YALE (F807) ERP1.8ATF Europe LIFT TRUCK Service Repair Manual

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.

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100 YRM 1073

CAPSCREW ATTACHING HARDWARE CLIP NUT HARNESS COVER (ELECTRIC VALVE) HARNESS COVER (MANUAL VALVE) CAPSCREW

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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.

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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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