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ERP20-30ALF (E216) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ DC MOTOR MAINTENANCE.......................................................................................... AC MOTOR MAINTENANCE.......................................................................................... DRIVE AXLE WET BRAKE............................................................................................ STEERING CONTROL UNIT.......................................................................................... STEERING SYSTEM...................................................................................................... BRAKE PEDAL AND LINKAGE..................................................................................... HYDRAULIC SYSTEM.................................................................................................... MAIN CONTROL VALVE................................................................................................ MAIN CONTROL VALVE E-CONTROLS....................................................................... CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564).......................................................................................................................... ELECTRICAL SYSTEM.................................................................................................. AC MOTOR CONTROLLER DESC/CHKS/ADJ/TRBSHT/REP&THEORY OF OPERATION/DISPLAY PANEL................................................................................. TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS PROGRAM................................................................................................................. INDUSTRIAL BATTERY................................................................................................. MAST - DESCRIPTION................................................................................................... MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ METRIC AND INCH (SAE) FASTENERS....................................................................... DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... PART NO. 524309197 (09/14)

PART NUMBER

YRM NUMBER

REV DATE

524256685 524158039 524183080 524256686 524158753 524183081 524264587 524179945 524179946 524256687

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

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

524223768 524183082

2100 YRM 1139 2200 YRM 1055

02/14 10/09

524183083

2200 YRM 1056

03/09

524183085 524158040 524158890

2200 YRM 1058 2240 YRM 0001 4000 YRM 0521

04/11 09/14 03/06

524223776 524150797 524256688 524309198 524256690

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

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


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

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

CAUTION Indicates a condition that can cause property damage!


Frame

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Description .......................................................................................................................................................... Main Frame ..................................................................................................................................................... Other Frame Weldments ................................................................................................................................. Overhead Guard ............................................................................................................................................. Battery Restraint, Hood, and Seat Assembly.................................................................................................. Hood With Manual Hydraulic Levers ............................................................................................................... Hood With E-Hydraulics .................................................................................................................................. Operator Restraint System and Seat Assembly.............................................................................................. Operator Restraint System ......................................................................................................................... Emergency Locking Retractor (ELR) ...................................................................................................... Hood and Seat Latches .............................................................................................................................. Overhead Guard Replacement............................................................................................................................ Remove ........................................................................................................................................................... Install............................................................................................................................................................... Hood, Seat Assembly, and Operator Restraint Replacement.............................................................................. Hood and Seat Assembly................................................................................................................................ Remove....................................................................................................................................................... Install .......................................................................................................................................................... Counterweight Replacement ............................................................................................................................... Remove ........................................................................................................................................................... Install............................................................................................................................................................... Hydraulic Tank Replacement............................................................................................................................... Remove ........................................................................................................................................................... Inspect............................................................................................................................................................. Clean............................................................................................................................................................... Steam Method ............................................................................................................................................ Chemical Solution Method .......................................................................................................................... Additional Preparations for Tank Repair.......................................................................................................... Small Leaks, Repair ........................................................................................................................................ Large Leaks, Repair ........................................................................................................................................ Preparations for Usage After Repair ............................................................................................................... Install............................................................................................................................................................... Painting Instructions ............................................................................................................................................ Safety Label Replacement .................................................................................................................................. Battery Specifications.......................................................................................................................................... ERP20-32ALF (ERP040-065DH) (E216) Model Trucks ..................................................................................

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

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

Š2006 Yale Materials Handling Corp.

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100 YRM 1222

Description

General This section has a description and the service procedures for the parts of the frame. These parts include the frame, counterweight assembly, overhead guard, hood and seat assembly, access panels, and label positions.

Description MAIN FRAME The main frame is a single weldment. See Figure 1. The main frame has mounts for the following: • Counterweight • Overhead guard • Battery restraint and hood • Tilt cylinders • Steering axle • Drive axle assembly • Cowl assembly • Floor pedals and floor plates • Side step and fender weldments • Hydraulic tank • Pump and motor assemblies (steer, lift, and traction motors) • Control valves and the levers The hood is part of the operator and battery restraint system. The seat is part of the operator restraint system. The hydraulic tank, lift pump motor assembly, and the steering pump motor assembly are in a compartment between the battery and the counterweight. The top cover between the counterweight and hood can be removed for access to the master controller. The rear cover of the counterweight can be removed for access to the controllers and contactors. See Figure 2.

