Service Repair ERP1.6,1.8,2.0ATF (ERP030-040TH) [F807]
PART NO. 524204507
8000 YRM 1080
8000 YRM 1080
General
General European Model ERP1.6ATF
ERP1.8ATF
ERP2.0ATF 1
Wheel Base
Grade Clearance
Turning Radius
Right Angle Aisle Clearance 1
1290.0 mm (50.8 in.)
31%
1470.0 mm (57.9 in.)
2581.0 mm (101.6 in.)
1385.0 mm (54.5 in.)
29%
1565.0 mm (61.6 in.)
2676.0 mm (105.4 in.)
1385.0 mm (54.5 in.)
29%
1565.0 mm (61.6 in.)
2676.0 mm (105.4 in.)
1495.0 mm (58.9 in.)
27%
1675.0 mm (65.9 in.)
2786.0 mm (109.6 in.)
1385.0 mm (54.5 in.)
29%
1565.0 mm (61.6 in.)
2676.0 mm (105.4 in.)
1495.0 mm (58.9 in.)
27%
1675.0 mm (65.9 in.)
2786.0 mm (109.6 in.)
Equipped with two-stage mast and carrying a 762 mm (30 in.) long × 813 mm (32 in.) wide load.
U.S.
1
Model
Wheel Base
Grade Clearance
Turning Radius
Right Angle Aisle Clearance 1
ERP030TH
1290.0 mm (50.8 in.)
32%
1470.0 mm (57.9 in.)
2581.0 mm (101.6 in.)
ERP035TH
1385.0 mm (54.5 in.)
30%
1565.0 mm (61.6 in.)
2676.0 mm (105.4 in.)
ERP040TH
1385.0 mm (54.5 in.)
30%
1565.0 mm (61.6 in.)
2786.0 mm (109.6 in.)
Equipped with two-stage mast and carrying a 762 mm (30 in.) long × 813 mm (32 in.) wide load.
Specifications Maximum Gross Vehicle Weight
5600 kg (12,346 lb)
Counterweight
670 kg (1477 lb)
Maximum Load
1815 kg (4000 lb)
Brake Drawbar Drag (BDBD) @125 lbs Pedal Effort
1633 kg (3600 lb)
1
Hydraulic System
8000 YRM 1080
Lubrication Specifications Application
Lubrication Area
Standard
Freezer/Food Processing
Hydraulic System
ISO VG 46 Antiwear Hydraulic Oil (HCE-140)
Low Temperature Hydraulic Oil (Exxon Univis® HVI 26)
Brake Master Cylinder
ISO VG 46 Antiwear Hydraulic Oil (HCE-140)
Low Temperature Hydraulic Oil (Exxon Univis® HVI 26)
Steering System Fluid
ISO VG 46 Antiwear Hydraulic Oil (HCE-140) (Drawn from Hydraulic Tank)
10W Hydraulic Oil (Exxon Univis® HVI 26 ) (Drawn from Hydraulic Tank)
Grease
Multipurpose (Lithium Complex) Grease with 2 to 4% Molybdenum Disulfide
Multipurpose (Lithium Complex) Grease with 2 to 4% Molybdenum Disulfide
Lift Chains and Sheaves
SAE 20 Motor Oil API CC/SG
SAE 20 Motor Oil API CC/SG
Operator Controls
Silicone Spray Lubricant
Silicone Spray Lubricant
Hydraulic System Hydraulic Pump Displacement Operating Temperature
17 cc/rev 0 to 80 C (32 to 176 F)
Filtration
10 Micron Nominal
Max Pressure
18.1 MPa (2611 psi)
Max Peak Pressure
20.6 MPa (2902 psi)
Hydraulic Lift Motor Power
36/48 Volt DC Motor @ 36 Volts
@ 48 Volts
9 kW (12 hp)
12 kW (16 hp)
Speed Thermal Rating Brush Wear Insulation
600-3000 RPM S3 = 15%
S3 = 15%
LED Indicator on Display Panel Class "H"
Hydraulic System Main Relief Pressure (Manual Valve)
17.9 MPa (2600 psi)
