This is the Highly Detailed factory service repair manual for theYALE E216 ERP20ALF LIFT TRUCK, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.YALE E216 ERP20ALF LIFT TRUCK Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.
Service Repair Manual Covers:
Frame
Dc motor maintenance
Ac motor maintenance
Drive axle wet brake
Steering control unit
Steering system
Brake pedal and linkage
Hydraulic system
Main control valve
Main control valve e-controls
Cylinder repair (mast s/n a551, a555, a559, a661, a662, a663, a66, b507,
B508, b509, b551, b555, b559, b562, b563, b564, b661, b662, b663, c515,
C551, c555, c559, d507, d508, d509, d515, d562, d563, d564, e509, and e564)
Electrical system
Ac motor controller desc/chks/adj/trbsht/rep&theory of operation/display panel
Troubleshooting and adjustments using the ac controls program
Industrial battery
Mast - description
Mast repairs (s/n a551, a555, a559, a661, a662, a663, a664, b507, b508,
B509, b551, b555, b559, b562, b563, b564, b661, b662, b663, c515, c551,
C555, c559, d507, d508, d509, d515, d562, d563, d564, e509, and e564)
Metric and inch (sae) fasteners
Diagrams
Periodic maintenance
Capacities and specifications
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader
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8
YALE E216 ERP20ALF LIFT TRUCK (EUROPE) Service Repair Manual
1. ERP20-30ALF (E216)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524256685 0100 YRM 1222 05/06
DC MOTOR MAINTENANCE.......................................................................................... 524158039 0620 YRM 0294 03/08
AC MOTOR MAINTENANCE.......................................................................................... 524183080 0620 YRM 1053 03/10
DRIVE AXLE WET BRAKE............................................................................................ 524256686 1400 YRM 1223 03/09
STEERING CONTROL UNIT.......................................................................................... 524158753 1600 YRM 0720 11/06
STEERING SYSTEM...................................................................................................... 524183081 1600 YRM 1054 11/06
BRAKE PEDAL AND LINKAGE..................................................................................... 524264587 1800 YRM 1253 09/06
HYDRAULIC SYSTEM.................................................................................................... 524179945 1900 YRM 0559 04/09
MAIN CONTROL VALVE................................................................................................ 524179946 2000 YRM 0562 02/09
MAIN CONTROL VALVE E-CONTROLS....................................................................... 524256687 2000 YRM 1224 04/08
CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507,
B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515,
C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND
E564).......................................................................................................................... 524223768 2100 YRM 1139 02/14
ELECTRICAL SYSTEM.................................................................................................. 524183082 2200 YRM 1055 10/09
AC MOTOR CONTROLLER DESC/CHKS/ADJ/TRBSHT/REP&THEORY OF
OPERATION/DISPLAY PANEL................................................................................. 524183083 2200 YRM 1056 03/09
TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS
PROGRAM................................................................................................................. 524183085 2200 YRM 1058 04/11
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
MAST - DESCRIPTION................................................................................................... 524158890 4000 YRM 0521 03/06
MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508,
B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551,
C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ 524223776 4000 YRM 1148 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
DIAGRAMS..................................................................................................................... 524256688 8000 YRM 1225 05/06
PERIODIC MAINTENANCE............................................................................................ 524309198 8000 YRM 1226 08/08
CAPACITIES AND SPECIFICATIONS........................................................................... 524256690 8000 YRM 1227 05/06
PART NO. 524309197 (09/14)
2. 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!
4. 100 YRM 1222 Description
General
This section has a description and the service procedures for the parts of the frame. These parts include the frame,
counterweight assembly, overhead guard, hood and seat assembly, access panels, and label positions.
Description
MAIN FRAME
The main frame is a single weldment. See Figure 1.
The main frame has mounts for the following:
• Counterweight
• Overhead guard
• Battery restraint and hood
• Tilt cylinders
• Steering axle
• Drive axle assembly
• Cowl assembly
• Floor pedals and floor plates
• Side step and fender weldments
• Hydraulic tank
• Pump and motor assemblies (steer, lift, and traction
motors)
• Control valves and the levers
The hood is part of the operator and battery restraint
system. The seat is part of the operator restraint sys-
tem. The hydraulic tank, lift pump motor assembly, and
the steering pump motor assembly are in a compart-
ment between the battery and the counterweight. The
top cover between the counterweight and hood can be
removed for access to the master controller. The rear
cover of the counterweight can be removed for access
to the controllers and contactors. See Figure 2.
The weight of the battery is a large part of the counter-
weight system on an electric lift truck. Make sure that
the battery is within the weight limits indicated on the
nameplate. Each model of lift truck has a cast iron coun-
terweight that provides additional weight necessary for
the indicated capacity.
OTHER FRAME WELDMENTS
These frame parts are the right-side and left-side step
and fender weldments and the cowl weldment. See Fig-
ure 1. Each part is a weldment fastened to the main
frame to make the frame assembly. The cowl weldment
is a mount for the front of the overhead guard, the steer-
ing column assembly, the parking brake release link-
age, and the dash panel with light switches. The display
panel is mounted into the dash panel. See Figure 3.
OVERHEAD GUARD
WARNING
Do not operate the lift truck without the overhead
guard and cowl correctly fastened to the lift truck.
The overhead guard is a weldment that fastens to the
main frame and cowl to help protect the operator from
falling objects. A slot in the overhead guard permits
removal of the battery without removing the overhead
guard. See Figure 2.
