ERC/P16-20AAF (C814) (ERC030-040AH) (C814) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ DC MOTOR MAINTENANCE.......................................................................................... AC MOTOR REPAIR...................................................................................................... DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL............................................. STEERING AXLE............................................................................................................ STEERING CONTROL UNIT.......................................................................................... STEERING SYSTEM...................................................................................................... BRAKE SYSTEM............................................................................................................ HYDRAULIC SYSTEM.................................................................................................... MAIN CONTROL VALVE................................................................................................ MAIN CONTROL VALVE E-CONTROLS....................................................................... CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564).......................................................................................................................... ELECTRICAL SYSTEM.................................................................................................. AC MOTOR CONTROLLER DESC/CHKS/ADJ/TRBSHT/REP&THEORY OF OPERATION/DISPLAY PANEL................................................................................. TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS PROGRAM................................................................................................................. INDUSTRIAL BATTERY................................................................................................. MAST - DESCRIPTION................................................................................................... MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ METRIC AND INCH (SAE) FASTENERS....................................................................... DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... PART NO. 524262629 (09/14)
PART NUMBER
YRM NUMBER
REV DATE
524179936 524158039 524205680 524179939 524179940 524158753 524183081 524179944 524179945 524179946 524256687
0100 YRM 0617 0620 YRM 0294 0620 YRM 1098 1400 YRM 0618 1600 YRM 0619 1600 YRM 0720 1600 YRM 1054 1800 YRM 0620 1900 YRM 0559 2000 YRM 0562 2000 YRM 1224
03/06 03/08 03/10 03/06 03/06 11/06 11/06 03/08 04/09 02/09 04/08
524223768 524183082
2100 YRM 1139 2200 YRM 1055
02/14 10/09
524183083
2200 YRM 1056
03/09
524183085 524158040 524158890
2200 YRM 1058 2240 YRM 0001 4000 YRM 0521
04/11 09/14 03/06
524223776 524150797 524183086 524183087 524213865
4000 YRM 1148 8000 YRM 0231 8000 YRM 1059 8000 YRM 1060 8000 YRM 1113
02/14 10/13 08/12 02/10 11/06
100 YRM 617
Description
General This section has a description and the service procedures for the parts of the frame. These parts include the frame, counterweight assembly, overhead guard, hood and seat assembly, access panels, and label positions. The procedure for removing the traction motor is also described in this section.
Description MAIN FRAME
WARNING
The main frame is a single weldment. See Figure 1, Figure 2 and Figure 3. The main frame has mounts for the following: • Counterweight • Overhead guard • Battery restraint and hood • Seat plate (with optional seat brake) • Tilt cylinders • Steering axle • Drive axle assembly • Cowl assembly • Floor pedals and floor plates • Side step and fender weldments • Hydraulic tank, pump, and motor assembly • Control valves and levers
The battery must fit the battery compartment so that the battery restraint will operate correctly. A loose battery can cause serious injury and property damage if the lift truck overturns. Adjust the spacers to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction. See Figure 4.
The hood is part of the operator and battery restraint system. The seat is also part of the operator restraint system. The floor plates can be removed for access to the traction motor. A panel in the bottom of the battery compartment can be removed for access to the hydraulic pump motor and the steering pump motor. The electronic controller and contactors are attached to the lift truck frame and surrounded by the counterweight. A panel in the counterweight can be removed for access to the controller and contactors.
The weight of the battery is a large part of the counterweight system on an electric lift truck. Make sure that the battery is within the weight limits indicated on the nameplate. Each model of lift truck has a cast-iron counterweight that provides the additional weight necessary for the indicated capacity. A slot in the overhead guard permits removal of the battery without removing the overhead guard.
WARNING Maximum clearance between the battery and battery compartment width is 13 mm (0.5 in.). Maximum clearance between the battery and the spacer plate is also 13 mm (0.5 in.). The Battery Specifications chart shows the minimum size compartment allowed.
Figure 5, Figure 6, and Figure 7 shows covers for instrument panel and control valve.
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Description
100 YRM 617
Figure 1. Lift Truck Frame Manual Hydraulics ERC/P16-20AAF ([ERC030-040AF]; ERC030-040AG/BG) (A814); ERC/P16-20AAF (ERC030-040AH) B814
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100 YRM 617
Description Legend for Figure 1
NOTE: OPTIONAL SIDE COVERS NOT SHOWN. A. BATTERY COMPARTMENT 1. 2. 3. 4.