Main Relief Pressure (Electro-Valve)
17.9 MPa (2600 psi)
Secondary Relief Valve
13.8 MPa (2000 psi)
Tank Capacity (To Full Mark)
19.0 liter (20.1 qt)
System Capacity
21.0 liter (22.2 qt)
2
8000 YRM 1080
Steering System
Steering System System Specifications Steering System Normal Operating Temperature
49 to 60 C (120 to 140 F)
Steering Control Unit Displacement
63 cm 3 /rev (3.84 cu in. 3 /rev)
Relief Valve 1
7.5 MPa (1100 psi)
Steering Pump Motor Voltage
36 Volts DC
48 Volts DC
Speed
2100 RPM
1850 RPM
Output
0.80 kW (1.07 HP)
0.80 kW (1.07 HP)
Steering Gear Pump Displacement Relief Valve
4.23 cm 3 /rev (.258 in. 3 /rev) Not Applicable
Steering Actuator Max Torque Oil Pressure (Max Torque) Range of Motion 1
570 N•m (420 lbf ft) 6.1 MPa (885 psi) 185
Refers to anti-kickback check valve. Anti-cavitation check valve is not adjustable.
3
Tire Sizes
8000 YRM 1080
Tire Sizes European Drive Tire
Model
ERP1.6-1.8ATF
ERP2.0ATF
Wheel
Size
Description
Quantity
Size
Description
Quantity
18 × 7 - 8
Solid Pneumatic
2
4.33R-8
Locking Ring Wheel
2
18 × 7 - 12.1
Solid Cushion
2
200/50-10
Solid Pneumatic
2
18 × 7 - 12.1
Solid Cushion
2
Cast Wheel 6.50F-10
Locking Ring Wheel
Cast Wheel
2 2 2
European Steer Model
ERP1.6-1.82.0ATF
Tires
Wheel
Size
Description
Quantity
Size
Description
Quantity
15 × 4.5 - 8
Solid Pneumatic
2
4.33R-8
Locking Ring Wheel
2
U.S. Drive Tire
Model
ERP030-035TH
ERP040TH
Wheel
Size
Description
Quantity
Size
Description
Quantity
18 × 7 - 8
Solid Pneumatic
2
4.33R-8
Locking Ring Wheel
2
18 × 7 - 12.1
Solid Cushion
2
200/50-10
Solid Pneumatic
2
18 × 7 - 12.1
Solid Cushion
2
Cast Wheel 6.50F-10
Locking Ring Wheel
Cast Wheel
2 2 2
U.S. Steer Model
ERP030-03540TH
4
Tires
Wheel
Size
Description
Quantity
Size
Description
Quantity
15 × 4.5 - 8
Solid Pneumatic
2
4.33R-8
Locking Ring Wheel
2
15 × 4 × 11.2
Solid Cushion
2
Cast Wheel
2
8000 YRM 1080
Torque Specifications
Torque Specifications ELECTRICAL Controller Terminals (All Locations) 13 N•m (115 lbf in)
Steering Gear Pump Outlet Fitting (1 Place) 56 N•m (41 lbf ft) Steering Gear Pump Plug 18 N•m (13 lbf ft)
Steering Potentiometer Jam Nut 1.25 N•m (11.00 lbf in)
HYDRAULIC SYSTEM
Accelerator Position Sensor 2.2 N•m (19.0 lbf in)
Filter Housing to Tank (2 Places) 8 N•m (72 lbf in)
STEERING SYSTEM
Filter Housing Cover (4 Places) 6 N•m (53 lbf in)
Steer Pump Motor to Lower Bracket (2 Places) (Loctite® 242) 15 N•m (133 lbf in) Steer Pump Motor to Upper Bracket (2 Places) (Loctite® 242) 3 N•m (26 lbf in) Upper Bracket to Frame (3 Places) (Loctite® 242) 25 N•m (19 lbf ft)
Pump Motor to Motor Bracket (4 Places) 48 N•m (35 lbf ft) Motor Bracket to Frame (4 Places) 48 N•m (35 lbf ft) Lift Pump to Motor (2 Places) 61 N•m (45 lbf ft)
