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ERC/P16-20AAF (B814) SERVICE MANUAL CONTENTS SECTION PART NUMBER YRM NUMBER REV DATE FRAME............................................................................................................................ 524179936 0100 YRM 0617 03/06 DC MOTOR MAINTENANCE.......................................................................................... 524158039 0620 YRM 0294 03/08 AC MOTOR REPAIR...................................................................................................... 524205680 0620 YRM 1098 03/10 DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL............................................. 524179939 1400 YRM 0618 03/06 STEERING AXLE............................................................................................................ 524179940 1600 YRM 0619 03/06 STEERING CONTROL UNIT.......................................................................................... 524158753 1600 YRM 0720 11/06 STEERING SYSTEM...................................................................................................... 524183081 1600 YRM 1054 11/06 BRAKE SYSTEM............................................................................................................ 524179944 1800 YRM 0620 03/08 HYDRAULIC SYSTEM.................................................................................................... 524179945 1900 YRM 0559 04/09 MAIN CONTROL VALVE................................................................................................ 524179946 2000 YRM 0562 02/09 TILT CYLINDERS........................................................................................................... 524150790 2100 YRM 0103 03/07 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).......................................................................................................................... 524223768 2100 YRM 1139 02/14 ELECTRICAL SYSTEM.................................................................................................. 524183082 2200 YRM 1055 10/09 AC MOTOR CONTROLLER DESC/CHKS/ADJ/TRBSHT/REP&THEORY OF OPERATION/DISPLAY PANEL................................................................................. 524183083 2200 YRM 1056 03/09 TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS PROGRAM................................................................................................................. 524183085 2200 YRM 1058 04/11 INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14 MAST - DESCRIPTION................................................................................................... 524158890 4000 YRM 0521 03/06 MAST - REPAIR.............................................................................................................. 524158891 4000 YRM 0522 07/10 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)........ 524223776 4000 YRM 1148 02/14 METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13 DIAGRAMS..................................................................................................................... 524183086 8000 YRM 1059 08/12 PERIODIC MAINTENANCE............................................................................................ 524183087 8000 YRM 1060 02/10 CAPACITIES AND SPECIFICATIONS........................................................................... 524213865 8000 YRM 1113 11/06 PART NO. 524201842 (09/14) 2. 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 proce- dure for removing the traction motor is also described in this section. Description MAIN FRAME 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 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 bat- tery compartment can be removed for access to the hy- draulic 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. 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 spac- ers to prevent the battery from moving more than 13 mm (0.5 in.) in any horizontal direction. See Fig- ure 4. WARNING Maximum clearance between the battery and bat- tery compartment width is 13 mm (0.5 in.). Maxi- mum clearance between the battery and the spacer plate is also 13 mm (0.5 in.). The Battery Specifica- tions chart shows the minimum size compartment allowed. The weight of the battery is a large part of the coun- terweight 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 nec- essary for the indicated capacity. A slot in the overhead guard permits removal of the battery without removing the overhead guard. Figure 5, Figure 6, and Figure 7 shows covers for in- strument panel and control valve. 1 3. 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 4. 100 YRM 617 Description Legend for Figure 1 NOTE: OPTIONAL SIDE COVERS NOT SHOWN. A. BATTERY COMPARTMENT 1. SPACER PLATE 2. ACCESS COVERS 3. COWL 4. FLOOR MATS 5. FLOOR PLATES 6. FRAME 7. SIDE STEP AND FENDER WELDMENT 3 5. Description 100 YRM 617 Figure 2. Lift Truck Frame Manual Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814) 4 6. 100 YRM 617 Description Legend for Figure 2 1. COWL 2. NUT 3. CAPSCREW 4. LOCKWASHER 5. PLATE 6. SPACER 7. FOAM RUBBER 8. WASHER 9. COVER 10. PLATE 11. PLATE 12. FENDER 13. PLUG 14. BOLT 15. FLOORPLATE 5 7. Description 100 YRM 617 Figure 3. Lift Truck Frame E-Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814) 6 8. 100 YRM 617 Description Legend for Figure 3 1. COWL 2. NUT 3. CAPSCREW 4. LOCKWASHER 5. PLATE 6. SPACER 7. FOAM RUBBER 8. WASHER 9. COVER 10. PLATE 11. PLATE 12. FENDER 13. PLUG 14. BOLT 15. FLOORPLATE Figure 4. Spacers of Battery Compartment Legend for Figure 4 1. BATTERY COMPARTMENT 2. BATTERY 3. BULKHEAD 4. SPACER PLATES 5. ADJUSTMENT CAPSCREWS 6. JAM NUTS A + B = 13 mm (0.5 in.) MAXIMUM 7 9. 