PDF Workshop Manual Yale ERC ERP 15 18 18X TCE - 2 MB
This workshop manual is the complete service and repair guide for Yale ERC/ERP 15, 18, and 18X TCE series electric forklifts.
It contains detailed instructions for diagnostics, repair, and maintenance procedures.
Professional technicians will find this manual essential for performing accurate and efficient service, ensuring the forklifts remain productive and safe.
It covers all aspects of the truck's systems.
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--- Page 1 ---
Publication Number
258725124
Workshop Manual
ERC/ERP 15/18/18X TCE
(ERWERP 030/035/040TCE)
Yale Materials Handling Limited
Flagship House
Reading Road North
Fleet, Hampshire GU13 8HR
United Kingdom
Tel: 0044 1252 770777
Fax: 0044 1252 770780
Copies of this and other publications for this range of lift trucks are available.
For details contact Your Local Dealer
--- Page 3 ---
4.5 OVERHAUL 5.5. BRUSH HOLDERS & COMMUTATOR END
BRACKETS
4.5.1 ELECTRIC MOTOR PRECAUTIONS
Check the insulation resistance between the
1. ALWAYS disconnect the battery at the connector brush holders and the commutator end bracket,
before commencing work on the truck. DO NOT using a 100 volt insulation tester. Minimum
pull the cables attached to the connectors. acceptable value 1 megaohm.
2. ALWAYS refer to the applicable procedures when 5.6. BRUSH SPRINGS
undertaking maintenance and overhaul
operations. Check the brush spring force. It will be necessary
to remove the motors from the installed position
3. NEVER guess or assume polarity or connections on the truck to check all brushes on each of the
of the truck wiring. NEVER use 'trial and error' three motors. However, it is possible to arrive at
techniques. a satisfactory conclusion through sample testing
of the accessible brushes without removal of the
4. ALWAYS refer to the truck wiring diagram (See motors as visual confirmation is possible through
Electrical Section). comparison with the readings obtained as above.
Renew the springs if the force is below the value
5. MOTOR MAINTENANCE stated in the SPECIFICATIONS. (See Fig. 1).
5.1 CLEANING I 7
Remove loose dust using a regulated supply of
clean compressed air. Degrease components
using a suitable solvent applied with a lint free
cloth or soft bristle brush. Allow the components
to dry before inspection.
5.2 ARMATURE
(a) Examine the armature core for indications of local
overheating (caused by shorted circuits) and
signs of chafing against the field windings
(indicating armature shaft distortion or excessive
wearing of bearings).
(b) Inspect the commutator for scoring, pitting,
wearing of the brush track and thrown solder.
Excessive pitting or blackening indicates a
winding defect.
5.3 FIELD WINDINGS
I
Inspect the windings for indications of chafing or
damaged insulation (Indicates a distorted Fig.1.
armature or worn bearings). Renew if defective.
5.7. BRUSHES - RENEWAL (Motor Removed From
N0TE:lf required, the field windings can be given an Truck)
extra coating of insulating varnish. Red glycol
can be used if a class H polyurethane varnish is TO REMOVE
not available. Ensure the varnish does not
contact the brush gear, pole shoe faces and end 1. Clean the motor externally, using a lint free cloth
head sets. dampened in a cleaning solvent (Yale Part No
296318300).
5.4 BEARINGS
2. Remove the brush gear cover to gain access to
Examine the armature bearings for excessive the brushes.
wear, pitting, discolouration and rough running.
Renew if defective. 3. Remove the screws securing the brush leads.
Lift the brush springs and withdraw the brushes
from their holders.
B. 02
--- Page 4 ---
NOTE: Excessive deformation during the above NOTE: In the case of Transmission 'V" (different tyres)
procedure can lead to the needle bearing inner washer (4) must also be put into position.
ring becoming deformed.
Assemble them together using the washer,
(e) Using tool "K" press on the inner ring of the threaded bolt and hexagon bolt from tool "L"
tapered roller bearing (See Figure 7.ltem 5). adjust until the bearing play 0.
I
Pre-stress bearing to 500 Nm.
Using a torque spanner pre-stress the gear shaft
and the satellite carrier with the aid of tool "L".
TIGHTENING TORQUE 10 Nm 10% -
Rotate the gear shaft in both directions several
.-
/ / I \ \ times, ca. 10 to 20 revolutions, so that the rollers
00000 of the tapered roller bearing become aligned.
Check that the tightening torque is still 10 Nm + 1-
10%.