Steer Pump Motor to Pump (2 Places) (Loctite® 242) 15 N•m (133 lbf in)
Lift Pump Hydraulic Fittings (2 Places) 80 N•m (59 lbf ft) (Maximum)
Steering Actuator to Frame (3 Places) 290 N•m (214 lbf ft)
Auxiliary Hose Mounting Plate (2 Places) 61 N•m (45 lbf ft)
Steering Control Unit Fittings (4 Places) 40 N•m (30 lbf ft)
MANUAL HYDRAULIC VALVE
Steering Control Unit Capscrews (4 Places) 40 N•m (30 lbf ft) Steering Encoder and Horn Contactor (4 Places) .5 N•m (4 lbf in) Steering Gear Pump Inlet Fitting (1 Place) 80 N•m (59 lbf ft)
Relief Valve Retaining Nuts (1 Each) 5 N•m (44 lbf in) Section Retaining Stud Nuts (Front) (1 Place) 24 N•m (18 lbf ft) Section Retaining Stud Nuts (Rear) (2 Places) 10 N•m (89 lbf in)
5
Transaxle Assembly
8000 YRM 1080
TRANSAXLE
Oil Drain Plug (1 Each) 40 N•m (30 lbf ft)
Transaxle to Frame (5 Each) (Loctite® 271) 220 N•m (162 lbf ft) Drive Motor to Transaxle (4 Each) (Loctite® 271) 48 N•m (35 lbf ft) Wheel Lugs (5 Each) 170 N•m (125 lbf ft) Trunnion Caps (2 Each) (Loctite® 290) 35 N•m (26 lbf ft) Oil Fill Plug (1 Each) 40 N•m (30 lbf ft)
Breather (1 Each) 10 N•m (89 lbf in) Brake Bleed Valve (1 Each) 10 N•m (89 lbf in) Brake Passage Plugs (2 Each) 10 N•m (89 lbf in) Wheel Hub Capscrews (1 Each) 280 N•m (207 lbf ft)
Transaxle Assembly Function Traction Motor
Specification 36 Volts AC
48 Volts AC
Power
4.80 kW (6.43 hp)
5.00 kW (6.70 hp)
Stator Resistance
6.10 ±0.10 ohms
10.00 ±0.10 ohms
Gear Ratio Drive Wheel Load Fluid Type Fluid Capacity
25.6:1 1080 kg (2380 lb) Hydraulic Oil (JDM J20) 350.0 cc (21.4 in. 3 ) 0.35 liter (0.37 qt)
Brake Specifications Torque at Axle
6
1795 N•m (1324 lbf ft)
Hold on Grade (Loaded)
16% Grade
Hold on Grade (No Load)
25% Grade
8000 YRM 1080
Travel Speeds
Travel Speeds European Maximum Travel Speed Model
Voltage
ERP1.6ATF
48
ERP1.8ATF
48
ERP2.0ATF
48
Extended Shift
No Load
Full Load
kph
mph
kph
mph
ON
14.3
8.9
13.0
8.1
OFF
14.3
8.9
14.1
8.8
ON
14.3
8.9
12.8
8.0
OFF
14.3
8.9
14.0
8.7
ON
14.3
8.9
11.9
7.4
OFF
14.3
8.9
13.8
8.6
U.S. Maximum Travel Speed Model
Voltage
36 ERP030TH 48
36 ERP035TH 48
36 ERP040TH 48
Extended Shift
No Load
Full Load
kph
mph
kph
mph
ON
13.2
8.2
13.0
8.1
OFF
14.3
8.9
14.0
8.7
ON
14.3
8.9
12.7
7.9
OFF
14.3
8.9
14.1
8.8
ON
13.2
8.2
13.0
8.1
OFF
14.3
8.9
14.0
8.7
ON
14.3
8.9
12.4
7.7
OFF
14.3
8.9
14.0
8.7
ON
13.2
8.2
13.0
8.1
OFF
14.3
8.9
14.0
8.7
ON
14.3
8.9
11.9
7.4
OFF
14.3
8.9
13.8
8.6
7
Battery
8000 YRM 1080
Battery
Figure 1. Battery Compartment Dimensions Battery Compartment Dimensions (European) Model
ERP1.6ATF
ERP1.8ATF
ERP2.0ATF
1
Wheel Base
Width (X)
Length (Y)
1290.0 mm (50.8 in.)
