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ERC20AGF, ERC25AGF, ERC30AGF, ERC32AGF (ERC040GH, ERC050GH, ERC060GH, ERC065GH) (A908) 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................................................................................................... FOUR STAGE MAST...................................................................................................... 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. 524201427 (09/14)

PART NUMBER

YRM NUMBER

REV DATE

524179934 524158039 524205680 524179937 524158906 524158753 524183081 524179942 524179945 524179946 524256687

0100 YRM 0558 0620 YRM 0294 0620 YRM 1098 1400 YRM 0285 1600 YRM 0258 1600 YRM 0720 1600 YRM 1054 1800 YRM 0574 1900 YRM 0559 2000 YRM 0562 2000 YRM 1224

11/07 03/08 03/10 06/10 11/06 11/06 11/06 04/08 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 524179953

2200 YRM 1058 2240 YRM 0001 4000 YRM 0521 4000 YRM 0563

04/11 09/14 03/06 04/05

524223776 524150797 524183086 524183087 524204007

4000 YRM 1148 8000 YRM 0231 8000 YRM 1059 8000 YRM 1060 8000 YRM 1083

02/14 10/13 08/12 02/10 11/06


100 YRM 558

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 The main frame is a single weldment. See Figure 1. 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 assemblies (steer, lift, and traction motors) • Control valves and levers The hood is part of the operator and battery restraint system. The seat is also part of the operator restraint system. The floor plates are removed for access to the steering motor. A panel in the bottom of the battery compartment is removed for access to the traction motor and the hydraulic pump motor. The electronic controller and contactors are attached to the frame. A panel in the counterweight is removed for access to the controller and contactors. See Figure 16. For the location of the Master Controller and Electro-Hydraulics Valve Driver Module, see the section Electro-hydraulic Control Valve 2000 YRM 1224.

WARNING 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 spacer plate to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward. The lift trucks are equipped with an adjustable spacer plate in the battery compartment. See Figure 2. Adjust the spacer plate to control the movement of the battery in the forward and backward directions. Tighten the jam nuts on the adjustment capscrew to prevent the adjustment from changing.

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. 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.

1


Description

100 YRM 558

Figure 1. Lift Truck Frame

2


100 YRM 558

Description Legend for Figure 1

NOTE: OPTIONAL SIDE PANELS FOR BATTERY COMPARTMENT NOT SHOWN. 1. 2. 3. 4.

COWL BATTERY COMPARTMENT ACCESS COVERS BATTERY SPACER PLATE* BATTERY SPACER PLATE**

5. 6. 7. 8.

SIDE STEP AND FENDER WELDMENT FRAME FLOOR MATS FLOOR PLATES (COVERS)

* BATTERY SPACER PLATE USED ON NEWER LIFT TRUCK MODELS ** BATTERY SPACER PLATE USED ON OLDER LIFT TRUCK MODELS

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. 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 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), and AC (Alternating Current) electronic controllers and contactors. See Figure 3, Figure 4, Figure 5, Figure 6, and Figure 7.

OVERHEAD GUARD WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck. The overhead guard is a weldment that fastens to the main frame and cowl to help protect the operator from falling objects. See Figure 5, Figure 6, Figure 7, or Figure 9. 1. BATTERY COMPARTMENT 2. BATTERY 3. BULKHEAD

4. SPACER PLATE 5. ADJUSTMENT CAPSCREW 6. JAM NUTS

Figure 2. Battery Spacer Plate

3


Description

A. STANDARD SEM DISPLAY PANEL

100 YRM 558

B. PREMIUM SEM DISPLAY PANEL Figure 3. SEM Display Panel

NOTE: FOR LIFT TRUCK 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 4. AC Display Panel

4


100 YRM 558

Overhead Guard Replacement

Overhead Guard Replacement REMOVE WARNING Do not weld, drill, grind, or cut the overhead guard for mounts, lights, or accessories. The strength of the overhead guard can be reduced. 1. Remove the battery from the truck. See How to Change Battery in your vehicle’s Periodic Maintenance or 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 5, Figure 6, Figure 7, Figure 8, and Figure 9. 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.

