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ERC/ERP16-20AAF (A814) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ DC MOTOR MAINTENANCE.......................................................................................... DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL............................................. STEERING SYSTEM...................................................................................................... STEERING HOUSING AND CONTROL UNIT (EARLY MODELS)................................ STEERING AXLE............................................................................................................ STEERING CONTROL UNIT.......................................................................................... BRAKE SYSTEM............................................................................................................ HYDRAULIC SYSTEM.................................................................................................... MAIN CONTROL VALVE................................................................................................ TILT CYLINDERS........................................................................................................... INSTRUMENT CLUSTER............................................................................................... EV-100ZX SCR MOTOR CONTROLLER DESC/ADJ/TRBL/REPAIR AND THEORY.. ELECTRICAL SYSTEM.................................................................................................. EV-100ZX SCR MOTOR CONTROLLER PARAMETER TABLES................................ SR/SP TRANSISTOR MOTOR CONTROLLERS DESCRIPTION, CHECKS AND ADJUSTMENTS, TROUBLESHOOTING, REPAIRS, AND THEORY OF OPERATON............................................................................................................... DISPLAY PANEL FOR SEM CONTROLS (DOS VERSION)......................................... SR/SP TRANSISTOR MOTOR CONTROLLER PARAMETER TABLES FOR FOURWHEEL ELECTRIC RIDER LIFT TRUCKS............................................................... DISPLAY PANEL FOR SEM CONTROLS..................................................................... SR(SEM)/SP TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER (WINDOWS VERSION).............................................................................................. INDUSTRIAL BATTERY................................................................................................. MAST - DESCRIPTION................................................................................................... MAST - REPAIR.............................................................................................................. FOUR STAGE MAST...................................................................................................... METRIC AND INCH (SAE) FASTENERS....................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS..................................................................................................................... DIAGRAMS (SEM)..........................................................................................................

PART NUMBER

YRM NUMBER

REV DATE

524179936 524158039 524179939 524166836 524179941 524179940 524158753 524179944 524179945 524179946 524150790 524158757 524179947 524166840 524179950

0100 YRM 0617 0620 YRM 0294 1400 YRM 0618 1600 YRM 0485 1600 YRM 0512 1600 YRM 0619 1600 YRM 0720 1800 YRM 0620 1900 YRM 0559 2000 YRM 0562 2100 YRM 0103 2200 YRM 0514 2200 YRM 0557 2200 YRM 0560 2200 YRM 0624

03/06 03/08 03/06 07/03 07/03 03/06 11/06 03/08 04/09 02/09 03/07 01/04 07/03 07/05 07/03

524179951 524166842

2200 YRM 0724 2200 YRM 0725

04/05 07/02

524179952 524166844

2200 YRM 0739 2200 YRM 0942

04/05 08/07

524167640 524158040 524158890 524158891 524179953 524150797 524179957 524179959 524179955 524179956

2200 YRM 0947 2240 YRM 0001 4000 YRM 0521 4000 YRM 0522 4000 YRM 0563 8000 YRM 0231 8000 YRM 0552 8000 YRM 0621 8000 YRM 0622 8000 YRM 0742

08/07 09/14 03/06 07/10 04/05 10/13 07/03 01/05 07/03 06/04

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 524179928 (09/14)


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.

1


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

2


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

3


Description

100 YRM 617

Figure 2. Lift Truck Frame Manual Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)

4


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)

6


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

7


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.

8

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)

9


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

11


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.

12


100 YRM 617

Description

Figure 10. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF (ERC030-40AF) (A814)

13


Description

100 YRM 617

Figure 11. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF (ERC030-40AG/BG) (A814)

14


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

15


Description

100 YRM 617

Figure 12. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF (ERC030, 040AH) (B814/C814)

16


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)

17


Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 617

INSTALL Put the overhead guard on the lift truck. Install any electric wires from the overhead guard legs through the holes in the frame. Install the capscrews, washers, and nuts that hold each front leg to the frame. Tighten the

1. 2. 3. 4.

