ERP13-15VC (B888) SERVICE MANUAL CONTENTS SECTION
PART NUMBER
YRM NUMBER
REV DATE
OPERATOR'S CAB........................................................................................................ 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............................................................
550025937 550038795 550038796 550038797 550038798 550038799 550038800 550073240 550038801 550038802 524223769 524319497 524319498 550038805 524158040 550038806 524150797 550038807 550038808 550038809 524319504
0100 YRM 1446 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
09/14 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. 550038790 (12/14)
0100 YRM 1446
General
General This Service Manual describes how the cab operates and includes replacement and repair instructions for the following cab components (see Figure 1): •
Front, rear, and cab door window panels
•
Windshield wipers
•
Roof liner
•
Roof top panel
•
Cab doors
1. FRONT WINDOW PANEL 2. DOOR WINDOW PANEL 3. WINDSHIELD WIPER
•
Cab heater
•
Weather panels
Some of the described components are options that may not be present on each cab. The operation of the various switches and controls can be found in the Operating Manual.
4. CAB DOOR 5. ROOF TOP PANEL Figure 1. Operator's Cab
1
Window Replacement
0100 YRM 1446
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 capacitor 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. Before performing work on the cab, the capacitors need to be discharged as described below: 1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below. 2. Turn the key or keyless switch to the OFF position. 3. Disconnect the battery by separating the connectors. 4. Block the drive wheels to prevent the lift truck from moving. 5. Make sure the Emergency-Disconnect switch HAS NOT been activated. If the EmergencyDisconnect switch is activated, rotate the switch to the right until it pops up. 6. Press horn button. Wait 30 seconds to be sure capacitors are fully discharged.
Window Replacement FRONT PANEL Remove, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955)
WARNING All windows installed in the cab are made of safety glass. All replacement windows must be made of the correct material and must be made
2
the correct thickness. Failure to have the correct material or thickness may cause the glass to break easily when struck and may cause personal injury.
WARNING Disconnect the battery before doing any work on the electrical system. Serious injury to personnel and/or damage to lift truck components can occur if battery is not disconnected. Discharge capacitors as directed in the General section of this manual.
0100 YRM 1446
Window Replacement
NOTE: In Step 1 and Step 2 note placement of components during removal to aid in installation.
3. Remove and discard seal from front window. See Figure 3.
1. Remove nut, bolt, and six washers from upper right hand corner of front window. See Figure 2.
NOTE: Perform Step 4 for the following lift truck models
2. Remove nut cover, nut, five washers, and screw from front window in five places. Remove front window from overhead guard. See Figure 3.
•
ERP22-35VL (ERP045-070VL) (A976)
•
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
4. Remove light brackets from overhead guard, if equipped. See manual Electrical System 2200YRM1369 for procedures.
NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY. NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY. WIPER KIT SHOWN NOT THE SAME ON ALL LIFT TRUCK MODELS. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
FRONT WINDOW INSERT WASHER SCREW NUT COVER WIRE HARNESS WIPER KIT SWITCH CAPSCREW BOLT NUT BRACKET
1. 2. 3. 4. 5. 6. 7. 8.
FRONT WINDOW SEAL SCREW WASHER BRACKET NUT NUT COVER LIGHT BRACKET Figure 3. Front Panel Assembly
Figure 2. Front Panel and Wiper
3
Window Replacement
Remove, Lift Truck Models ERP13VC, ERP15VC (B888)
WARNING All windows installed in the cab are made of safety glass. All replacement windows must be made of the correct material and must be made the correct thickness. Failure to have the correct material or thickness may cause the glass to break easily when struck and may cause personal injury.
WARNING Disconnect the battery before doing any work on the electrical system. Serious injury to personnel and/or damage to lift truck components can occur if battery is not disconnected.
0100 YRM 1446 1. Using compressed air, blow dirt and debris from components as needed. 2. Using a lint free cloth, wipe down front window and other components as needed.
Inspect 1. Inspect front window for damage and cracks, replace if damaged. 2. For lift truck models ERP13VC, ERP15VC (B888), inspect front panel and steel frame for damage and cracks, replace if damaged. 3. Inspect components and hardware for cracks and defects. Replace as needed.