SPACER PLATE ACCESS COVERS COWL FLOOR MATS
5. FLOOR PLATES 6. FRAME 7. SIDE STEP AND FENDER WELDMENT
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Description
100 YRM 617
Figure 2. Lift Truck Frame Manual Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)
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100 YRM 617
Description Legend for Figure 2
1. 2. 3. 4. 5. 6. 7. 8.
COWL NUT CAPSCREW LOCKWASHER PLATE SPACER FOAM RUBBER WASHER
9. 10. 11. 12. 13. 14. 15.
COVER PLATE PLATE FENDER PLUG BOLT FLOORPLATE
5
Description
100 YRM 617
Figure 3. Lift Truck Frame E-Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)
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100 YRM 617
Description Legend for Figure 3
1. 2. 3. 4. 5. 6. 7. 8.
COWL NUT CAPSCREW LOCKWASHER PLATE SPACER FOAM RUBBER WASHER
9. 10. 11. 12. 13. 14. 15.
COVER PLATE PLATE FENDER PLUG BOLT FLOORPLATE Legend for Figure 4
1. 2. 3. 4. 5. 6.
BATTERY COMPARTMENT BATTERY BULKHEAD SPACER PLATES ADJUSTMENT CAPSCREWS JAM NUTS
A + B = 13 mm (0.5 in.) MAXIMUM
Figure 4. Spacers of Battery Compartment
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Description
100 YRM 617
NOTE: OPTIONAL SIDE COVERS FOR BATTERY COMPARTMENT NOT SHOWN. 1. INSTRUMENT PANEL COVER 2. INNER COWL LINER
3. CONTROL VALVE COVER 4. BATTERY COMPARTMENT
Figure 5. Covers Manual Hydraulics ERC/P16-20AAF ([ERC030-040AF]; ERC030-040AG/BG) (A814); ERC/P16-20AAF (ERC030-040AH) B814 Legend for Figure 6 1. 2. 3. 4. 5.
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MOUNTING PANEL DASH NUT (FOLDOVER) CAPSCREW LINER
6. 7. 8. 9. 10.
WASHER LOCKWASHER NUT CATCH PLATE
11. 12. 13. 14. 15.
COVER PLATE COVER TRIM SCREW
100 YRM 617
Description
Figure 6. Covers Manual Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)
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Description
100 YRM 617
Figure 7. Covers E-Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)
10
100 YRM 617
Description Legend for Figure 7
1. 2. 3. 4. 5. 6. 7.
MOUNTING PANEL DASH NUT (FOLDOVER) CAPSCREW LINER WASHER LOCKWASHER
8. 9. 10. 11. 12. 13.
OTHER FRAME WELDMENTS These frame parts are the right-hand and left-hand side step and fender weldments and the cowl weldment (see Figure 1 and Figure 2.) Each part is a weldment fastened to the main frame to make the frame assembly. The cowl weldment is a mount for the front of the overhead guard, the steering column assembly, the release linkage of the parking brake and the instrument panel
A. STANDARD SEM DISPLAY PANEL
NUT CATCH PLATE COVER PLATE COVER
with light switches. The display panel is on the right side of the steering column and attached to the instrument panel for lift truck models with SEM (Separately Excited Motor), SCR (Silicon Controlled Rectifier), Alternating Current (AC) and electronic controllers and contactors. See Figure 5, Figure 8, Figure 9, Figure 10, Figure 11, and Figure 12.
B. PREMIUM SEM DISPLAY PANEL Figure 8. SEM Display Panel
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Description
100 YRM 617
NOTE: FOR LIFT TRUCKS MODELS WITH AC ELECTRONIC CONTROLLERS AND CONTACTORS, BOTH THE STANDARD AND PREMIUM DISPLAY PANELS LOOK IDENTICAL. THE ONLY DIFFERENCE IS IN THE DISPLAY SOFTWARE AND THE RESULTING FUNCTIONALITY. Figure 9. AC Display Panel
OVERHEAD GUARD
The overhead guard is a weldment that fastens to the main frame and cowl to help protect the operator from falling objects. See Figure 10, Figure 11, and Figure 12.
WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.