FRONT LEG, OVERHEAD GUARD SETSCREW ATTACHMENT PLATE REAR LEG, OVERHEAD GUARD

capscrews to 55 N•m (41 lbf ft). Install the capscrews, washers, and nuts that hold the rear legs to the frame. Tighten the capscrews to 68 N•m (50 lbf ft). Install the battery.

5. COUNTERWEIGHT 6. TOW PIN 7. BOLT

Figure 14. Overhead Guard and Counterweight

Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement BATTERY RESTRAINT SYSTEM WARNING On units with a shorter frame, the gas spring for the hood can raise the hood at a rapid rate and cause an injury. DO NOT bend over hood when raising hood.

18

NOTE: The steering column must be all the way forward before unlocking and raising the battery restraint system. A battery restraint system is installed as a safety device. See Figure 15. The function of the battery restraint system, when correctly locked in the down position, is to hold the battery in the battery compartment


100 YRM 617 Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement if an accident causes the lift truck to tip over. The battery restraint is a steel weldment that is connected to the frame with a hinge. A sliding latch mechanism (see Figure 15) locks the battery restraint in the down position for operation. The latch, at the top center of the counterweight, unlocks the battery restraint from the frame so that the battery restraint can be raised to the up position for access to the battery. The battery restraint is also the support for the hood. A gas spring helps lift the hood assembly. A rod is used to hold the hood in the up position on units with a longer frame. The operator must hold the hood assembly with one hand. Use the other hand to move the rod to the storage position. Lower the hood and battery restraint assembly to the operating position. Make sure that the battery restraint is correctly locked to the frame for operation of the lift truck.

13 mm (0.5 in.) horizontally. Make sure that the battery spacer plate is correctly adjusted.

WARNING The battery restraint and its latch mechanisms must operate correctly before a lift truck is operated.

Correct operation of the battery restraint system requires that the battery does not move more than

To operate correctly, the battery restraint must be locked in the down position. The battery must have the spacers correctly adjusted to prevent movement in any one horizontal direction of 13 mm (0.5 in.) maximum. See Figure 4. Raise the seat. Use the latch handle to release the battery restraint. See Figure 15. Use the handle on the hood to raise the battery restraint and hood. Make sure that the battery cannot move more than a total of 13 mm (0.5 in.) in any one horizontal direction. Make sure the spacer plate is correctly adjusted to prevent the movement. Push the hood and the battery restraint down until the latch locks. Make sure the battery restraint is locked securely. Lift on the handle to make sure it is latched and will not move.

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11. 12.

WARNING

HOOD SEAT LATCH ASSEMBLY BATTERY RESTRAINT AND HOOD FRAME GAS SPRING HINGE

STOP ROD RELEASE LABEL FOR STOP ROD COUNTERWEIGHT LATCH HANDLE LIFT HANDLE LATCH WARNING LABEL

Figure 15. Hood, Latch, and Battery Restraint System

19


Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 617

HOOD AND SEAT BRAKE NOTE: The steering column must be all the way forward before raising the hood. The hood must be locked in the down position during operation. The battery must have the spacers correctly adjusted to prevent movement of 13 mm (0.5 in.) maximum. On lift trucks ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814), if the unit has a seat brake, raise the seat and seat plate assembly. Use the latch handle at the rear of the hood (see Figure 16) to release the hood frame and battery restraint. Raise the latch handle and slide the handle toward the right side of the truck. A spring moves the handle back to the left.

1. 2. 3. 4.