1
5. Description 100 YRM 1222
1. COWL
2. BATTERY SPACER PLATE
3. BATTERY RETAINER ROD
4. FRAME
5. SIDE STEP AND FENDER WELDMENT
6. ACCESS PANEL
7. FLOOR PLATES
Figure 1. Lift Truck Main Frame
2
8. 100 YRM 1222 Description
Legend for Figure 3
1. ON-DEMAND STEERING COMPONENTS
2. SHIFT LEVER MECHANISM
3. STEERING WHEEL
4. DISPLAY PANEL
5. COLUMN COVER
6. COLUMN FRAME
7. STEERING CONTROL UNIT
8. COWL WELDMENT
9. DASH PANEL
10. COLUMN MOUNT
11. LATCH MECHANISM
12. HORN SWITCH CONNECTOR
13. HORN BUTTON
14. STEERING COLUMN
15. STEERING COLUMN NUT
16. STATIC STRAP
BATTERY RESTRAINT, HOOD, AND SEAT
ASSEMBLY
WARNING
The hood and battery restraint, as well as the latch
for the hand lever assembly, must operate correctly
before a lift truck is operated. These parts are part
of the battery restraint system. The battery restraint
system must operate correctly to help provide rea-
sonable protection to the operator if the lift truck
tips over.
A battery restraint system is installed as a safety de-
vice. The function on the battery restraint system is to
hold the battery in the battery compartment in case of a
tip over. Part of the battery restraint system is a battery
restraint at the rear of the battery compartment. See
Figure 4. This restraint rod extends over the rear edge
of the battery case to help hold the battery within the
battery compartment during tip over. A handle is used
to move the restraint rod. The handle of the battery re-
straint must be in the DOWN position to close the hood.
The handle can be moved to the DOWN position only
after the restraint rod is extended over the battery. The
restraint rod can only be retracted when the hood is in
the UP position.
WARNING
The battery must fit the battery compartment so
that the battery restraint will operate correctly. A
loose battery can cause serious injury and property
damage if the lift truck overturns. The battery must
not be able to move more than 13 mm (0.5 in.) for-
ward, backward, or side to side.
An adjustable spacer plate is used at the front of the
battery compartment to prevent forward and backward
movement of the battery. The adjustable spacer plate is
used inside the battery compartment. The spacer plate
must be adjusted for a maximum clearance of 13 mm
(0.5 in.) with the battery against the rear bulkhead. See
Figure 5. There must be some clearance to allow bat-
tery removal. See the section Periodic Maintenance
8000 YRM 1226 to remove the battery and adjust the
spacer plate.
A. EXTENDED
B. RETRACTED
1. BATTERY RESTRAINT WARNING LABEL
2. HOOD
3. BATTERY RESTRAINT HANDLE
4. BATTERY
Figure 4. Battery Restraint Rod
5
9. Description 100 YRM 1222
1. BATTERY COMPARTMENT
2. BATTERY
3. BULKHEAD
4. SPACER PLATE
5. ADJUSTMENT CAPSCREW
6. JAM NUT
Figure 5. Battery Spacer Plate
HOOD WITH MANUAL HYDRAULIC
LEVERS
WARNING
The gas spring for the hood can raise the hood at
a rapid rate and cause an injury. DO NOT lean over
hood when raising hood.
WARNING
The batteries for these lift trucks must fit the battery
compartment width with a maximum of 13 mm (0.5
in.) clearance. The Battery Specifications, at the
back of this manual, shows the minimum sizes of
the battery compartment.
Before raising the hood, move the steering column to
the forward position and slide the seat all the way back.
Another important part of the battery restraint system
is the steel weldment that is also the hood frame. This
hood frame is connected to the lift truck frame with
hinges at the rear of the hood. See Figure 15. The
front of the hood and frame is locked in the closed po-
sition by the assembly for the hydraulic hand levers. A
latch releases the assembly to tilt forward and allow the
hood to raise. See Figure 6. Gas springs help lift the
hood assembly. The seat and other parts of the opera-
tor restraint system fasten to the hood assembly.
A. CLOSED OVER HOOD B. OPEN
1. HAND LEVER ASSEMBLY
2. HOOD
3. SEAT
4. LATCH HANDLE
5. LATCH
Figure 6. Latch and Cover With Manual Hydraulic Levers
6
10. 100 YRM 1222 Description
HOOD WITH E-HYDRAULICS
WARNING
The gas spring for the hood can raise the hood at
a rapid rate and cause an injury. DO NOT lean over
hood when raising hood.
WARNING
The batteries for these lift trucks must fit the battery
compartment width with a maximum of 13 mm (0.5
in.) clearance. The Battery Specifications, at the
back of this manual, shows the minimum sizes of
the battery compartment.
Another important part of the battery restraint system
is the steel weldment that is also the hood frame. This
hood frame is connected to the lift truck frame with
hinges at the rear of the hood. See Figure 14. Gas
springs help lift the hood assembly. The seat and other
parts of the operator restraint system fasten to the hood
assembly.
NOTE: Before raising the hood, move the steering col-
umn to the forward position and slide the seat all the
way back, and, If necessary, move the armrest all the
way back. See Figure 7.
1. ARMREST ADJUSTMENT HANDLE
Figure 7. Armrest Latch Location
The latch that secures the cover for the hood release
handle can be either a locking or non-locking latch. If
the latch is a locking latch, unlock latch with key first.
The cover, latch, and hood release handle are located
on the right side of the hood. See Figure 8.
Pull the latch handle, located on the top of the latch, to
the up position and then pull on latch handle to move
cover away from hood release handle. Pull hood re-
lease handle up to release hood latch mechanism. See
Figure 8. Use handle on the hood to place hood in the
raised position.
Before lowering the hood, make sure the battery re-
straint rod is over the battery. Lower the hood and push
hood release handle down to secure hood to frame.
Move cover over hood release handle and push latch
handle down to secure cover to hood. If latch is a lock-
ing latch, lock latch with key.
1. LATCH
2. COVER
3. HOOD RELEASE
HANDLE
4. HOOD LATCH
MECHANISM
5. COMPRESSION
SPRING
6. PIN
7. SCREW
8. CAPSCREW
9. NUT
10. LOCKWASHER
11. WASHER
12. LATCH HANDLE
Figure 8. Latch and Cover With E-Hydraulics
7
11. Description 100 YRM 1222
OPERATOR RESTRAINT SYSTEM AND
SEAT ASSEMBLY
Operator Restraint System
The seat belt, hip restraint, seat, hood, and hood latch
are all part of the operator restraint system. See Fig-
ure 9. Each item must be checked to make sure it is
fastened correctly, functions correctly, and is in good
condition. The system helps the operator stay within
the lift truck in case of a tip over.