990 mm (39 in.)
1385.0 mm (54.5 in.)
Height (Z) BS Battery
DIN Battery 1
546.0 mm (21.5 in.)
673.0 mm (26.5 in.)
647.0 mm (25.5 in.)
990 mm (39 in.)
641.0 mm (25.2 in.)
673.0 mm (26.5 in.)
647.0 mm (25.5 in.)
1385.0 mm (54.5 in.)
990 mm (39 in.)
641.0 mm (25.2 in.)
673.0 mm (26.5 in.)
647.0 mm (25.5 in.)
1495.0 mm (58.9 in.)
990 mm (39 in.)
751.0 mm (29.6 in.)
673.0 mm (26.5 in.)
647.0 mm (25.5 in.)
1385.0 mm (54.5 in.)
990 mm (39 in.)
641.0 mm (25.2 in.)
673.0 mm (26.5 in.)
647.0 mm (25.5 in.)
1495.0 mm (58.9 in.)
990 mm (39 in.)
751.0 mm (29.6 in.)
673.0 mm (26.5 in.)
647.0 mm (25.5 in.)
Measurement with acid plate and appropriate counterweight/spacer installed.
Battery Compartment Dimensions (U.S.)
1
8
Model
Wheel Base
Width (X)
Length (Y)
ERP030TH
1290.0 mm (50.8 in.)
990 mm (39 in.)
546.0 mm (21.5 in.)
Height (Z) High Battery
Low Battery 1
663.0 mm (26.1 in.)
587.00 mm (23.12 in.)
Measurement with acid plate and appropriate counterweight/spacer installed.
8000 YRM 1080
Battery
Battery Compartment Dimensions (U.S.)
1
Model
Wheel Base
Width (X)
Length (Y)
ERP035TH
1385.0 mm (54.5 in.)
990 mm (39 in.)
ERP040TH
1385.0 mm (54.5 in.)
990 mm (39 in.)
Height (Z) High Battery
Low Battery 1
641.0 mm (25.2 in.)
663.0 mm (26.1 in.)
587.00 mm (23.12 in.)
641.0 mm (25.2 in.)
663.0 mm (26.1 in.)
587.00 mm (23.12 in.)
Measurement with acid plate and appropriate counterweight/spacer installed. Battery Discharge Rate (European.) 1 Model
Wheel Base
1290.0 mm (50.8 in.) ERP1.6ATF 1385.0 mm (54.5 in.)
1385.0 mm (54.5 in.) ERP1.8ATF 1495.0 mm (58.9 in.)
1385.0 mm (54.5 in.) ERP2.0ATF 1495.0 mm (58.9 in.) 1
Max Amp Hours
Max kW Hours
48 V
48 V
DIN
400
18.2
BS
602
28.9
DIN
500
24.0
BS
630
30.2
DIN
500
23.5
BS
720
34.5
DIN
600
28.8
BS
720
34.5
DIN
500
23.5
BS
720
34.5
DIN
600
28.8
BS
720
34.5
Type
Calculated using 6-hour rate. Battery Discharge Rate (U.S.) 1 Model
1
Max Amp Hours
Max kW Hours
36 V
48 V
36 V
48 V
ERP030TH
880
660
30.6
30.5
ERP035TH
1100
770
38.2
35.8
ERP040TH
1100
770
38.2
35.8
Calculated using 6-hour rate.