Discharge capacitors as directed in the General section of this manual. 1. Move wiper blades away from front panel. 2. Remove inserts, wheel nuts, capscrews, and grab handle from mounting bracket on front panel frame. See Figure 4. 3. If equipped, remove light brackets from top of front panel frame. See Electrical System 2200YRM1524 for procedures. 4. Remove top two capscrews used to mount steering column. See Figure 5. 5. Remove six capscrews, nuts, front panel and front panel frame from lift truck. See Figure 5.
Clean
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.
4
1. 2. 3. 4. 5. 6.
INSERT WHEEL NUT CAPSCREW GRAB HANDLE MOUNTING BRACKET FRONT PANEL FRAME Figure 4. Grab Handle, Remove and Install, Lift Truck Models ERP13VC, ERP15VC (B888)
0100 YRM 1446
Window Replacement NOTE: Perform Step 2 for the following lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
•
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
2. Install light brackets on overhead guard, if equipped. See section Electrical System 2200YRM1369 for procedures. 3. Install front window on overhead guard. Install two washers, screw, two washers, bracket, washer, nut, and nut cover on front window in five places. See Figure 3. 4. Install two washers, bolt, four washers, and nut on upper right hand corner of front window. See Figure 2.
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 1. Install grab handle to mounting bracket on front panel frame using inserts, wheel nuts, and capscrews. See Figure 4. 1. 2. 3. 4. 5. 6.
CAPSCREW (FRONT PANEL AND FRAME) NUT CAPSCREW (STEERING COLUMN) LIGHT BRACKET FRONT PANEL FRONT PANEL FRAME
Figure 5. Front Panel and Frame Components, Lift Truck Models ERP13VC, ERP15VC (B888)
Install, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955)
NOTE: Apply liquid sealant, Yale P/N 501702902, to capscrews prior to installation. 2. Install front panel and front panel frame to lift truck with six capscrews and nuts. Tighten capscrews to 19 N•m (168 lbf in). See Figure 5. 3. Install top two capscrews for steering column. See Figure 5. 4. If equipped, install light brackets from top of front panel frame. See Electrical System 2200YRM1524 for procedures. 5. Push wiper blades into position on the front panel.
1. Install seal on front window. See Figure 3.
5
Window Replacement
REAR PANEL Remove 1. Remove flange nut, cover, wiper arm, and wiper blade from wiper motor. See Figure 6. 2. Disconnect wiring harness from wiper motor and remove wiper motor from rear panel. See Figure 6. 3. Remove two screws and latch from overhead guard legs in two places. See Figure 6. 4. Remove five capscrews and bracket from cab body. See Figure 6. 5. Disconnect gas spring from lower ball stud in two places. See Figure 7. 6. Remove cap, capscrew and washer from overhead guard and rear panel in two places. Remove rear panel from overhead guard. See Figure 6. 7. If damaged, remove ball stud from overhead guard leg in two places. See Figure 7. 8. Remove nut cover, nut, four washers, and hinge from rear panel in two places. See Figure 7. 9. Remove nut cover, nut, plate, washer, screw, and cap from hinge. Repeat for second hinge. See Figure 7. 10. Disconnect gas spring from upper ball stud on knob in two places. See Figure 7. 11. Remove ball stud from knob in two places. See Figure 7. 12. Remove screw, three washers, o-ring, and knob from rear panel in two places. See Figure 7. 13. Remove nut cover, nut, and two washers from connector on outside of rear panel. Repeat for opposite side. See Figure 7.
0100 YRM 1446
Clean
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Using compressed air, blow dirt and debris from components as needed. 2. Using a lint free cloth, wipe down rear screen and other components as needed.
Inspect 1. Inspect components for cracks and defects. Replace as needed. 2. Inspect gas springs for proper travel and extension. Replace as necessary. a. Extended length; 735 mm (28.9 in.). b. Stroke length, 315 mm (12.4 in.). c. Resistance, 150 N (33.7 lbf). 3. Inspect wiper blade for cracks and tearing. Replace as needed.
Install 1. Install seal on rear screen. See Figure 7. 2. Install two washers, connector, plug, two washers, nut, grip, and plug on inside of rear panel. Repeat for opposite side. See Figure 7. 3. Install two washers, nut, and nut cover on connector on outside of rear panel. Repeat for opposite side. See Figure 7. 4. Install knob, O-ring, three washers, and screw on rear screen in two places. See Figure 7.
