PDF Service Manual Yale A985 Series Forklift - 8 MB
This service manual is the complete guide for maintaining and repairing the Yale A985 series of electric forklifts, including models from ERP080VM to ERP120VM.
It contains detailed diagnostic procedures, repair instructions, and system schematics.
Technicians will find this manual invaluable for troubleshooting and servicing these advanced machines.
Keep your Yale forklift fleet running efficiently with this comprehensive factory resource.
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--- Page 1 ---
Maintenance
METRIC AND INCH
(SAE) FASTENERS
PART NO. 524150797 8000 YRM 0231
--- Page 3 ---
2240 YRM 0001 Chemical Reaction in a Cell
During the discharge of the cell, lead peroxide and
sponge lead mix with sulfuric acid to make lead sulfate
(PbSO4) on both plates. See Figure 4. This action
decreases the voltage in the cell. When the sulfuric
acid is removed from the electrolyte, the specific
gravity of the electrolyte decreases. See Figure 5. The
potential difference of a discharged cell is
approximately 1.75 volts.
When a direct current is applied to a discharged cell,
the lead sulfate is changed into lead and sulfuric acid.
The lead goes to the positive plate and stays as lead
and to the negative plate and stays as lead peroxide.
See Figure 6. The concentration of sulfuric acid in the
electrolyte increases. The specific gravity of the
electrolyte increases as the concentration of sulfuric
acid increases. In a fully charged cell, the positive
plate again contains the lead peroxide and the
negative plate contains the sponge lead.
Figure 5. Discharged Cell
Figure 4. Discharging Cell
Figure 6. Charging Cell
3
--- Page 4 ---
Table of Contents
TABLE OF CONTENTS
Series Code / Model Designation Reference Table................................................................................................ 1
General....................................................................................................................................................................3
Deutsch Crimping Tool............................................................................................................................................ 4
How to Strip a Wire for Use With Deutsch Crimping Tool.....................................................................................4
How to Crimp With the Deutsch Crimping Tool.....................................................................................................5
Calibration Test for the Deutsch Crimping Tool.....................................................................................................7
Deutsch Connectors................................................................................................................................................9
DT, DTM, and DTP Series Connectors.................................................................................................................9
Connector Receptacle Replacement............................................................................................................... 18
Connector Plug Replacement.......................................................................................................................... 26
Connector Receptacle Pin Replacement......................................................................................................... 34
Connector Plug Socket Replacement.............................................................................................................. 43
HD Series Connectors........................................................................................................................................52
Connector Receptacle Replacement............................................................................................................... 54
Connector Plug Replacement.......................................................................................................................... 58
Connector Receptacle Pin Replacement......................................................................................................... 61
Connector Plug Socket Replacement.............................................................................................................. 67
Sealing Plugs......................................................................................................................................................71
Metri-Pack Connectors..........................................................................................................................................74
Remove and Install.............................................................................................................................................74
Micro-Pack Connectors.........................................................................................................................................77
Weather-Pack Connectors.................................................................................................................................... 78
Weather-Pack Terminal Repair...........................................................................................................................78
AMPSEAL Crimping Tools.....................................................................................................................................80
AMP Hand Crimping Tool With Certi-Crimp........................................................................................................80
Description....................................................................................................................................................... 80
Stripping Wire for Use with AMP Hand Crimping Tool..................................................................................... 81
Insulation Crimp Adjustment............................................................................................................................ 82
Maintenance and Inspection for AMP Hand Crimping Tool............................................................................. 82
AMP Hand Crimping Tool.............................................................................................................................. 82
Crimp Height Inspection................................................................................................................................ 82
How to use AMP Hand Crimping Tool................................................................................................................ 83
AMP Pro-Crimper II Tool.....................................................................................................................................83
Description....................................................................................................................................................... 83
Remove and Install Die Set and Locator Assembly...................................................................................... 84
Stripping Wire for Use With AMP PRO-CRIMPER II Tool................................................................................84
Contact Support Adjustment............................................................................................................................ 85
Crimp Height Adjustment................................................................................................................................. 86
Maintenance and Inspection Procedures.........................................................................................................86
PRO-CRIMPER II Tool.................................................................................................................................. 86
Crimp Height Inspection................................................................................................................................ 86
How to Use AMP PRO-CRIMPER II Tool........................................................................................................... 87
AMPSEAL Connector Assemblies........................................................................................................................ 88
Description for Plug Connector Assembly.......................................................................................................... 88
Seal Plug..........................................................................................................................................................89
Contact Crimping............................................................................................................................................. 89
Contact Removal..............................................................................................................................................90
Contact Insertion..............................................................................................................................................91
Description for Plug Connector and Header Assembly...................................................................................... 94
Voltage Reading...............................................................................................................................................97
Seal Plug..........................................................................................................................................................97
Contact Crimping............................................................................................................................................. 97
©2023 Yale Materials Handling Corp. i
--- Page 5 ---
2200 YRM 1128 Deutsch Connectors
STEP 5.
