YALE G807 ERP040VT LIFT TRUCK Service Repair Manual

ERP030/040VT (G807)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524295629 0100 YRM 1329 09/14
OPERATOR'S CAB........................................................................................................ 550025937 0100 YRM 1446 09/14
AC MOTOR REPAIR...................................................................................................... 524327049 0620 YRM 1385 09/14
TRANSAXLE................................................................................................................... 524295630 1300 YRM 1330 09/12
STEERING SYSTEM...................................................................................................... 524295631 1600 YRM 1331 09/14
BRAKE SYSTEM............................................................................................................ 524295632 1800 YRM 1332 12/10
HYDRAULIC SYSTEM.................................................................................................... 524295633 1900 YRM 1333 09/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVES............................................................................................. 524319495 2000 YRM 1334 09/14
CYLINDER REPAIR (MAST S/N A270-72, A551, A555, A559, A626, A627, A751-52,
B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515, D562-64, E509,
E564).......................................................................................................................... 524319496 2100 YRM 1382 03/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE SUPERVISOR................................................................................. 524319497 2200 YRM 1335 09/14
USER INTERFACE SERVICE TECHNICIAN................................................................. 524319498 2200 YRM 1336 09/14
ELECTRICAL SYSTEM.................................................................................................. 524320282 2200 YRM 1337 09/14
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
MAST REPAIR (S/N C661, C662, C663, C665)............................................................. 524333799 4000 YRM 1405 05/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
PERIODIC MAINTENANCE............................................................................................ 524320287 8000 YRM 1339 09/14
CAPACITIES AND SPECIFICATIONS........................................................................... 524306565 8000 YRM 1340 09/14
DIAGRAMS..................................................................................................................... 524319503 8000 YRM 1341 09/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524319504 9000 YRM 1377 10/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 524320413 (12/14)

Maintenance
FRAME
ERP15-20VT (ERP030-040VT) [G807];
ERP16-20VF (ERP30-40VF) [A955]
PART NO. 524295629 0100 YRM 1329

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
Introduction ...............................................................................................................................................................1
General .................................................................................................................................................................1
Description of Operation .......................................................................................................................................2
Discharging the Capacitors .................................................................................................................................. 3
Rapid Charge ....................................................................................................................................................... 3
Covers and Floor Plates ........................................................................................................................................... 4
Overhead Guard Replacement .................................................................................................................................6
Remove ................................................................................................................................................................ 6
Install .................................................................................................................................................................. 10
Hood and Seat Assembly ....................................................................................................................................... 12
Remove .............................................................................................................................................................. 15
Install .................................................................................................................................................................. 17
Ground Test ........................................................................................................................................................17
Counterweight Replacement .................................................................................................................................. 18
Remove .............................................................................................................................................................. 20
Install .................................................................................................................................................................. 23
Safety Labels ..........................................................................................................................................................25
Painting Instructions ............................................................................................................................................... 30
Battery Specifications ............................................................................................................................................. 31
European Model Trucks ERP15-20VT (G807)....................................................................................................31
US Model Trucks ERP030-040VT (G807)...........................................................................................................33
European Model Trucks ERP16-20VF (A955).................................................................................................... 34
US Model Trucks ERP30-40VF (A955)...............................................................................................................35
This section is for the following models:
ERP15-20VT (ERP030-040VT) [G807];
ERP16-20VF (ERP30-40VF) [A955]
Table of Contents
i

Introduction
GENERAL
This section contains 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, side panels, and
labels. Throughout this section, forward will refer to
travel in the direction of the forks and left and right will
be determined by an operator sitting in the seat facing
forward.
See Figure 1 for lift truck models
• ERP15-20VT (ERP030-040VT) (G807)
See Figure 2. for lift truck models
• ERP16-20VF (ERP30-40VF) (A955)
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 1. Truck Orientation for Lift Truck
ERP15-20VT (ERP030-040VT) (G807)
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 2. Truck Orientation for Lift Truck
ERP16-20VF (ERP30-40VF) (A955)
0100 YRM 1329 Introduction
1

DESCRIPTION OF OPERATION
The frame is a welded assembly with mounts for the
counterweight, overhead guard, mast, steering
system, side panels, hydraulic system and transaxles.
See Figure 3. The hood opens on hinges to provide
access to the battery compartment. The weight of the
battery is a major part of the counterweight system on
this truck. A slot in the overhead guard permits
removal of the battery without removing the overhead
guard. Spacers may be added around the battery as
required on some models.
Each lift truck has a cast-iron counterweight
appropriately weighted for the indicated capacity on
the nameplate.
The hydraulic pump and motor assembly and
hydraulic tank are in the counterweight. The
counterweight cover is removed for access.
The AC drive motors and transaxles are located
under the floor plates in the operator compartment.
The floor plates are held in position by tabs and are to
be removed to give access to components
underneath.
The hydraulic control valve is fastened to the front of
the battery compartment and has covers to protect
the control valve and control linkages.
NOTE: FRAME SHOWN FROM RIGHT SIDE AND REAR.
Figure 3. Frame
Introduction 0100 YRM 1329
2

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 any compartment
covers or inspecting or repairing the electrical
system. DO NOT place tools on top of the battery.
If a tool causes a short circuit, the high current
flow from the battery can cause personal injury or
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 adjustments, 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-Disconnect 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.
1. Ensure the capacitors are discharged by
performing Step 2 through Step 6 below.
2. Turn the key or keyless switch to the OFF
position.
3. Disconnect the battery by separating the
connectors.
4. Block the drive wheels to prevent the lift truck
from moving.
5. Make sure the Emergency-Disconnect switch
HAS NOT been activated. If the Emergency-
Disconnect switch is activated, rotate the switch
to the right until it pops up.
6. Push horn button. Wait 30 seconds to be sure
capacitors are fully discharged.
RAPID CHARGE
The lift trucks covered in this manual may be
equipped with a Rapid Charge System (see Figure 4).
With a Rapid Charge System, the battery is charged
during operator breaks or when the truck is not being
used. The rapid charge system provides extended
operation with a single battery.
Some of the features of the Rapid Charge System
include:
• Battery connector externally mounted for easy
access
• Vented side covers for improved battery
cooling
• Requires rapid charge vented battery and
sealed battery fan box with thermostat
1. RAPID CHARGE CONNECTOR
2. VENTED SIDE COVER
Figure 4. Rapid Charge System
0100 YRM 1329 Covers and Floor Plates
3

Covers and Floor Plates
Various covers and floor plates provide access to
components during service and securely cover areas
during normal operation. Covers in the floor of the op-
erator compartment allow access to the traction con-
trollers, AC drive motors, service and parking brakes.
A cover on the top of the counterweight provides ac-
cess to the hydraulic tank, hydraulic pump and motor
assembly, and the hoist controller. See Figure 5.
Covers and Floor Plates 0100 YRM 1329
4

Figure 5. Covers and Floor Plates
0100 YRM 1329 Covers and Floor Plates
5

Legend for Figure 5
NOTE: COUNTERWEIGHT FOR ERP15-20VT (ERP030-040VT) (G807) LIFT TRUCK SHOWN AS AN EXAM-
PLE ONLY.
A. COUNTERWEIGHT COVER WITH RAPID CHARGE, LIFT TRUCKS MANUFACTURED AFTER JUNE, 2012
1. FLOOR PLATE MANUAL HYDRAULIC
2. FLOOR PLATE BRAKE PEDAL
3. FLOOR PLATE E-HYDRAULIC
4. FLOOR MAT MANUAL HYDRAULIC
5. FLOOR MAT E-HYDRAULIC
6. MANUAL HYDRAULIC COVERS
7. HOSE COVER
8. COUNTERWEIGHT COVER
Overhead Guard Replacement
WARNING
The overhead guard is part of the operator protec-
tion system. DO NOT operate the lift truck without
the overhead guard correctly fastened to the lift
truck.
The overhead guard is designed to provide protection
to the operator from falling objects and in the event of
a tip over. A high visibility design allows for an unob-
structed view while maintaining structural integrity.
Removal of the battery is simplified by the slot in the
overhead guard. This provides access to the battery
with an overhead lifting device without removing the
overhead guard.
REMOVE
WARNING
The overhead guard is heavy. Make sure the sling,
chain, eye bolts, and crane or lifting device have
the capacity to lift the overhead guard.
1. Remove hood and seat. See Hood and Seat As-
sembly section in this manual.
2. Remove rear capscrew, washers, and vibration
mount top from rear leg and counterweight.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
3. Repeat Step 2 for opposite rear leg.
4. Remove three capscrews from cowl and front leg.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
5. Repeat Step 4 for opposite front leg.
6. Remove nut, washers, front capscrew, and vibra-
tion mount top from front leg and frame.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
8. Use a lifting device to lift overhead guard until it is
just higher than the counterweight.
NOTE: Tag electrical wiring and note routing during
removal to aid in installation.
9. Tag and disconnect electrical wiring for display.
Remove display from display cover.
NOTE: Note routing of electrical wires into, out of, or
on the overhead guard during removal to aid in instal-
lation.
NOTE: Tag electrical connectors during removal to
aid in installation.
Overhead Guard Replacement 0100 YRM 1329
6

