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Yale ERP15-20VT, Service Manual, Page: 3 / 32

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Transaxle

Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................

1

Discharging the Capacitors .............................................................................................................................

2

Special Tools ...................................................................................................................................................

2

Transaxle Assembly.............................................................................................................................................

3

Remove Transaxle From Frame ......................................................................................................................

3

Remove the Parking Brake and Traction Motor...............................................................................................

4

Install Parking Brake and Traction Motor.........................................................................................................

4

Install Transaxle to Frame ...............................................................................................................................

5

Maintenance and Repair .....................................................................................................................................

6

Speed Sensor Repair......................................................................................................................................

6

Trunnion Cap Repair .......................................................................................................................................

6

Fluid Level Check............................................................................................................................................

8

Fluid Change...................................................................................................................................................

8

Breather Repair...............................................................................................................................................

9

Stud Repair .....................................................................................................................................................

10

Brake Cylinder Repair .....................................................................................................................................

11

Input Seal Repair ............................................................................................................................................

13

Cover to Housing Seal ....................................................................................................................................

13

During the Transaxle Warranty Period ........................................................................................................

13

After the Transaxle Warranty Period ...........................................................................................................

14

Removing the Cover ...............................................................................................................................

14

Installing the Cover .................................................................................................................................

15

Wet Brakes......................................................................................................................................................

16

This section is for the following models:

ERP15-20VT (ERP030-040VT) [G807];

ERP16-20VF (ERP30-40VF) [A955]

©2012 Yale Materials Handling Corp.

i

Summary of Contents for ERP15-20VT

Page 1: ...524319496 2100 YRM 1382 03 14 WIRE HARNESS REPAIR 524223769 2200 YRM 1128 12 14 USER INTERFACE SUPERVISOR 524319497 2200 YRM 1335 09 14 USER INTERFACE SERVICE TECHNICIAN 524319498 2200 YRM 1336 09 14 ELECTRICAL SYSTEM 524320282 2200 YRM 1337 09 14 INDUSTRIAL BATTERY 524158040 2240 YRM 0001 09 14 MAST REPAIR S N A270 A271 A272 524327054 4000 YRM 1386 02 14 MAST REPAIR S N C661 C662 C663 C665 524333...

Page 2: ...ecifications 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 ...

Page 3: ...tenance and Repair 6 Speed Sensor Repair 6 Trunnion Cap Repair 6 Fluid Level Check 8 Fluid Change 8 Breather Repair 9 Stud Repair 10 Brake Cylinder Repair 11 Input Seal Repair 13 Cover to Housing Seal 13 During the Transaxle Warranty Period 13 After the Transaxle Warranty Period 14 Removing the Cover 14 Installing the Cover 15 Wet Brakes 16 This section is for the following models ERP15 20VT ERP03...

Page 4: ...on instructions for the transaxle assem blies used on these models WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so Improper repairs and adjustments can create dan gerous operating conditions DO NOT operate a lift truck that needs repairs Report the need for repairs to your supervisor immediately If repair is neces sary attach a DO NOT OPERAT...

Page 5: ...about 10 seconds after the battery is disconnected To prevent an electrical shock and personal injury discharge the capacitor s before inspecting or repairing any component in the drive unit compartment Make certain that the battery has been disconnected DO NOT short across the motor controller terminals with a screwdriver or jumper wire Make certain the Emergency Disconnect Switch has not been ac...

Page 6: ...king brake connector from main wiring harness 7 Disconnect manual override cable from parking brakes 8 Tag and disconnect power cables from traction mo tor studs 9 Disconnect traction motor temperature sensor at traction motor 10 Disconnect service brake line from port on transaxle Cap brake line and plug port on transaxle to reduce the possibility of contamination entering brake system 11 Loosen ...

Page 7: ...dequate capacity to eyebolt b Remove four capscrews and washers mounting traction motor to transaxle c Lift traction motor from transaxle using over head lifting device INSTALL PARKING BRAKE AND TRACTION MOTOR WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation When using cleaning solvents always follow the solvent manufacturer s recommended safety procedures WARNING...

Page 8: ...lled in transaxle housing and are in good condition Replace as necessary WARNING The transaxle and traction motor assembly are heavy Be sure that all lifting devices are suitable and of adequate capacity to lift the transaxle and traction motor 2 Move transaxle assembly onto a floor jack using an appropriate sling and lifting device Make sure assembly is balanced and properly supported so it will ...