If more than one socket is being removed, tag the
wire and mark it with the corresponding number
or letter on the back of the connector from which
the wire was removed.
STEP 6.
Using wire cutters, cut the wire behind the old
socket and discard old socket.
47
--- Page 6 ---
2200 YRM 1128 AMPSEAL Connector Assemblies
The wedge lock has slotted openings in the mating,
forward, end. The slots are for circuit test tabs
approximately 3.3 × 0.6 mm (0.13 × 0.02 in.), which
prevent damage to the receptacle. Circuit testing in the
field to be done by a flat probe, DO NOT use a sharp
point.
Voltage Reading
CAUTION
DO NOT pierce wire insulation to take voltage
readings.
When using AMPSEAL plug assembly DO NOT pierce
wire insulation with a sharp point. Pin holes in the
insulation allow moisture to invade the sealed
connector system nullifying effectiveness and resulting 1. PLUG CONNECTOR
in possible system failure. 2. SEAL PLUG
3. CIRCUIT CAVITY
Seal Plug
Figure 46. Seal Plug
All circuits are sealed by a diaphragm in the rubber
wire seal. This diaphragm is pierced when the contact
Contact Crimping
is pressed through it. Unused circuit cavities will
remain sealed unless perforated by accidental 1. Information on contact crimping can be found in
insertion and removal of contact in the wrong cavity. AMPSEAL Crimping Tools.
The seal plug is designed to keep out contaminants if
the diaphragm is accidentally pierced. NOTE: DO NOT cut contacts from "reel", use loose
contacts only.
1. Insert the seal plug, large end first, into the circuit
cavity as far as it will go. No insertion tool is 2. Crimped contacts to meet conditions shown in
required for this procedure. See Figure 46. Figure 47 and Table 7.
97
--- Page 7 ---
2200 YRM 1128 Wire Repair
STEP 4.
Using a heat gun, apply heat evenly, to
approximately 135°C (275°F), around the length
of the tubing (including the crimp area) from the
center out to the ends until the tubing fully
recovers and adhesive flows.
Continue distributing the heat over the solder
sleeve until solder flows into the terminal barrel.
Remove from the heat and let cool for ultimate
connection performance.
1. EXPOSED NOTCHES AFTER SOLDER BAND
MELTS
147
--- Page 8 ---
2200 YRM 1128 Deutsch Connectors
STEP 7.
Insert the wires into the back of the new
connector plug according to the number or letter
on the tag and connector plug. Push the wires
straight into the back of the plug until a click is
felt. Slightly tug each wire to verify the wire is
properly locked in place. Remove tags.
NOTE: Verify that the seal is in place on the connector plug before installing the secondary lock.
31
--- Page 9 ---
2200 YRM 1128 AMPSEAL Crimping Tools
Legend for Figure 31.
CAUTION
A. FRONT OF TOOL
B. BACK OF TOOL The crimping jaws bottom before the CERTI-
CRIMP ratchet releases. This is a design feature
1. UPPER INSERT that ensures maximum electrical and tensile
2. ANVIL performance of the crimp DO NOT readjust the
3. INSULATION CRIMP ADJUSTMENT LEVER ratchet.
4. CONTACT SUPPORT
5. LOCATOR The CERTI-CRIMP ratchet assures full crimping of the
6. CERTI-CRIMP RATCHET
7. STRIPPED WIRE contact. Once engaged, the ratchet will not release
until the handles have been fully closed.
The insulation adjust lever regulates the crimp height.
See Insulation Crimp Adjustment. Stripping Wire for Use with AMP Hand
The contact support prevents the contact from bending Crimping Tool
during crimping. 1. Choose the correct AWG for the contact being
The locator functions two ways: used.
• position the contact between the upper insert 2. See Table 2 for recommended strip length.
and the anvil before crimping
• limits the insertion distance of the stripped wire
into the contact.
The ejector pulls the locator down, and ejects the
crimped contact when the tool handles are fully
opened.