Make sure that the seat is not loose on the rails. Make
sure that the seat rails are not loose. The seat rails
must lock securely in position, but move freely when
unlocked. The seat rails must be securely attached to
the mounting surface.
Emergency Locking Retractor (ELR)
When the ELR style seat belt is properly buckled across
the operator, the belt will permit slight operator reposi-
tioning without activating the locking mechanism. If the
truck tips, travels off a dock, or comes to a sudden stop,
the locking mechanism will be activated and hold the
operator’s lower torso in the seat.
A seat belt that is damaged worn or does not operate
properly will not give protection when it is needed. The
end of the belt must fasten correctly in the latch. The
seat belt must be in good condition. Replace the seat
belt if damage or wear is seen. See Figure 9.
The following seat belt operation checks must be per-
formed:
• With the hood closed and in the locked position, pull
the seat belt slowly from the retractor assembly. Make
sure the seat belt pulls out and retracts smoothly. If
the seat belt cannot be pulled from the retractor as-
sembly or the belt will not retract, replace the seat belt
assembly.
• With the hood closed and in the locked position, pull
the seat belt with a sudden jerk. Make sure the seat
belt will not pull from the retractor assembly. If the
seat belt can be pulled from the retractor, when it is
pulled with a sudden jerk, replace the seat belt as-
sembly.
• With the hood in the open position, make sure the
seat belt will not pull from the retractor assembly. If
the seat belt can be pulled from the retractor, with
the hood in the open position, replace the seat belt
assembly.
1. OPERATOR WEIGHT ADJUSTMENT
2. FORWARD BACKWARD ADJUSTMENT
3. SEAT BELT
4. HIP RESTRAINT
5. SEAT
6. SEAT RAIL
Figure 9. Hood and Seat Check
1. FORWARD/BACKWARD ADJUSTMENT
2. SWIVEL ADJUSTMENT
3. OPERATOR WEIGHT ADJUSTMENT
4. SEAT POSITION ADJUSTMENT (SEAT RAIL)
5. SEAT BELT
Figure 10. Swivel Seat Option
8
12. 100 YRM 1222 Overhead Guard Replacement
Hood and Seat Latches
Make sure the seat rails and latch striker are not loose.
The seat rails must lock tightly in position, but move
freely when unlocked (see Figure 9 and Figure 10). The
seat rails must be correctly fastened to the hood and the
fastened to the hinges on the frame. Try to lift the hood
to make sure it is fastened correctly and will not move.
Overhead Guard Replacement
REMOVE
WARNING
Do not weld, drill, grind, or cut the overhead guard
for mounts of lights or accessories. The strength
of the overhead guard can be reduced.
1. Remove battery as described in the section Peri-
odic Maintenance 8000 YRM 1226.
2. Access to the capscrews that hold the rear legs of
the overhead guard to the frame is from the battery
compartment. See Figure 11. Remove the cap-
screws, washers, and nuts that fasten each leg.
3. Remove the capscrews, washers, and nuts that
hold each front leg of the overhead guard to the
cowl. Disconnect any electric wires from under the
cowl that go through the front legs of the overhead
guard. When the overhead guard is lifted from the
frame, make sure these electric wires move through
the holes in the frame at the front and rear so that
they are not damaged.
4. Use a lifting device or another person to help lift the
overhead guard from the lift truck.
INSTALL
1. Install the over head guard onto the lift using a lifting
device or another person.
2. Install any electrical wires from the overhead guard
legs through the holes in the frame. Make sure
location of the wires is routed in the same location
as was removed to assure that the wires do not get
pinched.
3. Install the capscrews, washers, and nuts that hold
each front leg to the frame. See Figure 11. Tighten
the capscrews to 102 N•m (75 lbf ft).
4. Install the caspcrews, washers, and nuts that hold
the rear legs to the frame. See Figure 11. Tighten
the capscrews to 102 N•m (75 lbf ft).
5. Install the battery as described in the section Pe-
riodic Maintenance 8000 YRM 1226.
9
14. 100 YRM 1222 Hood, Seat Assembly, and Operator Restraint Replacement
Hood, Seat Assembly, and Operator Restraint Replacement
HOOD AND SEAT ASSEMBLY
Remove
WARNING
The gas spring for the hood can raise the hood at
a rapid rate and cause an injury. DO NOT get over
hood when raising hood.
NOTE: The hood and seat assembly can be removed
as a unit or the seat assembly can be removed with the
hood assembly installed on the truck frame. Perform
only the steps necessary. If the hood and seat assem-
bly will be removed as a unit, perform Step 1 through
Step 5. To remove the seat assembly from the hood
assembly, perform Step 1 through Step 4 and Step 6
through Step 8.
Remove the hood and seat assembly as follows (see
Figure 12 and Figure 13).
1. Turn the key to the OFF position and remove the
key.
NOTE: Before raising the hood, move the steering col-
umn to the forward position and slide the seat all the
way to the rear. Lift trucks equipped with E-hydraulic
control levers, move the armrest all the way to the rear.
WARNING
Never put tools or other metal on the battery. Metal
on the battery can cause a short circuit and possi-
ble damage or injury.
2. Lift trucks equipped with manual hydraulic levers,
unlatch the hand lever assembly and pull back from
hood. See Figure 6. Lift trucks equipped with E-hy-
draulic levers, pull back on the latch handle to re-
move cover to access the latch handle. Pull up on
the latch handle to release the hood latch mecha-
nism. See Figure 8.
3. Open the hood and disconnect the battery connec-
tor. Install a cardboard or plywood cover on the top
of the battery to prevent accidental short circuits.
4. Disconnect the connector for the seat switch wires
near the rear of the hood frame. If the hood will be
removed, remove the emergency stop knob and the
power disconnect assembly from the hood.
5. Fasten the hood assembly so that it cannot lower
and carefully remove the gas springs from the hood.
Have an assistant help hold the hood assembly.