14. Remove plug, grip, nut, two washers, plug, connector, and two washers from inside of rear panel. Repeat for opposite side. See Figure 7.
5. Install ball stud on knob in two places. See Figure 7.
15. Remove and discard seal from rear screen. See Figure 7.
6. Connect gas spring to upper ball stud on knob in two places. See Figure 7.
6
0100 YRM 1446
Window Replacement
NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY. 1. 2. 3. 4. 5. 6. 7.
REAR PANEL CAP CAPSCREW WASHER SCREW WIRE HARNESS SWITCH
8. 9. 10. 11. 12. 13. 14.
WIPER MOTOR WIPER BLADE WIPER ARM BRACKET LATCH COVER FLANGE NUT
Figure 6. Rear Panel and Wiper Attachment
7
Window Replacement
0100 YRM 1446
NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY. 1. 2. 3. 4. 5. 6. 7. 8. 9.
REAR PANEL SEAL NUT COVER PLATE WASHER HINGE SCREW NUT BALL STUD
10. 11. 12. 13. 14. 15. 16. 17. 18.
GAS SPRING KNOB O-RING PLUG GRIP LATCH CONNECTOR BRACKET CAP
Figure 7. Rear Panel Assembly
8
0100 YRM 1446 7. Install plate, washer, screw, nut, nut cover, and cap on hinge. Repeat for second hinge. See Figure 7. 8. Install washer, hinge, screw, three washers, nut, and nut cover on rear panel in two places. See Figure 7. 9. If removed, install ball stud on overhead guard leg in two places. See Figure 7. 10. Install rear panel on overhead guard. Install washer, capscrew, and cap on rear panel and overhead guard in two places. See Figure 6. 11. Connect gas spring to two lower ball stud in two places. See Figure 7. 12. Install bracket and five capscrews on cab body. See Figure 6. 13. Install latch and two screws on overhead guard legs in two places. See Figure 6. 14. Install rear wiper motor on rear panel and connect wiring harness to rear wiper motor. See Figure 6. 15. If removed, install wiper blade on wiper arm. See Figure 6. 16. Using a flange nut, install wiper arm and wiper blade on wiper motor. See Figure 6.
DOOR WINDOW Disassemble Window NOTE: If repair to non-sliding window is necessary, contact local glass repair shop. NOTE: The following procedure applies to right and left doors with sliding windows. 1. Remove window frame and window assembly from door assembly. See Figure 8. 2. Remove two latches from two sliding windows. See Figure 8. 3. Remove two sliding windows from window frame. See Figure 8. 4. Remove and discard four guides from two sliding windows. See Figure 8. 5. Remove and discard seal from rear of sliding window. See Figure 8.
Window Replacement 6. Remove and discard five seals from window frame. See Figure 8. 7. Remove and discard strip seal from window frame. See Figure 8. 8. Remove and discard six clips from window frame. See Figure 8. 9. Remove and discard edge protector from window frame. See Figure 8.
Clean
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Using compressed air, blow dirt and debris from components as needed. 2. Using a lint free cloth, wipe down windows on both doors and other components as needed.
Inspect 1. Inspect all components and hardware for cracks and defects. Replace as needed. 2. Inspect latch assembly and hardware. Ensure proper operation. 3. Inspect windows for chips and cracks. Replace as necessary.
Assemble Window NOTE: The following procedure applies to right and left doors. 1. Install edge protector and six clips on window frame. See Figure 8. 2. Install strip seal and five seals on window frame. See Figure 8. 3. Install seal on rear of sliding window. See Figure 8. 4. Install four guides on two sliding windows. See Figure 8.
9
Window Replacement
0100 YRM 1446
5. Install two sliding windows on window frame. See Figure 8.
7. Install window frame and window assembly to door assembly. See Figure 8.
6. Install two latches to sliding windows. See Figure 8.
NOTE: RIGHT-HAND SIDE SHOWN. 1. 2. 3. 4.
SLIDING WINDOW SEAL LATCH STRIP SEAL
5. 6. 7. 8.