Page 9: ...rmation to the controller The speed sensor can be replaced with the transaxle installed to the lift truck 1 Park lift truck on a level surface Turn key switch to OFF position and unplug battery connector 2 Discharge capacitors See section Discharging the Capacitors 3 Remove floor mat and floor plates from operator compartment to access top of transaxle s 4 Disconnect sensor wiring harness from mai...

Page 10: ...s Tighten capscrews to 24 N m 216 lbf in 6 Grease fitting in mast stub shaft to lubricate trun nion cap 7 Connect battery turn key to ON position and test lift truck for proper operation 1 CAPSCREW 2 SPEED SENSOR 3 FILL PLUG 4 TRANSAXLE COVER 5 COVER CAPSCREWS 6 DRAIN PLUG Figure 5 Speed Sensor 1 CAPSCREWS 2 TRUNNION CAP 3 THREADED MOUNTING HOLES 4 TRANSAXLE HOUSING Figure 6 Trunnion Cap 7 ...

Page 11: ...g and add fluid through fill hole until level with bottom of check hole Each transaxle holds approximately 0 60 liter 0 63 qt of transmission fluid NOTE New sealing rings must be installed with the drain fill and check plugs 4 Replace check plug and fill plug if removed and tighten to 22 N m 192 lbf in See Figure 7 5 Reinstall drive tire and tighten lugs to 170 N m 125 lbf ft Remove truck from blo...

Page 12: ...Use only an approved magnetic type drain plug to prevent damage to the transaxle NOTE It may take as long as 10 minutes for the transaxle to drain completely depending on temper ature and contaminants Allow the transaxle to drain completely before continuing 7 After transaxle has drained completely install drain plug into transaxle as removed Tighten to 22 N m 192 lbf in Remove drip pan and dispos...

Page 13: ...ather 7 Reinstall drive tire and tighten lugs to 170 N m 125 lbf ft Remove truck from blocks STUD REPAIR Stud repair can be performed with the transaxle in stalled to the lift truck or removed 1 Remove drive tire and block lift truck frame to po sition transaxle at the same height and position as with drive tire installed See Periodic Maintenance 8000 YRM 1339 for lift truck models ERP15 20VT ERP0...

Page 14: ...tment actuates the master cylinder sending pressurized fluid to the brake pistons in the transaxles through the ser vice brake lines 1 Remove transaxle from lift truck Remove parking brake and traction motor from transaxle See sec tion Remove Transaxle From Frame 2 Drain oil from transaxle 3 Remove snap ring in brake cylinder See Figure 14 1 CYLINDRICAL PIN 2 PISTON SEAL 3 PISTON 4 SPRING 5 O RING...

Page 15: ...on and new seal are oriented as noted when removed 11 Lightly lubricate new piston seal with multipurpose grease and install in new brake piston as noted dur ing removal See Figure 16 1 SNAP RING 2 CAP 3 O RING 4 PISTON 5 SEAL 6 SPRING Figure 16 Piston Seal Orientation 12 Install new brake piston and seal into brake cylin der 13 Place spring into cavity in piston by hand 14 Lightly lubricate new O...

Page 16: ...to allow seal to seat properly on motor shaft It is not necessary to lubricate traction motor shaft Install traction motor on transaxle 8 Install brake on traction motor Install transaxle on lift truck See section Install Transaxle to Frame COVER TO HOUSING SEAL CAUTION DO NOT remove the cover from the transaxle hous ing during the warranty period Removing the cover from the housing will void the ...

Page 17: ...s down Securely support the transaxle in a stable position during these procedures 1 Remove the transaxle from the lift truck and remove the parking brake and traction motor See section Remove Transaxle From Frame 2 Drain fluid from transaxle 3 Remove ten socket head capscrews holding cover on housing See Figure 18 NOTE The cover is aligned to the housing with internal components of the transaxle ...

Page 18: ...Flange NOTE The cover is aligned to the housing with internal components of the transaxle Carefully align the cover to the housing and lower equally on every side until it is mated Dowel pins inside the housing must be aligned with the cover during installation 3 Position cover on transaxle and slowly lower into position Turn assembly while beginning to lower to ensure that internal components sea...

Page 19: ...le See sec tion Remove Transaxle From Frame 2 Drain fluid from transaxle 3 Remove cover from transaxle Refer to section Re moving the Cover CAUTION Always replace the full set of inner and outer splined brake discs NOTE Make note of the orientation of the brake discs during removal 4 Remove 4 brake discs outer spline and 3 brake discs inner spline from transaxle by hand Re move pressure plate from...

