Yale ERP15-20VT Service Manual page 22

Brake Pedal Assembly Repair
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 discharge the capaci-
tors before opening any compartment covers or in-
specting 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 capacitors in the transistor controllers can
hold an electrical charge after the battery is dis-
connected. To prevent an electrical shock and
REMOVE
It is not always necessary to remove the brake pedal
assembly to disassemble certain components. Parts
of the brake pedal assembly may be removed without
removing the assembly from the lift truck. The entire
removal procedure is outlined below. Evaluate the re-
quired service to determine if the entire brake assembly
should be removed. Perform only the steps necessary
to safely complete the required service.
1. Turn the key switch to the OFF position and discon-
nect the battery.
2
Brake Pedal Assembly Repair
personal injury, discharge the capacitors 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 the capacitors are discharged by perform-
ing Step 2 through Step 5 below.
2. Turn the key or keyless switch to the OFF position
and disconnect the battery by separating the con-
nectors.
3. Block load wheels to prevent lift truck from moving.
4. 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.
5. Wait at least 10 seconds to be sure the capacitors
are completely discharged.
2. Remove floor mat and floor covers.
3. Tag and disconnect transducer and fluid sensor
wiring.
NOTE: Position a catch can or a cloth to contain the
brake fluid spilled when the line is disconnected.
4. Remove the clamp and disconnect the main pres-
sure line from the elbow fitting on top of the master
cylinder. Cap or plug the lines and fittings to mini-
mize spills and prevent contamination to the brake
system. See Figure 3.
1800 YRM 1332