PDF Service Manual Yale A908 (ERC040-65GH) Forklift - 7 MB
This is the complete factory service manual for the Yale A908 forklift, also known as the ERC040-65GH series.
It contains detailed repair and maintenance procedures for every system on the truck, from the mast and hydraulics to the electrical system.
Professional technicians rely on this manual for accurate diagnostics, adjustments, and repairs.
Ensure your Yale forklift operates safely and efficiently with this essential guide.
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--- Page 1 ---
Maintenance
METRIC AND INCH
(SAE) FASTENERS
PART NO. 524150797 8000 YRM 0231
--- Page 3 ---
General 8000 YRM 0231
Table 3. Torque Nuts
6
--- Page 4 ---
Maintenance
METRIC AND INCH (SAE)
FASTENERS
PART NO. 524150797 8000 YRM 0231
--- Page 5 ---
General 8000 YRM 0231
FASTENER TORQUE TABLES
Table 5. Torque Values for Metric Fasteners*
Property Class 5.81 Grade 8.82 Grade 10.93
Size and Pitch
N•m lbf ft N•m lbf ft N•m lbf ft
M3 × 0.5 M3.5 × 0.6 M4 × 0.62 0.97 0.5 0.7 1.1 0.99 1.55 0.7 1.1 2.1 1.34 2.11 1.0 1.6 2.3
0.7 M5 × 0.8 M6 × 1 1.44 2.91 2.1 3.6 2.30 4.65 3.6 6 3.13 6.33 4.7 8
4.94 7.90 10.8
M8 × 1.25 M8 × 1 M10 × 12.0 12.8 9 9 18 19 19.2 20.5 14 15 28 30 26.1 27.9 19 21 38 41
1.5 M10 × 1.25 23.8 25.1 38.0 40.1 52 55
M12 × 1.75 M12 × 1.25 41.4 45.3 31 33 49 53 66 72 105 49 53 77 85 90 98 145 66 72 105
M14 × 2 M14 × 1.5 66 72 115 155 115
M16 × 2 M16 × 1.5 M20 × 105 110 200 77 81 150 165 175 122 130 225 240 165 175
2.5 M20 × 1.5 225 165 320 355 235 260 435 485 320 360
M24 × 3 M24 × 2 M27 × 3 345 375 255 275 555 605 410 445 755 820 560 605
M27 × 2 505 550 370 405 810 875 600 645 1,100 1,190 810 880
M30 × 3.5 M30 × 3 M30 × 690 715 510 530 1,100 1,140 810 840 1,500 1,550 1,100 1,140
2 M33 × 3.5 M33 × 2 765 940 565 695 1,220 1,500 900 1,100 1,660 2,040 1,230 1,510
1,030 760 1,640 1,210 2,240 1,660
M36 × 4 M36 × 3 M39 × 4 1,200 1,280 885 945 1,930 2,040 1,430 1,510 2,620 2,780 1,940 2,050
M39 × 3 1,560 1,640 1,150 1,210 2,490 2,630 1,840 1,940 3,390 3,570 2,500 2,640
M42 × 4.5 M42 × 3 M45 × 1,930 2,070 1,430 1,530 3,080 3,320 2,280 2,450 4,200 4,510 3,100 3,330
4.5 M45 × 3 M48 × 5 M48 2,410 2,580 1,780 1,910 3,850 4,120 2,840 3,040 5,240 5,610 3,870 4,140
×3 2,900 3,160 2,140 2,330 4,630 5,040 3,420 3,720 6,300 6,860 4,650 5,060
* Unless otherwise specified 1 Approximately equal to Grade 2 2 Approximately equal to Grade 5 3
Approximately equal to Grade 8
8
--- Page 6 ---
Table of Contents
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Brush and Commutator Inspection ........................................................................................................................... 2
Hydraulic Pump Motor and Traction Motor ...........................................................................................................2
Steering Pump Motor ............................................................................................................................................5
Normal Commutator Surface ................................................................................................................................5
Commutator Problems ..........................................................................................................................................5
Brush Replacement ................................................................................................................................................ 10
Stoning the Commutator .........................................................................................................................................13
Motors Repair ......................................................................................................................................................... 15
Disassemble ....................................................................................................................................................... 15
Traction Motor and Hydraulic Pump Motor .................................................................................................... 15
Steering Pump Motor ..................................................................................................................................... 16
Assemble ............................................................................................................................................................20
Traction Motor and Hydraulic Pump Motor .................................................................................................... 20
Steering Pump Motor ..................................................................................................................................... 22
Brush Alignment, Traction and Hydraulic Motors ................................................................................................... 25
Tests for Damaged Field and Armature ..................................................................................................................25
Test for an Open Circuit in One Armature Winding ............................................................................................ 25
Test for Short Circuit in One Armature Winding ................................................................................................. 25
Test for Short Circuit to Armature Shaft ............................................................................................................. 26
Test for Open Circuit in Field Coil .......................................................................................................................26
Test for Short Circuit in Field Coil .......................................................................................................................27
Test for Short Circuit Between Field and Motor Case ........................................................................................ 27
Brush Holder Test ...............................................................................................................................................27
Troubleshooting ...................................................................................................................................................... 28
This section is for the following models:
©2016 Yale Materials Handling Corp. i
--- Page 7 ---
Brush Replacement 0620 YRM 0294
Brush Replacement
1. Motor brushes must be replaced before they are The lead wire for some brushes is installed directly
worn enough to damage the surface of the com- into the carbon compound of the brush. New
mutator. Move the brush spring and remove a brushes must be installed before the lead wire cuts
brush from its brush holder. Install new brushes a groove in the commutator. Install a new brush set
as a set if length of any brush is worn to a mini- when a brush is worn to a short length.