6.4.2.2 PRE-ASSEMBLE GEAR SHAFT (See Fig.8.) Determine shim thickness "X".
Smear the edges of the 5 wheel studs (10) witt Place the dial indicator gauge on the end face of
Loctite 242 and press them into the gear shaf the satellite carrier and set to "0".
flange.
Unscrew tool "L" and remove.
Push the nilos ring (9) up the stop position on the
shaft. Position the required thickness "X" of shims (2).
Using tool "K" press on the inner ring of the Smear the pinch bolt with Loctite 242 and put it in
tapered roller bearing. position using tool "N".
Coat the hollow spaces on the bearing inner ring TIGHTENINGTORQUE MA P 80 Nm
between the rollers and the cage with grease. Do
the same to the sealing edge of the nilos ring.
Use Shell Alvania R3.
REMARK:
Other grease of the same specification may also
be used.
6.4.2.3 PRE-ASSEMBLE BEARING HOUSING (See
Fig.8.)
(a) Smear the outside diameter of the shaft oil seal
(6) with Loctite 574 and using too0 "F" plate it in
the correct position i.e. the open side of the ring
facing towards the transmission.
(b) Place both outer rings of tapered roller bearings
(5 and 7)in the housing.
(c) Smear the seating faces of the gamma ring (8)
with Loctite 242 and press it onto the bearing
housing.
6.4.2.4 ASSEMBLE GEAR SHAFT AND SATELLITE
-
CARRIER PRE-STRESSBEARING (See Fig.8.)
(a) Place the pre-assembled gear shaft into the Fig.8.
bearing housing.
(b) Place the pre-assembled satellite carrier (3) onto
the gear shaft.
C. 0 8
--- Page 5 ---
(d) Install steer axle assembly into truck frame 4.7 INTERUPTOR WELDMENT AND WHEEL
(Installation is the reversal of removal DETECTION BOARD - INSTALLATION
procedure).
For seauence of assemblv see fia.2.
I
NOTE: Ensure that correct torque is applied to flange
bolts. SETTING PROCEDURE
NOTE: Grease nipple must be aligned in a horizontal (a) Turn steer wheel to straight ahead position.
plane with reference to truck centre line.
(b) Install interruptor and wheel detection board,
Tightening torque 86 Nm 63 Ibs ft ensure interruptor cam plate is central to steer
tyre, and that the detection board is perfectly
(e) INSTALL TRAIL WHEEL flat.
NOTE: Ensure that correct torque is applied to wheel NOTE: Torque securing bolt should operate steer wheel
bolts. from LH/RH locks, and in each position, check
that the optical interruptor switches are blanked
Tightening torque 140 Nm 103 Ibs ft off.
(f) TORQUE ARM WELDMENT (c) Install main interface board.
Install drive key and torque arm. NOTE: Before connecting the interface plugs (three in
number) and after subsequent disconnection, the
NOTE: Ensure that correct torque is applied to slotted pins must be sprayed with electrolube 2 GAX
nut, back off to nearest split pin hole. contact treatment grease, Yale Part No
258345000.
Tightening torque 68 Nm 50 Ibs ft Max.
(d) Connect battery and check interruptor switches
(9) INSTALLATIONOF BELLCRANK for correct operation.
Shim to achieve a clean entry into interlink. (e) install remaining covers.
NOTE: Tighten nyloc locknut sufficiently to remove any
vertical movement in bellcrank.
(h) INSTALLATION OF INTERLINK
NOTE: Tighten nyloc locknut sufficiently to remove any
vertical movement.
4.6 POWER STEER ROD END - INSTALLATION
NOTE: Torque nyloc locknut to 210 Nm 155 Ibs ft.
4.6.1 SETTING PROCEDURE FOR STEERING
ANGLES
(a) Turn steer wh,eel to full lock position. Power steer
cylinder will be in closed position.
(b) Adjust piston rod end to obtain a dimension of 74
mm. See Fig 3.
I I
Fig.3.
E. 03
--- Page 6 ---
1. ELECTRICAL SYSTEM
The truck power source is a 36 volt lead acid traction battery, this provides power for
the drive, hoist and power steer functions.
2. TRACTION SYSTEM
The truck is driven by two reversible electric motors driving independent
transmission units. The motors are controlled by a General Electric EV100 Traction
ControIler.
The controller provides smooth speed control combined with electrical plug braking.
