ERP20-30ALF (B216) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ DC MOTOR MAINTENANCE.......................................................................................... DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL............................................. STEERING AXLE............................................................................................................ STEERING SYSTEM...................................................................................................... STEERING HOUSING AND CONTROL UNIT (EARLY MODELS)................................ STEERING CONTROL UNIT.......................................................................................... BRAKE SYSTEM............................................................................................................ HYDRAULIC SYSTEM.................................................................................................... MAIN CONTROL VALVE................................................................................................ TILT CYLINDERS........................................................................................................... INSTRUMENT CLUSTER............................................................................................... EV-100ZX SCR MOTOR CONTROLLER DESC/ADJ/TRBL/REPAIR AND THEORY.. ELECTRICAL SYSTEM.................................................................................................. EV-T100 TRANSISTOR MOTOR CONTROLLER DESCRIPTION, ADJUSTMENTS, TROUBLESHOOTING, REPAIRS AND THEORY..................................................... EV-100ZX SCR MOTOR CONTROLLER PARAMETER TABLES................................ EV-T100 TRANSISTOR MOTOR CONTROLLER PARAMETER TABLES................... TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER............................ SR/SP TRANSISTOR MOTOR CONTROLLERS DESCRIPTION, CHECKS AND ADJUSTMENTS, TROUBLESHOOTING, REPAIRS, AND THEORY OF OPERATON............................................................................................................... DISPLAY PANEL FOR SEM CONTROLS (DOS VERSION)......................................... SR/SP TRANSISTOR MOTOR CONTROLLER PARAMETER TABLES FOR FOURWHEEL ELECTRIC RIDER LIFT TRUCKS............................................................... DISPLAY PANEL FOR SEM CONTROLS..................................................................... SR(SEM)/SP TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER (WINDOWS VERSION).............................................................................................. INDUSTRIAL BATTERY................................................................................................. MAST - DESCRIPTION................................................................................................... MAST - REPAIR.............................................................................................................. FOUR STAGE MAST...................................................................................................... METRIC AND INCH (SAE) FASTENERS....................................................................... DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS..................................................................................................................... DIAGRAMS (SEM)..........................................................................................................
PART NUMBER
YRM NUMBER
REV DATE
524179935 524158039 524179938 524158752 524166836 524179941 524158753 524179943 524179945 524179946 524150790 524158757 524179947 524166840
0100 YRM 0582 0620 YRM 0294 1400 YRM 0575 1600 YRM 0316 1600 YRM 0485 1600 YRM 0512 1600 YRM 0720 1800 YRM 0566 1900 YRM 0559 2000 YRM 0562 2100 YRM 0103 2200 YRM 0514 2200 YRM 0557 2200 YRM 0560
07/05 03/08 03/03 08/06 07/03 07/03 11/06 03/03 04/09 02/09 03/07 01/04 07/03 07/05
524270784 524179949 524270785 524270787
2200 YRM 0581 2200 YRM 0595 2200 YRM 0596 2200 YRM 0597
01/13 07/03 03/06 03/06
524179951 524166842
2200 YRM 0724 2200 YRM 0725
04/05 07/02
524179952 524166844
2200 YRM 0739 2200 YRM 0942
04/05 08/07
524167640 524158040 524158890 524158891 524179953 524150797 524179954 524179957 524179958 524270788 524179956
2200 YRM 0947 2240 YRM 0001 4000 YRM 0521 4000 YRM 0522 4000 YRM 0563 8000 YRM 0231 8000 YRM 0551 8000 YRM 0552 8000 YRM 0561 8000 YRM 0589 8000 YRM 0742
08/07 09/14 03/06 07/10 04/05 10/13 07/03 07/03 07/03 03/06 06/04
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 524179922 (09/14)
100 YRM 582
Description
General This section has a description and the service procedures for the parts of the frame. These parts include the frame, counterweight assembly, overhead guard, hood and seat assembly, access panels, and label positions. The procedure for removing the traction motor is also described in this section.