mum length. See Table 3. If the brush lead is fas-
tened to the brush with a rivet, install a new set of Brushes are made to different specifications for
brushes if it is worn to within 3 mm (0.118 in.) of motors used in different applications. Use only new
the rivet. If a brush does not move easily in its brushes approved by Yale Company for that motor.
holder, a new set of brushes must be installed.
Table 3. Brush Wear Replacement Guide
17 mm 22 mm 28 mm 30 mm 31 mm 32 mm 40 mm
Brush Height
(0.67 in.) (0.87 in.) (1.10 in.) (1.18 in.) (1.22 in.) (1.26 in.) (1.57 in.)
8 mm 12 mm 14 mm 15 mm 16 mm 16 mm 16 mm
Wear
(0.31 in.) (0.47 in.) (0.55 in.) (0.59 in.) (0.63 in.) (0.63 in.) (0.63 in.)
9 mm 10 mm 14 mm 15 mm 15 mm 16 mm 20 mm
Worn Brush Height
(0.35 in.) (0.39 in.) (0.55 in.) (0.59 in.) (0.59 in.) (0.63 in.) (0.79 in.)
NOTE: For some models of lift trucks, the battery 3. Remove access plate to motors. Remove brush
does not need to be removed to access the electric covers to motor. See Figure 2. Wear eye protec-
motors. Other models will require the removal of the tion. Use a vacuum cleaner or compressed air to
battery before gaining access to the electric motors. remove dirt and brush dust from commutator
area.
2. Remove battery as necessary for your lift truck.
See How To Remove Battery in the Operating 4. Make a note of the arrangement and connections
Manual or the YRM section Periodic Mainte- of the brush assembly. See Figure 4. The new
nance for your lift truck. brushes must be installed in the same positions
from which the worn brushes were removed.
WARNING 5. Loosen screw that fastens brush wire to its termi-
Compressed air can move particles so they cause nal. Remove brush springs and brushes.
injury to the user or to other personnel. Verify the
path of the compressed air is away from all per- 6. Inspect brush holders for burns and damage.
sonnel. Wear protective goggles of a face shield Make sure brush holders are fastened tightly to
to prevent injury to the eyes. 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.
10
--- Page 8 ---
0620 YRM 0294 Motors Repair
1. BRUSH COVER 9. BEARING
2. COMMUTATOR END FRAME 10. ARMATURE
3. TERMINAL 11. FAN
4. BRUSH 12. BEARING
5. BRUSH HOLDER 13. DRIVE END FRAME
6. BRUSH SPRING (8) 14. FAN COVER
7. BUSH CONNECTOR (2) 15. WOODRUFF KEY
8. FIELD COILS 16. FIELD FRAME
Figure 11. Typical Hydraulic Pump Motor (Example 1)
21
--- Page 9 ---
0620 YRM 0294 9/16 (3/08)(6/15)(3/06)(8/03)
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2240 YRM 0001 Battery Selection
Battery Selection
NOTE: The capacity of the battery can be found on
the lift truck's Nameplate. See the Frame section or
Operating Manual for your lift truck for the location of
the Nameplate.
The battery needed to operate a period of 8 hours
depends on many conditions. Operations that require
the lift truck to go up ramps or require the use of
additional attachments increase the use of power from
the battery. Some work conditions require that more
than one battery must be used during a work period.