2.1 THE MAJOR COMPONENTS OF THE SYSTEM
1. GE-EV100 Power unit and logic PCB.
2. Sevcon Accelerator unit.
3. Yale Interface printed circuit board.
4. Yale Steer angle detection Board.
5. Direction, Bypass and plugging equalisation Contacts.
2.1.1 EV100 CONTROLLER
The EV100 controller contains all the power components for the for the pulse
control system and the fail safe system.
2.1.2 ACCELERATOR UNIT
The Sevcon accelerator unit is of a sealed construction and no maintenance is
required.
2.1.3 INTERFACE PCB
THE interface PCB containis all switching devices for the direction power steer by
pass and armature cross contacts. Stabilized supply devices. Relays for the key
switch pulse reduction and handbrake. Warning buzzer, also connected by a
ribbon type cable is the steer angle detection PCB.
2.1.4 STEER ANGLE DETECTION PCB
The steer angle detection board contains 4 infa red OPT0 interruptors set at 60
degrees and 90 degrees to detect steer wheel angle. The detection board is
mounted above the steer axle, mounted on the steer axle is a steel cam plate which
interrupts the infa red lighlt, when the steer angle attains 60 degrees. This is
detected by the interface board and turns off one drive motor, when the steering is
turned to full lock, Le. 90 degrees this reverses the previously stopped motor. At 60
degrees of lock the by-pass contactor is inhibited to prevent full speed operation at
90 degrees by-pass is inhibited and the pulse is reduced. The switching of the
motors gives a differential effect when the truck is being steered between 60
degrees and 90 degrees, when the truck is being steered between 0 degrees - 60
degrees by-pass is enabled and pulse reduction is inhibited to give full speed. The
control is operative on right and left hand steer locks and in forward and reverse
direction.
G.02
--- Page 7 ---
COMPONENT LOCATION
POWER UNIT
CONTACTOR PANEL
INTERFACE PCB
G.12
--- Page 8 ---
PEPLACEMENT OF EV-100 CO MPONENTS
When replacing stud semiconductors such as 3REC and 4REC it is not
necessary to torque these devices to a specific value.
The use of a heat-transfer grease (part number 295359000) is
recommended.
When replacing module semiconductors such as 1REC, 2REC or 5REC
(1) Remove all module connections. (As required).
(2)Remove module by backing out the two screws at the top device
sides.
(3) Clean the insulator surface with a clean rag and isopropyl alcohol.
(4) Inspect the insulator surface for tears or cracks. If defective,
replace. Wipe a light layer of machine oil on the base and smooth
the insulator into position.
NOTE: Insulator not required for 2REC and SREC.
(5) Coat insulator with a light coat of heat-transfer grease.
(6) Set new module on insulator and start screws back into base. Be
sure to use the original screws and washers. Run screws into
base "finger tight".
Check that the bottom of the module is flat against the insulator or
base.
Alternately tighten the two screws by 1/4 turn until firm.
(7) Replace all conniections removed in step 1.
Capacitor
(1) Remove nuts from capacitor connections and remove wires.
(2) Remove hold down brackets and lift out.
(3) Reverse procedure to replace capacitor.
22REC, 23REC and 25REC
(1) Remove mounting screws and lift out.
NOTE: When replacing these devices, use the original hardware in the
same holes, as the inserts are used for electrical connections.
Reactor/Choke
(1) Disconnect all leads to the reactor.
(2) Remove the two mounting bolts and lift out.
(3) Set new reactor on SCR base and start screws back into base. Be
sure to use the original screws and washers, run screws into base
"f inger t ight '.
Check that the bottom of the reactor is flat against the base.
Alternately tighten the two screws by 114 turn until firm.
(4) Replace all connections removed in step 1.
G.22
--- Page 10 ---
1 I REPLACE INTERFACE
LOGIG PCB.
TEST METER REGISTER
CHECK FOR BATTERY VOLTAGE
AT THE FOLLOWING'TERMINALS
YES
1 CONTACTOR K6 BYPASS.
SELECT A DIRECTION, DEPRESS 2 SWITCH S4 SEATSWITCH
THE ACCELERATOR. CHECK VOLTAGE
AT TERMINIALS TB5 OR TB6 (SEE NOTE 1
3 TB 3 EVlOO LOGIC CARD. .-1
4 OUTPUT FROM PIN X4R. I
I 5 PIN 8 SPEED CONTROL UNIT. I
I
6 PIN 7 SPEED CONTROL UNIT.
II
I
I
I
7 INPUTTO TB 2 EV100 LOGIC. I
NOTE. I
WHEN CHECKING VOLTAGE I I
I
AT TERMINALS TB4 OR TB6 I
VOLTAGE WILL ONLY BE I
PRESENTON THE SELECTED REPLACE INTERFACE VOLTAGES I
I
CONTACTOR THE NON SELECTED
WILL REGISTER ZERO VOLTS.