Remove the screws that fasten the hood assembly
to the lift truck frame. See Figure 12 and Figure 13.
Carefully remove the hood assembly.
6. Push the connector of the seat switch wire through
the grommet in the hood. It can be necessary to
remove the grommet from the hole in the hood for
enough clearance to get the connector through the
grommet. Inspect seat switch and replace if worn
or damaged. See Figure 12 and Figure 13.
7. Remove the screws that fasten the seat to the hood
and hood frame. Close and latch the hood and put
the seat on its side for access to the seat switch.
8. Use a flat-blade screwdriver or other tool with a flat
blade to carefully lift the switch free of the seat pan.
Slide the switch out of the seat cushion.
11
15. Hood, Seat Assembly, and Operator Restraint Replacement 100 YRM 1222
Figure 12. Hood Removal With Manual Hydraulics
12
16. 100 YRM 1222 Hood, Seat Assembly, and Operator Restraint Replacement
Legend for Figure 12
A. TOP VIEW
B. SIDE VIEW
C. HOOD IN OPEN POSITION
1. HOOD HANDLE
2. EMERGENCY STOP BUTTON
3. HOOD
4. SEAT SWITCH HARNESS
5. GAS SPRING
6. SEAT
7. SEAT RAILS
8. HOOD BRACKET SPRING
9. CAPSCREW, WASHER, AND NUT
10. WASHER, NUT, AND BOLT
11. SIDE COVER
12. OVERHEAD GUARD
Install
NOTE: Install procedures apply for hoods with Manual
and E-Hydraulics.
NOTE: If just the seat assembly was removed, install
seat assembly onto hood by performing Step 1, Step 2,
Step 4, and Step 5. If the hood and seat assembly were
removed, install hood and seat assembly by performing
Step 3 through Step 5.
1. Carefully slide the seat switch into the cavity of the
seat cushion until the end of the switch with the
wires is aligned over the hole in the pan. Push on
the switch until the clips of the switch are fastened
to the seat. See Figure 12 and Figure 13.
2. Carefully install the grommet over the wire connec-
tor See Figure 14 and Figure 15. Install the seat on
the hood and tighten the nuts. Install the grommet
in the hole of the hood, connect the wire connec-
tor, and push the connector back inside the hood
frame.
3. If the hood assembly was removed, have an assis-
tant help align the hood assembly in the correct po-
sition. Install the screws that fasten the hood as-
sembly to the lift truck frame. See Figure 12) and
Figure 13. Hold the hood assembly in the open po-
sition and carefully install the gas springs.
4. Install the power disconnect assembly on the hood.
Install the emergency stop knob.
5. Remove cardboard or plywood from top of battery.
13
17. Hood, Seat Assembly, and Operator Restraint Replacement 100 YRM 1222
A. TOP VIEW B. SIDE VIEW
1. WASHER
2. CAPSCREW
3. NUT
4. SPRING BRACKET
5. PLATE-LEFT SIDE SHOWN
6. BOLT
7. GAS SPRING
8. STRAP CLAMP
9. EMERGENCY STOP
10. HOOD
11. SEAT SWITCH HARNESS
12. SEAT RAIL
13. SEAT
Figure 13. Hood Removal With E-Hydraulics
14
20. 100 YRM 1222 Counterweight Replacement
Counterweight Replacement
If the lift truck must be put on blocks for maintenance
and repair, see Periodic Maintenance 8000 YRM 1226
for procedures of putting the lift truck on blocks.
WARNING
The counterweight is very heavy. Make sure that
the crane and lifting device have enough lifting ca-
pacity to safely lift the counterweight. The weight
of counterweights are shown in Table 1.
The counterweight normally is not removed for most re-
pairs. The counterweight is fastened to the frame with
four capscrews. The weight of the counterweights are
shown in Table 1.
REMOVE
1. Remove the battery. See section Periodic Main-
tenance 8000 YRM 1226 for the procedures to re-
move the battery.
2. Remove the top cover between the counterweight
and hood. The cover in the back part of the coun-
terweight that covers the electronic control com-
partment. See Figure 11. Fasten a sling or chain
around the counterweight. Make sure the chain or
sling and crane has the capacity to lift the counter-
weight. See Table 1.
3. From inside the battery compartment near the
bottom, remove the two top capscrews that hold
the counterweight to the frame. Remove the
capscrews, nuts, and washers that fasten the
counterweight between the wheels under the tow
pin. Use the crane to lift the counterweight away
from the frame. Make sure that you do not damage
the motor controller assembly.
INSTALL
1. Use a crane and either a sling or chain, as during
removal, to lift the counterweight into position at the
rear of the truck. See Figure 11. Install the two up-
per capscrews near the bottom of the battery com-
partment that hold the counterweight to the frame.
Tighten capscrews to 320 N•m (236 lbf ft). Install
the lower capscrews, washers, and nuts in the tow
pin area of the counterweight. Tighten the lower
capscrews (between wheels) and nuts to 66 N•m
(49 lbf ft). If removed, tighten the cover capscrews
to 75 N•m (56 lbf ft).
2. Disconnect the sling or chain. Install the top cover
and the electronic control compartment cover on
the back of the counterweight.
3. Install the battery. See the section Periodic Main-
tenance 8000 YRM 1226 for the procedures to in-
stall the battery.
Table 1. Counterweights
Model (mm*) Weight
+50 kg (110 lb)
0 kg (0 lb)
ERP20ALF and ERP25ALF (ERP040DH and
ERP050DH) (E216)
717 mm
ERP25ALF and ERP30ALF, ERP050DH and
ERP60DH (E216)
861 mm
685 kg (1510 lb)
ERP32ALF and ERP065DH (E216) 861 mm 750 kg (1653 lb)
*Approximate battery compartment lengths.
17
21. Hydraulic Tank Replacement 100 YRM 1222
Hydraulic Tank Replacement
REMOVE
1. Turn the key to the OFF position and remove the
key.
WARNING
Do not attempt to drain or replace hydraulic oil, until
hydraulic oil has cooled. The hydraulic oil is HOT at
operating temperatures. Do not permit the HOT oil
to contact skin and cause a burn.
