ERP30-40VF (A955) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ AC MOTOR REPAIR...................................................................................................... TRANSAXLE................................................................................................................... STEERING AXLE............................................................................................................ STEERING SYSTEM...................................................................................................... BRAKE SYSTEM............................................................................................................ HYDRAULIC SYSTEM.................................................................................................... HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVES............................................................................................. CYLINDER REPAIR (MAST S/N A270-72, A551, A555, A559, A626, A627, A751-52, B551, B555, B586-91, B749-54, C661-63, C665, D507-09, D515, D562-64, E509, E564).......................................................................................................................... WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE SUPERVISOR................................................................................. USER INTERFACE SERVICE TECHNICIAN................................................................. ELECTRICAL SYSTEM.................................................................................................. INDUSTRIAL BATTERY................................................................................................. MAST REPAIR (S/N C661, C662, C663, C665)............................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ PART NO. 550011081 (12/14)
PART NUMBER
YRM NUMBER
REV DATE
524295629 550025937 524327049 524295630 524319491 524319492 524295632 524295633 550073240 524319495
0100 YRM 1329 0100 YRM 1446 0620 YRM 1385 1300 YRM 1330 1600 YRM 1360 1600 YRM 1363 1800 YRM 1332 1900 YRM 1333 1900 YRM 1620 2000 YRM 1334
09/14 09/14 09/14 09/12 09/14 09/14 12/10 09/14 12/14 09/14
524319496 524223769 524319497 524319498 524320282 524158040 524333799 524150797 524319503 550011082 524320622 524319504
2100 YRM 1382 2200 YRM 1128 2200 YRM 1335 2200 YRM 1336 2200 YRM 1337 2240 YRM 0001 4000 YRM 1405 8000 YRM 0231 8000 YRM 1341 8000 YRM 1373 8000 YRM 1376 9000 YRM 1377
03/14 12/14 09/14 09/14 09/14 09/14 05/14 10/13 09/14 09/14 08/13 10/14
0100 YRM 1329
Introduction
Introduction GENERAL 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, side 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 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 2. for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
A. LEFT SIDE B. RIGHT SIDE
C. FORWARD TRAVEL
Figure 2. Truck Orientation for Lift Truck ERP16-20VF (ERP30-40VF) (A955)
A. LEFT SIDE C. FORWARD TRAVEL B. RIGHT SIDE Figure 1. Truck Orientation for Lift Truck ERP15-20VT (ERP030-040VT) (G807)
1
Introduction
0100 YRM 1329
DESCRIPTION OF OPERATION The frame is a welded assembly with mounts for the counterweight, overhead guard, mast, steering system, side panels, hydraulic system and transaxles. See Figure 3. The hood opens on hinges to provide access to the battery compartment. The weight of the battery is a major part of the counterweight system on this truck. A slot in the overhead guard permits removal of the battery without removing the overhead guard. Spacers may be added around the battery as required on some models.
The hydraulic pump and motor assembly and hydraulic tank are in the counterweight. The counterweight cover is removed for access. The AC drive motors and transaxles are located under the floor plates in the operator compartment. The floor plates are held in position by tabs and are to be removed to give access to components underneath. The hydraulic control valve is fastened to the front of the battery compartment and has covers to protect the control valve and control linkages.
Each lift truck has a cast-iron counterweight appropriately weighted for the indicated capacity on the nameplate.
NOTE: FRAME SHOWN FROM RIGHT SIDE AND REAR. Figure 3. Frame
2
0100 YRM 1329
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.
Covers and Floor Plates 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. Push horn button. Wait 30 seconds to be sure capacitors are fully discharged.
RAPID CHARGE The lift trucks covered in this manual may be equipped with a Rapid Charge System (see Figure 4). With a Rapid Charge System, the battery is charged during operator breaks or when the truck is not being used. The rapid charge system provides extended operation with a single battery. Some of the features of the Rapid Charge System include: •
Battery connector externally mounted for easy access
•
Vented side covers for improved battery cooling
•
Requires rapid charge vented battery and sealed battery fan box with thermostat
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. 1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below.
1. RAPID CHARGE CONNECTOR 2. VENTED SIDE COVER Figure 4. Rapid Charge System
2. Turn the key or keyless switch to the OFF position.
3
Covers and Floor Plates
0100 YRM 1329
Covers and Floor Plates Various covers and floor plates provide access to components during service and securely cover areas during normal operation. Covers in the floor of the operator compartment allow access to the traction con-
4
trollers, AC drive motors, service and parking brakes. A cover on the top of the counterweight provides access to the hydraulic tank, hydraulic pump and motor assembly, and the hoist controller. See Figure 5.
