Maintenance
AC MOTOR REPAIR
ERP15-20VT (ERP030-040VT) [G807];
ERP16-20VF (ERP30-40VF) [A955];
ERC22-35VG (ERC045-070VG) [A968];
ERC16-20VA (ERC030-040VA) [A969];
ERP22-35VL (ERP045-070VL) [A976];
ESC030-040AC [B883]; ERP40-50VM (EPR080-
100VM) [A985]; ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) [A938]
PART NO. 524327049 620 YRM 1385
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.
Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced techni-
cians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in
damage to the products, personal injury, property damage or death.
• 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. Discon-
nect 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 hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
AC Motor Repair Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................ 1
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883) ...................................................... 6
Discharging the Capacitors (All Other Models) ............................................................................................... 8
Traction Motor Repair .......................................................................................................................................... 8
For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955),
and ESC030-040AC (B883) ............................................................................................................................ 8
Remove....................................................................................................................................................... 8
Disassemble ............................................................................................................................................... 9
Electrical Connector Repair or Replacement .............................................................................................. 11
Clean .......................................................................................................................................................... 11
Inspect ........................................................................................................................................................ 11
Assemble .................................................................................................................................................... 12
Install .......................................................................................................................................................... 14
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969) .............. 16
Remove....................................................................................................................................................... 16
Disassemble ............................................................................................................................................... 16
Electrical Connector Repair or Replacement .............................................................................................. 19
Clean .......................................................................................................................................................... 19
Inspect ........................................................................................................................................................ 19
Assemble .................................................................................................................................................... 20
Install .......................................................................................................................................................... 20
For Lift Truck ERP2.2-3.5VL (ERP045-070VL) (A976) ................................................................................... 20
Remove....................................................................................................................................................... 20
Disassemble ............................................................................................................................................... 20
Clean .......................................................................................................................................................... 22
Inspect ........................................................................................................................................................ 22
Assemble .................................................................................................................................................... 23
Install .......................................................................................................................................................... 23
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) .......................................... 23
Remove....................................................................................................................................................... 23
Disassemble ............................................................................................................................................... 23
Electrical Connector Repair or Replacement .............................................................................................. 25
Clean .......................................................................................................................................................... 25
Inspect ........................................................................................................................................................ 25
Assemble .................................................................................................................................................... 26
Install .......................................................................................................................................................... 26
For Lift Truck ERP40-50VM (ERP080-100VM)(A985) .................................................................................... 26
Remove....................................................................................................................................................... 26
Clean .......................................................................................................................................................... 27
Install .......................................................................................................................................................... 27
Hydraulic Motor Repair ........................................................................................................................................ 28
For Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and
ESC030-040AC (B883) ................................................................................................................................... 28
Remove....................................................................................................................................................... 28
Disassemble ............................................................................................................................................... 29
Electrical Connector Repair or Replacement .............................................................................................. 30
Clean .......................................................................................................................................................... 31
Inspect ........................................................................................................................................................ 31
Assemble .................................................................................................................................................... 32
Install .......................................................................................................................................................... 33
For Lift Truck ERC22-35VG (ERC045-070VG) (A968) .................................................................................... 34
©2012 Yale Materials Handling Corp. i
Table of Contents AC Motor Repair
TABLE OF CONTENTS (Continued)
Remove....................................................................................................................................................... 34
Disassemble ............................................................................................................................................... 36
Standard Motor ....................................................................................................................................... 36
Enhanced Motor ..................................................................................................................................... 38
Electrical Connector Repair or Replacement .............................................................................................. 38
Clean .......................................................................................................................................................... 39
Inspect ........................................................................................................................................................ 39
Assemble .................................................................................................................................................... 40
Standard Motor ....................................................................................................................................... 40
Enhanced Motor ..................................................................................................................................... 40
Install .......................................................................................................................................................... 41
For Lift Truck Models ERP2.2-3.5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA)
(A969) ............................................................................................................................................................. 41
Remove....................................................................................................................................................... 41
Disassemble ............................................................................................................................................... 42
Electrical Connector Repair or Replacement .............................................................................................. 46
Clean .......................................................................................................................................................... 47
Inspect ........................................................................................................................................................ 47
Assemble .................................................................................................................................................... 48
Install .......................................................................................................................................................... 49
For Lift Truck Models ERP40-50VM (ERP080-100VM) (A985) and ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938) ........................................................................................................... 49
Remove....................................................................................................................................................... 49
Disassemble ............................................................................................................................................... 49
Electrical Connector Repair or Replacement .............................................................................................. 50
Clean .......................................................................................................................................................... 51
Inspect ........................................................................................................................................................ 51
Assemble .................................................................................................................................................... 52
Install .......................................................................................................................................................... 53
Torque Specifications .......................................................................................................................................... 53
Traction Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF)
(A955) ............................................................................................................................................................. 53
Traction Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA)
(A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) ............................................ 53
Traction Motor for Lift Truck ESC030-040AC (B883) ....................................................................................... 53
Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF
(ERP30-40VF) (A955) ..................................................................................................................................... 53
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) ........................................................... 53
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) ........................................................... 53
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) ............................................................ 53
Hydraulic Motor for Lift Truck ESC030-040AC (B883) .................................................................................... 53
Hydraulic Motor for Lift Truck ERP40-50VM (ERP080-100VM) (A985) and ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938) ........................................................................................................... 54
ii
AC Motor Repair Table of Contents
TABLE OF CONTENTS (Continued)
This section is for the following models:
ERP15-20VT (ERP030-040VT) [G807];
ERP16-20VF (ERP30-40VF) [A955];
ERC22-35VG (ERC045-070VG) [A968];
ERC16-20VA (ERC030-040VA) [A969];
ERP22-35VL (ERP045-070VL) [A976];
ESC030-040AC [B883];
ERP40-50VM (EPR080-100VM) [A985];
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) [A938]
iii
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$46.99
YALE A968 ERC20VG, ERC22VG, ERC25VG, ERC30VG, ERC32VG, ERC35VG Lift Truck Service Repair Manual (Europe)
Viewed 66 Times Today
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$46.99
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
If you are facing maintenance issues with the YALE A968 ERC20VG, ERC22VG, ERC25VG, ERC30VG, ERC32VG, ERC35VG LIFT TRUCK, worry no more. We have a comprehensive service repair manual that is suitable for both professional mechanics and DIY enthusiasts. This electronically available manual is rich in maintenance knowledge and practical for use at any location. It covers various aspects including frame, operator's cab, AC motor repair, drive axle, steering system, brake system, hydraulic system, cylinder repair, wire harness repair, electrical system, industrial battery, periodic maintenance, and more.
The manual is compatible with all versions of Windows and Mac, and is in English language. It is in PDF format and can be viewed using Adobe Reader. With this manual, your YALE A968 ERC20VG, ERC22VG, ERC25VG, ERC30VG, ERC32VG, ERC35VG LIFT TRUCK will receive excellent service. The electronic format makes it practical and easy to carry, ensuring that you have access to the necessary repair information at all times. Embracing electronic products is a modern approach, and using this electronic service repair manual will not only make maintenance easier but also showcase your technical proficiency.
