pump motors. 1. Disconnect battery connector. Remove floor plate from lift truck for access to steering pump motor. Open hood for access to motor. Remove screws that hold two brush cover plates to motor housing. 2. Inspect brushes and commutator as described in previous paragraphs for traction and hydraulic pump motors. The brush replacement procedure is also the same, although there are only two brushes for the steering pump motor. See Table 3.
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A very dark surface is also a normal and an acceptable condition if the commutator surface is smooth.
3. Install brush covers and screws. Install floor plate or close hood and connect battery connector.
NORMAL COMMUTATOR SURFACE A commutator that has been in service will have a smooth and polished surface with a darker brown color where it rotates under the brushes. See Table 1. A variation of color on the commutator surface between light brown and darker brown is normal. This surface condition is the lubrication between the commutator and the brushes. The brushes will wear rapidly if this surface condition does not develop during the first 6 to 10 hours of operation after a commutator with a new surface is installed.
620 YRM 294
Brush and Commutator Inspection
COMMUTATOR PROBLEMS Commutator and motor problems and are shown in Table 2. Table 2. Commutator Problems Problem
Possible Cause
Heavy streaks and fine grooves indicate the beginning of damage to the commutator.
• Operation of the motor in dirty and abrasive conditions. • Continuous operation of a motor with a light load. • Brush pressure is too low. • Worn brushes.
Grooves and lines that have followed the heavy streaks and fine grooves shown above. The armature must be removed from the motor so the commutator can be repaired. A commutator with this condition will cause the brushes to wear rapidly.
• Operation of the motor in dirty and abrasive conditions. • Continuous operation of a motor with a light load. • Brush pressure is too low. • Worn brushes.
Illustration
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