0100 YRM 1329
Covers and Floor Plates
Figure 5. Covers and Floor Plates
5
Overhead Guard Replacement
0100 YRM 1329 Legend for Figure 5
NOTE: COUNTERWEIGHT FOR ERP15-20VT (ERP030-040VT) (G807) LIFT TRUCK SHOWN AS AN EXAMPLE ONLY. A. COUNTERWEIGHT COVER WITH RAPID CHARGE, LIFT TRUCKS MANUFACTURED AFTER JUNE, 2012 1. 2. 3. 4.
FLOOR PLATE MANUAL HYDRAULIC FLOOR PLATE BRAKE PEDAL FLOOR PLATE E-HYDRAULIC FLOOR MAT MANUAL HYDRAULIC
5. 6. 7. 8.
FLOOR MAT E-HYDRAULIC MANUAL HYDRAULIC COVERS HOSE COVER COUNTERWEIGHT COVER
Overhead Guard Replacement WARNING 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. 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.
REMOVE WARNING The overhead guard is heavy. Make sure the sling, chain, eye bolts, and crane or lifting device have the capacity to lift the overhead guard. 1. Remove hood and seat. See Hood and Seat Assembly section in this manual. 2. Remove rear capscrew, washers, and vibration mount top from rear leg and counterweight. See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
3. Repeat Step 2 for opposite rear leg.
6
4. Remove three capscrews from cowl and front leg. See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
5. Repeat Step 4 for opposite front leg. 6. Remove nut, washers, front capscrew, and vibration mount top from front leg and frame. See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
7. Repeat Step 6 for opposite front leg. 8. Use a lifting device to lift overhead guard until it is just higher than the counterweight. NOTE: Tag electrical wiring and note routing during removal to aid in installation. 9. Tag and disconnect electrical wiring for display. Remove display from display cover. NOTE: Note routing of electrical wires into, out of, or on the overhead guard during removal to aid in installation. NOTE: Tag electrical connectors during removal to aid in installation.
0100 YRM 1329
Overhead Guard Replacement
Figure 6. Overhead Guard for Lift Truck ERP15-20VT (ERP030-040VT) (G807)
7
Overhead Guard Replacement
0100 YRM 1329 Legend for Figure 6
1. 2. 3. 4. 5. 6. 7. 8. 9.
8
REAR CAPSCREW WASHER REAR LEG VIBRATION MOUNT TOP VIBRATION MOUNT BOTTOM COUNTERWEIGHT NUT FRONT CAPSCREW FRONT LEG
10. 11. 12. 13. 14. 15. 16. 17.
FRAME CAPSCREW OVERHEAD GUARD GRAB HANDLE COWL DISPLAY COVER RETAINING WASHER CLIP NUT
0100 YRM 1329
Overhead Guard Replacement
Figure 7. Overhead Guard for Lift Truck ERP16-20VF (ERP30-40VF) (A955)
9
Overhead Guard Replacement
0100 YRM 1329 Legend for Figure 7
1. 2. 3. 4. 5. 6. 7. 8. 9.
REAR CAPSCREW WASHER REAR LEG VIBRATION MOUNT TOP COUNTERWEIGHT NUT FRONT CAPSCREW FRONT LEG FRAME
NOTE: On lift truck models ERP030-040VT (G807) and ERP30-40VF (A955) equipped with inboard tail lights, the rear lights are mounted inboard of the overhead guard, reducing the risk of damage to the lights. A protection shield above the lights also provides protection from above. The overhead guard will include mounting features for both inboard and outboard lights. 10. Tag and disconnect electrical wires that go through the legs of overhead guard. Carefully remove the wiring if necessary. 11. Completely remove overhead guard from lift truck. 12. Remove two vibration mount bottoms from counterweight; remove two vibration mount bottoms and two retaining washers from frame. See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models
10. 11. 12. 13. 14. 15. 16. 17.