9
Battery
8000 YRM 1080
Figure 2. Battery Dimensions Battery Specifications (European) Model
Type (48 V)
Wheel Base 1290.0 mm (50.8 in.)
Weight 673 kg (1484 lb)
826.0 mm (32.5 in.)
533.0 mm (21.0 in.)
MAX
743 kg (1638 lb)
836.0 mm (32.9 in.)
543.0 mm (21.4 in.)
MIN
813 kg (1792 lb)
826.0 mm (32.5 in.)
628.0 mm (24.7 in.)
MAX
899 kg (1982 lb)
836.0 mm (32.9 in.)
638.0 mm (25.1 in.)
MIN
800 kg (1764 lb)
977.0 mm (38.5 in.)
533.0 mm (21.0 in.)
MAX
1100 kg (2425 lb)
987.0 mm (38.9 in.)
543.0 mm (21.4 in.)
MIN
800 kg (1764 lb)
977.0 mm (38.5 in.)
628.0 mm (24.7 in.)
MAX
1200 kg (2646 lb)
987.0 mm (38.9 in.)
638.0 mm (25.1 in.)
ERP1.6ATF 1290.0 mm (50.8 in.) BS 1385.0 mm (54.5 in.) 1
Used with acid plate and appropriate counterweight/spacer installed.
10
Length (Y)
MIN
DIN 1 1385.0 mm (54.5 in.)
Width (X)
Height (Z) 627.0 mm (24.7 in.) MAX
627.0 mm (24.7 in.) MAX
670.0 mm (26.4 in.) MAX
670.0 mm (26.4 in.) MAX
8000 YRM 1080
Battery
Battery Specifications (European) Model
Type (48 V)
Wheel Base 1385.0 mm (54.5 in.)
Weight 813 kg (1792 lb)
826.0 mm (32.5 in.)
628.0 mm (24.7 in.)
MAX
899 kg (1982 lb)
836.0 mm (32.9 in.)
638.0 mm (25.1 in.)
MIN
962 kg (2121 lb)
826.0 mm (32.5 in.)
738.0 mm (29.1 in.)
MAX
1064 kg (2346 lb)
836.0 mm (32.9 in.)
748.0 mm (29.4 in.)
MIN
1000 kg (2205 lb)
977.0 mm (38.5 in.)
628.0 mm (24.7 in.)
MAX
1200 kg (2646 lb)
987.0 mm (38.9 in.)
638.0 mm (25.1 in.)
MIN
1000 kg (2205 lb)
977.0 mm (38.5 in.)
738.0 mm (29.1 in.)
MAX
1300 kg (2866 lb)
987.0 mm (38.9 in.)
748.0 mm (29.4 in.)
MIN
813 kg (1792 lb)
826.0 mm (32.5 in.)
628.0 mm (24.7 in.)
MAX
899 kg (1982 lb)
836.0 mm (32.9 in.)
638.0 mm (25.1 in.)
MIN
962 kg (2121 lb)
826.0 mm (32.5 in.)
738.0 mm (29.1 in.)
MAX
1064 kg (2346 lb)
836.0 mm (32.9 in.)
748.0 mm (29.4 in.)
MIN
1225 kg (2701 lb)
977.0 mm (38.5 in.)
628.0 mm (24.7 in.)
MAX
1300 kg (2866 lb)
987.0 mm (38.9 in.)
638.0 mm (25.1 in.)
MIN
1000 kg (2205 lb)
977.0 mm (38.5 in.)
738.0 mm (29.1 in.)
MAX
1300 kg (2866 lb)
987.0 mm (38.9 in.)
748.0 mm (29.4 in.)