CLIP WINDOW FRAME EDGE PROTECTOR GUIDE
Figure 8. Window Components
10
0100 YRM 1446
Window Wipers Replacement
Window Wipers Replacement FRONT WIPER ASSEMBLY NOTE: Lift truck models ERC22-35VG (ERC045-070VG) (A968) are not equipped with windshield wiper and motor.
NOTE: Perform Step 5 for the following lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
5. Disconnect hose (15) from connector (11). See Figure 10.
Remove, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955)
NOTE: Perform Step 6 and Step 7 for lift truck models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985).
1. Disconnect wire harness from wiper motor connector.
6. Disconnect hose (17) from connector (7). See Figure 11.
See Figure 9 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
See Figure 10 for lift truck models
7. Disconnect hose from nozzle clip. Remove nozzle clip and nozzle from wiper arm. See Figure 11.
•
ERP15-20VT (ERP030-040VT) (G807)
8. Remove two flange nuts, wiper arms, and wiper blade from wiper motor. See Figure 12.
•
ERP16-20VF (ERP30-40VF) (A955)
9. Remove wiper blade from wiper arm.
See Figure 11 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
2. Disconnect wire harness from washer pump connector. See Figure 9 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
See Figure 10 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
See Figure 11 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
NOTE: Perform Step 3 and Step 4 for lift truck models ERP22-35VL (ERP045-070VL) (A976). 3. Disconnect hose (6) from connector (7). See Figure 9. 4. Remove two clamps (5), hose (6), and nozzle (4) from wiper arm. Set aside for installation. See Figure 9.
See Figure 9 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
See Figure 10 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
See Figure 11 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
10. Remove two nut covers, two nuts, two washers, and wiper motor from lift truck. See Figure 12. 11. Disconnect hose from reservoir. See Figure 9 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
See Figure 10 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
See Figure 11 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
11
Window Wipers Replacement
1. 2. 3. 4. 5. 6. 7. 8.
WIPER MOTOR WIPER ARM WIPER BLADE NOZZLE (CLIP) CLAMP HOSE CONNECTOR (SPRAY NOZZLE) HOSE
0100 YRM 1446
9. 10. 11. 12. 13. 14. 15.
CHECK VALVE BRACKET RESERVOIR WASHER CAPSCREW WASHER PUMP CONNECTOR WIPER MOTOR CONNECTOR
Figure 9. Front Wiper Assembly for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)
12
0100 YRM 1446
1. 2. 3. 4. 5. 6. 7. 8.
WIPER MOTOR WIPER ARM WIPER BLADE RESERVOIR CAP CAPSCREW WASHER BRACKET
Window Wipers Replacement
9. 10. 11. 12. 13. 14. 15. 16.
NUT CHECK VALVE CONNECTOR CHECK VALVE CONNECTOR HOSE HOSE HOSE WIRING CONNECTOR
Figure 10. Front Wiper Assembly for Lift Truck Models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955)
13
Window Wipers Replacement
0100 YRM 1446
Figure 11. Front Wiper Assembly for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 14
0100 YRM 1446
Window Wipers Replacement Legend for Figure 11
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
CAPSCREW WASHER NUT WIPER ARM WIPER BLADE WIPER MOTOR CONNECTOR (SPRAY NOZZLE) CAP RESERVOIR BRACKET WASHER RESERVOIR
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
CHECK VALVE INSERT SWITCH FUSES FUSES MOUNTING BRACKET WIRE HARNESS HOSE NOZZLE CLIP HOSE WASHER PUMP CONNECTOR
1. 2. 3. 4.
WIPER MOTOR WASHER NUT NUT COVER
5. WIPER ARM 6. FLANGE NUTS 7. WIPER BLADE Figure 12. Wiper Attachment
15
Window Wipers Replacement
0100 YRM 1446
NOTE: Perform Step 12 and Step 13 for lift truck models ERP22-35VL (ERP045-070VL) (A976).
19. Disconnect and remove connector (11) from hose (13). Set aside for installation. See Figure 10.
12. Remove two capscrews, two washers, and reservoir from cowl.
NOTE: Perform Step 20 for lift truck models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985).
13. Remove four capscrews, washers, and reservoir from bracket. See Figure 9. NOTE: Perform Step 14 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
14. Remove three caps, three nuts, six washers, three capscrews, reservoir, and bracket from overhead guard leg. See Figure 10.