WARNING
Do not permit dirt to enter the hydraulic tank. Dirt
can cause damage to the components of the hy-
draulic system.
WARNING
Never put tools or other metal on the battery. Metal
on the battery can cause a short circuit and possi-
ble damage or injury.
2. Open the hood and install a cardboard or plywood
cover on the top of the battery to prevent accidental
short circuits.
3. Turn the steering wheel for a full left turn for ac-
cess to the drain plug near the front of the right rear
wheel. See Figure 16. Install a container under the
drain plug of the hydraulic tank with a capacity of
27.4 liter (7.25 gal).
4. Remove dipstick and fill cap.
5. Remove the drain plug and let the oil drain from the
hydraulic tank. Install and tighten the drain plug.
6. Disconnect hydraulic lines and install plugs in all the
hoses fastened to the hydraulic tank and hydraulic
filter assembly.
7. Remove the screws from the bracket that fastens
the hydraulic tank to lift truck frame. See Figure 16.
Remove the bracket assembly.
8. Carefully lift the hydraulic tank up out of the frame.
1. MOUNTING
BRACKET
2. CAPSCREW
3. WASHER
4. NUT
5. STRAP CLAMP
6. CLAMP
7. PLUG
8. BREATHER
9. BREATHER HOSE
10. PIPE
11. DIPSTICK
AND FILL CAP
ASSEMBLY
12. PLATE
13. ADAPTER
14. HYDRAULIC
FILTER ASSEMBLY
15. GAUGE
Figure 16. Hydraulic Tank Assembly
INSPECT
WARNING
Special procedures must be followed when large
leaks or other repairs need welding or cutting. All
work must be done by authorized personnel. If the
tank is cleaned inside of a building, make sure there
is enough ventilation. See the following manuals
for additional information:
• Safe Practices for Welding and Cutting Contain-
ers That Have Held Combustibles by the Ameri-
can Welding Society, F4.1 - 1999.
• Safety In Welding and Cutting, American National
Standard, AWS Z 49.1 - 1999.
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can cause
an explosion.
18
22. 100 YRM 1222 Hydraulic Tank Replacement
CAUTION
Additives may damage the hydraulic system. Be-
fore using additives, contact your local Yale dealer.
Make a visual inspection of all sides of the tank. Inspect
the welds for cracks and leakage. Check for wet areas,
accumulation of dirt, and loose or missing paint caused
by leakage.
The hydraulic tank is a separate sheet metal tank and
can be removed from the lift truck if necessary to check
for leaks or for replacement. Repairs for leaks in the hy-
draulic tank can require special procedures described in
the next paragraphs. The most common cause of leaks
is from rust caused by the moisture of condensation or
a plugged hydraulic tank breather. Drain any water out
of the tank by removing the drain plug and letting the
tank drain until there is no water in the oil.
CLEAN
WARNING
When cleaning the tank, do not use solutions that
make dangerous gases at normal temperatures or
when heated. Wear eye and face protection. Protect
the body from burns.
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can cause
an explosion.
When cleaning the tank, do not use solutions that
make dangerous gases at normal temperatures or
when heated. Wear eye and face protection. Protect
the body from burns.
Steam Method
When cleaning with steam, use a hose with a minimum
diameter of 19 mm (0.75 in.). Control the pressure of
the steam by a valve installed at the nozzle of the hose.
If a metal nozzle is used, it must be made of a material
that does not make sparks. Make an electrical connec-
tion between the nozzle and the tank. Connect a ground
wire to the tank to prevent static electricity.
Use the following procedure to clean the tank with
steam:
1. Remove all the parts from the tank. Install the drain
plug.
2. Fill the tank 1/4 full with a solution of water and
sodium bicarbonate (baking soda) or sodium car-
bonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
3. Mix the solution in the tank using air pressure.
Make sure all the surfaces on the inside of the tank
are flushed with the solution. Drain the tank.
4. Put steam into the tank until the tank does not have
odors and the metal is hot. Steam vapors must
come from all the openings.
5. Flush the inside of the tank with boiling water. Make
sure all the loose material is removed from the in-
side of the tank.
6. Make an inspection of the inside of the tank. If it
is not clean, repeat Step 4 and Step 5 and make
another inspection. When making inspections, use
a light that is approved for locations with flammable
vapors.
7. Put plugs in all the openings in the tank. Wait 15
minutes, then remove the inlet and outlet plugs.
Test a sample of the vapor with a special indicator
for gas vapors. If the amount of flammable vapors is
above the lower flammable limit, repeat the clean-
ing procedures.
Chemical Solution Method
If the tank cannot be cleaned with steam, use the fol-
lowing procedure:
1. Mix a solution of water and trisodium phosphate or
a cleaning compound with an alkali base. Follow
the instructions given by the manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
2. Fill the tank with the cleaning solution. Use com-
pressed air to mix the solution in the tank.
19
23. Hydraulic Tank Replacement 100 YRM 1222
3. Drain the tank. Flush the inside of the tank with
hot (boiling) water. Make sure all the cleaning com-
pound is removed.
4. Make an inspection of the inside of the tank. If the
tank is not clean, repeat Step 1 through Step 3.
Make another inspection of the tank. When mak-
ing inspections, use a light that is approved for lo-
cations with flammable vapors.
5. Check the tank for flammable vapors as described
in the previous section Step 7. If the amount of
flammable vapors is not below the lower flammable
limit, repeat the cleaning procedures.
ADDITIONAL PREPARATIONS FOR TANK
REPAIR
If nitrogen gas or carbon dioxide gas is available, pre-
pare the tank for welding using these gases. See the
manual Safe Practices For Welding and Cutting Con-
tainers That Have Held Combustibles by the American
Welding Society, F4.1 - 1999. If these gases are not
available, another method using water can be used as
follows:
1. Fill the tank with water to just below the point where
the work will be done. Make sure the space above
the level of the water has a vent.