The number of 8-hour work periods per day is normally
equal to the number of batteries needed. For example,
for three work periods, you need three batteries. The
capacity of the battery you need is found as follows:
• The size of the lift truck and the attachments.
• The type of work. Heavy-duty operation or
normal operation for one 8-hour work period.
Lift trucks are available in various voltage ranges. See
Figure 8. The small "walkie" lift trucks are normally 12
or 24 volts. The larger sit-down rider lift trucks are
normally 24, 36, 48, 72, or 80 volts. The number of
cells in a lead-acid battery gives the battery voltage.
See Figure 9. A fully charged cell has a potential
difference of approximately 2 volts. See Figure 8. This
potential difference does not change with size of the Figure 8. Cell Voltage
cell.
Figure 9. Multicell Battery for Electric Lift Truck
5
--- Page 11 ---
Battery Maintenance 2240 YRM 0001
• Install a NO SMOKING sign in the service area BATTERY CARE
• Keep the charger in a clean, dry area with good 1. Keep batteries clean. Remove any spilled
ventilation
electrolyte.
BATTERY CONNECTORS 2. DO NOT overcharge the battery. This action will
A special heavy-duty connector is used to connect the damage the battery.
battery to the electrical system of the lift truck. See
Figure 22 and Figure 23. When a connector has a 3. DO NOT discharge the battery to less than the
handle and is within the operator's reach, the recommendation. A deep discharge will shorten
connector is also a safety device that can be used to the battery life.
quickly disconnect the battery in an emergency. Most
connectors have a handle to connect the two halves of 4. Charge batteries in an area with good ventilation
the connector. The connector can be quickly to remove explosive gases and acid fumes.
disconnected by pulling the handle upward. This action
5. Keep the electrolyte at the correct level. Check
separates the two halves of the connector. The
the electrolyte level before and after charging the
connector and its attached handle must be kept in
battery. Use distilled water. Do not add acid.
good repair so that it will function correctly. The battery
connector must be disconnected when maintenance is
6. Prevent batteries from freezing.
done on the lift truck that does not require electric
power. The SBE, SBX, and FEM or DIN 12- volt 7. Keep batteries charged. A discharged battery in
battery connectors are shown in Figure 23. storage will shorten the battery life.
8. Use a battery charger that is correct for the
battery. A battery charger that is set for an
ampere-hour rate that is too high will cause a high
internal heat and damage the battery. A low
ampere-hour rate setting on a battery charger can
require a longer charging time but will not
damage the battery.
9. When batteries are moved, make sure a short
circuit does not occur. See the Safety Procedures
in Battery Maintenance of this section.
1. SB CONNECTOR FOR BATTERY CABLES
2. SB CONNECTOR FOR POWER CABLES TO
LIFT TRUCK
3. BRACKET
4. CONNECT AND DISCONNECT HANDLES
Figure 22. SB Battery Connector
16
--- Page 12 ---
2240 YRM 0001 General
General
This section describes how to select and do the batteries have a nameplate attached to the face of the
maintenance for large batteries used in electric lift battery cover. This nameplate communicates specific
trucks. This information is for service personnel that information about the battery including the name of the
must do the maintenance on large lead-acid batteries. battery manufacturer, battery type, serial number,
Battery repair requires special training and equipment. nominal voltage, capacity in amperes at the five-hour
Do not try to repair a battery unless you have the rate, and service mass (with ballast if used to
correct tools, equipment, and experience. Most battery compensate for lack of battery mass).
repairs are done by a special repair service. Some
Battery Type
LEAD-ACID BATTERIES
A lead-acid battery converts chemical energy into
electrical energy. See Figure 1. Chemical changes
within the battery give the electrical energy. When the
chemical reaction has occurred so the battery will not
give its rated voltage and current, the battery is
discharged. A reverse chemical action must occur so
the battery can be used again. The batteries described
in this section can be charged again by an electric
voltage and current from an outside source so there is
a reverse chemical action. The lead-acid chemicals
store the electric energy until the electric energy is
needed to operate an electric device.
