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ERP25-30VC (B888) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

FRAME............................................................................................................................ AC MOTOR REPAIR...................................................................................................... LOAD AXLE.................................................................................................................... STEERING SYSTEM...................................................................................................... BRAKE SYSTEM............................................................................................................ HYDRAULIC SYSTEM.................................................................................................... HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVES............................................................................................. CYLINDER REPAIR (MAST S/N A270, A271, A272, C661, C662, C663)..................... WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE SUPERVISOR................................................................................. USER INTERFACE SERVICE TECHNICIAN................................................................. ELECTRICAL SYSTEM.................................................................................................. INDUSTRIAL BATTERY................................................................................................. MAST REPAIR (S/N A270, A271, A272, C661, C662, AND C663)............................... METRIC AND INCH (SAE) FASTENERS....................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS..................................................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

550038795 550038796 550038797 550038798 550038799 550038800 550073240 550038801 550038802 524223769 524319497 524319498 550038805 524158040 550038806 524150797 550087451 550038808 550038809 524319504

0100 YRM 1514 0620 YRM 1515 1300 YRM 1516 1600 YRM 1517 1800 YRM 1518 1900 YRM 1519 1900 YRM 1620 2000 YRM 1520 2100 YRM 1521 2200 YRM 1128 2200 YRM 1335 2200 YRM 1336 2200 YRM 1524 2240 YRM 0001 4000 YRM 1525 8000 YRM 0231 8000 YRM 1526 8000 YRM 1527 8000 YRM 1528 9000 YRM 1377

12/13 12/13 12/13 12/13 12/13 05/14 12/14 05/14 05/14 12/14 09/14 09/14 09/14 09/14 02/14 10/13 09/14 05/14 09/14 10/14

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 550087448 (12/14)


0100 YRM 1514

Introduction

Introduction GENERAL This service manual contains a description of, and service procedures for parts of the frame. These parts include the frame, counterweight assembly, overhead guard, hood and seat assembly, side panels, master drive unit (MDU), 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.

A. LEFT SIDE B. RIGHT SIDE

C. FORWARD TRAVEL

Figure 1. Lift Truck Orientation

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Introduction

0100 YRM 1514

DESCRIPTION The frame is a welded assembly with mounts for the counterweight, overhead guard, mast, steering system, step plate, hydraulic system, side covers, hood, cowl, transaxle and master drive unit. See Figure 2. 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 battery without removing the overhead guard. Each lift truck has a cast-iron counterweight appropriately weighted for the indicated capacity on the Nameplate. See Figure 2.

The hydraulic pump and motor assembly and hydraulic tank are located under the floor mat and floor plate, in the front of the lift truck between the load axles. See Figure 3. Floor plates are held in position by tabs and can be removed to provide access to components underneath. The traction motor is in the counterweight. See Figure 3. Access to the traction motor is through removal of counterweight cover. The lift trucks covered in this Service Manual can be equipped with either a manual control valve or an E-Hydraulic control valve. Both are fastened to the front of the battery compartment. Both control valve types have covers to protect the control valve. The manual control valve also has covers to protect the control linkages.

A. FRONT VIEW

B. BACK VIEW

1. 2. 3. 4. 5.

6. 7. 8. 9. 10.

OVERHEAD GUARD MAST MOUNTS TRANSAXLE HYDRAULIC TANK COWL

STEP PLATE, FLOOR PLATE, FLOOR MAT SIDE COVER HOOD COUNTERWEIGHT STEERING SYSTEM

Figure 2. Frame Components

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0100 YRM 1514

Introduction

1. TRACTION MOTOR 2. HYDRAULIC CONTROL VALVE 3. HYDRAULIC TANK

4. HYDRAULIC PUMP AND MOTOR 5. COUNTERWEIGHT COVER 6. LOAD AXLE Figure 3. Motor Locations

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 capacitors 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.

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Covers and Floor Plate

0100 YRM 1514

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 the connectors. 4. Block drive wheels to prevent lift truck from moving.

5. Make sure the Emergency-Disconnect switch HAS NOT been activated. If EmergencyDisconnect 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.

Covers and Floor Plate Various covers and floor plates provide access to components during service and securely cover areas during normal operation. Covers in the floor of the operator compartment allow access to the hydraulic tank, hydraulic pump and motor assembly, and Vehicle Systems Manager (VSM). A cover on top of the counterweight provides access to the traction motor and motor controllers. See Figure 4 for lift trucks manufactured before January, 2013. See Figure 5 for lift trucks manufactured after January, 2013 and equipped with manual main control valve. See Figure 6 for lift trucks manufactured after January, 2013 and equipped with E-Hydraulic main control valve.

1. 2. 3. 4. 5. 6. 7. 8. 9.