I
CHECK INPUT VOLTAGES AT I
THE FOLLOWING TERMINAL I
NO I
1 X4/5ORX4/7
BATERY VOLTS AT CHECK OUTPUT VOLTAGE
TO TB PLUG FROM TERMINALS I
X4l4 OR X4l6. I
I
I
CHECK VOLTAGE AT POSITIVE IF NO VOLTAGES ARE PRESENT I
AT X4l4 OR X4/6 REPLACE M E
TERMINAL OF ALL DIRECTION
INTERFACE LOGIC PCB. I
CONTACTOR COILS. I
I
/
I I
I
NO I
I
CHECK SWITHES AND WIRING I
I
I
I REPEAT THE ABOVE CHECKS. I - -
I
1 CHECK IDIRECTDN CONTACTOR 1
II
1
COILS FOR CORRECT OHMIC
VALUE
1 1
NO
REPLACE FAULTY COILS
I 150 OHMS
NOTE THE DIRECTION SET TEST METER ON DC VOLTS
CONTACTOR COILS ARE SCALE, CONNECTTEST METER
POLARITY SENSITIVE AND ATTERMINAL X3R (INTERFACE
MUST BE CHECKED IN BOTH LOGIC CARD.)
DIRECTIONS. A READING OF
32 OHMS SHOULD BE READ
IN 1 DIRECTION AND 150 OHMS
IN THE OPPOSING DIRECTION.
TESTS TO BE CARRIED OUT
WITH AN ANALOGUE METER.
G. 32
--- Page 11 ---
-
FAULT FUNDING SPLIT VOLTAGE
G. 42
--- Page 12 ---
I I
CONTACTORS DO NOT ALTENATE
FOR SLOW SPEED OPERATION.
FULL SPEED OPERATION.
I
CHECK OUTPUT VOLTAGE AT TERMINALS
X5/4 &X5/5 WHILE OPERATING THE HOIST
LEVER ( LEVER TO BE OPERATED ALTERNATLY)
DOES
VOLTAGE ALTENATE
ON TERMINALS X514 & X5/5 REPLACE HOIST / TILT PCB.
WHEN THE HOIST LEVER
IS OPERATED
G. 52
--- Page 13 ---
SECTION H
HYDRAULIC SYSTEM PAGE
1.Description .......................................................................... 01
2.Specifications ..................................................................... 01
3. Maintenance ....................................................................... 01
3.1 Daily Inspection ..................................................................... 01
3.2 Every 50 Hours or 1 Week ........................................................ 01
3.3 Every 2000 Hours or 12 Months................................................. 01
4.0verhaul and Maintenance.............................................. 02
4.1 Hydraulic System Precautions .................................................. 02
4.2 Hoist Pump Assembly .Remove and Install ............................... ..O 2.
4.3 Hydraulic Oil Tank .................................................................. 02
4.4 Control Valve - Remove and Install ............................................. 02
4.5 Tilt Cylinder - Remove and Install............................................... 03
4.6 Tilt Cylinder - Overhaul ............................................................ 03
4.7 . Tilt Speed Setting................................................................... 04
5.Fault Diagnosis .Hoist System ....................................... 05
6 Fault Diagnosis .Tilt System ........................................... 06
--- Page 14 ---
SECTION I
MAST CONNECTING PARTS PAGE
1.Description .......................................................................... 01
2.Specifications ..................................................................... 01
3.Maintenance ....................................................................... 01
3.1 Daily Inspection .................................................................. 01
3.2 Weekly lnpsection .............................................................. 01
4.0ve rhauI ..............................................................................01
5.Mast Assembly ....................................................................01
5.1 Precautions ........................................................................ 01
5.2 Removal............................................................................. 01
5.3 Installation.......................................................................... 01
6.Forks .....................................................................................02
7.Load Backrest .................................................................... 03
--- Page 15 ---
I
2 With m,aster key switch OFF depress and release 4. MAINTENANCE.
accelerator pedal several times and check for
freedom of movement and full travel. 4.1 DAILY INSPECTION
3 Operate parking brake and ensure that braking 1. Inspect the truck for evidence of damage,
power is available. fracture, wear or leaks.Rectify as necessary.