Figure 6. Overhead Guard for Lift Truck ERP15-20VT (ERP030-040VT) (G807)
0100 YRM 1329 Overhead Guard Replacement
7

Legend for Figure 6
1. REAR CAPSCREW
2. WASHER
3. REAR LEG
4. VIBRATION MOUNT TOP
5. VIBRATION MOUNT BOTTOM
6. COUNTERWEIGHT
7. NUT
8. FRONT CAPSCREW
9. FRONT LEG
10. FRAME
11. CAPSCREW
12. OVERHEAD GUARD
13. GRAB HANDLE
14. COWL
15. DISPLAY COVER
16. RETAINING WASHER
17. CLIP NUT
8

Figure 7. Overhead Guard for Lift Truck ERP16-20VF (ERP30-40VF) (A955)
9

Legend for Figure 7
1. REAR CAPSCREW
2. WASHER
3. REAR LEG
4. VIBRATION MOUNT TOP
5. COUNTERWEIGHT
6. NUT
7. FRONT CAPSCREW
8. FRONT LEG
9. FRAME
10. CAPSCREW
11. GRAB HANDLE
12. OVERHEAD GUARD
13. COWL
14. DISPLAY COVER
15. VIBRATION MOUNT BOTTOM
16. RETAINING WASHER
17. CLIP NUT
NOTE: On lift truck models ERP030-040VT (G807)
and ERP30-40VF (A955) equipped with inboard tail
lights, the rear lights are mounted inboard of the over-
head guard, reducing the risk of damage to the lights.
A protection shield above the lights also provides pro-
tection from above. The overhead guard will include
mounting features for both inboard and outboard
lights.
10. Tag and disconnect electrical wires that go
through the legs of overhead guard. Carefully re-
move the wiring if necessary.
11. Completely remove overhead guard from lift truck.
12. Remove two vibration mount bottoms from coun-
terweight; remove two vibration mount bottoms
and two retaining washers from frame.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
13. Remove two capscrews and grab handle from
front leg.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
NOTE: Perform following step if grab handle is
mounted onto rear leg.
14. Remove two capscrews and grab handle from
rear leg.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
15. Remove two capscrews, display cover, and two
clip nuts from overhead guard.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
INSTALL
1. Install grab handle and capscrews onto front leg.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
NOTE: Perform the following step if grab handle is
mounted onto rear leg.
2. Install grab handle and two capscrews onto rear
leg. Tighten capscrews to 6.5 N•m (57.5 lbf in)
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
3. Install two retaining washers and two vibration
mount bottoms onto frame; install two vibration
mount bottoms onto counterweight.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
10

4. Using a lifting device, position overhead guard
just above mounting holes on counterweight and
frame.
5. Route electrical wires through overhead guard
legs as noted during removal.
NOTE: Make sure electrical wires do not get pinched
when overhead guard is lowered onto mounts.
6. Carefully lower overhead guard onto vibration
mount bottoms on counterweight and frame.
7. Install front capscrew, vibration mount top, wash-
ers, and nut into front leg and frame. Tighten cap-
screws to 66 N•m (49 lbf ft).
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
9. Install vibration mount top, washers and rear cap-
screw into rear leg and counterweight.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
10. Repeat Step 9 for opposite rear leg.
11. Install three capscrews into cowl and front leg.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
13. Install two clip nuts, display cover and two cap-
screws onto overhead guard.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
WARNING
The ignition switch is a reed switch which uses an
applied magnetic field. If a strong magnet is
placed near the ignition switch, it may not func-
tion properly (such as not shutting off power). To
ensure ignition switch functions properly, do not
place a magnet near the ignition switch.
14. Install display into display cover. Connect electri-
cal wiring to display as noted during removal.
15. Install hood and seat. See Hood and Seat As-
sembly Repair section in this manual.
11

Hood and Seat Assembly
The hood is the platform for the seat assembly and is
located above the battery. It functions as a battery re-
straint that completely covers the battery compart-
ment. See Figure 10. When correctly locked to the
frame, it will hold the battery in the battery compart-
ment if an accident causes the lift truck to tip over.
The hood is a stamped steel cover. Two hinges at the
back attach to the overhead guard. A latch assembly
on the front bulkhead locks the hood closed during
operation. A gas-controlled strut holds the hood in the
open position.
See Figure 10 for lift trucks manufactured before No-
vember, 2014
See Figure 11 for lift trucks manufactured after No-
vember, 2014
Opening the latch assembly unlocks the hood from
the frame so the hood can be raised to access the
battery. The latch assembly must be in good condition
and properly secured before the lift truck can be oper-
ated. To raise the hood on a lift truck with manual hy-
draulics, the manual hydraulic lever and linkage as-
sembly must be moved. Pull latch handle under man-
ual hydraulic cover toward the seat, allowing the lever
and linkage assembly to drop forward out of the way.
See Figure 8. If the sliding latch assembly does not
lock the hood in the closed position, the lever and
linkage assembly will not lock into position and the lift
truck will not operate.
A large, red push-button switch is mounted on the
lever and linkage assembly for manual hydraulics and
in the armrest console for the electro-hydraulics. This
switch is an emergency battery disconnect that allows
the operator to quickly disconnect the battery while
seated on the lift truck in case of an emergency. See
Figure 8.
A. MANUAL HYDRAULIC LEVERS
B. E-HYDRAULIC MINI-LEVERS
1. MANUAL HYDRAULIC LEVER LATCH HANDLE
2. EMERGENCY DISCONNECT SWITCH
Figure 8. Emergency Disconnect Switch
Hood and Seat Assembly 0100 YRM 1329
12

The seat assembly slides on seat rails that are fas-
tened to spacer plates (Figure 9) and hood by four
capscrews. A lever at the left front side of the base
controls the adjustment of the seat to the forward and
backward positions. Optional seats are available in
cloth or vinyl with features such as non-suspension,
full suspension, and limited swivel.
All seats have a seat switch installed in the bottom
cushion that senses operator presence. When the op-
erator is not on the seat, the seat switch opens and
interrupts the controller stopping operation of the lift
truck as follows:
• After 1.5 seconds, hydraulic functions will
cease to operate.
• The lift truck, through regenerative braking, will
slowly come to a complete stop.
NOTE: The seat belt can be either black or red.
The lift trucks covered in this Service Manual can be
equipped with one of three seat belt configurations:
• Seat belt with no operational interlock.
• Seat belt with operational interlock. Seat belt
must be fastened for lift truck to start or travel.
• Seat belt with sequencing interlock. Operator
must be in the seat, and the seat belt must be
fastened, before lift truck will operate. This seat
belt is used with the Optional Operator Pres-
ence System.
See the Operating Manual for more information on
these seat belt types.
The hood, seat belt, hip restraint brackets, seat, and
seat mount are all parts of the operator restraint sys-
tem.
Checks and adjustments for the operator restraint
system are described in the Operating Manual or
See Periodic Maintenance 8000YRM1339 for lift
truck models
• ERP15-20VT (ERP030-040VT) (G807)
truck models
• ERP16-20VF (ERP30-40VF) (A955)
1. HOOD
2. SEAT ASSEMBLY
3. SEAT SPACER PLATES
Figure 9. Seat Spacer Location
0100 YRM 1329 Hood and Seat Assembly
13