ERP1.8ATF 1385.0 mm (54.5 in.) BS 1495.0 mm (58.9 in.)
1385.0 mm (54.5 in.) DIN 1 1495.0 mm (58.9 in.) ERP2.0ATF 1385.0 mm (54.5 in.) BS 1495.0 mm (58.9 in.) 1
Length (Y)
MIN
DIN 1 1495.0 mm (58.9 in.)
Width (X)
Height (Z) 627.0 mm (24.7 in.) MAX
627.0 mm (24.7 in.) MAX
670.0 mm (26.4 in.) MAX
670.0 mm (26.4 in.) MAX
627.0 mm (24.7 in.) MAX
670.0 mm (26.4 in.) MAX
670.0 mm (26.4 in.) MAX
627.0 mm (24.7 in.) MAX
Used with acid plate and appropriate counterweight/spacer installed.
11
Battery
8000 YRM 1080
Battery Specifications (U.S.) Model
Wheel Base
Type (36/48 V)
Weight (approximate)
Width (X)
Length (Y)
MIN
775 kg (1700 lb)
970.0 mm (38.2 in.)
508.0 mm (20.0 in.)
MAX
1000 kg (2200 lb)
986.0 mm (38.8 in.)
538.0 mm (21.2 in.)
MIN
910 kg (2000 lb)
970.0 mm (38.2 in.)
508.0 mm (20.0 in.)
MAX
1135 kg (2500 lb)
986.0 mm (38.8 in.)
538.0 mm (21.2 in.)
MIN
955 kg (2100 lb)
975.0 mm (38.4 in.)
597.0 mm (23.5 in.)
MAX
1090 kg (2400 lb)
986.0 mm (38.8 in.)
635.0 mm (25.0 in.)
MIN
1140 kg (2500 lb)
975.0 mm (38.4 in.)
597.0 mm (23.5 in.)
MAX
1270 kg (2800 lb)
986.0 mm (38.8 in.)
635.0 mm (25.0 in.)
MIN
955 kg (2100 lb)
975.0 mm (38.4 in.)
597.0 mm (23.5 in.)
MAX
1090 kg (2400 lb)
986.0 mm (38.8 in.)
635.0 mm (25.0 in.)
MIN
1140 kg (2500 lb)
975.0 mm (38.4 in.)
597.0 mm (23.5 in.)
MAX
1270 kg (2800 lb)
986.0 mm (38.8 in.)
635.0 mm (25.0 in.)
Low 1 ERP030TH
1290.0 mm (50.8 in.) High
Low 1 ERP035TH
1385.0 mm (54.5 in.) High
Low 1 ERP040TH
1385.0 mm (54.5 in.) High
1
Used with acid plate and appropriate counterweight/spacer installed.
12
Height (Z)
579.0 mm (22.8 in.)
655.0 mm (25.8 in.)
579.0 mm (22.8 in.)
655.0 mm (25.8 in.)
579.0 mm (22.8 in.)
655.0 mm (25.8 in.)
100 YRM 1073
Introduction
Introduction GENERAL
DESCRIPTION OF OPERATION
This section contains 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 labels. Throughout this section, forward will refer to travel in the direction of the forks and left and right will be determined by an operator sitting in the seat facing forward. See Figure 1.
The frame is a single weldment with mounts for the counterweight, overhead guard, mast, steering system, hydraulic system and transaxles. See Figure 2. The battery cover opens on hinges to give access to the battery compartment. The weight of the battery is a major part of the counterweight system on an electric lift truck. A slot in the overhead guard permits removal of the battery without removing the overhead guard. Spacers may be added under the battery as required on some models. Each model of lift truck has a cast-iron counterweight with a weight necessary for the indicated capacity. An access panel on the top/rear of the counterweight gives access to the electronic controllers. The hydraulic pump and motor, steering pump and motor, drive motors and transaxles, and hydraulic tank are under the floor plates in the operator compartment. The floor plates are held in position by tabs and can be removed to give access to components underneath.