20. Disconnect and remove connector (7) from hose (19). See Figure 11.
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) 1. Disconnect wire harness from wiper motor connector. See Figure 13. 2. Disconnect washer pump connector from washer reservoir. See Figure 13.
NOTE: Perform Step 15 and Step 16 for lift truck models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985).
3. Disconnect hose (19) from connector (14). See Figure 13.
15. Remove two capscrews, washers, nuts, and reservoir from cowl. See Figure 11.
4. Disconnect hose from nozzle clip. Remove nozzle clip and nozzle from wiper arm. See Figure 13.
16. Remove caps, capscrews, washers, nuts, and reservoir from bracket. See Figure 11.
5. Remove two flange nuts, wiper arms, and wiper blade from wiper motor. See Figure 12.
17. Disconnect and remove check valve. Set aside for installation.
6. Remove screw, nut, washer, and wiper blade from wiper arm. See Figure 13.
See Figure 9 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
See Figure 10 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
See Figure 11 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
NOTE: Perform Step 18 for lift truck models ERP22-35VL (ERP045-070VL) (A976). 18. Disconnect and remove connector from hose (8). Set hose aside for installation. See Figure 9. NOTE: Perform Step 19 for lift truck models
16
•
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
7. Remove two nut covers, two nuts, two washers, and wiper motor from lift truck. See Figure 12. 8. Disconnect hose from reservoir. 9. Remove two capscrews, washers, nuts, caps, and reservoir from mounting bracket on right front overhead guard leg. 10. Remove two capscrews, washers, nuts, caps, and reservoir from reservoir mounting bracket. See Figure 13. 11. Disconnect and remove check valve. Set aside for installation. 12. Disconnect and remove connector (14) from hose (16). See Figure 13.
0100 YRM 1446
Clean
Window Wipers Replacement
Inspect
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the yes.
1. Inspect hoses for cracks and wear. Replace if damaged. 2. Check washer reservoir for leaks by filling with water and checking seams. Replace if leaking. 3. Inspect wiper blades for cracks and tearing. Replace as needed.
1. Using compressed air, clean outside of wiper motor, reservoir and wiper arms.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
CAP NUT WASHER CAPSCREW WASHER RESERVOIR WASHER RESERVOIR MOUNTING BRACKET SCREW WASHER PUMP CONNECTOR SWITCH NOZZLE CLIP
11. 12. 13. 14. 15. 16. 17. 18. 19.
WIPER BLADE WIPER ARM WIPER MOTOR CONNECTOR (SPRAY NOZZLE) CHECK VALVE HOSE WIRE HARNESS WIPER MOTOR CONNECTOR HOSE
Figure 13. Front Wiper Assembly, Lift Truck Models ERP13VC, ERP15VC (B888)
17
Window Wipers Replacement
Install, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) NOTE: Perform Step 1 through Step 4 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 1. Connect hose (8) to connector. See Figure 9. 2. Connect check valve into hose (8). Connect hose (8) to other end of check valve. See Figure 9. 3. Install reservoir, washers, and four capscrews on bracket. See Figure 9.
0100 YRM 1446
•
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
5. Connect hose (13) to connector (11). See Figure 10. 6. Connect check valve to hose (13). Connect hose (14) to other end of check valve. See Figure 10.
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
See Figure 11 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
13. Using two washers, two nuts, and two caps, install wiper motor to lift truck. See Figure 12. 14. Install wiper blade on wiper arm. See Figure 9 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
See Figure 10 for lift truck models
4. Using two washers and two capscrews, install reservoir on cowl. NOTE: Perform Step 5 through Step 7 for lift truck models
•
•
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
See Figure 11 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
15. Using two flange nuts, install wiper arm and wiper blade on wiper motor. See Figure 9 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
7. Install bracket, pump, six washers, three capscrews, three nuts, and three caps on overhead guard leg. See Figure 10.
See Figure 10 for lift truck models
NOTE: Perform Step 8 through Step 11 for lift truck models ERP40-50VM (ERP080-100VM) (A985).
See Figure 11 for lift truck models
8. Connect hose (19) to connector (7). See Figure 11.
•
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
•
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
9. Connect check valve to hose.
NOTE: Perform Step 16 and Step 17 for lift truck models ERP22-35VL (ERP045-070VL) (A976).