FLOOR MAT FLOOR PLATE COUNTERWEIGHT COVER STEERING COLUMN COVER DASH PANEL COVER MANUAL HYDRAULIC CONTROLS COVER PARKING BRAKE COVER RIGHT HOSE COVER STEP PLATE Figure 4. Floor Plates and Covers, Lift Trucks Manufactured Before January, 2013

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0100 YRM 1514

1. 2. 3. 4. 5. 6. 7. 8. 9.

FLOOR MAT FLOOR PLATE COUNTERWEIGHT COVER STEERING COLUMN COVER DASH PANEL COVER MANUAL HYDRAULIC CONTROLS COVER PARKING BRAKE COVER RIGHT HOSE COVER STEP PLATE Figure 5. Floor Plates and Covers, Lift Trucks Manufactured After January, 2013 With Manual Hydraulic Control Valve

Covers and Floor Plate

1. 2. 3. 4. 5. 6. 7. 8.

FLOOR MAT FLOOR PLATE COUNTERWEIGHT COVER STEERING COLUMN COVER DASH PANEL COVER STEP PLATE PARKING BRAKE COVER RIGHT HOSE COVER Figure 6. Floor Plates and Covers, Lift Trucks Manufactured After January, 2013 With EHydraulic Control Valve

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Overhead Guard Replacement

0100 YRM 1514

Overhead Guard Replacement WARNING The overhead guard is part of the operator protection 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 unobstructed 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

6. Tag and disconnect electrical wiring and hydraulic hoses from steering column and steering control unit. See Figure 7. 7. Remove four capscrews and nuts from steering column. See Figure 8. 8. Remove two inserts and two capscrews from each end of dash panel. See Figure 8. 9. Remove dash panel and steering column from cowl plate. 10. Access to rear capscrews and nuts is from the battery compartment. Remove rear capscrews and nuts from rear overhead guard legs and plates. See Figure 9. 11. Remove two bolts, washers, and nuts from cowl plate that connect front legs of overhead guard to frame. See Figure 9.

The overhead guard is heavy. Make sure the sling, chain, eyebolts, and crane or lifting device has the capacity to lift the overhead guard.

NOTE: Note routing of electrical wires prior to disconnecting.

1. Remove hood and seat assembly. See Hood and Seat Assembly.

NOTE: Tag electrical connectors during removal to aid in installation.

2. Remove battery. See the Operating Manual or service manual Periodic Maintenance 8000YRM1526.

12. Tag and disconnect any electrical wires that go through legs of overhead guard.

3. Remove parking brake and hose covers from cowl plate. See Figure 7. 4. Remove parking brake from cowl plate. See Brake System 1800YRM1518. 5. Remove steering column upper cover. See Figure 7. NOTE: Tag electrical wiring and hydraulic hoses and note routing during removal to aid in installation.

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NOTE: When overhead guard is lifted from frame assembly, make sure electrical wires move through holes in frame at the front and rear so that they are not damaged. 13. Using a lifting device, remove overhead guard from frame assembly. 14. Remove capscrews, inserts, and handle from overhead guard. See Figure 9.


0100 YRM 1514

Overhead Guard Replacement

NOTE: REAR RIGHT OVERHEAD GUARD LEG OMITTED FOR CLARITY. 1. 2. 3. 4. 5.

CAPSCREW PARK BRAKE COVER CLIP NUT PARK BRAKE STEERING HOSES

6. 7. 8. 9.

UPPER STEERING COLUMN COVER HOSE COVER COWL PLATE DASH PANEL

Figure 7. Overhead Guard Removal

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Overhead Guard Replacement

1. CAPSCREW 2. INSERT 3. COWL PLATE

0100 YRM 1514

4. DASH PANEL 5. GAS SPRING MOUNTING PLATE Figure 8. Dash Panel Removal

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0100 YRM 1514

Hood and Seat Assembly

INSTALL WARNING The overhead guard is heavy. Make sure the sling, chain, eyebolts, and crane or lifting device has the capacity to lift the overhead guard. NOTE: Make sure electrical wires are routed as noted during removal to assure that wires do not get pinched. 1. Using a lifting device, install overhead guard onto frame assembly. 2. Connect electrical wires, as tagged during removal. 3. Install two bolts, washers, and nuts to cowl plate and install overhead guard front legs to frame. See Figure 9. 4. Install rear capscrews and nuts into rear overhead guard legs and plates. See Figure 9. 5. Place dash panel and steering column onto cowl plate. Secure dash panel to cowl plate using two capscrews and inserts. Attach steering column to cowl plate with four bolts, washers, and nuts. See Figure 9. 6. Connect steering hoses and electrical connections as noted during removal. 1. 2. 3. 4.

