Yale ERP15-20VT User manual

ERP15-20VT (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 A270, A271, A272)........................................................................ 524327054 4000 YRM 1386 02/14
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............................................................................................ 524320290 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. 524320408 (12/14)

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-
bliesusedonthesemodels.
WARNING
DO NOT make repairs or adjustments unless you
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
DO NOT make repairs or adjustments unless you
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. Blockdrivewheelstopreventlifttruckfrommoving.
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
Ya l e Pa r t N o.
582000161
Breather Set Tool
Ya l e Pa r t N o.
582000187
Wheel Stud Tool
Ya l e Pa r t N o.
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. Tur n k ey swi tch 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)
See Periodic Maintenance 8000 YRM 1373 for lift
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
heavy. Be sure that all lifting devices are suitable
and of adequate capacity to lift the transaxle and
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 motorisheavy. Besurethatalllifting
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
heavy. Be sure that all lifting devices are suitable
and of adequate capacity to lift the transaxle and
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.
See Periodic Maintenance 8000 YRM 1339 for lift
truck models
•ERP15-20VT (ERP030-040VT) (G807)
See Periodic Maintenance 8000 YRM 1373 for lift
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

Maintenance and Repair 1300 YRM 1330
FLUID LEVEL CHECK
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.
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.
See Periodic Maintenance 8000 YRM 1339 for lift
truck models
•ERP15-20VT (ERP030-040VT) (G807)
See Periodic Maintenance 8000 YRM 1373 for lift
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
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.
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

1300 YRM 1330 Maintenance and Repair
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.
1. Remove drive tire and block lift truck frame to po-
sition transaxle at the same height and position as
with drive tire installed.
See Periodic Maintenance 8000 YRM 1339 for lift
truck models
•ERP15-20VT (ERP030-040VT) (G807)
See Periodic Maintenance 8000 YRM 1373 for lift
truck models
•ERP16-20VF (ERP30-40VF) (A955)
2. Tur n k ey swi tch t o 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.
1. Remove drive tire and block lift truck frame to po-
sition transaxle at the same height and position as
with drive tire installed.
See Periodic Maintenance 8000 YRM 1339 for lift
truck models
•ERP15-20VT (ERP030-040VT) (G807)
See Periodic Maintenance 8000 YRM 1373 for lift
truck models
•ERP16-20VF (ERP30-40VF) (A955)
2. Removebreathercapbyshearingofwithaflat
screwdriver. SeeFigure8.
Figure 8. Remove Breather Cap
9

Maintenance and Repair 1300 YRM 1330
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
facedhammer. SeeFigure10.
Figure 10. Installing the Breather
7. Reinstall drive tire and tighten lugs to 170 N•m
(125 lbf ft). Remove truck from blocks.
STUD REPAIR
Stud repair can be performed with the transaxle in-
stalled to the lift truck or removed.
1. Remove drive tire and block lift truck frame to po-
sition transaxle at the same height and position as
with drive tire installed.
See Periodic Maintenance 8000 YRM 1339 for lift
truck models
•ERP15-20VT (ERP030-040VT) (G807)
See Periodic Maintenance 8000 YRM 1373 for lift
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

1300 YRM 1330 Maintenance and Repair
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
8. Reinstall drive tire and tighten lugs to 170 N•m
(125 lbf ft). Remove truck from blocks.
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

Maintenance and Repair 1300 YRM 1330
Figure 15. Removing the Cap
5. Usingagri
nd stone, slightly bevel the end of a 7/16
x2inchrol
l pin. Allow pin to cool.
6. Carefully position roll pin to piston. Drive roll-pin
into cavityofpistonwithanylonfacedhammer.
NOTE: It may be helpful to apply compressed air to the
service brake line port (as with removing the cap) AF-
TER the piston has been pulled to the top end of the
brake cylinder.
NOTE: Make note of the piston and seal orientation dur-
ing removal.
7. Pull roll-pin (and piston) from cylinder using pliers.
NOTE: Make note of the cylindrical pin orientation dur-
ing removal.
8. Remove cylindrical pin from beneath piston.
9. Inspect cylinder walls for pits, cracks, and other
damage.
NOTE: Install the cylindrical pin in the orientation noted
during removal.
10. Lightly lubricate cylindrical pin with multipurpose
grease and install into brake cylinder as noted dur-
ing removal.
NOTE: An
ew brake piston and new seal should be used
when repairing the brake cylinder assembly. Make sure
the new piston and new seal are oriented as noted when
removed.
11. Lightly lubricate new piston seal with multipurpose
grease and install in new brake piston as noted dur-
ing removal. See Figure 16.
1. SNAP RING
2. CAP
3. O-RING
4. PISTON
5. SEAL
6. SPRING
Figure 16. Piston Seal Orientation
12. Install new brake piston (and seal) into brake cylin-
der.
13. Place spring into cavity in piston by hand.
14. Lightly lubricate new O-ring with multipurpose
grease and install on cap as noted during removal.
NOTE: Make sure the cap is oriented as noted when
removed.
15. Install cap into brake cylinder.
16. Press cap into cylinder, to expose snap ring groove,
and install snap ring on brake piston.
NOTE: It is recommended to verify the torque on the
transaxle cover capscrews before reinstalling the trac-
tion motor. See section Cover to Housing Seal.
17. Install brake and traction motor on transaxle and
install transaxle on lift truck. See section Install
Transaxle to Frame.
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.
18. Check transaxle fluid level. See section Fluid Level
Check.
19. Install drive tire and tighten lugs to 170 N•m
(125 lbf ft). Test lift truck for proper operation.
12