HINGE SEAT PLATE HOOD LATCH HANDLE Figure 17. Seat Brake Assembly, E-Hydraulics, Lift Truck Models ERC/P16-20AAF (ERC030, 040AH)(C814)

1. HINGE 2. LIFT HANDLE 3. HOOD

4. LATCH HANDLE 5. SEAT PLATE (WITH SEAT BRAKE*)

* THE SEAT PLATE (WITH SEAT BRAKE) IS USED ON ERC/P16-20AAF (ERC030-40AF, AG/BG) (A814) ONLY. Figure 16. Seat Brake Assembly, Manual Hydraulics, Lift Truck Models ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) ERC/P16-20AAF (ERC030, 040AH)(B814)

20

Use the lift handle by the seat to raise the hood (see Figure 16) or Figure 17. A gas spring and stop rod will hold the assembly in the up position. Make sure that the battery cannot move more than a total of 13 mm (0.5 in.) in any one horizontal direction. If necessary, adjust the battery spacers as shown in Figure 4. Release the stop rod by moving it to the right before lowering hood. See the label in Figure 15. Make sure the latch handle is fully to the right when closing the hood so that the latch can engage the latch plate. Make sure the hood is locked securely. Try to raise the hood using only the lift handle to make sure the hood is latched and will not move.


100 YRM 617 Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement On ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) units with a seat brake, there is a separate plate with a hinge fastened to the front of the battery compartment (see Figure 16). The seat is fastened to this plate instead of the hood on these units. The linkage for the seat plate has a spring that holds the plate up and applies the brake on the rear of the traction motor. The weight of the operator compresses the spring and applies the brake. On these units, push the seat and seat plate into position over the hood.

HOOD WITH E-HYDRAULICS WARNING The gas spring for the hood can raise the hood at a rapid rate and cause an injury. DO NOT lean over hood when raising hood.

WARNING The batteries for these lift trucks must fit the battery compartment width with a maximum of 13 mm (0.5 in.) clearance. The Battery Specifications, at the back of this manual, shows the minimum sizes of the battery compartment.

1. ARMREST ADJUSTMENT HANDLE Figure 18. Armrest Latch Location

Another important part of the battery restraint system is the steel weldment that is also the hood frame. This hood frame is connected to the lift truck frame with hinges at the rear of the hood. Gas springs help lift the hood assembly. The seat and other parts of the operator restraint system fasten to the hood assembly.

Pull the latch handle, located on the top of the latch, to the up position and then pull on latch handle to move cover away from hood release handle. Pull hood release handle up to release hood latch mechanism. See Figure 19. Use handle on the hood to place hood in the raised position.

NOTE: Before raising the hood, move the steering column to the forward position and slide the seat all the way back, and If necessary, move the armrest all the way back. See Figure 18.

Before lowering the hood, make sure the battery restraint rod is over the battery. Lower the hood and push hood release handle down to secure hood to frame. Move cover over hood release handle and push latch handle down to secure cover to hood. If latch is a locking latch, lock latch with key.

The latch that secures the cover for the hood release handle can be either a locking or non locking latch. If the latch is a locking latch, unlock latch with key first. The cover, latch and hood release handle are located on the right side of the hood. See Figure 19.

21


Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 617

1. LATCH 2. COVER 3. HOOD RELEASE HANDLE 4. HOOD LATCH MECHANISM 5. COMPRESSION SPRING

6. 7. 8. 9. 10. 11. 12.

PIN SCREW CAPSCREW NUT LOCKWASHER WASHER LATCH HANDLE

Figure 19. Latch and Cover With E-Hydraulics

OPERATOR RESTRAINT SYSTEM AND SEAT ASSEMBLY The seat belt, hip restraint brackets, seat and mounting, hood, and latches are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition. See Figure 20.

Automatic Locking Retractor (ALR) NOTE: ERC/P16-20AAF (ERC030-40AF, AG/BG) (A814), ERC/P16-20AAF (ERC030, 040AH) (B814) lift trucks produced before November 2005 are equipped with the ALR type seat belts. The seat belt must fasten securely. Make sure the seat belt extends and retracts smoothly and is not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced. See Figure 20.