A. LEFT SIDE B. RIGHT SIDE C. FORWARD TRAVEL
The hydraulic control valve is fastened to the front of the battery compartment. Three covers protect the control valve and control linkage. The covers are fastened in position by machine screws. The top covers are locked in place and must be released and swung open before attempting to open the battery cover.
Figure 1. Truck Orientation
Figure 2. Frame
1
Introduction
DISCHARGING THE CAPACITORS WARNING Do not make repairs or adjustments unless you have both authorization and training. Repairs and adjustments that are not correct 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. Remove the key from the key switch.
WARNING Disconnect the battery before opening the drive unit compartment cover or inspecting or repairing the electrical system. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage.
WARNING Some checks and adjustments are done with the battery connected. Do not connect the battery until the procedure tells you to do so. Never have any metal on your fingers, arms, or neck. Metal items can accidentally make an electrical connection and cause injury.
WARNING Before performing any tests or adjustments, block the lift truck to prevent unexpected movement.
WARNING The capacitor in the transistor controller(s) can hold an electrical charge 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. Wear safety glasses. Make certain that the battery has been disconnected.
2
100 YRM 1073
CAUTION To avoid controller damage, always disconnect the battery, discharge the capacitor(s), and never put power to the controller while any power wires are disconnected. Never short any controller terminal or motor terminal to the battery. Make sure to use proper procedure when servicing the controller. 1. Turn key switch to OFF position and disconnect the battery. Block load wheels to prevent lift truck from moving. 2. Open the electrical compartment at the rear of the truck. a. Remove the two screws securing the electrical compartment door closed. b. Tilt the door back on its hinges to open the compartment.
WARNING DO NOT short across the motor controller terminals with a screwdriver or jumper wire. NOTE: Some lift trucks are equipped with a premium controller, which controls the hydraulic motor as well as the traction motors. 3. Discharge the capacitor in the controller by connecting a 200-ohm, 2-watt resistor across the controller’s BT+ and B terminals for 10 seconds using insulated jumper wires. See Figure 3. 4. On the premium controller, also connect the 200ohm, 2-watt resistor across the controller’s P+ and B terminals for 10 seconds using insulated jumper wires. See Figure 4. 5. Remove the 200-ohm, 2-watt resistor before reconnecting the battery.
100 YRM 1073
1. 2. 3. 4.
Covers and Floor Plates
POSITIVE CONNECTION (BT+) NEGATIVE CONNECTION (B ) INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR
1. 2. 3. 4. 5.
POSITIVE CONNECTION (BT+) NEGATIVE CONNECTION (B ) INSULATED JUMPER WIRES 200-OHM, 2-WATT RESISTOR POSITIVE CONNECTION (P+)
Figure 3. Discharging the Capacitors (Standard) Figure 4. Discharging the Capacitors (Premium)
Covers and Floor Plates Many system components, such as hydraulic hoses, pump and motor, and wiring harnesses, are located in the area around and under the operator compartment.
Various covers and floor plates provide access to these components during service and securely cover these areas during normal operation. See Figure 5.
3
Covers and Floor Plates
1. 2. 3. 4. 5. 6.
100 YRM 1073
CAPSCREW ATTACHING HARDWARE CLIP NUT HARNESS COVER (ELECTRIC VALVE) HARNESS COVER (MANUAL VALVE) CAPSCREW
7. 8. 9. 10. 11. 12.
ANTI-SLIP PAD ANTI-SLIP PAD RIGHT FLOOR PLATE CENTER FLOOR PLATE LEFT FLOOR PLATE HOSE COVER
Figure 5. Covers and Floor Plates
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100 YRM 1073
Overhead Guard Repair
Overhead Guard Repair WARNING
INSTALL
The overhead guard is part of the operator protection system. Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.