OVERHEAD GUARD NUT CAPSCREW INSERT

5. 6. 7. 8.

HANDLE WASHER BOLT FRAME

Figure 9. Overhead Guard Components

7. Install steering column upper cover. 8. Install parking brake to cowl plate. See service manual Brake System 1800YRM1518 for procedures. 9. Install parking brake and hose covers using capscrews and clip nuts. Tighten capscrews to 2.55 to 2.75 N•m (23 to 24 lbf in). 10. Install battery. See the Operating Manual or service manual Periodic Maintenance 8000YRM1526. 11. Install hood and seat assembly. See Hood and Seat Assembly.

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Hood and Seat Assembly

0100 YRM 1514

Hood and Seat Assembly GENERAL The hood is the platform for the seat assembly and is located above the battery. It functions as a battery restraint that completely covers the battery compartment. See Figure 12. When correctly locked to the frame, it will hold the battery in the battery compartment if an accident causes the lift truck to tip over. The hood is a stamped steel cover. Two hinges at the back attach to overhead guard. A rotor lock latch assembly on the front of hood locks hood closed during operation. A gas-controlled spring holds hood in open position. Opening hood latch assembly unlocks hood from frame so hood can be raised to access the battery. See Figure 12. The hood latch assembly must be in good condition and properly secured before lift truck can be operated. If lift truck is equipped with manual hydraulic control levers, the levers and linkage assembly must be moved to raise the hood. Pull latch handle under manual hydraulic cover toward seat, allowing lever and linkage assembly to drop forward and out of the way. See Figure 10. If lift truck is equipped with E-Hydraulic mini-levers, pull up on the smaller adjustment handle, located on right side of armrest, and move armrest all the way back before raising hood. See Figure 11.

The seat assembly slides on seat rails that are fastened to the 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. See Figure 12. 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 operator is not on 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.

The hood, seat belt, arm rest, seat, and seat mount are all parts of the operator restraint system. Checks and adjustments for the operator restraint system are described in the Operating Manual and in the following service manual, Periodic Maintenance 8000YRM1526.

If rotor lock latch assembly does not lock hood in closed position, the lever and linkage assembly will not lock into position and lift truck will not operate. On lift trucks equipped with manual hydraulic control levers, a large, red push-button switch is mounted on the levers and linkage assembly. See Figure 10. On lift trucks equipped with E-Hydraulic mini-levers, the large, red push-button switch is located on right side of armrest. See Figure 11. This switch is an emergency battery disconnect switch and it allows operator to quickly disconnect the battery while seated on lift truck in case of an emergency.

1. LATCH HANDLE 2. MANUAL HYDRAULIC LEVER ASSEMBLY 3. EMERGENCY BATTERY DISCONNECT SWITCH Figure 10. Latch Handle, Manual Hydraulic Control Levers

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0100 YRM 1514

Hood and Seat Assembly Legend for Figure 11 1. EMERGENCY BATTERY DISCONNECT SWITCH 2. SMALL ADJUSTMENT HANDLE 3. LARGE ADJUSTMENT HANDLE

Figure 11. Armrest Adjustment Handle, EHydraulic Mini-Levers

NOTE: FULL SUSPENSION SEAT SHOWN. ARMREST FOR MANUAL HYDRAULIC CONTROL LEVERS SHOWN. 1. 2. 3. 4. 5. 6. 7.

COUNTERWEIGHT COVER 8. SEAT RAIL HOOD 9. SEAT BELT SEAT SWITCH CONNECTOR 10. ARM REST HOOD HINGE 11. SEAT HOOD LATCH 12. FORWARD/BACKWARD ADJUSTMENT LEVER HOOD LATCH HANDLE 13. WEIGHT ADJUSTMENT KNOB HOOD HANDLE Figure 12. Hood and Seat Assembly Components 11


Hood and Seat Assembly

0100 YRM 1514

To raise hood and seat assembly, perform the following:

NOTE: The hood can be raised from either side of lift truck. The hood latch handle is spring loaded.

1. Use tilt memory lever and tilt steering column all the way up. See Figure 13.

5. To raise the hood, lift hood latch handle upwards to unlatch hood. See Figure 12. Place hand in hood handle provided and raise hood to UP position.

2. Slide seat all the way back. 3. If lift truck is equipped with manual hydraulic control levers, pull latch handle for manual hydraulic lever assembly and move manual hydraulic lever assembly to forward position before raising hood. See Figure 10.

To close hood, place hand in hood handle and pull hood down until hood latch clicks. Try to lift hood to make sure hood is locked down.

4. If lift truck is equipped with E-Hydraulic mini-levers, pull up on the smaller adjustment handle, located on right side of armrest, and move armrest all the way back. See Figure 11.