2. Use acceptable welding practices to repair the
tank. See the American National Standard "Safety
in Welding and Cutting," AWS Z 49.1 - 1999.
SMALL LEAKS, REPAIR
Use the following procedure to seal small leaks:
1. Use steam to clean the area around the leak. Re-
move all paint and dirt around the leak.
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can cause
an explosion.
2. Apply Loctite®
290 to the leak. Follow the instruc-
tions of the manufacturer.
LARGE LEAKS, REPAIR
1. Use one of the procedures described under Re-
move, Steam Method of cleaning tank or Chemical
Solution Method of cleaning tank to clean and pre-
pare the tank for repairs.
2. Use acceptable welding practices to repair the
tank. See the American National Standard Safety
In Welding and Cutting AWS Z 49.1 - 1999.
PREPARATIONS FOR USAGE AFTER
REPAIR
1. Add more water to the tank so that the water goes
above the point of where the work was done. Check
to see if there are any leaks coming from tank.
2. If there are no leaks coming from the tank, remove
all the water from the tank.
INSTALL
1. Turn the key to the OFF position and remove the
key.
WARNING
Never put tools or other metal on the battery. Metal
on the battery can cause a short circuit and possi-
ble damage or injury.
2. Open the hood and install a cardboard or plywood
cover on the top of the battery to prevent accidental
short circuits.
3. Carefully position the hydraulic tank over the correct
position in the frame and connect the hoses to the
bottom of the tank. Lower the tank into the correct
position in the frame.
4. Connect the hoses to the hydraulic tank and hy-
draulic filter assembly. Install the bracket that fas-
tens the hydraulic tank to truck frame. See Fig-
ure 16.
5. Fill the tank to the FULL mark on the dipstick and
install the dipstick/fill cap.
6. Operate the lift and steering systems and check for
leaks.
20
24. 100 YRM 1222 Painting Instructions
Painting Instructions
WARNING
Always wear protection equipment like: Gloves,
goggles, face shield, safety glasses, and a mask if
an electric sander or spraying paint either aerosol
can or spray gun is used.
WARNING
Always use solvents and paints in an area with
ventilation. Do not use solvents or paints near
heat, fire, or electrical equipment that can make
sparks. Follow the manufacturer’s instructions
and cautions.
1. Remove all dirt from the surface to be painted.
Clean the area to be painted. Use a solvent for
painted surfaces to remove grease and oil before
sanding. Do not use solvent on new paint. Make
sure all oil and grease is removed.
2. Use sandpaper to remove the top surface of the
paint and rust from the metal. All metal surfaces
where the paint is completely removed, must be
painted. Use a primer. Apply the primer before
applying the final coat of paint.
3. Protect all surfaces that will not be painted. See the
list of items in Figure 17.
CAUTION
Do not paint the pads, plastic covers or knobs,
cables, labels, and information plates, or controls.
Paint can make some assemblies not operate cor-
rectly.
4. Paint the surfaces. Use the correct paint from your
dealer for Yale lift trucks. Follow the directions on
the container. The correct arrangement of colors is
shown in Figure 17.
WARNING
Make sure all labels are installed after painting is
complete. Safety labels are installed on the lift truck
to give information about possible hazards. It is
important that all safety labels are installed on the
lift truck and can be read.
5. Check that all labels are installed in the correct lo-
cations on the lift truck. See Figure 18. New labels
are available from your dealer for Yale lift trucks.
21
25. Painting Instructions 100 YRM 1222
NOTE: USE COLORS APPROVED BY YALE CORPORATION. DO NOT PAINT THE FOLLOWING ITEMS: PEDAL
PADS, LEVER KNOBS, INSTRUMENTS, STEERING WHEEL, SEAT ASSEMBLY AND SEAT RAILS, INFORMA-
TION CASE AND COVER, TIRES, MAST CHAINS, AND HOSES, ALL LABELS AND INFORMATION PLATES,
BATTERY CONNECTOR, PARKING BRAKE HANDLE, KEY SWITCH, CYLINDER RODS, ALL PLASTIC COVERS,
AND STEERING COLUMN COVER.
NOTE: LIGHT AREAS = GOLD; DARK AREAS = BLACK; AND PARCHMENT = LOAD BACKREST, FORKS, AND
WHEELS.
Figure 17. Color Arrangement
22
26. 100 YRM 1222 Safety Label Replacement
Safety Label Replacement
WARNING
Labels that have WARNINGS or CAUTIONS must be
replaced if they are damaged. If a mast of a differ-
ent size or an accessory carriage is installed, the
capacity rating can change. Changes in the kind of
drive tires can change the capacity rating. See a
dealer for YALE lift trucks for a replacement name-
plate. The nameplate information is a safety item
and must be correct for the equipment and config-
uration of the lift truck.
NOTE: If the labels or information plates are missing or
have damage, they must be replaced.
NOTE: The nameplate is installed using rivets. The old
rivets must be removed before installing a new name-
plate.
1. Before installing a new label, make sure the surface
is dry and has no oil or grease. Do not use solvent
on new paint. Clean the surface of old paint using
a cleaning solvent. See Figure 18.
2. Remove the paper from the back of the label. Do
not touch the adhesive surface.
3. Carefully hold the label in the correct position above
the surface. The label cannot be moved after it
touches the surface. Put the label on the surface.
Make sure all air is removed from under the label
and the corners and edges are tight.
23
28. 100 YRM 1222 Battery Specifications
Legend for Figure 18
NOTE: NOT ALL LABELS USED ON THESE LIFT TRUCK MODELS ARE SHOWN IN FIGURE 18. SEE THE
PARTS MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON THESE LIFT TRUCKS.