CAPSCREW GRAB HANDLE OVERHEAD GUARD COWL DISPLAY COVER VIBRATION MOUNT BOTTOM RETAINING WASHER CLIP NUT
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
15. Remove two capscrews, display cover, and two clip nuts from overhead guard. See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
INSTALL 1. Install grab handle and capscrews onto front leg. See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
ERP16-20VF (ERP30-40VF) (A955)
NOTE: Perform the following step if grab handle is mounted onto rear leg.
13. Remove two capscrews and grab handle from front leg.
2. Install grab handle and two capscrews onto rear leg. Tighten capscrews to 6.5 N•m (57.5 lbf in)
•
See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
NOTE: Perform following step if grab handle is mounted onto rear leg. 14. Remove two capscrews and grab handle from rear leg. See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 6 for lift truck models •
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
3. Install two retaining washers and two vibration mount bottoms onto frame; install two vibration mount bottoms onto counterweight. See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
10
ERP15-20VT (ERP030-040VT) (G807)
ERP16-20VF (ERP30-40VF) (A955)
0100 YRM 1329 4. Using a lifting device, position overhead guard just above mounting holes on counterweight and frame. 5. Route electrical wires through overhead guard legs as noted during removal.
Overhead Guard Replacement 11. Install three capscrews into cowl and front leg. See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
NOTE: Make sure electrical wires do not get pinched when overhead guard is lowered onto mounts.
12. Repeat Step 11 for opposite front leg.
6. Carefully lower overhead guard onto vibration mount bottoms on counterweight and frame.
13. Install two clip nuts, display cover and two capscrews onto overhead guard.
7. Install front capscrew, vibration mount top, washers, and nut into front leg and frame. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
8. Repeat Step 7 for opposite front leg. 9. Install vibration mount top, washers and rear capscrew into rear leg and counterweight. See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
See Figure 6 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Figure 7 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
WARNING The ignition switch is a reed switch which uses an applied magnetic field. If a strong magnet is placed near the ignition switch, it may not function properly (such as not shutting off power). To ensure ignition switch functions properly, do not place a magnet near the ignition switch. 14. Install display into display cover. Connect electrical wiring to display as noted during removal. 15. Install hood and seat. See Hood and Seat Assembly Repair section in this manual.
10. Repeat Step 9 for opposite rear leg.
11
Hood and Seat Assembly
0100 YRM 1329
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 10. When correctly locked to the frame, it will hold the battery in the battery compartment if an accident causes the lift truck to tip over. The hood is a stamped steel cover. Two hinges at the back attach to the overhead guard. A latch assembly on the front bulkhead locks the hood closed during operation. A gas-controlled strut holds the hood in the open position. See Figure 10 for lift trucks manufactured before November, 2014 See Figure 11 for lift trucks manufactured after November, 2014 Opening the latch assembly unlocks the hood from the frame so the hood can be raised to access the battery. The latch assembly must be in good condition and properly secured before the lift truck can be operated. To raise the hood on a lift truck with manual hydraulics, the manual hydraulic lever and linkage assembly must be moved. Pull latch handle under manual hydraulic cover toward the seat, allowing the lever and linkage assembly to drop forward out of the way. See Figure 8. If the sliding latch assembly does not lock the hood in the closed position, the lever and linkage assembly will not lock into position and the lift truck will not operate. A large, red push-button switch is mounted on the lever and linkage assembly for manual hydraulics and in the armrest console for the electro-hydraulics. This switch is an emergency battery disconnect that allows the operator to quickly disconnect the battery while seated on the lift truck in case of an emergency. See Figure 8.
A. MANUAL HYDRAULIC LEVERS B. E-HYDRAULIC MINI-LEVERS 1. MANUAL HYDRAULIC LEVER LATCH HANDLE 2. EMERGENCY DISCONNECT SWITCH Figure 8. Emergency Disconnect Switch
12
0100 YRM 1329 The seat assembly slides on seat rails that are fastened to spacer plates (Figure 9) and 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 non-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 as follows: •
After 1.5 seconds, hydraulic functions will cease to operate.
•
The lift truck, through regenerative braking, will slowly come to a complete stop.
Hood and Seat Assembly Checks and adjustments for the operator restraint system are described in the Operating Manual or See Periodic Maintenance 8000YRM1339 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Periodic Maintenance 8000YRM1373 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
NOTE: The seat belt can be either black or red. The lift trucks covered in this Service Manual can be equipped with one of three seat belt configurations: •
Seat belt with no operational interlock.
•
Seat belt with operational interlock. Seat belt must be fastened for lift truck to start or travel.
