YALE G807 ERP030VT, ERP035VT, ERP040VT Lift Truck Service Repair Manual
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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
1. Ensure the capacitors are discharged by
performing Step 2 through Step 6 below.
2. Turn key or keyless switch to OFF position.
3. Disconnect the battery by separating the
connectors.
4. Block drive wheels to prevent lift truck from
moving.
5. Make sure the Emergency-Stop switch HAS NOT
been activated. If the Emergency-Stop switch is
activated, rotate the switch to the right until it pops
up.
6. Wait at least 30 seconds to be sure that the
capacitors are fully discharged.
Steering Pressure Check, Lift Trucks Equipped With Hydraulic
Steering
NOTE: The information in this section does not apply
to lift truck models ERP15-20VT (G807) manufac-
tured after November, 2014; these lift trucks are
equipped with E-Steering (Electronic Steering) and do
not use hydraulic fluid to control the steering axle.
The steering system can be evaluated by checking
the system pressure. Using a hydraulic pressure
gauge, tee into the steering lines and check pressure
between the steering control unit (on steering column)
and steering actuator (steer axle). See Figure 2.
1. Remove floor mats and floor plates.
2. Turn key switch to the OFF position and discon-
nect the battery connector.
NOTE: Perform Step 3 through Step 14 for both right
and left steer lines.
3. Insert a tee fitting at point A as shown in Figure 2,
with gauge between steer line and hose assem-
bly.
4. Connect battery connector and turn key switch to
the ON position.
5. Ensure hydraulic oil in steer cylinder is between
49 to 60°C (120 to 140°F).
NOTE: Step 6 through Step 8 apply to lift truck mod-
els ERP030-040VT (G807) manufactured before No-
vember, 2014
6. Turn steering wheel to full left or full right position
to activate steering control unit and check pres-
sure. Maximum pressure to be 7.5
±0.25 MPa (1100 ± 36 psi).
7. If pressure is above 7.75 MPa (1136 psi) replace
steering control unit. See Steering Control Unit
(SCU) Repair, Lift Trucks Equipped With Hy-
draulic Steering section.
A. INSERT TEE FITTING WITH GAUGE
1. LEFT STEER LINE
2. RIGHT STEER LINE
3. HOSE ASSEMBLY
4. STEERING CONTROL UNIT
5. STEER AXLE
Figure 2. Steering Pressure Check
Steering Pressure Check, Lift Trucks Equipped With Hydraulic Steering 1600 YRM 1331
2
8. If pressure is below 7.25 bar (1064 psi) check the
supply pressure from hydraulic pump:
a. Turn key switch to OFF position and dis-
connect battery connector.
b. Install a gate valve (open) between steer
line and tee fitting.
c. Connect battery connector and turn key
switch to ON position.
d. Turn steering wheel to full left or full right
position to activate steering control unit.
e. SLOWLY
close the gate valve to restrict flow of hy-
draulic oil until gauge rises to
7.25 MPa (1064 psi), while steering wheel
is in full left or full right position.
f. If system pressure does not rise above
7.25 MPa (1064 psi), the hydraulic pump is
not performing properly. Repair or replace
hydraulic pump and motor assembly. See
Hydraulic System 1900YRM1333.
NOTE: Step 9 through Step 11 apply to lift truck
models ERP030-040VT (G807) manufactured after
November, 2014
9. Turn steering wheel to full left or full right position
to activate steering control unit and check pres-
sure. Maximum pressure to be
11.5 MPa (1667 psi).
10. If pressure is above 11.5 MPa (1667 psi) replace
steering control unit. See Steering Control Unit
(SCU) Repair, Lift Trucks Equipped With Hy-
draulic Steering section.
11. If pressure is below 11.0 bar (1595 psi) check the
supply pressure from hydraulic pump:
a. Turn key switch to OFF position and dis-
connect battery connector.
b. Install a gate valve (open) between steer
line and tee fitting.
c. Connect battery connector and turn key
switch to ON position.
d. Turn steering wheel to full left or full right
position to activate steering control unit.
e. SLOWLY
close the gate valve to restrict flow of hy-
draulic oil until gauge rises to
11.0 MPa (1595 psi), while steering wheel
is in full left or full right position.
f. If system pressure does not rise above
11.0 MPa (1595 psi), the hydraulic pump is
not performing properly. Repair or replace
hydraulic pump and motor assembly. See
Hydraulic System 1900YRM1333.
12. When pressure checks are complete, turn key
switch to OFF position and disconnect the battery
connector.
13. Remove tee fitting between steer line and hose
assembly.
14. Reconnect steer line and hose assembly.
15. Reconnect the battery connector.
16. Install floor plates and floor mats.
17. Perform Operation Check.
Operation Check
The purpose of this check is to make sure steering
trunnion turns the correct degrees of its rotation (ap-
proximately 180 degrees). Put the lift truck on blocks
so the weight of the lift truck is removed from the
steering trunnion. See How to Put Lift Truck on
Blocks in either Operating Manual or Periodic
Maintenance 8000YRM1339.
To operate steering system, rotate trunnion to its stop
in one direction, then rotate trunnion to its stop in the
other direction.
Check that steering wheel turns trunnion smoothly.