4 With master key swithc ON check the following 4.2 EVERY 200 HOURS OR 1 MONTH
for correct functioning:-
1. Inspect all attaching and fixing parts for security.
a) Direction control lever.
2. Thoroughly wash or steam clean the truck.
b) Hoist control lever.
4.3 EVERY 1000 HOURS OR 6 MONTHS
c)Tilt control lever.
Visually inspect all load structures such as mast
d)Third function control lever - if attachment is channels, fork carriage, overhead guard, frame
fitted. weld joints etc., for cracks, fractures or damage.
e) Horn button. WARNING: DO NOTOPEPRATE THE TRUCK WITH ANY
CRACKED, FRACTURED OR DAMAGED
1) Check footbrake and parking brake. STRUCTURES.
g) On completion of checks switch master key 5. OVERHAUL
switch OFF and apply parkihg brake.
5.1 OVERHEAD CANOPY GUARD - REMOVE AND .
2.4 HYDRAULIC OIL TANK INSTALL (FIG 2.)
1 When a low level is indicated on the dipstick, TO REMOVE:
examine the truck for evidence of oil leakage.
Report any defects to appropriate authority 1. Attach suitable overhead lifting equipment to the
before topping up the tank with clean hydraulic overhead canopy guard. Tension the lifitng
fluid. equipment to take up the chain slack.
2.5 TYRES 2. Remove two bolts securing the canopy guard to
the front of the truck frame.
1 Inspect the tyres for wear and damge. Remove
stones, swarf, etc. from tyre tread. 3. Unscrew and remove two bolts and washers
securing canopy guard to the counterweight.
2 Check tyre pressures (ERP only):
4. Raise the canopy guard from the truck and lower
9.5 bar on all models 138 Ibs ft in sq onto a level working surface.
WARNING: INFLATE TYRES TO CORRECT
PRESSURES TO MAINTAIN TRUCK STABILITY.
ALWAYS USE A SAFETY CAGE OR
RESTRAINING DEVICE WHEN INFLATING
TYRES F l l T E D TO WHEELS WITH SPLIT
RIMS.BEFORE INFLATING THE WRES ALWAYS
ENSURE THE RETAINER RINGS ARE
CORRECTLY SEATED.
3. SPECIFICATIONS
COUNTERWEIGHTS
TRUCK MODEL WEIGHT
ERCP 030 TCE 695 Kg
ERCP 035 TCE 695 Kg
TIGHTENING TORQUES
Counterweight Bolts = 405 Nm I 3 0 0 Ibs ft
Overhead Guard Bolts:-
Front Legs = 135 Nm I 100 Ibs ft
Rear Legs = 470 Nm I350 Ibs ft
Fig.2.
J. 03
--- Page 16 ---
at base of cylinder. valve if defective.
5. Worn hoist cylinder seals. 5. Renew seals.
6. Defective pump. 6. Renew pump.
7. Incorrect hoist control 7. Adjust or renew valve as
valve spool setting. necessary.
8. Electrical fault. 8. Refer to electrical section.
(a) Check flip-flop module
operation.
(b) Check fast lift switch on
control valve.
5.3 FAULT HOIST CYLINDER WILL NOT LOWER OR LOWERS SLOWLY
Possible cause: Remedy:
1. Lack of lubrication. 1. Check mast channels,
lubricate as necessary.
2. Defective control valve. 2. Check and renew, if
necessary, valve in hoist
cylinder inlet connection.
3. Restriction in hose to 3. Check and clear hoses, as
hoist cylinder. necessary.
4. Rollers defective or 4. Check and renew or adjust
incorrect clearances. the rollers as necessary.
5. Defective hoist cylinder 5. Renew cylinder seals or
seals. cy Iinde r .
6. FAULT DIAGNOSIS -Tilt System
6.1 FAULT TILT CYLINDER WILL NOT OPERATE IN EITHER DIRECTION
Possible cause: Remedy:
1. Battery discharged. 1. Check and recharge battery.
2. Hydraulic fluid 2. Check fluid level in tank
starvation. and/or check for fluid leaks.
3. Incorrectly adjusted 3. Adjust stops.
tilt spool stops.
4. Defective relief valve 4. Check relief valve, renew as
in control valve. necessary.
5. Worn or damaged 5. Renew defective parts.
control levers.
6. Restrictions in hoses to 6. Check and clear hoses.
tilt cylinders.
7. Defective pump motor. 7. Check: Contactors,
continuity of control harness