•
Seat belt with sequencing interlock. Operator must be in the seat, and the seat belt must be fastened, before lift truck will operate. This seat belt is used with the Optional Operator Presence System.
See the Operating Manual for more information on these seat belt types.
1. HOOD 2. SEAT ASSEMBLY 3. SEAT SPACER PLATES Figure 9. Seat Spacer Location
The hood, seat belt, hip restraint brackets, seat, and seat mount are all parts of the operator restraint system.
13
Hood and Seat Assembly
0100 YRM 1329
A. LOCKED POSITION
B. OPEN (RELEASE) POSITION
1. SEAT 2. HOOD
3. SEAT SWITCH CONNECTOR 4. LATCH ASSEMBLY
Figure 10. Hood and Seat Assembly, Lift Trucks Manufactured Before November, 2014
14
0100 YRM 1329 To raise the hood and seat assembly, move the seat to the rear of the hood. For lift trucks equipped with Rapid/Fast Charging, slide the seat all the way forward. If necessary, move the armrest all the way back if lift truck is equipped with E-Hydraulic control levers. Move the steering column to the most forward position. If lift truck is equipped with manual hydraulics, release and move the hydraulic lever and linkage assembly forward. See Figure 8. Open the latch mechanism and raise the hood. See Figure 10 for lift trucks manufactured before November, 2014 See Figure 11 for lift trucks manufactured after November, 2014
REMOVE 1. Disconnect battery connector.
Hood and Seat Assembly NOTE: Tag electrical connectors during removal to aid in installation. 2. Tag and disconnect the electrical connectors to the emergency battery disconnect and the seat switch. 3. Disconnect seat harness and remove from hood. NOTE: The seat assembly does not have to be removed from the hood for the hood to be removed from the lift truck. Perform Step 4 if removing seat assembly. 4. To remove seat assembly, disconnect electrical connectors if not already done, remove four screws, washers, spacers if required, and seat assembly from hood. 5. Raise hood. 6. Remove gas spring. See Figure 12.
A. OPEN (RELEASE) POSITION 1. SEAT 2. HOOD
3. SEAT SWITCH CONNECTOR 4. LATCH ASSEMBLY Figure 11. Hood and Seat Assembly, Lift Trucks Manufactured After November, 2014
15
Hood and Seat Assembly
0100 YRM 1329
7. Lower hood. 8. Remove two captive screws, tow pin, and counterweight cover from counterweight. 9. Remove two nuts securing hood mounting bolts. See Figure 12.
1. 2. 3. 4. 5.
HOOD GAS SPRING NUT WASHER HOOD MOUNTING BOLT
10. Remove washers and hood mounting bolts from hood hinges and hood mounting brackets. See Figure 12. 11. Release latch and lift hood out of lift truck.
6. 7. 8. 9.
HOOD HINGE OVERHEAD GUARD REAR LEG HOOD MOUNTING BRACKET CAPSCREW
Figure 12. Hood Mounting
16
0100 YRM 1329 12. If necessary, hood mounting brackets can be removed from overhead guard rear legs by removing the nuts and capscrews. See Figure 12.
INSTALL 1. Install hood mounting brackets, capscrews, and nuts onto overhead guard rear legs, if removed. Do not fully tighten capscrews at this time. See Figure 12. 2. Lower hood into position. 3. Install hood mounting bolts and washers onto hood hinges and hood mounting brackets. See Figure 12. 4. Install nuts onto hood mounting bolts. See Figure 12.
Hood and Seat Assembly
GROUND TEST NOTE: If the static discharge ground connection is not secured properly it could lead to the possible failure of the traction and/or pump motor controllers. 1. To ensure proper installation of seat assembly and associated bracketing, perform continuity test. 2. Using an ohm meter, place a test lead at the armrest mounting bolt and another at the truck frame. The resistance needs to read 5 Ohms or less. See Figure 13. 3. If the resistance is greater than 5 Ohms, double check installation of seat assembly, both ends of seat wiring harness, and wiring harness ground strap.
5. Allow hood to engage latch and adjust hood for adequate latch engagement with the hood striker. Adequate engagement is when the latch completely clears the 90 degree bend of the hood striker. 6. Tighten capscrews on hood mounting brackets. 7. Raise hood. 8. Install gas spring. See Figure 12. 9. Install seat, if removed, and route seat harness through hood and connect to seat. 10. Connect the electrical wiring harness to the seat switch. 11. Close the hood. Make certain that the latch is properly engaged. 12. Install counterweight cover, captive screws, and tow pin onto counterweight. 13. Move manual hydraulic lever and linkage assembly back to upright position and lock in place.