The face of the wheel should be approximately paral-
lel to the frame plate at the back of the battery com-
partment when the steering trunnion is rotated fully in
each direction to its stops.
Perform required repairs if steering system is not
working correctly.
1600 YRM 1331 Operation Check
3
Steering Control Unit (SCU) Repair, Lift Trucks Equipped With
Hydraulic Steering
The information in this section does not apply to lift
truck models ERP15-20VT (G807) manufactured after
November, 2014; these lift trucks are equipped with
E-Steering (Electronic Steering) and do not use hy-
draulic fluid to control the steering axle.
REMOVE
NOTE: The following procedure to be used for fixed
and telescopic steering columns.
1. Disconnect battery connector.
2. Discharge capacitors, for procedures see General
section of this manual.
NOTE: Tag all electrical connectors during removal
to aid in installation.
3. Remove horn button, nut, and rod from steering
wheel. See Figure 3.
4. Remove hex nut, washer (if equipped) and steer-
ing wheel from steering column. If necessary, use
puller tool to remove steering wheel. See Fig-
ure 4.
1. HORN BUTTON
2. NUT
3. ROD
4. STEERING WHEEL
Figure 3. Horn Button Assembly and Electrical
Connections
NOTE: Follow Step 5 through Step 9 for a fixed
steering column.
5. Remove steering column upper cover by pressing
from both sides and pulling up. Clips should re-
main attached. See Figure 5.
6. Remove four capscrews and steering column
lower cover. See Figure 5.
7. Remove four capscrews and steering column top
cover. See Figure 5.
NOTE: Tag wires prior to removal to aid in installa-
tion.
8. Disconnect the horn wires from the horn switch.
9. Remove capscrews from dash panel and cowl
plate. Lift dash panel over fixed steering column,
maneuvering it past tilt adjust lever.
NOTE: Follow Step 10 through Step 15 for a tele-
scopic steering column.
10. Remove steering column top cover by pressing
from both sides and pulling up. Clips should re-
main attached. See Figure 6.
1. HEX NUT
2. WASHER
3. STEERING WHEEL
4. STEERING COLUMN
Figure 4. Steering Wheel
Steering Control Unit (SCU) Repair, Lift Trucks Equipped With Hydraulic
Steering
1600 YRM 1331
4
1. STEERING COLUMN UPPER COVER
2. CLIP
3. STEERING COLUMN LOWER COVER
4. CAPSCREW
5. STEERING COLUMN TOP COVER
6. DASH PANEL
7. TILT ADJUST LEVER
Figure 5. Fixed Steering Column Covers
11. Remove four capscrews and steering column tel-
escoping cover. See Figure 6.
12. Remove capscrew and washer; press steering
column upper cover from both sides and pull up.
Clips should remain attached. See Figure 6.
13. Remove four capscrews and steering column
lower cover. Maneuver steering column lower
cover around tilt memory lever. See Figure 6.
NOTE: Tag wires prior to removal to aid in installa-
tion.
14. Disconnect the horn wires from the horn switch.
15. Remove capscrews from dash panel and cowl
plate. Lift dash panel over telescopic steering col-
umn, maneuvering it past tilt memory lever, adjust
lever, and column locking knob.
NOTE: Tag all hoses and fittings during removal to
aid in installation.
NOTE: Install plugs at all hose ports and hose ends
to prevent foreign material from entering hydraulic
system.
16. Disconnect the hydraulic hoses from the steering
control unit fittings. See Figure 7. Set the hy-
draulic hoses aside to prevent possible damage.
1. STEERING COLUMN TOP COVER
2. CLIP
3. CAPSCREW
4. STEERING COLUMN TELESCOPING COVER
5. STEERING COLUMN UPPER COVER
6. WASHER
7. STEERING COLUMN LOWER COVER
8. TILT ADJUST LEVER
9. TELESCOPIC STEERING COLUMN
10. DASH PANEL
11. TILT MEMORY LEVER
Figure 6. Telescopic Steering Column Covers
1600 YRM 1331 Steering Control Unit (SCU) Repair, Lift Trucks Equipped With Hydraulic
Steering
5
1. STEERING CONTROL UNIT FITTING
2. HYDRAULIC HOSE
Figure 7. Hydraulic Hose Connections
17. Remove spring, e-ring, and steering direction sen-
sor from steering column. See Figure 8.
1. STEERING COLUMN
2. STEERING DIRECTION SENSOR
3. E-RING
4. SPRING
Figure 8. Steering Direction Sensor
NOTE: Perform Step 18 for lift trucks equipped with
synchronous steering.
18. Disconnect wiring harness from synchronous
steering valve kit. See Figure 10.
NOTE: Note placement and orientation of steering
control unit prior to removal to aid in installation.
19. Remove capscrews, washers, and steering con-
trol unit from tilt base bracket. See Figure 9.
1. STEERING CONTROL UNIT
2. TILT BASE BRACKET
3. CAPSCREW
4. WASHER
Figure 9. Steering Control Unit
Steering Control Unit (SCU) Repair, Lift Trucks Equipped With Hydraulic
Steering
1600 YRM 1331
6
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File Format: .PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe Reader & Win
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