22

1. SEAT 2. HIP RESTRAINT 3. SEAT BELT AND MOUNT

4. HOOD 5. SEAT RAILS 6. SEAT PLATE (WITH SEAT BRAKE)*

* THE SEAT PLATE (WITH SEAT BRAKE) IS USED ON ERC/P16-20AAF (ERC030-40AF, AG/BG) (A814) ONLY. Figure 20. Seat Assembly

Emergency Locking Retractor (ELR) NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt. When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator’s lower torso in the seat. A seat belt that is damaged worn or does not operate properly will not give protection when it is needed. The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 21.


100 YRM 617

Counterweight Replacement

The following seat belt operation checks must be performed: • With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. if the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly. • With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly. • With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly. Make sure the seat rails and latch striker are not loose. The seat rails must lock securely in position but move freely when unlocked. The seat rails must be securely attached to the mounting surface. The hood must be fully closed. Lift the hood to make sure it is closed and will not move. Adjust hood, hood latch, and latch striker when any of the parts of the operator restraint system are installed or

replaced. See the section Hood Repair in this manual for the adjustment procedures for the hood.

1. 2. 3. 4. 5. 6.

OPERATOR WEIGHT ADJUSTMENT FORWARD/BACKWARD ADJUSTMENT SEAT BELT HIP RESTRAINT SEAT SEAT RAIL Figure 21. Hood and Seat Check

Counterweight Replacement If the lift truck must be put on blocks for maintenance or repair, see How to Put Lift Truck on Blocks in the Operating Manual or Periodic Maintenance section for your vehicle.

WARNING The counterweight is very heavy. Make sure that the crane and lifting devices have enough lifting capacity to safely lift the counterweight. The weights of the counterweights are shown in Table 1. The counterweight normally is not removed for most repairs. Replacement of the SCR Electronic Controllers is easier with the counterweight removed. Replacement of the SEM, and AC Controllers is accomplished by removing the cover from the counterweight. See Figure 22. The counterweight is fastened to the frame with four capscrews. The weights for the counterweights are in Table 1.

REMOVE 1. Remove the battery from the truck. See How to Change Battery in your vehicle’s Periodic Maintenance section or Operating Manual for the procedures. 2. Install the counterweight lifting tool to the counterweight with a 1 UNC × 2 in. (50 mm) bolt. See Figure 23 and Figure 24. Connect a clevis to the counterweight lifting tool. The clevis must have a pin diameter of 16.0 to 19.0 mm (0.625 to 0.750 in.). Fasten a chain or sling to the clevis. Make sure the chain or sling and crane has the capacity to lift the counterweight. See Table 1. Use the crane to hold the weight of the counterweight.

23


Counterweight Replacement

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

100 YRM 617

SEAL COUNTERWEIGHT TOW PIN ACCESS COVER UPPER CAPSCREW AND WASHER LOWER CAPSCREW AND WASHER COVER CAPSCREW AND WASHERS Figure 22. Counterweight Assembly Table 1. Counterweights Model

Weight

+30 kg (66 lb) 0 kg (0 lb)

ERC030AF, AG/BG (A814), and ERC030AH (B814/C814)

467 kg (1030 lb)

ERC/P16-18AAF (A814), and ERC/P16-18AAF (B814/C814)

563 kg (1240 lb)

ERC/P20AAF (ERC040AF, AG/BG) (A814) and ERC/P20AAF (ERC040AH) (B814/C814)

738 kg (1630 lb)

24

1. LIFT CHAIN 2. LIFTING TOOL

3. CLEVIS 4. COUNTERWEIGHT

Figure 23. Lift Counterweight 3. From inside the battery compartment near the bottom, remove the two top capscrews that hold the counterweight to the frame. Remove the capscrews, nuts, and washers from the tow pin area of the counterweight. Use the crane to lift the counterweight away from the frame. Make sure that you do not damage the electronic controller.