A. LOCKED POSITION B. OPEN (RELEASE) POSITION
1. SEAT
2. HOOD
3. SEAT SWITCH CONNECTOR
4. LATCH ASSEMBLY
Figure 10. Hood and Seat Assembly, Lift Trucks Manufactured Before November, 2014
14

To raise the hood and seat assembly, move the seat
to the rear of the hood. For lift trucks equipped with
Rapid/Fast Charging, slide the seat all the way for-
ward. If necessary, move the armrest all the way back
if lift truck is equipped with E-Hydraulic control levers.
Move the steering column to the most forward posi-
tion. If lift truck is equipped with manual hydraulics,
release and move the hydraulic lever and linkage as-
sembly forward. See Figure 8. Open the latch mecha-
nism and raise the hood.
See Figure 10 for lift trucks manufactured before No-
vember, 2014
See Figure 11 for lift trucks manufactured after No-
vember, 2014
REMOVE
1. Disconnect battery connector.
NOTE: Tag electrical connectors during removal to
aid in installation.
2. Tag and disconnect the electrical connectors to
the emergency battery disconnect and the seat
switch.
3. Disconnect seat harness and remove from hood.
NOTE: The seat assembly does not have to be re-
moved from the hood for the hood to be removed
from the lift truck. Perform Step 4 if removing seat as-
sembly.
4. To remove seat assembly, disconnect electrical
connectors if not already done, remove four
screws, washers, spacers if required, and seat
assembly from hood.
5. Raise hood.
6. Remove gas spring. See Figure 12.
A. OPEN (RELEASE) POSITION
1. SEAT
2. HOOD
3. SEAT SWITCH CONNECTOR
4. LATCH ASSEMBLY
Figure 11. Hood and Seat Assembly, Lift Trucks Manufactured After November, 2014
15

7. Lower hood.
8. Remove two captive screws, tow pin, and coun-
terweight cover from counterweight.
9. Remove two nuts securing hood mounting bolts.
See Figure 12.
10. Remove washers and hood mounting bolts from
hood hinges and hood mounting brackets. See
Figure 12.
11. Release latch and lift hood out of lift truck.
1. HOOD
2. GAS SPRING
3. NUT
4. WASHER
5. HOOD MOUNTING BOLT
6. HOOD HINGE
7. OVERHEAD GUARD REAR LEG
8. HOOD MOUNTING BRACKET
9. CAPSCREW
Figure 12. Hood Mounting
16

12. If necessary, hood mounting brackets can be re-
moved from overhead guard rear legs by remov-
ing the nuts and capscrews. See Figure 12.
INSTALL
1. Install hood mounting brackets, capscrews, and
nuts onto overhead guard rear legs, if removed.
Do not fully tighten capscrews at this time. See
Figure 12.
2. Lower hood into position.
3. Install hood mounting bolts and washers onto
hood hinges and hood mounting brackets. See
Figure 12.
4. Install nuts onto hood mounting bolts. See Fig-
ure 12.
5. Allow hood to engage latch and adjust hood for
adequate latch engagement with the hood striker.
Adequate engagement is when the latch com-
pletely clears the 90 degree bend of the hood
striker.
6. Tighten capscrews on hood mounting brackets.
7. Raise hood.
8. Install gas spring. See Figure 12.
9. Install seat, if removed, and route seat harness
through hood and connect to seat.
10. Connect the electrical wiring harness to the seat
switch.
11. Close the hood. Make certain that the latch is
properly engaged.
12. Install counterweight cover, captive screws, and
tow pin onto counterweight.
13. Move manual hydraulic lever and linkage assem-
bly back to upright position and lock in place.
14. Connect the battery connector.
GROUND TEST
NOTE: If the static discharge ground connection is
not secured properly it could lead to the possible fail-
ure of the traction and/or pump motor controllers.
1. To ensure proper installation of seat assembly
and associated bracketing, perform continuity
test.
2. Using an ohm meter, place a test lead at the arm-
rest mounting bolt and another at the truck frame.
The resistance needs to read 5 Ohms or less.
See Figure 13.
3. If the resistance is greater than 5 Ohms, double
check installation of seat assembly, both ends of
seat wiring harness, and wiring harness ground
strap.
1. ARMREST BOLT
2. FRAME
Figure 13. Ground Test
17

Counterweight Replacement
WARNING
DO NOT operate the lift truck if the capscrews for
the counterweight are not installed. The counter-
weight is a structural member of the truck chas-
sis. The counterweight cannot be removed with-
out first supporting the frame. If the capscrews
are not properly installed the counterweight will
not support the lift truck.
A one-piece, cast iron counterweight is used to offset
the weight of the load and support the rear suspen-
sion of the lift truck, see figures indicated below. The
weight of the counterweight is shown in the tables be-
low.
See Figure 14 and Table 1 for lift truck models
• ERP15-20VT (G807) manufactured before No-
vember, 2014
• ERP030-040VT (G807)
• ERP15-20VT (G807) manufactured after No-
vember, 2014
• ERP16-20VF (ERP30-40VF) (A955)
A compartment space, accessed by removal of the
counterweight cover, has been designed to house the
hydraulic tank, hydraulic pump and motor, hoist con-
troller, and electrical connections.
A battery platform is used to support the battery on
the lift truck frame. The battery platform also serves
as part of the counterweight system and requires the
use of an overhead lifting device for removal or instal-
lation. Be sure to replace the same battery platform,
or one of equal weight, if the platform must be re-
moved.
Figure 14. Counterweight for Lift Truck
ERP15-20VT (G807) Manufactured Before
November, 2014 and ERP030-040VT(G807)
Figure 15. Counterweight for Lift Truck
ERP15-20VT (G807) Manufactured After
November, 2014
Counterweight Replacement 0100 YRM 1329
18

Figure 16. Counterweight for Lift Truck ERP16-20VF (ERP30-40VF) (A955)
Table 1. Counterweights for Lift Truck ERP15-20VT (ERP030-040VT) (G807)
Model mm (in)* Weight + 13.8 kg (30 lb) -
13.8 kg (30 lb)
ERP15-20VT (ERP030-04VT) 546 mm (21.5 in.) 690 kg (1521 lb)
*Approximate battery compartment lengths.
Table 2. Counterweights for Lift Truck ERP16-20VF (ERP30-40VF) (A955)
Model mm (in)* Weight + 20 kg (44 lb) -
0 kg (0 lb)
ERP16-20VF (ERP30-40VF) 546 mm (21.5 in.) 670 kg (1477 lb)
*Approximate battery compartment lengths.
0100 YRM 1329 Counterweight Replacement
19

REMOVE
1. Remove battery.
truck models
• ERP15-20VT (ERP030-040VT) (G807)
truck models
• ERP16-20VF (ERP30-40VF) (A955)
2. Remove overhead guard. See Overhead Guard
Replacement section in this manual.
3. Remove hydraulic pump and motor and hydraulic
tank from counterweight. See Hydraulic System
1900YRM1333.
4. Remove controller from counterweight. See Elec-
trical System 2200YRM1337.
5. Remove steer axle, including wheels and tires.
See Steering System 1600YRM1331 for lift truck
models
• ERP15-20VT (ERP030-040VT) (G807)
models
• ERP16-20VF (ERP30-40VF) (A955).
NOTE: Perform Step 6 through Step 10 for lift truck
models ERP15-20VT (ERP030-040VT) (G807).
6. Remove nuts, capscrews, washers, and steer
plate from counterweight.
• ERP15-20VT (G807) manufactured before
November, 2014
• ERP030-040VT (G807)
• ERP15-20VT (G807) manufactured after
November, 2014
WARNING
The counterweight is very heavy. Make sure the
chains, eyebolts, and overhead lifting device have
the capacity to lift the counterweight.
7. Insert eye bolts into counterweight. See Fig-
ure 19. Attach lifting device to eye bolts to hold
counterweight.
NOTE: Ensure frame is supported, as specified in
Steering System 1600YRM1331 prior to removal.
8. Remove upper capscrews and washers from
frame and counterweight.
9. Remove lower capscrews and washers from
frame and counterweight.
November, 2014
• ERP030-040VT (G807)
November, 2014
10. Using lifting device, lift counterweight away from
lift truck frame.
ERP16-20VF (ERP30-40VF) (A955).
NOTE: Ensure frame is supported, as specified in
Steering System 1600YRM1363 prior to removal.
11. Remove two capscrews from top of rear bulkhead
and counterweight. See Figure 20.
20

