Maintenance
STEERING SYSTEM
ERP15-20VT (ERP030-040VT) [G807]
PART NO. 524295631 1600 YRM 1331
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 technicians. Failure to properly maintain equipment or to follow instructions con-
tained 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. 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 re-
move 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 man-
ual:
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 back-
ground. The CAUTION symbol and word are on yellow background.
©2014 Yale Materials Handling Corp.
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Introduction ........................................................................................................................................................... 1
Discharging The Capacitors ................................................................................................................................. 1
Steering Pressure Check, Lift Trucks Equipped With Hydraulic Steering ................................................................ 2
Operation Check ....................................................................................................................................................... 3
Steering Control Unit (SCU) Repair, Lift Trucks Equipped With Hydraulic Steering ................................................ 4
Remove ................................................................................................................................................................ 4
Disassemble ......................................................................................................................................................... 7
Clean .................................................................................................................................................................. 10
Inspect ................................................................................................................................................................ 10
Assemble ............................................................................................................................................................ 10
Install .................................................................................................................................................................. 11
Steering Wheel and Fixed Steering Column Assembly Repair .............................................................................. 12
Remove .............................................................................................................................................................. 12
Disassemble ....................................................................................................................................................... 16
Clean .................................................................................................................................................................. 18
Inspect ................................................................................................................................................................ 18
Assemble ............................................................................................................................................................ 18
Install .................................................................................................................................................................. 18
Gear Replacement for Lift Trucks Built Prior to 10/2008 .................................................................................... 19
Steering Wheel and Telescopic Column Assembly Repair .................................................................................... 20
Remove .............................................................................................................................................................. 20
Disassemble ....................................................................................................................................................... 24
Clean .................................................................................................................................................................. 26
Inspect ................................................................................................................................................................ 27
Assemble ............................................................................................................................................................ 27
Install .................................................................................................................................................................. 28
Gear Replacement for Lift Trucks Built Prior to 10/2008 .................................................................................... 29
Hydraulic Pump and Motor ..................................................................................................................................... 34
Steering Actuator Components ............................................................................................................................... 34
Steer Tire and Wheel Assembly ......................................................................................................................... 35
Remove .......................................................................................................................................................... 35
Install .............................................................................................................................................................. 35
Wheel Hub Assembly, Lift Trucks Equipped With Hydraulic Steering ................................................................ 35
Remove .......................................................................................................................................................... 35
Clean .............................................................................................................................................................. 37
Inspect ............................................................................................................................................................37
Install .............................................................................................................................................................. 37
Wheel Hub Assembly, Lift Trucks Equipped With E-Steering ............................................................................ 38
Remove .......................................................................................................................................................... 38
Clean .............................................................................................................................................................. 38
Inspect ............................................................................................................................................................38
Install .............................................................................................................................................................. 38
Steering Axle Assembly, Lift Trucks Equipped With Hydraulic Steering ............................................................ 40
Remove .......................................................................................................................................................... 40
Disassemble ...................................................................................................................................................40
Clean .............................................................................................................................................................. 41
Inspect ............................................................................................................................................................42
Assemble ....................................................................................................................................................... 42
Install .............................................................................................................................................................. 42
Table of Contents
i
TABLE OF CONTENTS (Continued)
Steering Axle Assembly, Lift Trucks Equipped With E-Steering .........................................................................43
Remove .......................................................................................................................................................... 43
Disassemble ...................................................................................................................................................44
Clean .............................................................................................................................................................. 44
Inspect ............................................................................................................................................................44
Assemble ....................................................................................................................................................... 44
Install .............................................................................................................................................................. 47
Torque Specifications ............................................................................................................................................. 48
Fixed Steering Column ....................................................................................................................................... 48
Telescopic Steering Column ...............................................................................................................................48
Steering Control Unit .......................................................................................................................................... 48
Steer Axle, Lift Trucks Equipped With Hydraulic Steering ..................................................................................48
Steer Axle, Lift Trucks Equipped With E-Steering .............................................................................................. 48
This section is for the following models:
ERP15-20VT (ERP030-040VT) [G807]
Table of Contents
ii
General
INTRODUCTION
This section contains the description and repair
procedures for the steering system. Components
covered are the steering wheel and column assembly,
steering control unit, and steering actuator. Some
parts associated with the steering system are not
covered in this section because they are more closely
associated with other systems. See the following for
information not included in this section:
See Electrical System 2200YRM1337 section for
information on wiring and power supply for hydraulic
pump and motor assembly.
See Hydraulic System 1900YRM1333 section for
information on hydraulic tank and system.
See Periodic Maintenance 8000YRM1339 manual
for information on regular schedule maintenance.
Throughout this section, forward will refer to travel in
the direction of the forks and left and right determined
by an operator sitting in the seat facing forward. See
Figure 1.
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 1. Truck Orientation
DISCHARGING THE CAPACITORS
WARNING
DO NOT make repairs or adjustments unless you
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag on the
steering wheel and disconnect the battery.
Disconnect the battery and allow the capacitors to
discharge before opening an compartment covers
or inspecting or repairing the electrical system.
DO NOT place tool on top of the battery. If a tool
causes a short circuit, the high current flow from
the battery can cause personal injury and
property damage.
Some checks and adjustments are performed with
the battery connected. DO NOT connect the
battery until the procedure instructs you to do so.
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidentally make
an electrical connection and cause injury
Before performing any tests or adjustment, block
the lift truck to prevent unexpected movement.
The capacitor in the transistor controller(s) can
hold an electrical charge for about 10 seconds
after the battery is disconnected. To prevent an
electrical shock and personal injury, discharge
the capacitor(s) before inspecting or repairing any
component in the drive unit compartment. Make
certain that the battery has been disconnected.
DO NOT short across the motor controller
terminals with a screwdriver or jumper wire.
Make certain the Emergency-Stop switch has not
been activated. This will isolate the controller and
prevent the capacitors from discharging properly.
The proper way to disconnect the battery is by
separating the battery connectors.
1600 YRM 1331 General
1
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