Legend for Figure 10 NOTE: THE DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH SCR ELECTRONIC CONTROLLERS AND CONTACTORS. A. STEERING CONTROL UNIT USED ON EARLY MODEL LIFT TRUCKS B. STEERING CONTROL UNIT USED ON LATER MODEL LIFT TRUCKS 1. OVERHEAD GUARD 2. STEERING WHEEL 3. ON-DEMAND STEERING COMPONENTS (NOT ALL UNITS) 4. HORN SWITCH CONNECTOR 5. COLUMN COVER 6. COLUMN FRAME 7. STEERING CONTROL UNIT
8. 9. 10. 11. 12. 13. 14.
LATCH MECHANISM OPTIONAL PREMIUM DISPLAY PANEL OPTIONAL BASIC DISPLAY PANEL REGULAR DISPLAY PANEL* HORN BUTTON STEERING COLUMN STEERING COLUMN NUT
*CURTIS METER SHOWN. PANEL AVAILABLE WITH OPTIONAL GENERAL ELECTRIC METER.
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100 YRM 617
Description
Figure 10. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF (ERC030-40AF) (A814)
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Description
100 YRM 617
Figure 11. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF (ERC030-40AG/BG) (A814)
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100 YRM 617
Description Legend for Figure 11
NOTE: THE DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH SEM ELECTRONIC CONTROLLERS AND CONTACTORS. 1. 2. 3. 4. 5. 6. 7. 8.
STEERING WHEEL SHIFT LEVER MECHANISM COLUMN COVER LATCH MECHANISM STEERING CONTROL UNIT COLUMN FRAME ON DEMAND STEERING COMPONENTS DISPLAY PANEL (PREMIUM DISPLAY PANEL SHOWN) 9. OVERHEAD GUARD
10. 11. 12. 13. 14. 15. 16. 17. 18.
CAPSCREW WASHER NUT SCREW OVERHEAD GUARD HANDLE HORN SWITCH CONNECTOR HORN BUTTON STEERING COLUMN STEERING COLUMN NUT
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Description
100 YRM 617
Figure 12. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF (ERC030, 040AH) (B814/C814)
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100 YRM 617
Overhead Guard Replacement Legend for Figure 12
NOTE: DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH AC ELECTRIC CONTROLLERS AND CONTACTORS. NOTE: OVERHEAD GUARD FOR LIFT TRUCK MODELS ERC030, 040AH (B814/C814) SHOWN. SEE FIGURE 13 FOR OVERHEAD GUARD USED ON ERC/P16-20AAF (B814/C814) LIFT TRUCKS. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
ON-DEMAND STEERING COMPONENTS SHIFT LEVER MECHANISM STEERING WHEEL DISPLAY PANEL COLUMN COVER COLUMN FRAME STEERING CONTROL UNIT COWL WELDMENT DASH COLUMN MOUNT OVERHEAD GUARD
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
LATCH MECHANISM CAPSCREW WASHER NUT SCREW OVERHEAD GUARD HANDLE HORN SWITCH CONNECTOR HORN BUTTON STEERING COLUMN STEERING COLUMN NUT
Overhead Guard Replacement REMOVE WARNING Do not weld, drill, grind, or cut the overhead guard for mounts for lights or accessories. The strength of the overhead guard can be reduced. 1. Remove the battery as described in the section Periodic Maintenance 8000 YRM 552 for lift truck models ERC/P16-20AAF (ERC030-40AF, AG/BG) (A814), and Periodic Maintenance 8000 YRM 1060 for lift truck models ERC/P16-20AAF (ERC030, 040AH) (B814/C814), or your vehicle’s Operating Manual. 2. Access to the capscrews that hold the rear legs of the overhead guard to the frame is from the battery compartment. Remove the, capscrews, washers, and nuts that fasten each leg. See Figure 10, Figure 11, Figure 12, Figure 13, and Figure 14. 3. Remove the capscrews, washers, and nuts that hold each front leg of the overhead guard to the cowl. Disconnect any electric wires from under the cowl that go through the front legs of the overhead guard. When the overhead guard is lifted from the frame, make sure these electric wires move through the holes in the frame at the front and rear so that they are not damaged. 4. Use a lifting device or another person to help lift the overhead guard from the lift truck.
1. 2. 3. 4. 5.
CAPSCREW WASHER NUT OVERHEAD GUARD HANDLE OVERHEAD GUARD Figure 13. Overhead Guard, Lift Truck Models ERC/P16-20AAF (ERC030, 040AH) (B814/C814)
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