1. STEER PLATE
2. COUNTERWEIGHT
3. CAPSCREW
4. NUT
5. WASHER
6. UPPER CAPSCREW
7. LOWER CAPSCREW
8. FRAME
Figure 17. Frame and Counterweight for Lift Trucks ERP15-20VT (G807) Manufactured Before November,
2014 and ERP030-040VT (G807)
21

1. STEER PLATE
2. COUNTERWEIGHT
3. CAPSCREW
4. NUT
5. WASHER
6. UPPER CAPSCREW
7. LOWER CAPSCREW
8. FRAME
Figure 18. Frame and Counterweight for Lift Trucks ERP15-20VT (G807) Manufactured After November,
2014
22

NOTE: COUNTERWEIGHT FOR LIFT TRUCKS
ERP15-20VT (G807) MANUFACTURED BEFORE
NOVEMBER, 2014 AND ERP030-040VT (G807)
SHOWN. HOLES FOR EYEBOLTS FOR COUNTER-
WEIGHT USED ON LIFT TRUCKS ERP15-20VT
(G807) MANUFACTURED AFTER NOVEMBER,
2014 ARE IN SAME LOCATIONS.
1. COUNTERWEIGHT
2. EYE BOLT
Figure 19. Counterweight Lift for Lift Truck
ERP15-20VT (ERP030-040VT) (G807)
12. Remove two capscrews from rear bulkhead and
spacer plates. Remove rear bulkhead. See Fig-
ure 20.
WARNING
slings and overhead lifting device have the ca-
pacity to lift the counterweight.
13. Wrap two slings through slots in top of counter-
weight. Attach slings to lifting device. See Fig-
ure 21.
14. Remove lower capscrews, nuts, and washers
from frame and counterweight. See Figure 20.
15. Remove upper capscrews and washers from
frame and counterweight. See Figure 20. Using
lifting device, lift counterweight away from frame.
INSTALL
WARNING
chains, eyebolts, and overhead lifting device have
the capacity to lift the counterweight.
models ERP15-20VT (ERP030-040VT) (G807).
1. Using a lifting device, lower counterweight into
position on lift truck.
2. Install washers and lower capscrews into frame
and counterweight. Tighten capscrews to
250 N•m (184 lbf ft).
November, 2014
• ERP030-040VT (G807)
November, 2014
3. Install washers and upper capscrews into frame
and counterweight. Tighten capscrews to
755 N•m (557 lbf ft).
4. Remove lifting device and eye bolts from counter-
weight. See Figure 19.
5. Install steer plate, washers, capscrews, and nuts
onto counterweight. Tighten capscrews to
300 N•m (221 lbf ft).
November, 2014
• ERP030-040VT (G807)
November, 2014
models ERP16-20VF (ERP30-40VF) (A955).
6. Using a lifting device, lower counterweight into
position on lift truck frame.
23

7. Install washers and upper capscrews into frame
and counterweight. See Figure 20. Tighten cap-
screws to 755 N•m (557 lbf ft).
8. Install washers, lower capscrews, and nuts into
frame and counterweight. See Figure 20. Tighten
capscrews to 250 N•m (184 lbf ft).
9. Detach both slings and remove from counter-
weight. See Figure 21.
10. Place rear bulkhead in position and install two
capscrews into rear bulkhead and spacer plates.
See Figure 20.
11. Install two capscrews into top of rear bulkhead
and counterweight. See Figure 20.
12. Install steer axle, with wheels and tires, onto
counterweight.
models
• ERP15-20VT (ERP030-040VT) (G807)
models
• ERP16-20VF (ERP30-40VF) (A955)
13. Install controller into counterweight. See Electri-
cal System 2200YRM1337.
NOTE: MAJOR COMPONENTS NOT SHOWN FOR CLARITY.
1. REAR BULKHEAD
2. CAPSCREW
3. SPACER PLATE
4. FRAME
5. COUNTERWEIGHT
6. LOWER CAPSCREW
7. NUT
8. WASHER
9. UPPER CAPSCREW
Figure 20. Frame and Counterweight for Lift Truck ERP16-20VF (ERP30-40VF) (A955)
24

Figure 21. Counterweight Lift for Lift Truck
ERP16-20VF (ERP30-40VF) (A955)
Legend for Figure 21
1. COUNTERWEIGHT
2. SLING
14. Install hydraulic tank and hydraulic pump and mo-
tor into counterweight. See Hydraulic System
1900YRM1333.
15. Install overhead guard. See Overhead Guard
Replacement section in this manual.
16. Install battery.
truck models
• ERP15-20VT (ERP030-040VT) (G807)
truck models
• ERP16-20VF (ERP30-40VF) (A955)
Safety Labels
WARNING
Safety labels are installed on the lift truck to give
information about operation and possible haz-
ards. It is important that all safety labels are in-
stalled on the lift truck and can be read.
DO NOT add to or modify the lift truck. Any
change to the lift truck, the tires, or its equipment
can change the lifting capacity. The lift truck must
be rated as equipped and the nameplate must
show the new capacity rating. Contact your Yale
lift truck dealer for a replacement nameplate.
If a label must be replaced, use the following proce-
dure to install a new label.
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
WARNING
Always use solvents and paints in an area with
adequate ventilation. DO NOT use solvents or
paints near heat, fire, or electrical equipment that
can create sparks. Follow the manufacturer's in-
structions and cautions.
1. Clean the painted surface. Use household clean-
ing products to clean new paint and clean old
paint with cleaning solvent. DO NOT use solvent
on new paint. Make sure the surface is dry and is
clean of dirt, oil, and grease.
2. Remove the paper from the back of the label and
hold the label by the edges. Do not touch the ad-
hesive surface.
CAUTION
The label cannot be moved after it touches the
surface.
0100 YRM 1329 Safety Labels
25

3. Carefully hold the label in the correct position
above the surface and carefully apply to the cor-
rect location. Make sure that all air is removed
from under the label by smoothing any wrinkles or
bubbles with your fingers working from the center
out. Check that the corners and edges are tight
against the surface.
Safety Labels 0100 YRM 1329
26

Figure 22. Label Locations for Lift Truck ERP15-20VT (ERP030-040VT) (G807)
27

NOTE: NOT ALL LABELS USED ON ERP15-20VT (ERP030-040VT) (G807) LIFT TRUCK MODELS ARE
SHOWN IN FIGURE 22. SEE PARTS MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON
ERP15-20VT (ERP030-040VT) (G807) LIFT TRUCKS.
1. OVERHEAD GUARD IMPACT WARNING (IN-
NER LEFT SIDE)
2. BATTERY SPACER
3. MAST WARNING
4. TILT COLUMN
5. PINCH POINT
6. OPERATOR WARNING
7. PINCH POINT
8. OPERATOR RESTRAINT
9. MAST WARNING
10. YALE
11. CAPACITY PLATE
12. AC LABEL
13. COUNTERWEIGHT LABEL
14. PATENTS AND TRADEMARKS
15. "EE" UL LABEL (OPTIONAL)
16. FREEZER (OPTIONAL)
17. CAPACITY LABEL
18. UL LABEL
19. NO RIDER LABEL
Safety Labels 0100 YRM 1329
28