1. Disconnect battery connector.

REMOVE 2. Tag and disconnect the electrical connectors to the emergency battery disconnect switch. See Electrical System 2200YRM1524 for procedures. 3. Tag and disconnect seat switch. See Figure 12. Remove seat harness from hood. NOTE: The seat assembly does not have to be removed from hood for hood to be removed from lift truck. Perform Step 4 if removing seat assembly. 4. To remove seat assembly, disconnect electrical connectors if not already done. See Step 2 and Step 3. Remove four screws, washers, spacers if required, and seat assembly from hood. 5. Raise hood. 6. Remove gas spring: a. Remove two clips and pins from gas spring. See Figure 14. b. Slide gas spring off mounting plates and remove from lift truck. See Figure 8 and Figure 14. 7. Lower the hood. 8. Remove two capscrews, standoffs, and tow pin from counterweight cover and remove cover from counterweight. See Figure 15.

NOTE: OPTIONAL TELESCOPIC STEERING COLUMN SHOWN. 1. TILT POSITION LEVER 2. TILT MEMORY LEVER 3. TELESCOPIC COLUMN LOCKING HANDLE Figure 13. Steering Column Tilt Memory Lever

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9. Remove two capscrews, spacers, and washers from hood hinges and hood mounting plates. See Figure 15. 10. Release hood latch and lift hood off of lift truck.


0100 YRM 1514

Hood and Seat Assembly

11. If hood latch needs to be removed, remove four capscrews from hood latch assembly and remove hood latch assembly from mounting plate and front bulkhead. See Figure 16.

NOTE: SOME COMPONENTS OF HOOD REMOVED FOR CLARITY. 1. 2. 3. 4. 5.

PIN CLIP GAS SPRING HOOD GAS SPRING MOUNTING PLATE Figure 14. Remove Gas Spring 1. 2. 3. 4. 5. 6. 7. 8. 9.

OVERHEAD GUARD HOOD MOUNTING PLATE HOOD HOOD HINGE WASHER SPACER CAPSCREW STANDOFF COUNTERWEIGHT COVER Figure 15. Hood Removal

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Hood and Seat Assembly

0100 YRM 1514

NOTE: HOOD OMITTED FOR CLARITY. 1. CAPSCREW 2. HOOD LATCH 3. FRONT BULKHEAD

4. HOOD LATCH HANDLE 5. LATCH STRIKER 6. MOUNTING PLATE Figure 16. Hood Latch Assembly

INSTALL 1. If hood latch assembly was removed from hood, install by doing the following: a. Place hood latch assembly onto mounting plate on front bulkhead. b. Install four capscrews to secure hood latch assembly to mounting plate. See Figure 16. 2. Place hood onto lift truck frame. Be sure holes on hood hinges line up with holes on mounting plates on overhead guard. 3. Install two capscrews, spacers, and washers in hood hinges. See Figure 15. DO NOT tighten capscrews. 4. Allow hood to engage latch and adjust hood for adequate latch engagement with hood striker. Adequate engagement is when the latch completely

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clears the 90 degree bend of the hood striker. After adjustment is complete, tighten capscrews to secure hood to hood mounting plates. 5. Raise hood. NOTE: When installing gas spring, be sure rod end is mounted to frame and shell end is mounted to hood. 6. Align gas spring to holes in mounting plates. Install pins and clips and secure gas spring to mounting plates. See Figure 8 and Figure 14. 7. Reinstall seat, if removed, and route seat harness through hood and connect to seat. 8. Connect electrical wiring harness to seat switch. See Figure 12. 9. Close hood. Make certain that latch is properly engaged.


0100 YRM 1514

Counterweight Replacement

10. Install counterweight cover, capscrews, standoffs and tow pin onto counterweight. Tighten capscrews to 10 N•m (89 lbf in) and standoffs to 30 N•m (266 lbf in). 11. Connect the emergency battery disconnect switch. See Electrical System 2200YRM1524 for procedures. 12. If lift truck is equipped with manual hydraulic levers, move manual hydraulic lever and linkage assembly back to upright position and lock in place. 13. Connect battery connector.

GROUND TEST NOTE: If the static discharge ground connection is not secured properly it could lead to possible failure of traction and/or pump motor controllers. To ensure proper installation of seat assembly and associated brackets, perform continuity test as described below. 1. Using an ohm meter, place a test lead at the armrest mounting bolt and another at the truck frame. The resistance needs to read 5 Ohms or less. See Figure 17. 2. 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.

A. ARMREST FOR LIFT TRUCK MODELS ERP25VC, ERP30VC (B888) B. ARMREST FOR LIFT TRUCK MODELS ERP13VC, ERP15VC (B888) 1. ARMREST BOLT 2. FRAME Figure 17. Ground Test

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