1. ARMREST BOLT 2. FRAME Figure 13. Ground Test
14. Connect the battery connector.
17
Counterweight Replacement
0100 YRM 1329
Counterweight Replacement WARNING DO NOT operate the lift truck if the capscrews for the counterweight are not installed. The counterweight is a structural member of the truck chassis. The counterweight cannot be removed without first supporting the frame. If the capscrews are not properly installed the counterweight will not support the lift truck. A one-piece, cast iron counterweight is used to offset the weight of the load and support the rear suspension of the lift truck, see figures indicated below. The weight of the counterweight is shown in the tables below. See Figure 14 and Table 1 for lift truck models •
ERP15-20VT (G807) manufactured before November, 2014
•
ERP030-040VT (G807)
See Figure 15 and Table 1 for lift truck models •
ERP15-20VT (G807) manufactured after November, 2014
Figure 14. Counterweight for Lift Truck ERP15-20VT (G807) Manufactured Before November, 2014 and ERP030-040VT(G807)
See Figure 16 and Table 2 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
A compartment space, accessed by removal of the counterweight cover, has been designed to house the hydraulic tank, hydraulic pump and motor, hoist controller, and electrical connections. A battery platform is used to support the battery on the lift truck frame. The battery platform also serves as part of the counterweight system and requires the use of an overhead lifting device for removal or installation. Be sure to replace the same battery platform, or one of equal weight, if the platform must be removed.
Figure 15. Counterweight for Lift Truck ERP15-20VT (G807) Manufactured After November, 2014
18
0100 YRM 1329
Counterweight Replacement
Figure 16. Counterweight for Lift Truck ERP16-20VF (ERP30-40VF) (A955) Table 1. Counterweights for Lift Truck ERP15-20VT (ERP030-040VT) (G807) Model
mm (in)*
Weight
+ 13.8 kg (30 lb) 13.8 kg (30 lb)
ERP15-20VT (ERP030-04VT)
546 mm (21.5 in.)
690 kg (1521 lb)
ERP15-20VT (ERP030-04VT)
642 mm (25.3 in.)
690 kg (1521 lb)
ERP15-20VT (ERP030-04VT)
750 mm (29.5 in.)
690 kg (1521 lb)
*Approximate battery compartment lengths.
Table 2. Counterweights for Lift Truck ERP16-20VF (ERP30-40VF) (A955) Model
mm (in)*
Weight
+ 20 kg (44 lb) 0 kg (0 lb)
ERP16-20VF (ERP30-40VF)
546 mm (21.5 in.)
670 kg (1477 lb)
ERP16-20VF (ERP30-40VF)
642 mm (25.3 in.)
670 kg (1477 lb)
ERP16-20VF (ERP30-40VF)
750 mm (29.5 in.)
670 kg (1477 lb)
*Approximate battery compartment lengths.
19
Counterweight Replacement
REMOVE 1. Remove battery.
0100 YRM 1329 See Figure 18 for lift truck models •
See Periodic Maintenance 8000YRM1339 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Periodic Maintenance 8000YRM1373 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955)
2. Remove overhead guard. See Overhead Guard Replacement section in this manual. 3. Remove hydraulic pump and motor and hydraulic tank from counterweight. See Hydraulic System 1900YRM1333. 4. Remove controller from counterweight. See Electrical System 2200YRM1337. 5. Remove steer axle, including wheels and tires. See Steering System 1600YRM1331 for lift truck models •
ERP15-20VT (ERP030-040VT) (G807)
See Steering System 1600YRM1363 for lift truck models •
ERP16-20VF (ERP30-40VF) (A955).