1. Position overhead guard just above mounts on the counterweight and cowl using an overhead lifting device and sling.
The overhead guard is designed to provide protection to the operator from falling objects and in the event of a tip over. A high visibility design allows for an unobstructed view while maintaining structural integrity. Removal of the battery is simplified by the slot in the overhead guard. This provides access to the battery with an overhead lifting device without removing the overhead guard.
2. Route the wires through each overhead guard post and install to lights as removed.
REMOVE
3. Lower overhead guard supports onto the mounts. 4. Install and tighten six capscrews, washers, and nuts securing overhead guard to the lift truck. Tighten capscrews to 134 N•m (99 lbf ft). 5. Remove sling and overhead guard.
WARNING The overhead guard is heavy. Make sure the sling, chain, eyebolts, and crane or lifting device have the capacity to lift the overhead guard. 1. Remove the six capscrews, washers, and nuts that secure the supports of the overhead guard to the counterweight and cowl. See Figure 6. 2. Use an overhead lifting device and sling to lift the overhead guard until it is just higher than the counterweight mounts. NOTE: Tie a cord around the wires from each post of the overhead guard before removal. Remove the wires from the post. Untie the cord from the wires and tape each end of the cord to the overhead guard where it enters the post. Use the cord to pull the wires up through the post when installing the overhead guard. 3. Tag and disconnect the wiring from each post of the overhead guard. Carefully remove the wiring if necessary. 4. Completely remove the overhead guard from the lift truck.
1. 2. 3. 4. 5. 6. 7.
OVERHEAD GUARD COUNTERWEIGHT FRAME CAPSCREWS (4) FRONT CAPSCREWS (2) REAR CAPSCREWS (2) UPPER CAPSCREWS (2) LOWER Figure 6. Overhead Guard Mounting
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Hood and Seat Assembly
100 YRM 1073
Hood and Seat Assembly The hood is the platform for the seat assembly and is located above the battery. It functions as a battery restraint that completely covers the battery compartment. See Figure 7. Its function as the battery restraint, when correctly locked to the frame, is to hold the battery in the battery compartment if an accident causes the lift truck to tip over. The hood is composed of a plastic cover attached to a metal frame. Two hinges at the back of the hood attach it to the frame. A sliding latch mechanism on the front of the hood locks the hood closed during operation. A double-dampened, gas-controlled strut holds the hood in the open position. Opening the sliding latch unlocks the hood from the frame so the hood can be raised to access the battery. See Figure 8. The latch can only be accessed after releasing and raising the hydraulic levers and linkage assembly up and out of the way. A button on each side of the assembly can be pressed to release the assembly so it can be moved clear of the hood on its hinged bracket. The latch must be in good condition and properly secured before the lift truck can be operated. If the latch does not lock the hood in the closed position, the hydraulic levers and linkage assembly will not lock into position and the lift truck will not operate.
emergency battery disconnect that allows the operator to quickly disconnect the battery while seated on the lift truck in case of an emergency. The seat assembly slides on seat rails that are fastened to the hood by four capscrews. A lever at the left front side of the base controls the adjustment of the seat to the forward and backward positions. Optional seats are available in cloth or vinyl with features such as semi-suspension, full suspension, and limited swivel. All seats have a seat switch installed in the bottom cushion that senses operator presence. When the operator is not on the seat, the seat switch opens and interrupts the controller stopping operation of the lift truck. The hood, seat belt, hip restraint brackets, seat, and seat mount are all parts of the operator restraint system. Checks and adjustments for the operator restraint system are described in the Operating Manual and the section Periodic Maintenance 8000 YRM 1079. To raise the hood and seat assembly, move the seat to the rear of the hood if necessary. Move the steering column to the most forward position. Release and raise the hydraulic levers and linkage. Open the latch mechanism and raise the hood.
A large, red button switch is mounted on the hood at the right side of the seat assembly. This switch is an
1. SEAT
2. HOOD Figure 7. Hood and Seat Assembly
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3. SEAT SWITCH CONNECTOR
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