Table 2. Wire Size (AWG)
Wire Size Insulation Diameter Tool Wire Contact Wire Strip Length
(AWG) Range Size
Marking
16 1.7 to 2.7 mm (0.067 16 Yale P/N 520202601 5.5 mm (0.215 in.)
20 - 18 to 0.106 in.) 20 - 18 4.7 mm (0.185 in.)
CAUTION
DO NOT cut or nick the wire strands.
3. Strip wire to recommended strip length. A small
piece of insulation should come off the wire after
stripping. See Figure 32.
NOTE: SEE TABLE 2 FOR WIRE STRIP LENGTH.
1. STRIPPED WIRE
2. LOCATOR SLOT
Figure 32. Strip Length
81
--- Page 10 ---
2200 YRM 1128 AMP Fastin-Faston Hand Tools
MAINTENANCE AND INSPECTION
For proper operation, tool to conform to measurements
indicated in Figure 71. Inspections to be performed at
regular intervals, refer to manufacturers data for
specifics.
A. TOP VIEW B. SIDE VIEW
Figure 71. Tool Tip Inspection
Clean extraction tool with clean, soft, lint-free cloth and 3. Push wire from BACK of housing TOWARD tool
store in clean, dry place. and depress locking lance. See view C of
Figure 72.
HOW TO USE AMP EXTRACTION TOOL
4. Pull BACK on wire and remove receptacle from
It is necessary to depress locking lance of receptacle housing. See view D of Figure 72.
from its cavity inside connector housing. Procedure
below describes steps of extraction. 5. Remove extraction tool from housing.
1. Orient extraction tool tip with mating face of
connector. See view A of Figure 72.
2. Insert tip of extraction tool, aligned in center of
housing cavity where locking lance is located.
See view B of Figure 72.
131
--- Page 11 ---
2200 YRM 1128 Deutsch Connectors
A. DTM SECONDARY LOCK TYPE HA F. DTM SECONDARY LOCK TYPE HF
B. DTM SECONDARY LOCK TYPE HB G. DTM SECONDARY LOCK TYPE HG
C. DTM SECONDARY LOCK TYPE HC H. DTP SECONDARY LOCK TYPE HH
D. DTP SECONDARY LOCK TYPE HD I. DTM SECONDARY LOCK TYPE HJ
E. DTM SECONDARY LOCK TYPE HE
Figure 22. DTM and DTP Connector Plug Secondary Locks
17
--- Page 12 ---
2200 YRM 1128 Deutsch Connectors
Connector Plug Socket Replacement
STEP 1.
Separate the connector plug from the connector
receptacle.
NOTE: Be sure to use correct extraction tool; see Special Tools section of this manual.
STEP 2.
Insert a Deutsch extraction tool over the wire
being removed.
NOTE: Do not twist the tool or insert the tool at an angle.
67
--- Page 13 ---
2200 YRM 1128 AMP Superseal 1.5 Connector Assemblies
STEP 3.
Push the two lances for position 2 housing, the
central lance for positions 3 and 5 housing, and
the two central lances for positions 4 and 6
housing inward. Then push until the side arms
lock.
1. ANTI-BACK OUT DEVICE
STEP 4.
For position 1, manually or machine operated,
push the anti-backout device until its upper end is
the same level as the housing mating face.
1. ANTI-BACK OUT DEVICE
NOTE: Different jigs are needed for position 1 and 2 housings and position 3 to 6 housings.
STEP 5.
To close the anti-backout device for tab housings,
either manually or by machine, push the device in
with a jig until it meets the stop.
1. ANTI-BACK OUT DEVICE
Removal of Contacts
Since the locking lance of contacts can be reached from the mating side of the housings, it is necessary to
remove the anti-backout device first.
NOTE: Perform Step 1 and Step 2 for removal of receptacle contact.
117
--- Page 14 ---
0100 YRM 1342 General
1. FRONT OVERHEAD GUARD MOUNTING 6. LEFT FRAME CHANNEL
BRACKET 7. REAR BULKHEAD
2. REAR OVERHEAD GUARD MOUNTING 8. TILT ANCHOR PLATE
BRACKET 9. SIDE STEP MOUNTING BRACKET
3. COUNTERWEIGHT MOUNTING PLATE
4. FRONT BULKHEAD
5. RIGHT FRAME CHANNEL
Figure 7. Frame Weldment for Lift Trucks ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
The hydraulic and traction motor electronic controllers NOTE: Lift truck models ERC22-35VG
and contactors are located in the counterweight cavity (ERC045-070VG) (A968) manufactured after June,
for the following lift truck models 2012 are equipped with a removable floor plate that
ERC22-35VG (ERC045-070VG) (A968) requires no tools to remove.