1300 YRM 1330 Maintenance and Repair
INPUTSEALREPAIR
The input seal is located between the traction motor
and the transaxle. The seal covers the transaxle input
bearing and input pinion. The traction motor shaft slides
through the center of the seal into the input pinion. To
replace the input seal:
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 motorisheavy. Besurethatalllifting
devices are suitable and of adequate capacity to lift
the traction motor.
1. Remove transaxle from lift truck. Remove parking
brake and traction motor from transaxle. See sec-
tion Remove Transaxle From Frame.
CAUTION
The transaxle is heavy and can be difficult to stabi-
lize when positioned with the studs down. Securely
support the transaxle in a stable position during
these procedures.
2. Carefully position transaxle with drive tire mounting
studs down. Support transaxle with wooden blocks
to stabilize.
3. Use solvent to clean outside of transaxle before re-
moving seal.
NOTE: Removal is destructive to the seal.
4. Puncture seal with a flat screwdriver (carefully near
center of seal to avoid damaging bearing) and pry
around the edge under the seal to remove from
cover.
5. Clean around flange to remove any dirt or debris.
6. Install input seal using Yale input seal installation
tool (refer to section General, Special Tools).
NOTE: It is recommended to verify the torque on the
transaxle cover capscrews before reinstalling the trac-
tion motor. See section Cover to Housing Seal.
7. Lightly lubricate center of input seal with multipur-
pose grease to allow seal to seat properly on motor
shaft. It is not necessary to lubricate traction motor
shaft. Install traction motor on transaxle.
8. Install brake on traction motor. Install transaxle on
lift truck. See section Install Transaxle to Frame.
COVER TO HOUSING SEAL
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.
The transaxle cover is mated to the housing using
an anaerobic sealant and secured in place with ten
socket-head capscrews. DO NOT remove the cover
from the housing during the transaxle warranty period.
THIS WILL VOID THE WARRANTY. Internal parts
of the transaxle are press fit and cannot be repaired
or properly preloaded without specialized equipment.
If a leak develops from between the cover and the
housing, different procedures are required depending
on whether your transaxle is within the warranty period
or beyond the warranty period. Refer to section During
the Transaxle Warranty Period or After the Transaxle
Warranty Period.
During the Transaxle Warranty Period
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
The transaxle is heavy and can be difficult to stabi-
lize when positioned with the studs down. Securely
support the transaxle in a stable position during
these procedures.
1. Remove transaxle from lift truck. Remove parking
brake and traction motor from transaxle. See sec-
tion Remove Transaxle From Frame.
13

Maintenance and Repair 1300 YRM 1330
2. Tighten capscrews to 110 N•m (81 lbf ft). See Fig-
ure 17.
1. SOCKET-HEAD SCREW
2. SPEED SENSOR
3. FILL PLUG
4. COVER
5. SOCKET-HEAD CAPSCREW
6. DRAIN PLUG
Figure 17.CoverAssembly
3. Install brake and traction motor on transaxle. Install
transaxle on lift truck. See section Install Transaxle
to Frame.
4. If the leak persists, the unit must be reported to Yale
Company Contact Management.
After the Transaxle Warranty Period
RemovingtheCover
CAUTION
The transaxle is heavy and can be difficult to stabi-
lize when positioned with the studs down. Securely
support the transaxle in a stable position during
these procedures.
1. Remove the transaxle from the lift truck and remove
the parking brake and traction motor. See section
Remove Transaxle From Frame.
2. Drain fluid from transaxle.
3. Remove ten socket-head capscrews holding cover
on housing. See Figure 18.
NOTE: The cover is aligned to the housing with internal
components of the transaxle. Carefully pry the cover
from the housing by levering equally on each side.
4. Separate cover from housing by tapping around
seam of cover and housing using a thin flat chisel.
Gently pry around cover in small equal increments
to remove from housing.
1. SOCKET-HEAD SCREW
2. SPEED SENSOR
3. FILL PLUG
4. COVER
5. SOCKET-HEAD CAPSCREW
6. DRAIN PLUG
Figure 18. Cover Assembly
14