Page 20: ... 60 liter 0 63 qt of transmission fluid b Fill transaxle until fluid begins to emerge from check hole c Install check and fill plugs with new sealing rings and tighten to 22 N m 192 lbf in 15 Connect battery connectors turn key switch to ON position and test lift truck for proper operation 1 PRESSURE PLATE 2 BRAKE DISC OUTER SPLINED 3 BRAKE DISC INNER SPLINED 4 PLUG 5 SEALING RING 6 SCREW 7 INPUT ...

Page 21: ..._________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ _____________________________________________________...

Page 22: ... with a screwdriver or jumper wire Make certain the Emergency Disconnect Switch has not been activated This will isolate the con troller and prevent the capacitors from discharging properly The proper way to disconnect the battery is by separating the battery connectors 1 Ensure the capacitors are discharged by perform ing Step 2 through Step 5 below 2 Turn the key or keyless switch to the OFF pos...

Page 23: ...r if necessary See Master Cylinder Repair in this section 2 Remove brake pedal a Remove the return spring See Figure 4 b Pull the cotter pin and remove clevis pin and washer from the clevis if the master cylinder has not been removed Discard the cotter pin c Remove nut then slide bolt from assembly See Figure 3 and Figure 4 d Lift pedal from assembly Recover washer and sleeve from pedal See Figure...

Page 24: ...ssembly in position and align the bracket with the mounting holes in the frame 2 Install three capscrews and nuts securing bracket to frame 3 Connect transducer and fluid sensor wiring as re moved 4 Connect the main pressure line to the elbow fitting on top of the master cylinder 5 Bleed air from the brake system See Master Cylin der Repair Bleed the Brake System in this section 6 Adjust the brake...

Page 25: ...om the clevis pin and remove the clevis pin and washer connecting the clevis to the pedal Discard the cotter pin 6 Remove capscrews and nuts securing master cylin der to bracket 7 Remove master cylinder from bracket See Fig ure 7 DISASSEMBLE 1 Remove master cylinder assembly from the truck See Remove 2 Remove the brake switch by unscrewing it from the cylinder housing See Figure 8 3 Remove the elb...

Page 26: ...YLINDER HOUSING 2 PISTON ASSEMBLY 3 CUP 4 PISTON 5 SPACER 6 CUP 7 RETAINER 8 SPRING 9 RETAINING RING 10 BOOT 11 PUSH ROD 12 NUT 13 CLEVIS PIN 14 CLEVIS 15 WASHER 16 COTTER PIN 17 CLAMP 18 RESERVOIR 19 GASKET 20 CAP Figure 9 Master Cylinder 6 ...

Page 27: ...Dexron III to ease in installation 7 Install the push rod through the hole in the boot into the cylinder housing 8 Install master cylinder assembly to the truck See Install INSTALL CAUTION The brake system uses Dexron III same as used in the transaxle Use of other fluids can damage the brake system 1 Position master cylinder to bracket and align mount ing holes 2 Install capscrews and nuts securin...

Page 28: ... Check the oil level in the master cylinder every cycle and fill reservoir as necessary 7 Perform Step 2 through Step 5 on the other transaxle until all air has been bled from the sys tem Adjust Linkage To adjust the master cylinder linkage 1 Check that the pedal is adjusted properly before ad justing the master cylinder linkage Refer to Brake Pedal Assembly Repair section for procedures 2 Loosen ...

Page 29: ...r the front of the frame They con tinue from there as separate left hand LH and right hand RH lines through the frame to a fitting on each transaxle The drive wheel may be removed to access this connection See Figure 11 BRAKE LINE REPLACEMENT 1 Clean around the component s to be replaced to reduce the risk of contaminating the brake system CAUTION Disposal of fluids must meet local environmental r...

Page 30: ...the parking brake actuators when the manual release lever is UP 1 Check the adjustment of the manual release lever by placing the lever in the UP position and checking the tension on the parking brake actuators See Figure 12 2 If the parking brake actuators have more than 2 to 4 mm 0 08 to 0 16 in of free travel available adjust the nuts to tighten the cable and check free travel again 3 If the pa...

Page 31: ...tor shaft Re cover the Woodruff key INSTALL 1 Install the Woodruff key to the motor shaft See Figure 13 2 Install the hub onto the motor shaft with key groove aligned with the Woodruff key in the motor shaft 3 Install the snap ring into the groove in the motor shaft to secure hub in place 4 Position the brake assembly onto the hub and se cure to the motor housing using four capscrews lockwashers a...

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