10. Install reservoir to bracket using, four nuts, washers, capscrews, and caps. See Figure 11.
16. Install nozzle (4), hose (6), and two clamps (5) on wiper arm. See Figure 9.
11. Using two nuts, washers, and capscrews, install reservoir to cowl.
17. Connect hose (6) to connector (7). See Figure 9.
12. Connect hose to reservoir. See Figure 9 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
See Figure 10 for lift truck models
18
NOTE: Perform Step 18 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
18. Connect hose (15) to connector (11). See Figure 10.
0100 YRM 1446 NOTE: Perform Step 19 for lift truck models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985). 19. Install nozzle clip and nozzle into wiper arm. Connect hose (17) to nozzle. See Figure 11. 20. Connect wire harness to wiper motor connector. See Figure 9 for lift truck models •
ERP22-35VL (A976)
See Figure 10 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
See Figure 11 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
21. Connect wire harness to washer pump connector. See Figure 9 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
See Figure 10 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
See Figure 11 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
Window Wipers Replacement
Install, Lift Truck Models ERP13VC, ERP15VC (B888) 1. Connect hose (16) to connector (14). See Figure 13. 2. Connect check valve to hose. 3. Install reservoir to mounting bracket using two capscrews, nuts, washers, and caps. See Figure 13. 4. Using two capscrews, nuts, washers, and caps, install reservoir and mounting bracket to right overhead guard leg. 5. Connect hose to reservoir. See Figure 13. 6. Using two washers, two nuts, and two caps, install wiper motor to lift truck. See Figure 12. 7. Install wiper blade on wiper arm using screw, washer, and nut. See Figure 13. 8. Using two flange nuts, install wiper arm and wiper blade on wiper motor. See Figure 12. 9. Install nozzle clip and nozzle into wiper arm. Connect hose (19) to nozzle. See Figure 13. 10. Connect hose (19) to connector (14). See Figure 13. 11. Connect washer pump to washer reservoir. 12. Connect wire harness to wiper motor. See Figure 13.
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Cab Component Repair
0100 YRM 1446
Cab Component Repair ROOF LINER
2. Remove seven capscrews and seven washers from roof liner. See Figure 15.
Remove NOTE: Perform Step 1 for lift truck model ERP22-35VL (ERP045-070VL) (A976). 1. Remove seven caps, seven capscrews, and seven washers from roof liner. See Figure 14.
1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 5. 6. 7.
TOP PANEL CAP CAPSCREW WASHER ROOF LINER DOME LIGHT SCREW Figure 14. Roof Liner for Lift Truck Model ERP22-35VL (ERP045-070VL) (A976)
NOTE: Perform Step 2 for lift truck models
20
•
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
TOP PANEL CAPSCREW WASHER ROOF LINER DOME LIGHT SCREW Figure 15. Roof Liner for Lift Truck Model ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955)
NOTE: Perform Step 3 for lift truck models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985). 3. Remove eight capscrews and eight washers from roof liner. See Figure 16. NOTE: Note position of wire harness and washer hose through notched cutout in rear of roof liner. 4. Disconnect dome light harness and rear wiper switch harness (if equipped).
0100 YRM 1446
Cab Component Repair 7. Remove roof liner from overhead guard.
Clean
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 1. Using compressed air, blow dirt and debris off of roof liner. 2. Using a lint free cloth, wipe down overhead guard.
Inspect 1. Inspect roof liner for cracks and defects. Replace as needed. 1. 2. 3. 4. 5. 6.
TOP PANEL CAPSCREW WASHER ROOF LINER DOME LIGHT SCREW Figure 16. Roof Liner for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
5. Remove two screws and dome light from roof liner. See Figure 14 for truck models •
ERP22-35VL (ERP045-070VL) (A976)
See Figure 15 for truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
See Figure 16 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
6. Remove rear wiper switch from roof liner (if equipped).
2. Inspect hardware for defects, replace as needed.
Install 1. Install roof liner on overhead guard. 2. Route wire harness and washer hose through notched cut out in rear of roof liner as noted during removal. 3. Install rear wiper switch to preformed cutout of roof liner (if equipped). 4. Using two screws, install dome light on roof liner. See Figure 14 for truck models •
ERP22-35VL (ERP045-070VL) (A976)
See Figure 15 for truck models •
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
See Figure 16 for lift truck models •
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
5. Connect dome light harness and rear wiper switch harness, if equipped.
21
Cab Component Repair
0100 YRM 1446
NOTE: Perform Step 6 for lift truck model ERP22-35VL (ERP045-070VL) (A976).