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 capscrews to 55 N•m (41 lbf ft). Install the capscrews, washers, and nuts that hold the rear legs to the frame. For lift truck models ERC20-30AGF (ERC040-065RF/ZF, ERC040-065RG/ZG) (E108), tighten the capscrews to 68 N•m (50 lbf ft). For lift truck models ERC20-30AGF (ERC040-065GH) (A908), tighten the capscrews to 90 N•m (66 lbf ft). Install the battery. See How to Change Battery in your vehicle’s Periodic Maintenance or Operating Manual.

5


Overhead Guard Replacement

100 YRM 558

Figure 5. Overhead Guard, Steering Column, and Display Panel, Truck Models ERC20-30AGF (ERC040-065RF/ZF) (E108)

6


100 YRM 558

Overhead Guard Replacement Legend for Figure 5

NOTE: 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. LATCH MECHANISM 9. OPTIONAL PREMIUM DISPLAY PANEL

10. 11. 12. 13. 14. 15. 16. 17. 18.

REGULAR DISPLAY PANEL* CAPSCREW WASHER NUT SCREW OVERHEAD GUARD HANDLE HORN SWITCH CONNECTOR STEERING COLUMN STEERING COLUMN NUT

*CURTIS METER SHOWN. PANEL AVAILABLE WITH OPTIONAL GENERAL ELECTRICâ„¢ METER.

7


Overhead Guard Replacement

100 YRM 558

Figure 6. Overhead Guard, Steering Column, and Display Panel, Truck Models ERC20-30AGF (ERC040-065RG/ZG) (E108)

8


100 YRM 558

Overhead Guard Replacement Legend for Figure 6

NOTE: 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

9


Overhead Guard Replacement

100 YRM 558

Figure 7. Overhead Guard, Steering Column, and Display Panel, Truck Models ERC20-30AGF (ERC040-065GH) (A908)

10


100 YRM 558

Overhead Guard Replacement Legend for Figure 7

NOTE: DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH AC ELECTRONIC CONTROLLERS AND CONTACTORS. NOTE: OVERHEAD GUARD FOR LIFT TRUCK MODELS ERC040-065GH (A908) SHOWN. SEE FIGURE 8 FOR OVERHEAD GUARD USED ON ERC20-30AGF (A908) MODELS. 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 Legend for Figure 8

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

OVERHEAD GUARD PLUG NUT LOCKWASHER CAPSCREW WASHER HANDLE SCREW

Figure 8. Overhead Guard, Lift Truck Models ERC20-30AGF (A908)

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Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 558

1. 2. 3. 4.

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

5. COUNTERWEIGHT 6. TOW PIN 7. BOLT

Figure 9. 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. A battery restraint system is installed as a safety device. See Figure 10. The function of the battery restraint system, when correctly locked in the down position, is to hold the battery in the battery compartment if an accident causes the lift truck to tip over. The battery restraint is a steel weldment that is connected to the

12

frame with a hinge. A sliding latch mechanism (see Figure 10.) 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.


100 YRM 558 Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement

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

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

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

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

Figure 10. Hood, Latch, and Battery Restraint System

WARNING Correct operation of the battery restraint system requires that the battery does not move more than 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. To operate correctly, the battery restraint must be locked in the down position. The battery compartment has an adjustable spacer plate, which is used to prevent forward and backward movement of the battery. Adjust the spacer plate to prevent movement in any one horizontal direction of 13 mm (0.5 in.) maximum. See Figure 2. Raise the seat. Use the knob for the latch to release the battery restraint. See Figure 10. 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 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.