A. LABEL IS UNDER HOOD, NEAR CENTER
1. MAST WARNING LABEL
2. TIP OVER (OPERATOR RESTRAINT)
3. OVERHEAD GUARD TEST PLATE (LEFT SIDE)*
4. OPERATOR WARNING LABEL (RIGHT SIDE)
5. PARK BRAKE WARNING
6. PATENT PLATE
7. U.L. INSPECTION PLATE*
8. BATTERY SPACER
9. EMERGENCY BATTERY DISCONNECT
10. LIFT AND TILT LABEL
11. AUXILIARY FUNCTIONS LABEL
12. YALE LOGO
13. FIRE SAFETY LABEL*
14. NO RIDERS
15. PINCH POINT
16. NO ONE ON OR UNDER FORKS
17. NAMEPLATE
18. WARNING LABEL FOR RESTRAINT ROD
(UNDERSIDE OF HOOD)
19. BLACK YALE LETTERS
20. AC POWER LABEL
*NORTH AMERICA ONLY
Battery Specifications
ERP20-32ALF (ERP040-065DH) (E216)
MODEL TRUCKS
Battery Size Min/Max Weight
Model
Minimum
Compartment
Size
Length × Width Length Width Minimum Maximum
ERP20-25ALF
(ERP040-050DH)
712 × 1032 mm
(28.0 × 40.6 in.)
1025/1028 mm
(40.4/40.5 in.)
708/711 mm
(27.9/28.0 in.)
1470 kg
(3241 lb)
1625 kg
(3582 lb)
ERP25-32ALF
(ERP050-065DH)
856 × 1032 mm
(33.7 × 40.6 in.)
1025/1028 mm
(40.4/40.5 in.)
852/855 mm
(33.5/33.7 in.)
1770 kg
(3902 lb)
1965 kg
(4332 lb)
NOTE: Tolerances of the battery compartment are +3 and 0 mm (+0.12 and 0 in.). The battery size column
shows the size range that will permit the battery to still fit into a battery compartment.
NOTE: Battery compartment length is front to back. Width is side to side. The "length" dimension of the battery must
fit within the battery compartment side-to-side dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum.
Battery width must fit within the battery compartment front-to-back dimension.
WARNING
The battery must fit the battery compartment so that the battery restraint system will operate correctly. Use
only batteries with the correct length shown in this table. Adjust the spacer plate to prevent the battery
from moving more than 13 mm (0.5 in.) forward or backward.
25
29. 1400 YRM 1223 Description
General
This section has the description and repair procedures for the differential, drive axle, traction motor, and the wet disc
brakes.
Description
The drive unit consists of following main components
(see Figure 1):
• The traction motor with hollow shaft.
• Mechanical differential assembly (located on
left-hand side of traction motor shaft).
• The gearbox with intermediate flange, containing the
wet disc brakes.
• Main housings, containing the pistons for the wet disc
brakes and the parking brake levers.
• Speed sensor and reluctor wheel (located on traction
motor shaft, see Figure 8).
1. WHEEL HUB
2. GEARBOX (LH)
3. INTERMEDIATE FLANGE (LH)
4. MAIN HOUSING (LH)
5. PARKING BRAKE LEVER
6. TRACTION MOTOR
7. MAIN HOUSING (RH)
8. INTERMEDIATE FLANGE (RH)
9. GEARBOX (RH)
10. SPEED SENSOR
11. DIFFERENTIAL ASSEMBLY
Figure 1. Drive Unit
1
30. Description 1400 YRM 1223
The drive unit assembly is fastened to the frame of the
lift truck by the frame mounts of the main housings. See
Figure 2.
The mast is mounted on the J-hook mountings of the
main housings of the drive unit. See Figure 3.
The traction motor is mounted in between the two main
housings. The traction motor generates the power to
the differential assembly. See Figure 4.
1. FRAME MOUNTS
Figure 2. Drive Unit Frame Mounts
2
32. Description 1400 YRM 1223
The differential then transfers the power through the
axle shaft to the input shafts located in the intermediate
flange assemblies. The input shaft drive gears transfer
the power to the driven gears. The driven gears then
transfer the power to the sun pinion. See Figure 5.
1. DRIVE GEAR
2. INTERMEDIATE FLANGE
3. INPUT SHAFT
4. AXLE SHAFT
5. DRIVEN GEAR
6. SUN PINION
Figure 5. Drive Gear, Driven Gear, and Sun Pinion
The sun pinion then transfers the power to the plane-
tary gears and planetary carrier which then engages the
wheel hubs. See Figure 6.
The wet brake discs are mounted on the intermediate
flanges. The piston, which is located in the main hous-
ing (one in each main housing), is activated when the
brake pedal is applied. The piston presses against the
disc pusher which compresses the brake friction discs
and steel discs which causes the braking. See Figure 7.
1. PLANETARY CARRIER
2. PLANETARY GEARS
3. RING GEAR
4. WHEEL HUB
Figure 6. Planetary Gears
1. INTERMEDIATE FLANGE
2. DISC PUSHER
3. BRAKE DISC PACK
Figure 7. Brake Disc Pack
4
33. 1400 YRM 1223 Wet Disc Brake Repair
The parking brake levers press against the back of the
piston which forces the piston to press against the disc
pusher to compress the brakes friction discs and steel
discs to mechanically apply the parking brake.
The speed sensor is mounted on the main housing on
the right-hand side of the drive unit. The reluctor wheel
is mounted on the traction motor shaft on the right-hand
side of the traction motor. The speed sensor is a hall
effect sensor which reads the variation in its magnetic
field when a tooth of the reluctor wheel passes the sen-
sor. See Figure 8.
1. SPEED SENSOR
2. RELUCTOR WHEEL
Figure 8. Speed Sensor and Reluctor Wheel
Wet Disc Brake Repair
WET DISC BRAKES
For replacement of the pistons and piston seals, refer
to the section Main Housing Repair.
Remove
STEP 1.
Remove the gearbox. Refer to the section Gearbox Replacement.
STEP 2.
Press down on the disc pusher device and remove the
retaining rings from the studs.
5
34. Wet Disc Brake Repair 1400 YRM 1223
STEP 3.
Remove the disc pusher device from the studs.
1. DISC PUSHER DEVICE
2. STUDS
STEP 4.
Remove the springs from the studs.
If necessary, remove the studs.
6
35. 1400 YRM 1223 Wet Disc Brake Repair
1. STUDS
2. SPRINGS
STEP 5.