•
• ERC16-20VA (ERC030-040VA) (A969) For all lift truck models covered in this Service
Manual, the Vehicle Systems Manager (VSM) is either
• ERC40-55VH, ERC50VHS (ERC80-120VH,
mounted on or near the front bulkhead underneath the
ERC100VHS) (A938)
floor mat and floor plate.
The hydraulic motor electronic controller and contactor
are located in the counterweight cavity and the traction
motor controller is attached to the front bulkhead for
the following lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
• ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
7
--- Page 15 ---
0100 YRM 1342 Hood and Seat Assembly Replacement
NOTE: 1015 mm (40 in.) HOOD SHOWN. OTHER SIZES SIMILAR.
NOTE: SEAT NOT SHOWN FOR CLARITY.
A. RELEASE DIRECTION C. BOTTOM VIEW
B. FRONT VIEW
1. HOOD LATCH ASSEMBLY 5. HOOD HINGE
2. HOOD 6. BATTERY STOPPER
3. HOOD RELEASE LEVER 7. HANDLE
4. GAS-CONTROLLED STRUT
Figure 42. Hood and Latch Assembly, Lift Truck Models Manufactured Prior to June, 2012ERC22-35VG
(ERC045-070VG) (A968)
57
--- Page 16 ---
Hood and Seat Assembly Replacement for Lift Truck Model ERP40-50VM, ERP50-55VM6
0100 YRM 1342 (ERP080-120VM, ERP100VML) (A985)
12. Remove locking clip from gas-controlled strut 3. Open and close hood to check for proper
front end. Remove gas-controlled strut front end clearance. See section Opening and Closing the
from ball stud and hood hinge arm. See Hood for procedures.
Figure 74.
4. Install counterweight cover. See section
13. Remove locking clip from gas-controlled strut Counterweight Replacement for Lift Truck Models
back end. Remove gas-controlled strut back end ERP22-35VL (ERP045-070VL) (A976) and
from ball stud and hood hinge. See Figure 74. ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985) for procedures.
14. Repeat Step 12 and Step 13 for opposite gas-
controlled strut. 5. Raise hood. Install gas-controlled strut back end
onto ball stud on hood hinge. Install locking clip
15. Close hood. See the section Opening and Closing on gas-controlled strut back end and ball stud.
the Hood for procedures. See Figure 74.
16. Remove counterweight cover. See the section 6. Install gas-controlled strut front end onto ball stud
Counterweight Replacement for Lift Truck Models on hood hinge arm. Install locking clip on gas-
ERP22-35VL (ERP045-070VL) (A976) and controlled strut front end and ball stud. See
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, Figure 74.
ERP100VML) (A985) for procedures.
7. Repeat Step 5 and Step 6 for opposite gas-
NOTE: Note placement of washers prior to removal to controlled strut.
aid in installation.
8. If seat rails were removed from seat assembly,
17. Remove nuts, shoulder bolts, washers, and plates
hold ride position indicator in the open position
from hood hinges and hood hinge arms. See
and slide seat onto seat rails. Install stop screws.
Figure 74.
See Electrical System 2200YRM1369 for
18. On left hood hinge, remove washers and snap procedures.
ring from bottom of link plate. Remove bottom of
9. If seat assembly has been removed from hood,
link plate from pin. See Figure 74.
position seat onto hood and install capscrews and
19. Using a lifting device, remove hood from lift truck washers into hood and seat rails. See Figure 70.
frame.
NOTE: Remove tags as electrical connections are
made.
INSTALL
10. Connect operator presence system connector to
1. Using a lifting device, position hood onto hinges
main wire harness. See Figure 70.
and install washers, shoulder bolts, nuts, and
plates as noted during removal. See Figure 74. 11. Install hood and latch switches and emergency
Tighten nuts. battery disconnect switch, if removed, and adjust
Nuts must be fully engaged with shoulder bolt as necessary. See Electrical System
and hood hinge arm assembly must be free to 2200YRM1369 for procedures.
move.
Add or subtract washers, if necessary, to allow 12. Connect electrical wires, as tagged during
hood hinge arm assembly to move freely when removal, to emergency battery disconnect and
opening and closing hood. hood and latch position switches. See Electrical
System 2200YRM1369 for procedures.