Figure 23. Label Locations for Lift Truck ERP16-20VF (ERP30-40VF) (A955)
29

NOTE: NOT ALL LABELS USED ON ERP16-20VF (ERP30-40VF) (A955) LIFT TRUCK MODELS ARE SHOWN
IN FIGURE 23. SEE PARTS MANUAL FOR A COMPLETE LISTING OF ALL LABELS USED ON ERP16-20VF
(ERP30-40VF) (A955) LIFT TRUCKS.
1. FREEZER
2. "EE" UL LABEL (OPTIONAL)
3. YALE - AC TECHNOLOGY
4. PATENTS AND TRADEMARKS
5. UL LABELS
6. UL LABEL
7. LIFTING EYE
8. PINCH POINT
9. BATTERY DISCONNECT
10. OPERATOR WARNING
11. LOCK/UNLOCK LABEL
12. NO RIDER
13. BATTERY SPACER
14. MAST WARNING
15. YALE DECAL
16. MAST WARNING
17. PINCH POINT
18. OPERATOR RESTRAINT
19. TILT COLUMN
20. BRAND LABEL
21. NAMEPLATE
22. CAPACITY PLATE
23. COUNTERWEIGHT LABEL
24. STABILITY SYSTEM LABEL*
*LABEL USED ONLY ON LIFT TRUCK MODELS ERP30-40VF (A955) MANUFACTURED AFTER JUNE, 2012.
Painting Instructions
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 paint
and rust from the metal. All metal surfaces where
the paint is completely removed, must be primed.
Apply primer before applying the paint.
CAUTION
DO NOT put tape on cylinder rods to protect from
paint. Use a thick layer of multipurpose grease to
protect cylinder rods. Cylinders can be damaged
if operated with tape on the cylinder rod.
3. Protect all surfaces that will not be painted. DO
NOT paint:
Pedal Pads
Lever Knobs
Instrument Panel
Steering Wheel
Labels and Information Plates
Seat Assembly and Rails
Information Case
Tires
Mast Chains and Hoses
Battery Connector
Key Switch
Cylinder Rods
All Plastic Covers
CAUTION
DO NOT paint the pads, plastic covers or knobs,
cables, labels, information plates, or controls.
Paint can make some assemblies not operate cor-
rectly.
NOTE: Use colors approved by Yale Material Han-
dling Corporation.
4. Paint the surfaces. Use the correct paint from
your dealer for Yale®
lift trucks. Follow the direc-
tions on the container.
Painting Instructions 0100 YRM 1329
30

WARNING
Make sure all labels are installed after painting is
complete. Safety labels are installed on the lift
truck to provide information about possible haz-
ards.
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 Safety Labels.
Battery Specifications
ERP15-20VT (G807) EUROPEAN MODEL TRUCKS
Model/ Wheel
Base
Maximum
Compart-
ment Size
Length ×
Width
Maximum Battery Size Weight
Maximum Battery
Compartment Height
Length Width Minimum Maximum
ERP15-16VT
1290 mm
(50.8 in.) 546 x
991 mm
(21.5 x
39 in.)
Standard
Battery
537 mm
(21.1 in.)
Standard
Battery
980 mm
(38.6 in.)
Standard
Battery
800 kg
(1765 lb)
Standard
Battery
1100 kg
(2425 lb)
Standard Battery
677 mm (26.7 in.)
DIN Bat-
tery
522 mm
(20.6 in.)
DIN Bat-
tery
830 mm
(32.7 in.)
DIN Bat-
tery
673 kg
(1480 lb)
DIN Bat-
tery
743 kg
(1640 lb)
DIN Battery 643 mm
(25.3 in.)
ERP16-20VT
1385 mm
(54.5 in.) 643 x
991 mm
(25.3 x
39 in.)
Standard
Battery
632 mm
(24.9 in.)
Standard
Battery
980 mm
(38.6 in.)
Standard
Battery
1000 kg
(2205 lb)
Standard
Battery
1200 kg
(2646 lb)
Standard Battery
677 mm (26.7 in.)
DIN Bat-
tery
630 mm
(24.8 in.)
DIN Bat-
tery
830 mm
(32.7 in.)
DIN Bat-
tery
813 kg
(1790 lb)
DIN Bat-
tery
899 kg
(1980 lb)
DIN Battery 643 mm
(25.3 in.)
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 front-to-back dimension with a clearance of 0 to 13 mm (0 to 0.5 in.) maximum. Battery width
must fit within the battery compartment side-to-side 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.
0100 YRM 1329 Battery Specifications
31

Model/ Wheel
Base
Maximum
Compart-
ment Size
Length ×
Width
Maximum Battery
Compartment Height
ERP16-20VT
1495 mm
(58.9 in.) 750 x
991 mm
(29.5 x
39 in.)
Standard
Battery
742 mm
(29.2 in.)
Standard
Battery
980 mm
(38.6 in.)
Standard
Battery
1000 kg
(2205 lb)
Standard
Battery
1300 kg
(2865 lb)
Standard Battery
677 mm (26.7 in.)
DIN Bat-
tery
738 mm
(29.1 in.)
DIN Bat-
tery
830 mm
(32.7 in.)
DIN Bat-
tery
962 kg
(2120 lb)
DIN Bat-
tery
1064 kg
(2350 lb)
DIN Battery 643 mm
(25.3 in.)
WARNING
Battery Specifications 0100 YRM 1329
32

ERP030-040VT (G807) US MODEL TRUCKS
Model/ Wheel
Base
Maximum
Compart-
ment Size
Length ×
Width
Battery Size Min/Max Weight
Maximum Battery
Compartment Height
ERP030VT
1290 mm (50.8 in.)
546 x
991 mm
(21.5 x
39 in.)
508 to
532 mm
(20 to
21.2 in.)
970 to
986 mm
(38.2 to
38.8 in.)
771 kg
(1700 lb)
998 kg
(2200 lb)
587 mm (23.1 in.)
ERP035VT
1385 mm (54.5 in.)
642 x
991 mm
(25.3 x
39 in.)
597 to
635 mm
(23.5 to
25 in.)
975 to
986 mm
(38.4 to
38.8 in.)
953 kg
(2100 lb)
1089 kg
(2400 lb)
587 mm (23.1 in.)
ERP040VT
1385 mm (54.5 in.)
642 x
991 mm
(25.3 x
39 in.)
597 to
635 mm
(23.5 to
25.0 in.)
975 to
986 mm
(38.2 to
38.8 in.)
953 kg
(2100 lb)
1089 kg
(2400 lb)
587 mm (23.1 in.)
WARNING
33

ERP16-20VF (A955) EUROPEAN MODEL TRUCKS
Model/ Wheel
Base
Maximum
Compart-
ment Size
Length ×
Width
Maximum Battery
Compartment Height
ERP16-18VF
1290 mm
(50.8 in.) 546 x
991 mm
(21.5 x
39 in.)
Standard
Battery
537 mm
(21.1 in.)
Standard
Battery
980 mm
(38.6 in.)
Standard
Battery
800 kg
(1765 lb)
Standard
Battery
1100 kg
(2425 lb)
Standard Battery
677 mm (26.7 in.)
DIN Bat-
tery
522 mm
(20.6 in.)
DIN Bat-
tery
830 mm
(32.7 in.)
DIN Bat-
tery
673 kg
(1480 lb)
DIN Bat-
tery
743 kg
(1640 lb)
DIN Battery 643 mm
(25.3 in.)
ERP16-20VF
1431 mm
(56.3 in.) 643 x
991 mm
(25.3 x
39 in.)
Standard
Battery
632 mm
(24.9 in.)
Standard
Battery
980 mm
(38.6 in.)
Standard
Battery
1000 kg
(2205 lb)
Standard
Battery
1200 kg
(2646 lb)
Standard Battery
677 mm (26.7 in.)
DIN Bat-
tery
630 mm
(24.8 in.)
DIN Bat-
tery
830 mm
(32.7 in.)
DIN Bat-
tery
813 kg
(1790 lb)
DIN Bat-
tery
899 kg
(1980 lb)
DIN Battery 643 mm
(25.3 in.)
ERP16-20VF
1539 mm
(60.6 in.) 750 x
991 mm
(29.5 x
39 in.)
Standard
Battery
742 mm
(29.2 in.)
Standard
Battery
980 mm
(38.6 in.)
Standard
Battery
1000 kg
(2205 lb)
Standard
Battery
1300 kg
(2865 lb)
Standard Battery
677 mm (26.7 in.)
DIN Bat-
tery
738 mm
(29.1 in.)
DIN Bat-
tery
830 mm
(32.7 in.)
DIN Bat-
tery
962 kg
(2120 lb)
DIN Bat-
tery
1064 kg
(2350 lb)
DIN Battery 643 mm
(25.3 in.)
WARNING
Battery Specifications 0100 YRM 1329
34