Note the position of the notches on the steel discs for
correct positioning during assembly.
Remove one steel disc.
1. STEEL DISC
2. NOTCH
7
36. Wet Disc Brake Repair 1400 YRM 1223
STEP 6.
Remove the one friction disc.
1. FRICTION DISC
STEP 7.
Remove four springs/spacers.
1. SPRINGS/SPACERS
8
37. 1400 YRM 1223 Wet Disc Brake Repair
STEP 8.
Repeat STEP 5 through STEP 7 until the last steel disc is removed.
STEP 9.
Remove the aluminum reaction disc.
Inspect
1. Inspect the brake friction discs and brake steel
discs. The discs must be measured as a pack
(6 steel discs and 5 friction discs) to determine if
the discs need replaced. Replace discs as a pack
when the thickness is less than 23 mm (0.91 in.).
A new disc pack will have a thickness of 23.95 to
24.45 mm (0.94 to 0.96 in.). When replacing the
disc pack, all springs must also be replaced.
2. Inspect the aluminum reaction disc. Replace the
aluminum reaction disc when the thickness is equal
or less than 4.5 mm (0.18 in.). A new aluminum re-
action disc will have a thickness of 4.95 to 5.05 mm
(0.195 to 0.199 in.).
Install
STEP 1.
If removed, install the four pins.
9
38. Wet Disc Brake Repair 1400 YRM 1223
STEP 2.
If removed, apply Loctite®
242 to the studs and install
the studs. Tighten the studs to 2 N•m (17.7 lbf in).
STEP 3.
Install the aluminum reaction disc.
NOTE: The first and last disc installed must be a smooth steel disc.
STEP 4.
Align the notch of the steel disc as noted during disas-
sembly.
Install one steel disc.
1. NOTCH
10
39. 1400 YRM 1223 Wet Disc Brake Repair
STEP 5.
Install one friction disc.
STEP 6.
Install four springs/spacers.
STEP 7.
Repeat STEP 4 through STEP 6 until six steel discs and five frictions discs have been installed.
11
40. Wet Disc Brake Repair 1400 YRM 1223
STEP 8.
Install the springs onto the studs.
1. STUDS
2. SPRINGS
STEP 9.
Install the disc pusher device onto the studs.
12
41. 1400 YRM 1223 Wet Disc Brake Repair
1. DISC PUSHER DEVICE
2. STUDS
STEP 10.
Press down on the disc pusher device and install the
retaining rings into the seats on the studs.
STEP 11.
Install the gearbox. Refer to the section Gearbox Re-
placement.
13
42. Gearbox Replacement 1400 YRM 1223
Gearbox Replacement
REMOVE
Gearbox Removal
WARNING
When putting the lift truck on blocks, make sure the
surface is solid, even, and level. Any blocks used to
support the lift truck must be solid, one-piece units.
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift truck.
2. Raise the lift truck and put blocks under the frame
so that the drive wheels do not touch the floor. Put
blocks under the counterweight for stability.
3. Remove the mast assembly as described in the
section Mast Repairs, 2, 3, and 4-Stage Masts
4000 YRM 1148.
4. Disconnect the battery connector.
5. Remove the wheel from the wheel hub of the gear-
box being replaced.
6. Remove the gearbox oil fill plug. See Figure 9.
7. Remove the gearbox magnetic drain plug to drain
the oil from the gearbox into a suitable container.
See Figure 9.
8. Remove the brake oil fill/breather plug from main
housing. See Figure 9.
9. Remove the brake oil drain plug to drain the oil from
the main housing into a suitable container. See
Figure 9.
10. Place a sling connected to an overhead lift around
the gearbox and wheel hub assembly and apply
light tension to the sling.
11. Remove the socket-head screws retaining the gear-
box to the main housing. Note the positions of the
short and long socket-head screws for when the
gearbox is installed. See Figure 10.
12. Remove the gearbox and wheel hub assembly.
1. BRAKE OIL FILL/BREATHER PLUG
2. GEARBOX OIL FILL PLUG
3. GEARBOX OIL DRAIN PLUG (MAGNETIC)
4. BRAKE OIL DRAIN PLUG
Figure 9. Oil Refill and Drain Plugs
14
43. 1400 YRM 1223 Gearbox Replacement
Figure 10. Gearbox Removal/Installation
Legend for Figure 10
1. M8 SOCKET-HEAD SCREWS, 3 EACH
2. M12 X 1.75 X 70 MM LONG SOCKET-HEAD
SCREWS, 11 EACH
3. M12 X 1.75 X 40 MM SHORT SOCKET-HEAD
SCREWS, 2 EACH
Intermediate Flange Removal
STEP 1.
Remove the brake discs and friction plates. Refer to the section Wet Disc Brake Repair.
STEP 2.
For the left-hand side gearbox only, remove the spacer
from the input shaft.
15
44. Gearbox Replacement 1400 YRM 1223
STEP 3.
Remove the socket-head screws used to retain the in-
termediate flange to the gearbox housing.
Insert a prybar into the pry slots between the interme-
diate flange and the gearbox housing and pry upwards
to break the seal between the flange and housing.
1. SOCKET-HEAD SCREWS
2. PRY SLOTS
16
45. 1400 YRM 1223 Gearbox Replacement
STEP 4.
Remove the intermediate flange assembly from the
gearbox housing.
DISASSEMBLE
Due to the requirement of specialized tools and
equipment (which most service departments do not
possess) to properly service this gearbox, it is highly
recommended to replace rather than rebuild this as-
sembly.
Intermediate Flange
NOTE: If the inner ring for the needle bearing is being replaced, the needle bearing in the gearbox housing must be
replaced.
STEP 1.
Using an appropriate puller, remove the needle bearing
from the gearbox housing.
1. GEARBOX
2. NEEDLE BEARING
17
46. Gearbox Replacement 1400 YRM 1223
STEP 2.
Remove the snap ring retaining the input shaft into the
intermediate flange.
1. SNAP RING
2. INPUT SHAFT
18
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