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. MOUNTING PANEL 2. DASH 3. NUT (FOLDOVER) 4. CAPSCREW 5. LINER 6. WASHER 7. LOCKWASHER 8. NUT 9. CATCH 10. PLATE 11. COVER 12. PLATE 13. COVER 14. TRIM 15. SCREW 8 10. 100 YRM 617 Description Figure 6. Covers Manual Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814) 9 11. Description 100 YRM 617 Figure 7. Covers E-Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814) 10 12. 100 YRM 617 Description Legend for Figure 7 1. MOUNTING PANEL 2. DASH 3. NUT (FOLDOVER) 4. CAPSCREW 5. LINER 6. WASHER 7. LOCKWASHER 8. NUT 9. CATCH 10. PLATE 11. COVER 12. PLATE 13. COVER 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 fas- tened to the main frame to make the frame assembly. The cowl weldment is a mount for the front of the over- head 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), Alternating Current (AC) and electronic controllers and contactors. See Figure 5, Figure 8, Figure 9, Figure 10, Figure 11, and Figure 12. A. STANDARD SEM DISPLAY PANEL B. PREMIUM SEM DISPLAY PANEL Figure 8. SEM Display Panel 11 13. 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 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 10, Figure 11, and Figure 12. 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. LATCH MECHANISM 9. OPTIONAL PREMIUM DISPLAY PANEL 10. OPTIONAL BASIC DISPLAY PANEL 11. REGULAR DISPLAY PANEL* 12. HORN BUTTON 13. STEERING COLUMN 14. STEERING COLUMN NUT *CURTIS METER SHOWN. PANEL AVAILABLE WITH OPTIONAL GENERAL ELECTRIC METER. 12 14. 100 YRM 617 Description Figure 10. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF (ERC030-40AF) (A814) 13 15. Description 100 YRM 617 Figure 11. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF (ERC030-40AG/BG) (A814) 14 16. 100 YRM 617 Description Legend for Figure 11 NOTE: THE DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH SEM ELECTRONIC CONTROLLERS AND CONTACTORS. 1. STEERING WHEEL 2. SHIFT LEVER MECHANISM 3. COLUMN COVER 4. LATCH MECHANISM 5. STEERING CONTROL UNIT 6. COLUMN FRAME 7. ON DEMAND STEERING COMPONENTS 8. DISPLAY PANEL (PREMIUM DISPLAY PANEL SHOWN) 9. OVERHEAD GUARD 10. CAPSCREW 11. WASHER 12. NUT 13. SCREW 14. OVERHEAD GUARD HANDLE 15. HORN SWITCH CONNECTOR 16. HORN BUTTON 17. STEERING COLUMN 18. STEERING COLUMN NUT 15 17. Description 100 YRM 617 Figure 12. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF (ERC030, 040AH) (B814/C814) 16 18. 100 YRM 617 Overhead Guard Replacement Legend for Figure 12 NOTE: DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH AC ELECTRIC CONTROLLERS AND CON- TACTORS. 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. ON-DEMAND STEERING COMPONENTS 2. SHIFT LEVER MECHANISM 3. STEERING WHEEL 4. DISPLAY PANEL 5. COLUMN COVER 6. COLUMN FRAME 7. STEERING CONTROL UNIT 8. COWL WELDMENT 9. DASH 10. COLUMN MOUNT 11. OVERHEAD GUARD 12. LATCH MECHANISM 13. CAPSCREW 14. WASHER 15. NUT 16. SCREW 17. OVERHEAD GUARD HANDLE 18. HORN SWITCH CONNECTOR 19. HORN BUTTON 20. STEERING COLUMN 21. 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, Fig- ure 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. CAPSCREW 2. WASHER 3. NUT 4. OVERHEAD GUARD HANDLE 5. OVERHEAD GUARD Figure 13. Overhead Guard, Lift Truck Models ERC/P16-20AAF (ERC030, 040AH) (B814/C814) 17 19. 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 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. 1. FRONT LEG, OVERHEAD GUARD 2. SETSCREW 3. ATTACHMENT PLATE 4. REAR LEG, OVERHEAD GUARD 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. NOTE: The steering column must be all the way for- ward before unlocking and raising the battery restraint system. A battery restraint system is installed as a safety de- vice. See Figure 15. The function of the battery re- straint system, when correctly locked in the down posi- tion, is to hold the battery in the battery compartment 18 20. 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 bat- tery restraint is a steel weldment that is connected to the frame with a hinge. A sliding latch mechanism (see Fig- ure 15) locks the battery restraint in the down position for operation. The latch, at the top center of the coun- terweight, unlocks the battery restraint from the frame so that the battery restraint can be raised to the up po- sition 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 oper- ator 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. WARNING Correct operation of the battery restraint system re- quires that the battery does not move more than 13 mm (0.5 in.) horizontally. Make sure that the bat- tery 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 must have the spacers correctly adjusted to prevent movement in any one hor- izontal direction of 13 mm (0.5 in.) maximum. See Fig- ure 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 re- straint is locked securely. Lift on the handle to make sure it is latched and will not move. 1. HOOD 2. SEAT 3. LATCH ASSEMBLY 4. BATTERY RESTRAINT AND HOOD FRAME 5. GAS SPRING 6. HINGE 7. STOP ROD 8. RELEASE LABEL FOR STOP ROD 9. COUNTERWEIGHT 10. LATCH HANDLE 11. LIFT HANDLE 12. LATCH WARNING LABEL Figure 15. Hood, Latch, and Battery Restraint System 19 21. 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.) maxi- mum. 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. 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) 1. HINGE 2. SEAT PLATE 3. HOOD 4. LATCH HANDLE Figure 17. Seat Brake Assembly, E-Hydraulics, Lift Truck Models ERC/P16-20AAF (ERC030, 040AH)(C814) 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 low- ering 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. 20 22. 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 in- stead of the hood on these units. The linkage for the seat plate has a spring that holds the plate up and ap- plies the brake on the rear of the traction motor. The weight of the operator compresses the spring and ap- plies 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 o