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

OTHER FRAME WELDMENTS These frame parts are the right-side and left-side step and fender weldments and the cowl weldment. See Figure 1. Each part is a weldment fastened to the main frame to make the frame assembly. The cowl weldment is a mount for the front of the overhead guard, the steering column assembly, the parking brake release linkage, and the dash panel with light switches. The display panel is mounted into the dash panel. See Figure 3.

OVERHEAD GUARD WARNING Do not operate the lift truck without the overhead guard and cowl correctly fastened to the lift truck. The overhead guard is a weldment that fastens to the main frame and cowl to help protect the operator from falling objects. A slot in the overhead guard permits removal of the battery without removing the overhead guard. See Figure 2.

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

1


Description

1. 2. 3. 4.

COWL BATTERY SPACER PLATE BATTERY RETAINER ROD FRAME

100 YRM 1222

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

2


100 YRM 1222

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

Description

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

10. 11. 12. 13. 14. 15. 16. 17. 18.

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

Figure 2. Overhead Guard and Counterweight

3


Description

100 YRM 1222

Figure 3. Steering Column and Display Panel

4


100 YRM 1222

Description Legend for Figure 3

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

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

BATTERY RESTRAINT, HOOD, AND SEAT ASSEMBLY WARNING The hood and battery restraint, as well as the latch for the hand lever assembly, must operate correctly before a lift truck is operated. These parts are part of the battery restraint system. The battery restraint system must operate correctly to help provide reasonable protection to the operator if the lift truck tips over.

9. 10. 11. 12. 13. 14. 15. 16.

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

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

A battery restraint system is installed as a safety device. The function on the battery restraint system is to hold the battery in the battery compartment in case of a tip over. Part of the battery restraint system is a battery restraint at the rear of the battery compartment. See Figure 4. This restraint rod extends over the rear edge of the battery case to help hold the battery within the battery compartment during tip over. A handle is used to move the restraint rod. The handle of the battery restraint must be in the DOWN position to close the hood. The handle can be moved to the DOWN position only after the restraint rod is extended over the battery. The restraint rod can only be retracted when the hood is in the UP position.

WARNING The battery must fit the battery compartment so that the battery restraint will operate correctly. A loose battery can cause serious injury and property damage if the lift truck overturns. The battery must not be able to move more than 13 mm (0.5 in.) forward, backward, or side to side. An adjustable spacer plate is used at the front of the battery compartment to prevent forward and backward

A. EXTENDED B. RETRACTED 1. 2. 3. 4.

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

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Description

100 YRM 1222

HOOD WITH MANUAL HYDRAULIC LEVERS WARNING The gas spring for the hood can raise the hood at a rapid rate and cause an injury. DO NOT lean over hood when raising hood.

WARNING The batteries for these lift trucks must fit the battery compartment width with a maximum of 13 mm (0.5 in.) clearance. The Battery Specifications, at the back of this manual, shows the minimum sizes of the battery compartment. Before raising the hood, move the steering column to the forward position and slide the seat all the way back. 1. 2. 3. 4. 5. 6.

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

Another important part of the battery restraint system is the steel weldment that is also the hood frame. This hood frame is connected to the lift truck frame with hinges at the rear of the hood. See Figure 15. The front of the hood and frame is locked in the closed position by the assembly for the hydraulic hand levers. A latch releases the assembly to tilt forward and allow the hood to raise. See Figure 6. Gas springs help lift the hood assembly. The seat and other parts of the operator restraint system fasten to the hood assembly.