ERP30-40VF (A955) US MODEL TRUCKS
Model/ Wheel
Base
Maximum
Compart-
ment Size
Length ×
Width
Battery Size Min/Max Weight
Maximum Battery
Compartment Height
ERP30VF 1290 mm
(50.8 in.)
546 x
991 mm
(21.5 x
39 in.)
508 to
532 mm
(20 to
21.2 in.)
970 to
986 mm
(38.2 to
38.8 in.)
771 kg
(1700 lb)
998 kg
(2200 lb)
587 mm (23.1 in.)
ERP35VF 1385 mm
(54.5 in.)
642 x
991 mm
(25.3 x
39 in.)
597 to
635 mm
(23.5 to
25 in.)
975 to
986 mm
(38.4 to
38.8 in.)
953 kg
(2100 lb)
1089 kg
(2400 lb)
587 mm (23.1 in.)
ERP40VF 1385 mm
(54.5 in.)
642 x
991 mm
(25.3 x
39 in.)
597 to
635 mm
(23.5 to
25.0 in.)
975 to
986 mm
(38.2 to
38.8 in.)
953 kg
(2100 lb)
1089 kg
(2400 lb)
587 mm (23.1 in.)
WARNING
35

Maintenance
TRANSAXLE
ERP15-20VT (ERP030-040VT) [G807];
ERP16-20VF (ERP30-40VF) [A955]
PART NO. 524295630 1300 YRM 1330

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.

Transaxle Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Discharging the Capacitors............................................................................................................................. 2
Special Tools................................................................................................................................................... 2
Transaxle Assembly............................................................................................................................................. 3
Remove Transaxle From Frame ...................................................................................................................... 3
Remove the Parking Brake and Traction Motor............................................................................................... 4
Install Parking Brake and Traction Motor......................................................................................................... 4
Install Transaxle to Frame ............................................................................................................................... 5
Maintenance and Repair ..................................................................................................................................... 6
Speed Sensor Repair...................................................................................................................................... 6
Trunnion Cap Repair ....................................................................................................................................... 6
Fluid Level Check............................................................................................................................................ 8
Fluid Change................................................................................................................................................... 8
Breather Repair............................................................................................................................................... 9
Stud Repair ..................................................................................................................................................... 10
Brake Cylinder Repair ..................................................................................................................................... 11
Input Seal Repair ............................................................................................................................................ 13
Cover to Housing Seal .................................................................................................................................... 13
During the Transaxle Warranty Period ........................................................................................................ 13
After the Transaxle Warranty Period ........................................................................................................... 14
Removing the Cover............................................................................................................................... 14
Installing the Cover................................................................................................................................. 15
Wet Brakes...................................................................................................................................................... 16
This section is for the following models:
ERP15-20VT (ERP030-040VT) [G807];
ERP16-20VF (ERP30-40VF) [A955]
©2012 Yale Materials Handling Corp. i

1300 YRM 1330 General
General
CAUTION
DO NOT remove the cover from the transaxle hous-
ing during the warranty period. Removing the cover
from the housing will void the transaxle warranty.
The transaxle warranty period may vary from truck
hours or other warranties. Contact Yale Company
Contact Management if you have questions about
warranty status.
CAUTION
Use only transmission fluid from approved ven-
dors. Using fluid from unapproved vendors will
void the warranty. Contact Yale Company Contact
Management if you have questions about warranty
status.
This section contains the removal, repair, inspection,
and installation instructions for the transaxle assem-
blies used on these models.
WARNING
have been properly trained and authorized to do so.
Improper repairs and adjustments can create dan-
gerous operating conditions. DO NOT operate a lift
truck that needs repairs. Report the need for repairs
to your supervisor immediately. If repair is neces-
sary, attach a DO NOT OPERATE tag on the steering
wheel and disconnect the battery.
Throughout this section, forward will refer to travel in
the direction of the forks and left and right will be deter-
mined by sitting in the seat facing forward. See Figure 1
or Figure 2.
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD
TRAVEL
Figure 1. Truck Orientation (Three-Wheel Trucks)
A. LEFT SIDE
B. RIGHT SIDE
C. FORWARD
TRAVEL
Figure 2. Truck Orientation (Four-Wheel Trucks)
1

General 1300 YRM 1330
DISCHARGING THE CAPACITORS
WARNING
have been properly trained and authorized to do so.
Improper repairs and adjustments can create dan-
gerous operating conditions. DO NOT operate a lift
truck that needs repairs. Report the need for repairs
to your supervisor immediately. If repair is neces-
sary, 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 any compartment cov-
ers or inspecting or repairing the electrical system.
DO NOT place tools on top of the battery. If a tool
causes a short circuit, the high current flow from
the battery can cause personal injury or 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 electri-
cal connection and cause injury.
Before performing any tests or adjustments, 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 Disconnect Switch
has not been activated. This will isolate the con-
troller and prevent the capacitors from discharging
properly. The proper way to disconnect the battery
is by separating the battery connectors.
1. Ensure capacitors are discharged by performing
Step 2 through Step 6 below.
2. Turn key or keyless switch to OFF position.
3. Disconnect battery by separating connectors.
4. Block drive wheels to prevent lift truck from moving.
5. Make sure Emergency Disconnect Switch HAS
NOT been activated. If Emergency Disconnect
Switch is activated, rotate switch to the right until it
pops up.
6. Press horn button. Wait 30 seconds to be sure
capacitors are fully discharged.
SPECIAL TOOLS
Special tools are necessary to properly perform some
repairs. These tools are available from your Yale
dealer. Warranty will not cover damage resulting from
work done using improper tools. Refer to Table 1.
Table 1. Yale Special Tools
Input Seal Driver
Yale Part No.
582000161
Breather Set Tool
Yale Part No.
582000187
Wheel Stud Tool
Yale Part No.
582000162
2

1300 YRM 1330 Transaxle Assembly
Transaxle Assembly
REMOVE TRANSAXLE FROM FRAME
WARNING
The lift truck must be put on blocks for some types
of maintenance and transaxle repair. The removal
of the battery, mast, transaxle, or the counterweight
will cause large changes in the center of gravity.
Position additional blocks under the frame when the
lift truck is on blocks, so the lift truck cannot tip
over.
1. Remove mast assembly.
See Mast Repair, 2- and 3-Stage High Visibility
Masts 4000 YRM 1386 for European lift truck mod-
els
• ERP15-20VT (G807)
• ERP16-20VF (A955)
See Mast Repair, 2-, 3-, And 4-Stage Heavy Duty
Masts 4000 YRM 1405 for European and American
lift truck models
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
2. Turn key switch to OFF position and disconnect bat-
tery.
3. Position lift truck frame on blocks so drive tires are
suspended off the floor.
See Periodic Maintenance 8000 YRM 1339 for lift
truck models
• ERP15-20VT (ERP030-040VT) (G807)
truck models
• ERP16-20VF (ERP30-40VF) (A955)
4. Remove drive tire lug nuts and drive tire and wheel
assembly.
5. Disconnect transaxle speed sensor connector from
main wiring harness.
6. Disconnect parking brake connector from main
wiring harness.
7. Disconnect manual override cable from parking
brakes.
8. Tag and disconnect power cables from traction mo-
tor studs.
9. Disconnect traction motor temperature sensor at
traction motor.
10. Disconnect service brake line from port on
transaxle. Cap brake line and plug port on transaxle
to reduce the possibility of contamination entering
brake system.
11. Loosen, but do not remove, five mounting cap-
screws and nuts that hold transaxle assembly on
lift truck.
WARNING
The transaxle and traction motor assemblies are
heavy. Be sure that all lifting devices are suitable
and of adequate capacity to lift the transaxle and
traction motor.
12. Position a floor jack under transaxle assembly.
Make sure assembly is properly balanced on floor
jack so it will not fall once mounting capscrews
have been removed.
CAUTION
Check that cables, hoses, and wires do not interfere
with the removal of the transaxle assembly.
13. Remove five capscrews and washers holding
transaxle on lift truck frame. Carefully lower
transaxle assembly from lift truck frame using floor
jack.
WARNING
The transaxle and traction motor assemblies are
traction motor.
14. Transfer transaxle assembly from floor jack to a
clean workbench using an appropriate sling and
overhead lifting device.
3