1. VENT AND FILL 5. POSITIVE PLATE
Figure 1. Lead-Acid Industrial Battery CAP 6. EXPANSION MATS
2. POST 7. RETAINER
A lead-acid battery is made from several lead-acid 3. POST SEAL 8. SEPARATOR
4. PLATE 9. NEGATIVE PLATE
batteries called cells. Each cell has positive and PROTECTOR 10. BATTERY JAR
negative plates with dielectric spacers between each (SHIELD)
plate. All of the plates are within a solution of
electrolyte. See Figure 2. Figure 2. Battery Cell
1
--- Page 13 ---
Battery Maintenance 2240 YRM 0001
If the lift truck has been operated with a low
battery, check the contactors for welded contacts
before a charged battery is connected. The circuit
will not reset and lift truck operation cannot be
controlled if the contacts are welded. To check the
contacts, see the Contactor inspection procedure
for your lift truck.
CAUTION
Use only battery chargers approved by the battery
manufacturer or dealer.
CAUTION
NEVER connect the battery charger plug to the
plug of the lift truck. You can damage the traction
Figure 16. Battery Thermometer control circuit. Make sure the charger voltage is
the correct voltage for the battery.
CHARGING BATTERY
NOTE: There can be one of two types of batteries. Correct use of the hydrometer (see Figure 14) and
One type has removable cell caps. The other type has proper operation of the battery charger is important.
sealed cells. The sealed batteries require a different Also see Figure 15. Follow the instructions of the
charger. The electrolyte level or specific gravity cannot charger manufacturer. NEVER let the battery
be checked, and water cannot be added to the discharge below the minimum value given by the
electrolyte of these sealed batteries. battery manufacturer. A fully charged battery will have
a specific gravity of 1.265 to 1.310 at 25°C (77°F). See
Figure 15. NEVER charge a battery at a rate that will
WARNING raise the electrolyte temperature above 49°C (120°F).
The acid in the electrolyte can cause injury. If Never let a battery stay discharged for long periods.
electrolyte is spilled, use water to flush the area.
Make the acid neutral with a solution of sodium Types of Battery Charges
bicarbonate. 1. NORMAL CHARGE. This charge is usually given
Batteries generate explosive fumes when they are to a battery that is discharged from normal
being charged. Keep fire, sparks, and burning operation. This is often an 8-hour charge. Many
material away from the battery charger area. customers charge the battery at regular intervals
Prevent sparks from the battery connectors. that depend on use. This procedure will keep the
battery correctly charged if the battery is not
Charge batteries only in the special area for
discharged below the limit. Always use a
charging batteries. When charging the batteries,
hydrometer to check the battery if the battery is
keep the vent caps clean. The battery charger area
charged at regular intervals. Frequent charging of
must have ventilation so that explosive fumes are
a battery that has a 2/3 or more charge can
removed. Open the hood over the battery or
decrease the life of the battery.
remove the cover if the battery has a cover.
Disconnect the battery when doing cleaning and
maintenance.
12
--- Page 14 ---
Maintenance
STEERING HOUSING
AND CONTROL UNIT
ERC20-30AGF (ERC040-065RG/ZG) [E108];
ERC/P16-20AAF (ERC030-040AG/BG) [A814];
ERP20-30ALF [B216];
GC/GLC030-040AF [B809];
GLP/GDP16-20AF
(GP/GLP/GDP030-040AF) [B810];
GP/GLP/GDP2.00-3.00RF/TF
(GP/GLP/GDP040-060RG/TG/ZG) [A875];
GC/GLC040-065RG/TG/ZG [E187];
ERP20-30ALF (ERP040-060DH) [D216];
ERP20-32ALF (ERP040-065DH) [E216];
ERC/P16-20AAF (ERC030-040AH) [B814];
ERC20-32AGF (ERC040-065GH) [A908];
ERC35-55HG (ERC70-120HH) [B839/C839]
PART NO. 524158753 1600 YRM 720
--- Page 15 ---
Steering Wheel and Column Assembly Repair 1600 YRM 720
11. Remove the tilt stop screw located at the bottom left 8. Remove the retaining ring from the spool assembly.
side of the steering column bracket.
9. Press the cross pin out of the spool assembly.
12. Remove the capscrews, lockwashers, and lock
plates that fasten the steering column to the pivots 10. Press the spool from the sleeve and remove the
on the lift truck. Remove the steering column from springs from the spool. Press the spool from the
the lift truck. Make sure the electric wires and the sleeve and remove the springs from the spool.
hydraulic hoses are not damaged as the steering
11. Remove the shaft seals from the pump housing.
column is removed.
Discard the seals.
13. Remove the four capscrews that hold the steering
column to the bracket. Remove the four capscrews STEERING CONTROL UNIT, CLEAN
or nuts that fasten the steering control unit to the
steering column. WARNING
Cleaning solvents can be flammable and toxic and
STEERING CONTROL UNIT, can cause skin irritation. When using cleaning
DISASSEMBLE solvents, always follow the solvent manufacturer’s
recommended safety precautions.