A. CLOSED OVER HOOD

B. OPEN

1. HAND LEVER ASSEMBLY 2. HOOD 3. SEAT

4. LATCH HANDLE 5. LATCH

Figure 6. Latch and Cover With Manual Hydraulic Levers

6


100 YRM 1222

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

WARNING The batteries for these lift trucks must fit the battery compartment width with a maximum of 13 mm (0.5 in.) clearance. The Battery Specifications, at the back of this manual, shows the minimum sizes of the battery compartment. Another important part of the battery restraint system is the steel weldment that is also the hood frame. This hood frame is connected to the lift truck frame with hinges at the rear of the hood. See Figure 14. Gas springs help lift the hood assembly. The seat and other parts of the operator restraint system fasten to the hood assembly.

Description The latch that secures the cover for the hood release handle can be either a locking or non-locking latch. If the latch is a locking latch, unlock latch with key first. The cover, latch, and hood release handle are located on the right side of the hood. See Figure 8. Pull the latch handle, located on the top of the latch, to the up position and then pull on latch handle to move cover away from hood release handle. Pull hood release handle up to release hood latch mechanism. See Figure 8. Use handle on the hood to place hood in the raised position. Before lowering the hood, make sure the battery restraint rod is over the battery. Lower the hood and push hood release handle down to secure hood to frame. Move cover over hood release handle and push latch handle down to secure cover to hood. If latch is a locking latch, lock latch with key.

NOTE: Before raising the hood, move the steering column to the forward position and slide the seat all the way back, and, If necessary, move the armrest all the way back. See Figure 7.

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

6. 7. 8. 9. 10. 11. 12.

PIN SCREW CAPSCREW NUT LOCKWASHER WASHER LATCH HANDLE

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

7


Description

100 YRM 1222

OPERATOR RESTRAINT SYSTEM AND SEAT ASSEMBLY Operator Restraint System The seat belt, hip restraint, seat, hood, and hood latch are all part of the operator restraint system. See Figure 9. Each item must be checked to make sure it is fastened correctly, functions correctly, and is in good condition. The system helps the operator stay within the lift truck in case of a tip over. Make sure that the seat is not loose on the rails. Make sure that the seat rails are not loose. The seat rails must lock securely in position, but move freely when unlocked. The seat rails must be securely attached to the mounting surface. Emergency Locking Retractor (ELR) When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator’s lower torso in the seat.

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

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

A seat belt that is damaged worn or does not operate properly will not give protection when it is needed. The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 9. The following seat belt operation checks must be performed: • With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. If the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly. • With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly. • With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly.

1. 2. 3. 4. 5.

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

8


100 YRM 1222

Overhead Guard Replacement

Hood and Seat Latches Make sure the seat rails and latch striker are not loose. The seat rails must lock tightly in position, but move freely when unlocked (see Figure 9 and Figure 10). The

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

Overhead Guard Replacement REMOVE WARNING Do not weld, drill, grind, or cut the overhead guard for mounts of lights or accessories. The strength of the overhead guard can be reduced. 1. Remove battery as described in the section Periodic Maintenance 8000 YRM 1226. 2. Access to the capscrews that hold the rear legs of the overhead guard to the frame is from the battery compartment. See Figure 11. Remove the capscrews, washers, and nuts that fasten each leg. 3. Remove the capscrews, washers, and nuts that hold each front leg of the overhead guard to the cowl. Disconnect any electric wires from under the cowl that go through the front legs of the overhead guard. When the overhead guard is lifted from the frame, make sure these electric wires move through the holes in the frame at the front and rear so that they are not damaged.

4. Use a lifting device or another person to help lift the overhead guard from the lift truck.

INSTALL 1. Install the over head guard onto the lift using a lifting device or another person. 2. Install any electrical wires from the overhead guard legs through the holes in the frame. Make sure location of the wires is routed in the same location as was removed to assure that the wires do not get pinched. 3. Install the capscrews, washers, and nuts that hold each front leg to the frame. See Figure 11. Tighten the capscrews to 102 N•m (75 lbf ft). 4. Install the caspcrews, washers, and nuts that hold the rear legs to the frame. See Figure 11. Tighten the capscrews to 102 N•m (75 lbf ft). 5.

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

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YALE E216 ERP30ALF LIFT TRUCK (EUROPE) Service Repair Manual  

YALE E216 ERP30ALF LIFT TRUCK (EUROPE) Service Repair Manual  

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