2. On left side of hood hinge, install washer and
bottom of link plate to pin. Install other washer 13. If equipped, connect electrical connector for E-
and snap ring to secure bottom of link plate to pin. Hydraulic controller. See Electrical System
See Figure 74. 2200YRM1369 for procedures.
107
--- Page 17 ---
0100 YRM 1342 Hydraulic Tank Inspection
1. FILL CAP 1. FILL CAP
2. FILTER HOUSING 2. FILTER HOUSING
3. DIPSTICK 3. DIPSTICK
4. BREATHER FILTER 4. BREATHER FILTER
5. OPTIONAL LEVEL SENSOR 5. LEVEL SENSOR
6. OPTIONAL FILTER PRESSURE SWITCH 6. PRESSURE SWITCH
7. TEMPERATURE SENSOR 7. TEMPERATURE SENSOR
8. SUCTION STRAINER W/O-RING 8. SUCTION STRAINER W/ O-RING
9. MAGNETIC PLUG W/O-RING 9. DRAIN VALVE
10. HYDRAULIC TANK 10. HYDRAULIC TANK
Figure 110. Nylon Hydraulic Tank for Lift Truck Figure 111. Hydraulic Tank for Lift Truck
ERC22-35VG (ERC045-070VG) (A968) ERP22-35VL (ERP045-070VL) (A976)
157
--- Page 18 ---
0100 YRM 1342 Covers and Floor Plates
A. MANUAL HYDRAULIC CONTROL LEVERS B. E-HYDRAULIC CONTROL LEVERS
1. CAPTIVE CAPSCREW* 7. FRAME
2. COUNTERWEIGHT COVER 8. MANUAL HYDRAULIC COVERS
3. COUNTERWEIGHT 9. COWL
4. MANUAL HYDRAULIC FLOOR MAT 10. E-HYDRAULIC FLOOR MAT
5. MANUAL HYDRAULIC FLOOR PLATE 11. E-HYDRAULIC FLOOR PLATE
6. MANUAL HYDRAULIC FLOOR PLATE 12. E-HYDRAULIC FLOOR PLATE
*Capscrew after May, 2019
Figure 18. Covers and Floor Plates for Lift Truck Models Equipped With Side Battery Removal Option
ERP40-55VM (ERP080-120VM ) (A985)
19
--- Page 19 ---
0100 YRM 1342 Hood and Seat Assembly Replacement
Figure 56. Seat Assembly, Lift Trucks Manufactured After June, 2012
69
--- Page 20 ---
Counterweight Replacement for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)
0100 YRM 1342 and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
Table 4. Counterweights for Lift Truck Manufactured Prior to June 2016 ERP22-35VL (ERP045-070VL)
(A976)
Model (mm*) Weight + 50 kg (110 lb) - 0 kg
(0 lb)
ERP22-25VL (ERP045-050VL) 717 725 kg (1598 lb)
ERP30VL (ERP060VL) 861 801 kg (1766 lb)
ERP35VL (ERP070VL) 861 1116 kg (2460 lb)
*Approximate battery compartment lengths.
Table 5. Counterweights for Lift Truck Manufactured After June 2016 ERP22-35VL (ERP045-070VL) (A976)
Model (mm*) Weight + 50 kg (110 lb) - 0 kg
(0 lb)
ERP22-25VL (ERP045-050VL) 717 736 kg (1623 lb)
ERP30VL (ERP060VL) 861 812 kg (1790 lb)
ERP35VL (ERP070VL) 861 1126 kg (2482 lb)
*Approximate battery compartment lengths.
Table 6. Counterweights for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
Model (mm*) Weight + 50 kg (110 lb) - 0 kg
(0 lb)
ERP40-45VM (ERP080-090VM) 859 1453 kg (3203 lb)
ERP40-50VM, 1006
ERP50-55VM6 (ERP080-120VM, 2621 kg (5778 lb)
ERP100VML)
*Approximate battery compartment lengths.
The counterweight normally is not removed for most • ERP22-35VL (ERP045-070VL) (A976)
repairs. Replacement of controller and hydraulic manufactured after November, 2015
components is easier with counterweight installed. The See Figure 88 for lift truck model
counterweight is fastened to rear bulkhead with
mounting bolts. • ERP22-35VL (ERP045-070VL) (A976)
manufactured after June, 2016
See Figure 85 for lift truck models
See Figure 89 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
manufactured prior to June, 2012 • ERP40-50VM (ERP080-100VM) (A985)
manufactured before Nov, 2014
See Figure 86 for lift truck models
See Figure 90 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
manufactured after June, 2012 • ERP40-50VM, ERP50-55VM6