1. Place the steering pump into a soft jaw vise with the
splined shaft facing down.
WARNING
2. Remove the hydraulic fittings and the special Compressed air can move particles so that they
screws, and rotate the steering pump 90 degrees cause injury to the user or to other personnel.
sideways in the vise. Discard the O-rings. See Make sure that the path of the compressed air is
Figure 7. away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
3. Remove the end cover, spacer, gear housing, and
gear from the steering pump. Discard the O-rings. Clean all the parts in solvent. Dry the parts with com-
pressed air. Do not dry the parts with a cloth. Make sure
4. Remove the cardan shaft from the spool assembly.
all surfaces are free of scratches and sharp edges.
5. Remove the check ball, ball stop, and emergency
steering ball from the pump housing. STEERING CONTROL UNIT, ASSEMBLE
6. Remove the spool assembly from the pump hous- 1. Using a seal installer, install the shaft seals in the
ing. pump housing.
NOTE: To help with installation of the thrust bearing as- 2. Install the spool into the sleeve with the key slots
sembly, note the positions of the thrust washers on ei- opposite each other.
ther side of the thrust bearing while performing Step 7.
3. Insert the curved springs between the flat springs.
7. Remove the thrust bearing assembly from the shaft See Figure 7. Install the spring set into the spool
end of the spool assembly. assembly.
8
--- Page 16 ---
Mast Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Description and Operation................................................................................................................................... 1
Carriages......................................................................................................................................................... 1
Mast Mounts.................................................................................................................................................... 3
Two-Stage Mast, Limited Free-Lift (LFL) ............................................................................................................. 4
Description and Operation .............................................................................................................................. 4
Two-Stage Mast, Full Free-Lift (FFL) ................................................................................................................... 6
Description and Operation .............................................................................................................................. 6
Three-Stage Mast, Full Free-Lift (FFL) ................................................................................................................ 8
Description and Operation .............................................................................................................................. 8
Four-Stage Mast.................................................................................................................................................. 10
Description and Operation .............................................................................................................................. 10
Cylinder Cushion During Lifting Sequence.......................................................................................................... 14
Cylinder Cushion During Lowering Sequence..................................................................................................... 15
This section is for the following models:
GP/GLP/GDP16-20AF/BF (GP/GLP/GDP030-040AF/BF) [A810];
GC/GLC030-040AF [B809];
GLP/GDP16-20AF (GP/GLP/GDP030-040AF) [B810];
ERC/P16-20AAF (ERC030-040AF, ERC030-040AG/BG) [A814];
ERP20-30ALF [B216];
GC/GLC040-065RG/TG/ZG [E187];
ERC20/25/30AGF (ERC040-065RF/ZF, ERC040-065RG/ZG) [E108];
GP/GLP/GDP20-30RF/TF (GP/GLP/GDP040-060RG/TG/ZG) [A875];
ERP030-040TGN [E807];
ERP20-30ALF (ERP040-060DH) [D216];
ERP20-32ALF (ERP040-065DH) [E216];
ERC20-32AGF (ERC040-065GH) [A908];
ERC/P16-20AAF (ERC030-040AH) [B814/C814];
ERP1.60-1.80-2.0ATF (ERP030-040TH) [F807]
©2006 Yale Materials Handling Corp. i
--- Page 17 ---
Four-Stage Mast 4000 YRM 521
1. LIFT CYLINDER 7. INTERMEDIATE WELDMENT
2. FREE-LIFT CYLINDER 8. INNER WELDMENT
3. LOWERING CONTROL VALVE (INTERNAL) 9. MAIN LIFT CHAIN
4. LOWERING CONTROL VALVE (EXTERNAL) 10. CARRIAGE
5. TO/FROM MAIN CONTROL VALVE 11. FREE-LIFT CHAIN
6. OUTER WELDMENT
Figure 11. Operation of Three-Stage Mast, Full Free-Lift (FFL)
Four-Stage Mast
DESCRIPTION AND OPERATION rollers are installed at the top of the outer, inter#2, and
inter#3 masts. Load rollers are also used at the bottom
The full free-lift, four-stage mast has four mast uprights: of the inter#2, inter#3, and the inner mast. These load
outer, inter#2, inter#3, and inner. See Figure 12. Two rollers travel along the flanges of the masts. The angle
single-stage main lift cylinders and a free-lift cylinder of the load rollers permits them to control the forces