HOOD The hood must be locked in the down position during operation. The battery must have the spacer plate correctly adjusted to prevent forward or backmaximum. ward movement of 13 mm (0.5 in.) On lift trucks ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108), 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 11) 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. Use the lift handle by the seat to raise the hood. See Figure 11. 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 spacer plate as shown in Figure 2.

13


Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 558 in.) clearance. The Battery Specifications, at the back of this manual, shows the minimum sizes of the battery compartment. 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. 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 12.

1. 2. 3. 4. 5.

HINGE LIFT HANDLE HOOD LATCH HANDLE SEAT BRAKE PLATE

Figure 11. Hood and Seat Brake Plate Assembly, Lift Truck Models ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ZG) (E108) Release the stop rod by moving it to the right before lowering hood. See the label in Figure 10. Make sure the latch handle is fully to the right when closing the hood so that the latch can engage the latch piece. 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.

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

14

1. ARMREST ADJUSTMENT HANDLE Figure 12. Armrest Latch Location 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 13. 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 13. Use handle on the hood to place hood in the raised position.


100 YRM 558 Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 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.

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 14.

Automatic Locking Retractor (ALR) NOTE: ERC20-30AGF (ERC40-065RF/ZF, ERC40065RG/ZG) (E108) 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 14.

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 13. Latch and Cover With E-Hydraulics

SEAT BRAKE On ERC20-30AGF (ERC40-065RF/ZF, ERC40-065RG/ ZG) (E108) units with a seat brake, there is a separate plate with a hinge fastened to the front of the battery compartment (see Figure 11.) 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. During operation of the lift truck, the seat brake will be applied to the traction motor if the seat brake switch, located under the seat, senses that the operator has left the seat and the parking brake has not been applied. On these units, push the seat and seat plate into position over the hood. See Figure 11 and Figure 14.

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

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

*THE SEAT PLATE IS NOT USED ON ERC20-30AGF (ERC040-065GH) (A908) TRUCKS. Figure 14. Operator Restraint and Seat Assembly

15


Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 558

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 15. 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 does not pull out of the retractor assembly, the internal latch may be locked. Pull firmly on the seat belt and hold for a moment to remove slack from the belt in the retractor. Release the seat belt. Seat belt will retract and the internal latch will unlock. 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

16

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 15. Hood and Seat Check


100 YRM 558

Counterweight Replacement

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.

Table 1. Counterweights Model

(mm*)

ERC040-050RF/ ZF, RG/ZG (E108) and ERC040-050GH (A908)

700

578 kg (1274 lb)

ERC040-050RF/ ZF, RG/ZG (E108) and ERC040-050GH (A908)

786

794 kg (1750 lb)

ERC20-25AGF (E108) and ERC040-060RF/ ZF, RG/ZG (E108) and ERC20-25AGF (A908) and ERC040-060GH (A908)

847

942 kg (2076 lb)

ERC30AGF (E108) and ERC065RF/ZF, RG/ZG (E108) and ERC30AGF (A908) and ERC065GH (A908)

933

942 kg (2076 lb)

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 16. The counterweight is fastened to the frame with four capscrews. The weights for the counterweights are shown in Table 1.

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

SEAL COUNTERWEIGHT TOW PIN ACCESS COVER UPPER CAPSCREW AND WASHER LOWER CAPSCREW AND WASHER COVER CAPSCREWS AND WASHERS

Weight

+ 50 kg (110 lb) 0 kg (0 lb)

*Approximate battery compartment lengths.

REMOVE 1. Remove the battery from the truck. See How to Change Battery in your vehicle’s Periodic Maintenance or Operating Manual for the procedures.

Figure 16. Counterweight Assembly

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YALE A908 ERC25AGF (ERC040GH, ERC050GH, ERC060GH, ERC065GH) LIFT TRUCK Service Repair Manual  
YALE A908 ERC25AGF (ERC040GH, ERC050GH, ERC060GH, ERC065GH) LIFT TRUCK Service Repair Manual  
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