4. Remove and discard seal from screen. See Figure 17.
6. Install seven washers, seven capscrews, and seven caps on roof liner. See Figure 14.
5. Remove two nuts, four washers, two hinges, and pin from screen. See Figure 17.
NOTE: Perform Step 7 for lift truck models
6. Remove two nut covers, two nuts, two washers, and plate from screen. See Figure 17.
•
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
7. Install seven washers and seven capscrews on roof liner. See Figure 15. NOTE: Perform Step 8 for lift truck models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985). 8. Install eight washers and eight capscrews on roof liner. See Figure 16.
TOP PANEL Remove, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) NOTE: Perform Step 1 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
•
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
1. Disconnect front light wiring. See section Electrical System 2200YRM1369, Lights, for proper procedures.
WARNING All windows installed in the cab are made of safety glass. All replacement windows must be made of the correct material and must be the correct thickness. Failure to use the correct material or thickness may cause the glass to break easily when struck and may cause personal injury. NOTE: Due to use of glue and RTV sealer, replacement of top screen is to be done only if damaged. 2. Remove and discard grommets from top panel assembly. See Figure 17. 3. Remove four nuts, four washers, four capscrews, and roof panel from top panel assembly. See Figure 17.
22
7. Remove screw, spring, and grip from screen. See Figure 17. 8. Remove two nut covers, two nuts, two washers, and grip mounting plate from screen. See Figure 17.
Remove, Lift Truck Models ERP13VC, ERP15VC (B888) The top panel is attached to top of overhead guard using adhesive tape and pressing it on. See Figure 18.
WARNING All windows installed in the cab are made of safety glass. All replacement windows must be made of the correct material and must be the correct thickness. Failure to use the correct material or thickness may cause the glass to break easily when struck and may cause personal injury. NOTE: Due to use of glue and adhesive tape, replacement of top screen is to be done only if damaged. 1. Remove damaged top panel from lift truck. Pull top panel from overhead guard, using a cutting tool to remove glue and adhesive tape from overhead guard as top panel is pulled from overhead guard. See Figure 18.
Clean
WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the yes. 1. Using compressed air, blow dirt and debris from all components as needed.
0100 YRM 1446
Cab Component Repair
Figure 17. Top Panel
23
Cab Component Repair
0100 YRM 1446 Legend for Figure 17
1. 2. 3. 4. 5. 6. 7. 8.
ROOF PANEL TOP PANEL ASSEMBLY GROMMET SCREEN PIN HINGE WASHER NUT
9. 10. 11. 12. 13. 14. 15.
PLATE GRIP MOUNTING PLATE NUT COVER GRIP SPRING SCREW SEAL
3. For lift truck models ERP13VC, ERP15VC (B888), clean top of overhead guard to remove any glue residual from use of adhesive tape.
Inspect 1. Inspect hinges, rod, spring and grip for damage or cracks. Replace as needed.
Install, Lift Truck Models ERP22-35VL (ERP045-070VL) (A976), ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985), ERP15-20VT (ERP030-040VT) (G807), and ERP16-20VF (ERP30-40VF) (A955) 1. Install grip mounting plate, two washers, two nuts, and two nut covers on screen. See Figure 17. 2. Install grip, spring, and screw on screen. See Figure 17. 3. Install plate, two washers, two nuts, and two nut covers on screen. See Figure 17. 4. Install pin, two hinges, four washers, and two nuts on screen. See Figure 17. 5. Install seal on screen. See Figure 17. 6. Install roof panel, four washers, four capscrews, and four nuts on top panel assembly. See Figure 17. 1. TOP PANEL ASSEMBLY 2. ADHESIVE TAPE 3. OVERHEAD GUARD Figure 18. Top Panel, Lift Truck Models ERP13VC, ERP15VC (B888) 2. Using warm soapy water, clean plastic, rubber, and vinyl components. Wipe dry with a lint free cloth.
