Yale E807 Electric Forklift Truck Service & Repair Manual

Maintenance BRAKE SYSTEM ERP16/18/20ATF [C807, D807]; ERP030-040TGN [E807] PART NO. 524164216 1800 YRM 570

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas- tened, 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. • Disconnect 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 condition that can cause immediate death or injury! CAUTION Indicates a condition that can cause property damage!

Brake System Table of Contents TABLE OF CONTENTS General ................................................................................................................................................................ 1 Description .......................................................................................................................................................... 1 Service Brake Pads Repair ................................................................................................................................. 1 Remove ........................................................................................................................................................... 1 Install ............................................................................................................................................................... 1 Service Brake Caliper Repair .............................................................................................................................. 3 Remove ........................................................................................................................................................... 3 Install ............................................................................................................................................................... 4 Disassemble.................................................................................................................................................... 4 Assemble ........................................................................................................................................................ 4 Park Brake Caliper Repair ................................................................................................................................... 5 Remove ........................................................................................................................................................... 5 Install ............................................................................................................................................................... 6 Disassemble.................................................................................................................................................... 6 Assemble ........................................................................................................................................................ 6 Master Cylinder Repair ........................................................................................................................................ 6 Remove ........................................................................................................................................................... 6 Install ............................................................................................................................................................... 7 Disassemble.................................................................................................................................................... 7 Assemble ........................................................................................................................................................ 8 Foot-Operated Park Brake Lever Assembly Repair ............................................................................................. 8 Remove ........................................................................................................................................................... 8 Install ............................................................................................................................................................... 10 Electrically Released Park Brake Repair ............................................................................................................. 11 Mechanical Operation ..................................................................................................................................... 11 Remove ........................................................................................................................................................... 11 Install ............................................................................................................................................................... 13 Electrically Released Park Brake - Electrical Components Repair ...................................................................... 15 Control Box ..................................................................................................................................................... 15 Remove....................................................................................................................................................... 15 Install .......................................................................................................................................................... 15 Terminal Block ................................................................................................................................................. 17 Remove....................................................................................................................................................... 17 Install .......................................................................................................................................................... 17 Park Brake Adjustment ........................................................................................................................................ 19 Service Brake Adjustment ................................................................................................................................... 20 Brake System Air Removal .................................................................................................................................. 20 Troubleshooting ................................................................................................................................................... 21 This section is for the following models: ERP16/18/20ATF [C807, D807]; ERP030-040TGN [E807] ©2003 Yale Materials Handling Corp. i

1800 YRM 570 Service Brake Pads Repair General This manual has the description and repairs for the brake system. These parts include the park brake, service brake, and master cylinder. It also covers disassembly and assembly of the service brakes and the park brakes. The electrically released park brake is also described in this section. Checks and Adjustments are described at the end of this section. Description The ERP16/18/20ATF and ERP030-040TGN lift trucks feature dual, hydraulically operated service disc brakes and mechanically operated park disc brakes. Both brake systems operate independently of each other, although they both use a single disc mounted on the bevel gear shaft of the transaxle for braking. The location provides a mechanical advantage for effective braking. The service brake master cylinder and sep- arate reservoir are sealed. The reservoir has a level sensor connected to a warning light in the instrument panel, which displays when the brake fluid is low. The service brake is actuated by the large pedal located in the operator’s compartment. The pedal can be operated with either the left or right foot. The park brake is set by a pedal operated by the operator’s left foot. The park brake is released by operating the release lever located on the left side of the instrument panel. Both a warning buzzer and indicator light are used to remind the operator to set and release the park brake. The lift truck may also be furnished with an optional electrically operated park brake. When furnished, the park brake applies when the operator leaves the seat of the lift truck. The park brake mechanism is attached to the park brake linkage at the front of the lift truck and replaces the standard park brake linkage. Service Brake Pads Repair REMOVE WARNING To access the brakes, the mast and carriage must be raised and a safety chain installed. Follow the instructions in section Periodic Maintenance 8000 YRM 528 or 8000 YRM 584 for Safety Procedures When Working Near the Mast. 1. Move the lift truck to a safe, level area. Block the tires. Raise the carriage high enough to chain the carriage so it does not move. Disconnect the battery. See Figure 1. 2. Remove the capscrews retaining the disc brake shield and remove the disc brake shield. 3. Remove the spring clips retaining the pins on both ends of the service brake caliper. See Figure 2. 4. Remove the pins and the brake pads. NOTE: The original brake pad installed in the carrier side of the service brake is affixed to the carrier side with hot glue. Use a screwdriver to pry the pad from the carrier side. Clean the carrier side before installing a replacement pad. INSTALL 1. Install the brake pads in both the carrier side and the cam side of the caliper. 2. Install the pins to retain the pads. 3. Install the spring clips to retain the pins. 4. Install the disc brake shield. 5. Remove the air from the brake system. See Brake System Air Removal. 6. Connect the battery. Remove the safety chain and lower the mast. Remove the blocks from the tires. 1

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Yale E807 Electric Forklift Truck Service & Repair Manual

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