NOTE: Perform Step 6 through Step 10 for lift truck models ERP15-20VT (ERP030-040VT) (G807). 6. Remove nuts, capscrews, washers, and steer plate from counterweight. See Figure 17 for lift truck models
20
•
ERP15-20VT (G807) manufactured before November, 2014
•
ERP030-040VT (G807)
ERP15-20VT (G807) manufactured after November, 2014
WARNING The counterweight is very heavy. Make sure the chains, eyebolts, and overhead lifting device have the capacity to lift the counterweight. 7. Insert eye bolts into counterweight. See Figure 19. Attach lifting device to eye bolts to hold counterweight. NOTE: Ensure frame is supported, as specified in Steering System 1600YRM1331 prior to removal. 8. Remove upper capscrews and washers from frame and counterweight. 9. Remove lower capscrews and washers from frame and counterweight. See Figure 17 for lift truck models •
ERP15-20VT (G807) manufactured before November, 2014
•
ERP030-040VT (G807)
See Figure 18 for lift truck models •
ERP15-20VT (G807) manufactured after November, 2014
10. Using lifting device, lift counterweight away from lift truck frame. NOTE: Perform Step 11 through Step 15 for lift truck ERP16-20VF (ERP30-40VF) (A955). NOTE: Ensure frame is supported, as specified in Steering System 1600YRM1363 prior to removal. 11. Remove two capscrews from top of rear bulkhead and counterweight. See Figure 20.
0100 YRM 1329
1. 2. 3. 4.
STEER PLATE COUNTERWEIGHT CAPSCREW NUT
Counterweight Replacement
5. 6. 7. 8.
WASHER UPPER CAPSCREW LOWER CAPSCREW FRAME
Figure 17. Frame and Counterweight for Lift Trucks ERP15-20VT (G807) Manufactured Before November, 2014 and ERP030-040VT (G807)
21
Counterweight Replacement
1. 2. 3. 4.
STEER PLATE COUNTERWEIGHT CAPSCREW NUT
0100 YRM 1329
5. 6. 7. 8.
WASHER UPPER CAPSCREW LOWER CAPSCREW FRAME
Figure 18. Frame and Counterweight for Lift Trucks ERP15-20VT (G807) Manufactured After November, 2014
22
0100 YRM 1329
Counterweight Replacement
INSTALL WARNING The counterweight is very heavy. Make sure the chains, eyebolts, and overhead lifting device have the capacity to lift the counterweight. NOTE: Perform Step 1 through Step 5 for lift truck models ERP15-20VT (ERP030-040VT) (G807). 1. Using a lifting device, lower counterweight into position on lift truck. 2. Install washers and lower capscrews into frame and counterweight. Tighten capscrews to 250 N•m (184 lbf ft). See Figure 17 for lift truck models
NOTE: COUNTERWEIGHT FOR LIFT TRUCKS ERP15-20VT (G807) MANUFACTURED BEFORE NOVEMBER, 2014 AND ERP030-040VT (G807) SHOWN. HOLES FOR EYEBOLTS FOR COUNTERWEIGHT USED ON LIFT TRUCKS ERP15-20VT (G807) MANUFACTURED AFTER NOVEMBER, 2014 ARE IN SAME LOCATIONS. 1. COUNTERWEIGHT 2. EYE BOLT Figure 19. Counterweight Lift for Lift Truck ERP15-20VT (ERP030-040VT) (G807) 12. Remove two capscrews from rear bulkhead and spacer plates. Remove rear bulkhead. See Figure 20.
WARNING The counterweight is very heavy. Make sure the slings and overhead lifting device have the capacity to lift the counterweight. 13. Wrap two slings through slots in top of counterweight. Attach slings to lifting device. See Figure 21. 14. Remove lower capscrews, nuts, and washers from frame and counterweight. See Figure 20.
•
ERP15-20VT (G807) manufactured before November, 2014
•
ERP030-040VT (G807)
See Figure 18 for lift truck models •
ERP15-20VT (G807) manufactured after November, 2014
3. Install washers and upper capscrews into frame and counterweight. Tighten capscrews to 755 N•m (557 lbf ft). 4. Remove lifting device and eye bolts from counterweight. See Figure 19. 5. Install steer plate, washers, capscrews, and nuts onto counterweight. Tighten capscrews to 300 N•m (221 lbf ft). See Figure 17 for lift truck models •
ERP15-20VT (G807) manufactured before November, 2014
•
ERP030-040VT (G807)
See Figure 18 for lift truck models •
ERP15-20VT (G807) manufactured after November, 2014
NOTE: Perform Step 6 through Step 11 for lift truck models ERP16-20VF (ERP30-40VF) (A955). 6. Using a lifting device, lower counterweight into position on lift truck frame.
15. Remove upper capscrews and washers from frame and counterweight. See Figure 20. Using lifting device, lift counterweight away from frame. 23
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