100 YRM 617

Counterweight Replacement

INSTALL NOTE: The access panel to the electronic controller can be removed from the counterweight to make checks and adjustments on the controller. Before installing access panel, check the seal to make sure it fully seals the controls compartment and that there are no gaps between the seal, seal blocks, wire harness, battery bulkhead covers, or counterweight. Make sure the lugs are correctly engaged when the access panel is installed again or the panel will fall from the counterweight during operation. 1. Use a crane and the lifting tool, as during removal, to lift the counterweight into position. Make sure that you do not damage the electronic controller during installation. Install the two upper capscrews near the bottom of the battery compartment that hold the counterweight to the frame. Install the lower capscrews, washers, and nuts in the tow pin area of the counterweight. Tighten the upper capscrews to 380 N•m (280 lbf ft). Tighten the lower (tow pin) capscrews and nuts to 66 N•m (49 lbf ft). If removed, tighten the cover capscrews to 52 N•m (38 lbf ft). 2. Disconnect the sling or chain. Remove the lifting tool from the counterweight. NOTE: THE MATERIAL IS ASTM A36 STEEL 12.7 mm (0.50 in.) THICK. Figure 24. Counterweight Lifting Tool

3. Install the battery. See the secton Periodic Maintenance 8000 YRM 552 for the ERC/P16-20AAF (ERC030-40AF, AG/BG) (A814), and Periodic Maintenance 8000 YRM 1060 for the ERC/P16-20AAF (ERC030, 040AH) (B814/C814), or your vehicle’s Operating Manual.

25


Traction Motor Replacement

100 YRM 617

Traction Motor Replacement REMOVE This procedure describes the removal of the traction motor through the battery compartment. See Figure 25. Some lift trucks have a seat brake that actuates a brake on the armature shaft of the traction motor. See Figure 26 and Figure 27. A lifting device can be fastened to the overhead guard to lift the motor. If a crane will be used, remove the overhead guard for crane access. The steering pump and motor must be removed for clearance. See Steering System for Electric Lift Trucks 1600 YRM 485 for the ERC/P16-20AAF (ERC030-40AF, AG/BG) (A814), and Steering System for AC Electric Lift Trucks 1600 YRM 1054 for the ERC/P16-20AAF (ERC030, 040AH) (B814/C814) removal procedures.

NOTE: TRACTION MOTOR FOR MODELS ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) SHOWN. TRACTION MOTOR FOR ERC/P16-20AAF (ERC030,040AH) (B814/C814) IS SIMILAR. Figure 25. Traction Motor for Lift Truck Models NOTE: The traction motor can also be removed from under the lift truck with the use of a floor jack, but is more difficult. If the traction motor is removed from under the lift truck, the lift truck must be on blocks with enough clearance for the jack and traction motor. Some lift trucks require removal of hydraulic lines to remove the traction motor from under the lift truck. 1. See How to Change Battery in your vehicle’s Periodic Maintenance or Operating Manual. Remove

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the battery from the truck. Then remove the floor plates and the access panel in the bottom of the battery compartment. 2. For the ERC/P16-20AAF (ERC030-40AF, AG/BG) (A814) trucks, if there is a seat brake, put a weight on the seat that will hold the seat in the down position. See Figure 26. Remove the nut, capscrew, washers, and bushing at the pivot of the brake linkage. Make a note of the arrangement of the parts for correct assembly during installation. Disconnect the spring between the linkage and the brake assembly.

1. 2. 3. 4.

TRACTION MOTOR LEVER OF SEAT BRAKE LINKAGE NUT, CAPSCREW, WASHERS, AND BUSHING SPRING

Figure 26. Traction Motor With Seat Brake, Lift Trucks ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) 3. On lift truck models ERC/P16-20AAF (ERC030,040AH) (B814/C814) the guide pipe and electrical connections for the seat brake must be disconnected from the traction motor before motor is removed. See Figure 27. 4. Disconnect the power cables from the traction motor. Make an identification of which cable is connected to each terminal. Disconnect the wires to the brush wear indicator and the thermal switch, if installed.


100 YRM 617

Traction Motor Replacement the sling as shown in Figure 28 to control the traction motor during removal. Use the crane to hold the weight of the traction motor.

1. 2. 3. 4. 5.