Transaxle Assembly 1300 YRM 1330
REMOVE THE PARKING BRAKE AND
TRACTION MOTOR
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.
WARNING
The traction motor is heavy. Be sure that all lifting
devices are suitable and of adequate capacity to lift
the traction motor.
1. Position transaxle on blocks with studs down. Se-
curely support in this position.
2. Remove parking brake assembly from traction mo-
tor:
a. Remove four capscrews, lockwashers, and
washers holding brake assembly on traction
motor. See Figure 3.
b. Pry evenly on opposite sides to remove brake
assembly from brake hub. Remove brake as-
sembly by hand.
c. Remove snap ring holding brake hub on trac-
tion motor shaft. Slide hub from shaft. Remove
snap ring and woodruff key from beneath hub.
3. Remove traction motor from transaxle:
a. Install an eyebolt to traction motor shaft and
attach an overhead lifting device of adequate
capacity to eyebolt.
b. Remove four capscrews and washers mounting
traction motor to transaxle.
c. Lift traction motor from transaxle using over-
head lifting device.
INSTALL PARKING BRAKE AND
TRACTION MOTOR
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety procedures.
WARNING
The traction motor is heavy. Be sure that all lifting
devices are suitable and of adequate capacity to lift
the traction motor.
1. Position transaxle on blocks with studs down. Se-
curely support in this position.
2. Install traction motor on transaxle:
a. Install an eyebolt to traction motor shaft and
attach an overhead lifting device of adequate
capacity to eyebolt.
b. Lightly lubricate inside lip of transaxle input
shaft with multipurpose grease to ensure seal
seats properly on traction motor shaft. It is not
necessary to lubricate traction motor shaft as
it is lubricated internally within the transaxle.
See Figure 4.
1. CAPSCREW
2. LOCKWASHER
3. WASHER
4. PARKING BRAKE
ASSEMBLY
5. TRACTION MOTOR
6. CAPSCREW
7. WASHER
8. MOTOR SHAFT
9. TRANSAXLE
10. INPUT SEAL
Figure 3. Traction Motor and Parking Brake
4

1300 YRM 1330 Transaxle Assembly
c. Lift traction motor and position it on transaxle
using overhead lifting device. Guide traction
motor shaft into transaxle through input seal.
Align motor with transaxle.
d. Install four capscrews and washers mounting
traction motor on transaxle. Tighten capscrews
to 48 N•m (35 lbf in).
e. Remove eyebolt from traction motor shaft.
3. Install parking brake assembly to traction motor:
a. Install lower snap ring and woodruff key on
traction motor shaft. Align groove in hub with
woodruff key and slide hub onto shaft. Install
upper snap ring holding brake hub onto trac-
tion motor shaft.
b. Position brake assembly onto brake hub. Align
splines and seat brake on traction motor end
head.
1. CAPSCREW
2. LOCKWASHER
3. WASHER
4. PARKING BRAKE
ASSEMBLY
5. TRACTION MOTOR
6. CAPSCREW
7. WASHER
8. MOTOR SHAFT
9. TRANSAXLE
10. INPUT SEAL
Figure 4. Traction Motor and Parking Brake
c. Install four capscrews, lockwashers, and wash-
ers to secure brake assembly. Tighten cap-
screws to 8 N•m (71 lbf in).
INSTALL TRANSAXLE TO FRAME
1. Check that dowels are installed in transaxle housing
and are in good condition. Replace as necessary.
WARNING
The transaxle and traction motor assembly are
traction motor.
2. Move transaxle assembly onto a floor jack using
an appropriate sling and lifting device. Make sure
assembly is balanced and properly supported so it
will not fall during installation.
3. Carefully position transaxle on frame using floor
jack. Align transaxle mounting dowels with their
mounting holes in frame.
4. Apply Loctite® 271 to five socket head capscrews
and washers. Install capscrews with washers
through transaxle and into mounting holes in
frame. Tighten capscrews to 220 N•m (162 lbf ft).
5. Remove cap and plug from service brake line and
service brake port. Install service brake line to ser-
vice brake port. Tighten to 12 to 16 N•m (108 to
192 lbf in).
6. Connect power cables to traction motor studs as
tagged during removal. Tighten to 8 N•m (71 lbf in).
7. Connect traction motor temperature sensor con-
nectors to main wiring harness.
8. Connect parking brake connector to main wiring
harness.
9. Connect manual override cable to parking brakes.
10. Connect transaxle speed sensor connector to main
wiring harness.
5

Maintenance and Repair 1300 YRM 1330
CAUTION
Make sure the lift truck is blocked at the same
height as with the drive tire installed to ensure the
proper fluid level reading.
11. Bleed the service brakes. Refer Brake System
1800 YRM 1332 for procedures.
12. Check fluid level in transaxle. Fill as necessary.
See Fluid Level Check.
13. Install drive tire and wheel assembly on wheel hub.
Install lug nuts and tighten to 170 N•m (125 lbf ft).
14. Connect battery connector, turn key switch to ON
position, and test lift truck for proper operation.
15. Lower lift truck from the blocks.
truck models
• ERP15-20VT (ERP030-040VT) (G807)
truck models
• ERP16-20VF (ERP30-40VF) (A955)
16. Install mast on lift truck.
See Mast Repair, 2- and 3-Stage High Visibility
Masts 4000 YRM 1386 for European lift truck mod-
els
• ERP15-20VT (G807)
• ERP16-20VF (A955)
See Mast Repair, 2-, 3-, And 4-Stage Heavy Duty
Masts 4000 YRM 1405 for European and American
lift truck models
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
Maintenance and Repair
SPEED SENSOR REPAIR
The speed sensor monitors the speed of the transaxle
and relays the information to the controller. The speed
sensor can be replaced with the transaxle installed to
the lift truck.
1. Park lift truck on a level surface. Turn key switch to
OFF position and unplug battery connector.
2. Discharge capacitors. See section Discharging the
Capacitors.
3. Remove floor mat and floor plates from operator
compartment to access top of transaxle(s).
4. Disconnect sensor wiring harness from main wiring
harness.
CAUTION
Use a brush to clean around the sensor before re-
moving to avoid contaminating the transaxle.
5. Remove capscrew holding sensor to transaxle us-
ing a 5mm Allen wrench. See Figure 5.
6. Pull sensor out of transaxle.
7. Insert new sensor into transaxle.
8. Align screw holes and install capscrew. Tighten
capscrew to 9.5 N•m (84.0 lbf in).
9. Connect sensor wiring harness to main wiring har-
ness.
10. Replace floor plates and floor mat in operator com-
partment.
11. Connect battery, turn key to ON position and test lift
truck for proper operation.
TRUNNION CAP REPAIR
To repair the trunnion cap:
1. Remove load from forks and park lift truck on a level
surface. Adjust mast to a vertical position, then turn
key switch to OFF position and separate battery
connectors.
2. Remove four capscrews holding trunnion cap on
transaxle housing. Remove trunnion cap. See Fig-
ure 6.
3. Wipe away any dirt or grease near mounting holes.
Clean holes with a proper sized tap and tap wrench
as necessary.
6

