YALE A839 ERC100HG LIFT TRUCK Service Repair Manual

ERC070-120HG (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................................

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

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.................................................................................................

LIFT CYLINDERS...........................................................................................................

VISTA MASTS-DESCRIPTION AND REPAIRS.............................................................

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 524166842

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 2200 YRM 0725

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

524166843 524166844

2200 YRM 0808 2200 YRM 0942

06/05 08/07

524167640 524158040 524150794 524166845 524153920 524153919 524150797 524166846 524166847 524166848

2200 YRM 0947 2240 YRM 0001 4000 YRM 0135 4000 YRM 0340 4000 YRM 0736 4000 YRM 0741 8000 YRM 0231 8000 YRM 0915 8000 YRM 0916 8000 YRM 0917

08/07 09/14 03/11 09/02 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. 524166807 (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

4

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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Brush and Commutator Inspection

620 YRM 294

Table 2. Commutator Problems (Continued) Problem

Possible Cause

Grooves that are the width of the brushes.

• Operation of the motor in dirty and abrasive conditions.

• Wrong type of brushes for this motor and operation.

• Brush pressure is too high.

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

The brushes will wear rapidly.

• Operation of the motor in dirty and abrasive conditions.

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

• Wrong type of brushes for this motor and operation.

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

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

• Open armature winding.

• Motor has been stalled.

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Illustration

620 YRM 294

Brush and Commutator Inspection

Table 2. Commutator Problems (Continued) Problem

Possible Cause

Copper wears rapidly at the edge of the commutator bars.

• Operation of the motor in dirty and abrasive conditions.

• Wrong type of brushes for this motor and operation.

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

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

3. Overheating causes damage to varnish insulation.

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

• Motor has been stalled.

• Open armature winding.

• Open field coil.

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

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

Check for loose or high commutator bars.

• Motor has been stalled.

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

• Motor has been too hot.

Illustration

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

2. Rapid brush wear from high commutator bars.

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Brush Replacement

620 YRM 294

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

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

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

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

Table 3. Brush Wear Replacement Guide Brush Height

17 mm (0.67 in.)

22 mm (0.87 in.)

28 mm (1.10 in.)

30 mm (1.18 in.)

31 mm (1.22 in.)

32 mm (1.26 in.)

40 mm (1.57 in.)

Wear

8 mm (0.31 in.)

12 mm (0.47 in.)

14 mm (0.55 in.)

15 mm (0.59 in.)

16 mm (0.63 in.)

16 mm (0.63 in.)

16 mm (0.63 in.)

Worn Brush Height

9 mm (0.35 in.)

10 mm (0.39 in.)

14 mm (0.55 in.)

15 mm (0.59 in.)

15 mm (0.59 in.)

16 mm (0.63 in.)

20 mm (0.79 in.)

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

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

2. Remove battery as necessary for your lift truck.

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

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

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

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

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

Remove brush springs and brushes.

1.

2.

3.

4.

BRUSH BRUSH BRUSH BRUSH

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

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620 YRM 294

Brush Replacement

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

7. Connect new brush wire to its terminal mount.

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

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

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

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

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

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

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

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

3. COMMUTATOR 4. BRUSH SPRING

Figure 5. Brush Spring Pressure Check

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

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

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

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

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Stoning the Commutator

620 YRM 294

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

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

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

is most easily done when the motor rotates slowly.

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

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

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

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

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

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

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

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

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

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

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

620 YRM 294

Stoning the Commutator Legend for Figure 6 1.

2.

3.

4.

RAISE DRIVE WHEELS JUMPER BATTERY BRUSH SEATER STONE

Figure 6. Stoning the Commutator

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Motors Repair

620 YRM 294

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

plastic or rubber hammer as necessary to loosen end frame.

6. Remove drive end frame from armature.

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

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

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

Traction Motor and Hydraulic Pump Motor

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

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

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

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

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

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

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

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

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

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

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

1.

2.

3.

4.

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

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

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620 YRM 294

1.

2.

3.

4.

5.

6.

7.

8.

9.

Motors Repair

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

10.

11.

12.

13.

14.

15.

16.

17.

18.

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

19.

20.

21.

22.

23.

24.

25.

26.

27.

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

Figure 8. Typical Traction Motor (Example 1)

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