GUIDE PIPE CONNECTION ELECTRICAL CONNECTION SEAT BRAKE SPRING TRACTION MOTOR Figure 27. Traction Motor With Seat Brake, Lift Trucks ERC/P16-20AAF (ERC030,040AH) (B814/C814)

WARNING The motor is heavy. Make sure that any lifting device has enough capacity to lift the weight. The motor can weigh approximately 90 to 140 kg (200 to 310 lb). 5. Put the lift truck on blocks for maintenance or repair, see How to Put Lift Truck on Blocks in the Operating Manual or Periodic Maintenance of your vehicle. Raising the lift truck will allow easier access to the bottom bolts between the traction motor and the speed reducer. Install a sling to hold the traction motor. Use a wood block and a board under

NOTE: TRACTION MOTOR FOR MODELS ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) SHOWN. TRACTION MOTOR FOR ERC/P16-20AAF (ERC030,040AH) (B814C814) IS SIMILAR. 1. SLING 2. USE A WOOD BLOCK AND BOARD UNDER SLING FOR A LEVER 3. TRACTION MOTOR Figure 28. Install Sling to Lift Traction Motor, Lift Truck Models 6. Disconnect the motor mount. Remove the bolts between the speed reducer housing and the motor. NOTE: The traction motors are in different configurations for different applications of the lift trucks. Traction motors weigh approximately 90 to 140 kg (200 to 310 lb). Make sure that the sling cannot slide and permit the traction motor to fall. 7. Use the crane or special lifting device to move the traction motor to a work space to make repairs as shown in Figure 29.

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Traction Motor Replacement

100 YRM 617 3. Lower the traction motor into position. Align the traction motor with the speed reducer. See Figure 30. Make sure the spacer and correct shims are installed in the speed reducer housing.

NOTE: TRACTION MOTOR FOR MODELS ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) SHOWN. TRACTION MOTOR FOR ERC/P16-20AAF (ERC030,040AH) (B814/C814) IS SIMILAR. Figure 29. Use Crane to Lift Traction Motor

INSTALL WARNING The motor is heavy. Make sure that any lifting device has enough capacity to lift the weight. The motor can weigh approximately 90 to 140 kg (200 to 310 lb).

NOTE: TRACTION MOTOR FOR MODELS ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) SHOWN. TRACTION MOTOR FOR ERC/P16-20AAF (ERC030,040AH) (B814/C814) IS SIMILAR. 1. SLING 2. BOARD AND BLOCK 3. TRACTION MOTOR

1. Make sure the mount surfaces of the motor and speed reducer housing are clean with no old adhesive.

Figure 30. Align Traction Motor With Speed Reducer

2. Install a sling to lift the traction motor. Use a wood block and a board under the sling as shown in Figure 28 to control the traction motor during installation.

4. Make sure the surface of the speed reducer and motor housings are clean with no adhesive. Apply liquid adhesive (Yale part number 520042831) to seal the motor to the speed reducer housing.

CAUTION

5. Use a board or pry bar as necessary to carefully push the traction motor into the speed reducer.

There must be 0 to 0.15 mm (0 to 0.006 in.) clearance between the bearing for the input gear of the speed reducer and the traction motor housing. Shims must be installed, if necessary, for this clearance.

6. Align the bolt holes in the speed reducer and the motor housing. Install the six bolts that hold the traction motor to the speed reducer. Tighten the bolts to 71 to 83 N•m (52 to 61 lbf ft).

NOTE: If the motor, bearing, or speed reducer are different than when the motor was removed, a new shim set is required. See the Drive Axle, Speed Reducer, and Differential 1400 YRM 618 to select the correct shim set before doing Step 3.

NOTE: If the drive unit assembly is in the lift truck, continue with this procedure. If the drive unit assembly is out of the lift truck, install the drive unit assembly. See the section Drive Axle, Speed Reducer, and Differential 1400 YRM 618.

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YALE A814 ERP16-20AAF LIFT TRUCK Service Repair Manual  
YALE A814 ERP16-20AAF LIFT TRUCK Service Repair Manual  
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