1300 YRM 1330 Maintenance and Repair
Installing the Cover
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.
CAUTION
Make sure the cover has been thoroughly drained
of any fluid so the new sealant is not contaminated
when the cover is turned over to be assembled.
1. Clean housing flange and cover flange thoroughly
before reassembly. The flanges must be clean of
oil, dirt, and old sealant to ensure a proper seal.
Make sure cover has been thoroughly drained of
any oil so new sealant is not contaminated when
coveristurnedovertobeassembled.
2. Apply a continuous coating of Loctite® 5188 com-
pletely around housing flange using a clean, lint
free paint roller to ensure a proper seal. See Fig-
ure 19.
Figure 19. Applying Sealant to the Flange
NOTE: The cover is aligned to the housing with internal
components of the transaxle. Carefully align the cover
to the housing and lower equally on every side until it is
mated. Dowel pins inside the housing must be aligned
with the cover during installation.
3. Position cover on transaxle and slowly lower into
position. Turn assembly while beginning to lower to
ensure that internal components seat properly and
do not bind. Make sure assembly holes and dowels
are aligned as the cover and housing meet. Lightly
tap evenly around cover with a rubber mallet to seat
cover onto housing.
CAUTION
DO NOT install the capscrews until the cover is
completely seated. Tightening capscrews can
damage internal components if the cover is not
properly seated.
4. When cover is completely seated onto housing, in-
stall ten socket head screws holding cover on hous-
ing. Incrementally tighten screws in a non-concen-
tric pattern to 110 N•m (81 lbf ft). See Figure 20.
1. SOCKET-HEAD SCREW
2. ENCODER SENSOR
3. FILL PLUG
4. COVER
5. SOCKET-HEAD CAPSCREW
6. DRAIN PLUG
Figure 20. Cover Assembly
15

Maintenance and Repair 1300 YRM 1330
5. Install brake and traction motor on transaxle. Install
transaxle on lift truck. See section Install Transaxle
to Frame.
CAUTION
Make certain to use the proper magnetic plug for the
drain plug. The drain plug is not interchangeable
with the fill and check plugs.
6. Fill transaxle with fluid to the proper level:
a. Install drain plug with new sealing ring and
tighten to 22 N•m (192 lbf in).
NOTE: Each transaxle requires approximately 0.60 liter
(0.63 qt) of transmission fluid.
b. Fill transaxle until fluid begins to emerge from
check hole.
c. Install check and fill plugs with new sealing
ringsandtightento22N•m(192lbfin).
WET BRAKES
The wet brake discs can be replaced after the warranty
period. To replace the brake discs:
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
The transaxle is heavy and can be difficult to stabi-
lize when positioned with the studs down. Securely
support the transaxle in a stable position during
these procedures.
1. Remove transaxle from lift truck. Remove parking
brake and traction motor from transaxle. See sec-
tion Remove Transaxle From Frame.
2. Drain fluid from transaxle.
3. Remove cover from transaxle. Refer to section Re-
moving the Cover.
CAUTION
Always replace the full set of inner and outer
splined brake discs.
NOTE: Make note of the orientation of the brake discs
during removal.
4. Remove 4 brake discs (outer spline) and 3 brake
discs (inner spline) from transaxle by hand. Re-
move pressure plate from transaxle by hand. See
Figure 21.
NOTE: New pressure plate thicknesses are 4.8 mm
(0.19 in.), 5.3 mm (0.20 in.), and 5.8 mm (0.23 in.).
5. Measure thickness of old pressure plate. Select
new pressure plate with next highest thickness.
6. Install the pressure plate into transaxle housing by
hand.
7. Soak new brake discs in clean transaxle fluid before
installing.
8. Install a brake disc (external spline) against pres-
sure plate in transaxle.
CAUTION
Brake discs with internal splines should be in-
stalled in the transaxle housing so that the rounded
off side of teeth point upward.
9. Install a brake disc (internal spline) against brake
disc (external spline) with rounded off side of teeth
pointing upward.
10. Install remainder of brake discs alternating between
internal and external splined discs. The disc pack
should have a total of 1 pressure plate, 4 brake
discs (external spline) and 3 brake discs (internal
spline).
11. Align splines of internal discs using a screwdriver.
12. Install cover to transaxle. Refer to section Installing
the Cover.
13. Install traction motor and brake on transaxle. Install
transaxle on lift truck. See section Install Transaxle
to Frame.
16

1300 YRM 1330 Maintenance and Repair
CAUTION
Make certain to use the proper magnetic plug for the
drain plug. The drain plug is not interchangeable
with the fill and check plugs.
14. Fill transaxle with fluid to proper level:
a. Install drain plug with new sealing ring and
tighten to 22 N•m (192 lbf in).
NOTE: Each transaxle requires approximately 0.60 liter
(0.63 qt) of transmission fluid.
b. Filltransaxleuntilfluidbeginstoemergefrom
check hole.
c. Install check and fill plugs with new sealing
rings and tighten to 22 N•m (192 lbf in).
15. Connect battery connectors, turn key switch to ON
position, and test lift truck for proper operation.
1. PRESSURE PLATE
2. BRAKE DISC (OUTER
SPLINED)
3. BRAKE DISC (INNER
SPLINED)
4. PLUG
5. SEALING RING
6. SCREW
7. INPUT SEAL
8. SNAP RING
9. COVER
10. O-RING
11. SPRING
12. PISTON
13. RING
14. PIN
15. BLEEDER VALVE
16. PLUG
17. SPEED SENSOR
18. SCREW
Figure 21. Brake Discs
17