1300 YRM 1330 Maintenance and Repair
4. Position new cap over mast pin and onto transaxle.
5. Apply Loctite® 242 to threads and install four cap-
screws and tighten alternately in small increments.
Tighten capscrews to 24 N•m (216 lbf in).
6. Grease fitting in mast stub shaft to lubricate trun-
nion cap.
7. Connect battery, turn key to ON position and test lift
truck for proper operation.
1. CAPSCREW
2. SPEED SENSOR
3. FILL PLUG
4. TRANSAXLE COVER
5. COVER CAPSCREWS
6. DRAIN PLUG
Figure 5. Speed Sensor
1. CAPSCREWS
2. TRUNNION CAP
3. THREADED MOUNTING HOLES
4. TRANSAXLE HOUSING
Figure 6. Trunnion Cap
7

FLUID LEVEL CHECK
CAUTION
status.
Each transaxle has a separate fluid supply which must
be checked every 2000 hours or 1 year or when other
maintenance procedures require the fluid level to be
checked. Make sure the transaxle is installed to the lift
truck and the lift truck is positioned on a level surface
when checking fluid levels for an accurate reading.
CAUTION
Clean around the fill and check plugs with solvent
before removal to prevent contamination of the sys-
tem.
CAUTION
Blocking the lift truck higher or lower or at a dif-
ferent angle than it normally sits with the drive tire
installed will result in an incorrect fluid level check.
1. Remove drive tire and block lift truck frame to po-
sition transaxle at the same height and position as
with drive tire installed.
truck models
• ERP15-20VT (ERP030-040VT) (G807)
truck models
• ERP16-20VF (ERP30-40VF) (A955)
2. Remove check plug. Fluid should be level with bot-
tom of check hole.
3. If necessary, remove fill plug and add fluid through
fill hole until level with bottom of check hole. Each
transaxle holds approximately 0.60 liter (0.63 qt) of
transmission fluid.
NOTE: New sealing rings must be installed with the
drain, fill, and check plugs.
4. Replace check plug (and fill plug if removed) and
tighten to 22 N•m (192 lbf in). See Figure 7.
5. Reinstall drive tire and tighten lugs to 170 N•m
(125 lbf ft). Remove truck from blocks.
6. Repeat for other transaxle. Check fluid level in each
transaxle every 2000 hours or one year.
1. FILL PLUG
2. WHEEL HUB
3. DRAIN PLUG
4. CHECK PLUG
Figure 7. Transaxle Plug Locations
FLUID CHANGE
CAUTION
status.
The fluid is not normally changed unless contamination
is suspected or other maintenance procedures require
draining the transaxle. If changing the fluid is neces-
sary, refer to the following procedures.
WARNING
The fluid is hot at normal operating temperatures.
Be careful when draining the transaxles.
CAUTION
Blocking the lift truck higher or lower or at a dif-
ferent angle than it normally sits with the drive tire
installed will result in an incorrect fluid level check.
CAUTION
Clean around the fill and check plugs with solvent
before removal to prevent contamination of the sys-
tem.
NOTE: Install new sealing rings on the plugs anytime
the drain, check, or fill plugs are removed.
8

NOTE: Operate the lift truck for 5 minutes or until the
transaxle is warm to the touch. Transaxle fluid will drain
easier and more thoroughly when it is warm. Each
transaxle uses separate, self-contained fluid supplies.
truck models
• ERP15-20VT (ERP030-040VT) (G807)
truck models
• ERP16-20VF (ERP30-40VF) (A955)
2. Turn key switch to OFF position and disconnect bat-
tery. Block thewheels to prevent unexpected move-
ment.
3. Place a drip pan with at least a 3.0 liter (3.3 qt)
capacity under transaxle.
CAUTION
Clean around plugs with solvent before removal to
prevent contamination of the transaxles.
4. Remove fill plug on transaxle. Inspect breather for
proper operation. Clean or replace as necessary.
See section Breather Repair.
5. Remove check plug.
6. Remove drain plug. Clean drain plug thoroughly,
removing any metallic debris that has collected on
drain plug magnet.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
CAUTION
The drain plug must not be interchanged with the
fill or check plugs. Use only an approved magnetic
type drain plug to prevent damage to the transaxle.
NOTE: It may take as long as 10 minutes for the
transaxle to drain completely depending on temper-
ature and contaminants. Allow the transaxle to drain
completely before continuing.
7. After transaxle has drained completely, install drain
plug into transaxle as removed. Tighten to 22 N•m
(192 lbf in). Remove drip pan and dispose of waste
fluid properly.
NOTE: Use a funnel or a funnel with a tube attached to
add fluid to the transaxle. Pour slowly.
8. Fill transaxle with fluid until level with bottom of
check hole. Each transaxle should be filled with ap-
proximately 0.60 liter (0.63 qt) of fluid.
9. When fluid reaches bottom of check hole, install
check plug and fill plug and tighten each to 22 N•m
(192 lbf in).
BREATHER REPAIR
The breather can be repaired with the transaxle in-
stalled to the lift truck and the drive tire removed. The
breather equalizes air pressure inside the transaxle
with the air pressure outside. If the breather is visibly
damaged then the breather should be replaced.
truck models
• ERP15-20VT (ERP030-040VT) (G807)
truck models
• ERP16-20VF (ERP30-40VF) (A955)
2. Remove breather cap by shearing of with a flat
screwdriver. See Figure 8.
Figure 8. Remove Breather Cap
9

3. Remove spring by hand. A small breather ball is
located under spring. Blow into breather at a slight
angle with compressed air to force breather ball out.
4. Install a 6mm thread tap into breather using a tap
wrench, and pull breather out of housing. See Fig-
ure 9.
Figure 9. Extracting the Breather
5. Position new breather into housing by hand.
CAUTION
A special tool is require to set the proper gap be-
tween housing and breather head. DO NOT drive
the breather flush against the housing.
6. Drive breather into housing using Breather Set Tool
(refer to section General, Special Tools) and a nylon
faced hammer. See Figure 10.
Figure 10. Installing the Breather
STUD REPAIR
Stud repair can be performed with the transaxle in-
stalled to the lift truck or removed.
truck models
• ERP15-20VT (ERP030-040VT) (G807)
truck models
• ERP16-20VF (ERP30-40VF) (A955)
2. Remove damaged stud using adjustable grip pliers.
3. If stud is sheared off:
a. Mark center of stud with a center punch and
nylon faced hammer.
b. Drill into center of stud with a 3mm drill bit. See
Figure 11.
Figure 11. Drilling the Stud
c. Drill hole larger with a 7mm drill bit.
d. Lightly tap an easy-out into hole in stud. Install
tap wrench and unscrew stud from hub. See
Figure 12.
10

Figure 12. Removing the Stud
4. Run a thread tap (size M14 x 1.5) into stud hole to
clean and repair any damaged threads.
5. Test threads with a thread plug gauge (size M14 x
1.5 - 6H).
6. If threads are within specification, install new stud
using Stud Installation Tool (refer to section Gen-
eral, Special Tools).
7. Tighten studs to 80 N•m (59 lbf ft). See Figure 13.
Figure 13. Stud Installation
BRAKE CYLINDER REPAIR
WARNING
Always wear eye protection and use the proper
tools when installing/removing snap rings.
The service brake pedal in the operator compartment
actuates the master cylinder sending pressurized fluid
to the brake pistons in the transaxles through the ser-
vice brake lines.
1. Remove transaxle from lift truck. Remove parking
brake and traction motor from transaxle. See sec-
tion Remove Transaxle From Frame.
2. Drain oil from transaxle.
3. Remove snap ring in brake cylinder. See Figure 14.
1. CYLINDRICAL PIN
2. PISTON SEAL
3. PISTON
4. SPRING
5. O-RING
6. CAP
7. SNAP RING
Figure 14. Brake Piston Assembly
CAUTION
Cover the cap with a cloth to control it in case it is
ejected from the piston.
NOTE: Make note of the piston and cap orientation as
well as the orientation of the seal on the piston before
removal.
4. Direct pressurized air into service brake line port in
cover to force cap out of cylinder. Recover spring
from beneath cap. Remove seal from thecap and
cut it in two to prevent accidental reuse. See Fig-
ure 15.
11

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