24
7. Install two grommets to top panel assembly. See Figure 17. NOTE: Perform Step 8 for lift truck models •
ERP22-35VL (ERP045-070VL) (A976)
•
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
8. Install front light wiring. See section Electrical System 2200YRM1369, Lights, for proper procedures.
0100 YRM 1446
Cab Door Assembly
Install, Lift Truck Models ERP13VC, ERP15VC (B888)
3. Position top panel above top of overhead guard. See Figure 18.
1. Ensure overhead guard is clean and free of old adhesive tape and glue.
4. Press top panel onto top perimeter of overhead guard and adhesive tape, making sure all edges are aligned correctly.
2. Peel off backing from adhesive tape and attach adhesive tape to all four sides of overhead guard. See Figure 18.
Cab Door Assembly DOOR ASSEMBLY
7. Repeat Step 1 through Step 6 for opposite side.
Remove
Lift Truck Models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955)
Lift Truck Models ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
WARNING The door assemblies are heavy, verify the lifting device being used during repairs can lift the weight of the parts and assembly. 1. Disconnect gas spring from top of door assembly. See Figure 19. 2. Remove three capscrews from upper hinge. Remove three capscrews from lower hinge. See Figure 19. 3. Using a lifting device, remove door assembly from lift truck and set aside. 4. Remove three caps, three bolts, four washers, bolt, guard, striker, and block from front overhead guard leg. See Figure 19.
WARNING The door assemblies are heavy, verify the lifting device being used during repairs can lift the weight of the parts and assembly. 1. Disconnect gas spring from top of door assembly. See Figure 20. 2. Remove two screws from mounting plate and hinge in two places. Remove three bolts from mounting plate and overhead guard leg in two places. See Figure 20. 3. Using a lifting device, remove door assembly from lift truck and set aside. 4. Remove two caps, two capscrews, two washers, bolt, guard, bracket and block from front overhead guard leg. See Figure 20. 5. Remove gas spring from overhead guard.
5. Remove gas spring from overhead guard.
6. Remove two caps, two capscrews, two washers, and bracket from overhead guard. See Figure 20.
6. Remove two caps, two capscrews, two washers, and bracket from overhead guard. See Figure 19.
7. Repeat Step 1 through Step 6 for opposite side.
25
Cab Door Assembly
1. 2. 3. 4. 5. 6. 7. 8.
DOOR ASSEMBLY (RH) DOOR ASSEMBLY (LH) HINGE (UPPER) HINGE (LOWER) BOLT GUARD BLOCK STRIKER
0100 YRM 1446
9. 10. 11. 12. 13. 14. 15.
BRACKET GAS SPRING NUT BALL STUD CAPSCREW WASHER CAP
Figure 19. Door Assembly for Lift Truck Model ERP22-35VL (ERP045-070VL) (A976) and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985) 26
0100 YRM 1446
Cab Door Assembly
Figure 20. Door Assembly for Lift Truck Model ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955)
27
Cab Door Assembly
0100 YRM 1446 Legend for Figure 20
1. 2. 3. 4. 5. 6. 7.
DOOR ASSEMBLY DOOR ASSEMBLY MOUNTING PLATE HINGE GAS SPRING BRACKET BLOCK
Disassemble Left Door NOTE: Perform Step 1 for lift truck models
8. 9. 10. 11. 12. 13. 14.
GUARD BOLT SCREW CAPSCREW WASHER CAP CAP
3. Remove screw, washer, lock plate cover, and plate from door assembly. See Figure 21.
•
ERP22-35VL (ERP045-070VL) (A976)
4. Disconnect rod from latch. See Figure 21.
•
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
5. Remove screw, washer, door handle, tube, rod, and lock from door assembly. See Figure 21.
1. Remove and discard two seals from door assembly. See Figure 21.
6. Remove seven fasteners and door cover from door assembly. See Figure 21.
NOTE: Perform Step 2 for lift truck models
7. Remove two screws and latch from door assembly. See Figure 21.
•
ERP15-20VT (ERP030-040VT) (G807)
•
ERP16-20VF (ERP30-40VF) (A955)
NOTE: Lift truck models ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) have a one piece seal around door assembly. 2. Remove and discard seal from door assembly. See Figure 21.
28
8. Remove screw and plate from grip. See Figure 21. 9. Remove two screws, two washers, seal, and grip from door assembly. See Figure 21.
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