Description MAIN FRAME The main frame is a single weldment. See Figure 1. The main frame has mounts for the following: • Counterweight • Overhead guard, • Battery restraint and hood • Tilt cylinders • Steering axle • Drive axle assembly • Cowl assembly • Floor pedals and floor plates • Side step and fender weldments • Hydraulic tank • Pump and motor assemblies (steer, lift, and traction motors) • Control valves, and the levers The hood is part of the operator and battery restraint system. The seat is part of the operator restraint system. The floor plates can be removed for access to the traction motor. The panels on the sides of the battery compartment can also be easily removed. The hydraulic tank, lift pump motor assembly, and the steering pump motor assembly are in a compartment between the battery and the counterweight. The SCR (silicon controlled rectifier) or transistor electronic controllers and contactors are in the top of the counterweight. The top cover of the counterweight can be removed for access to the controllers and contactors for early model ERP20-30ALF (B216) lift trucks. See Figure 2. The rear cover of the counterweight can be removed for access to the controllers and contactors for later model ERP20-30ALF (B216) trucks and ERP2030ALF (ERP040-060DH) (D216) trucks. See Figure 3. There are two main frames for lift trucks made for use in North America and two main frames for lift trucks made for use in Europe. The frames are different because of the different battery compartment sizes. There are two battery compartment lengths. The battery compartment widths are also different for Europe and North
America. See Battery Specifications, at the back of this manual.
WARNING The battery must fit the battery compartment so that the battery restraint will operate correctly. A loose battery can cause serious injury and property damage if the lift truck overturns. Adjust the spacer plate to prevent the battery from moving more than 13 mm (0.5 in.) forward or backward.
WARNING Maximum clearance between the battery and battery compartment width is 13 mm (0.5 in.). Maximum clearance between the battery and the spacer plate is also 13 mm (0.5 in.). The Battery Specifications chart shows the minimum size compartment allowed. The weight of the battery is a large part of the counterweight system on an electric lift truck. Make sure that the battery is within the weight limits indicated on the nameplate. Each model of lift truck has a cast-iron counterweight that provides the additional weight necessary for the indicated capacity.
OTHER FRAME WELDMENTS These frame parts are the right-hand and left-hand side step and fender weldments, and the cowl weldment. See Figure 1. Each part is a weldment fastened to the main frame to make the frame assembly. The cowl weldment is a mount for the front of the overhead guard (see Figure 2 and Figure 3), the steering column assembly (see Figure 4, Figure 5, and Figure 6), the release linkage of the parking brake, and the instrument panel with light switches. The display panels for these models of lift trucks are mounted into the instrument panel. See Figure 4, Figure 5, and Figure 6.
1
Description
1. 2. 3. 4.
100 YRM 582
COWL BATTERY SPACER PLATE BATTERY RETAINER ROD FRAME
5. SIDE STEP AND FENDER WELDMENT 6. ACCESS PANEL 7. FLOOR PLATES Figure 1. Lift Truck Main Frame
Legend for Figure 2 1. OVERHEAD GUARD 2. COVER OF ELECTRONICS COMPARTMENT 3. COUNTERWEIGHT
2
4. 5. 6. 7.
TOW PIN AND HANDLE CAPSCREW LOCKWASHER WASHER
8. 9. 10. 11.
HANDLE SCREW NUT FOAM TAPE
100 YRM 582
Description
Figure 2. Overhead Guard and Counterweight Early Model ERP20-30ALF (B216) Trucks
3
Description
100 YRM 582
OVERHEAD GUARD WARNING Do not operate the lift truck without the overhead guard and cowl correctly fastened to the lift truck.
falling objects. For early model ERP20-30ALF (B216), see Figure 2. For later model ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216) trucks, see Figure 3. A slot in the overhead guard permits removal of the battery without removing the overhead guard.
The overhead guard is a weldment that fastens to the main frame and cowl to help protect the operator from Legend for Figure 3 A. OVERHEAD GUARD USED ON LATER MODEL ERP20-30ALF (B216) TRUCKS B. OVERHEAD GUARD USED ON ERP20-30ALF (ERP040-060DH) (D216) TRUCKS 1. 2. 3. 4. 5. 6. 7. 8. 9.
4
OVERHEAD GUARD HANDLE ROLLING THREAD SCREW NUT WASHER CAPSCREW COVER TOW PIN TAPE
10. 11. 12. 13. 14. 15. 16. 17.
COVER SOCKET CAPSCREW LOCKWASHER COUNTERWEIGHT FOAM TAPE SPACER BRACKET SELF RETAINING NUT
100 YRM 582
Description
Figure 3. Overhead Guard and Counterweight Later Model ERP20-30ALF (B216) Trucks and ERP20-30ALF (ERP040-060DH) (D216) Trucks
5
Description
100 YRM 582
A. CURTIS METER B. GE METER (OPTIONAL) C. STEERING CONTROL UNIT USED ON EARLY MODEL LIFT TRUCKS
D. STEERING CONTROL UNIT USED ON LATER MODEL LIFT TRUCKS
1. 2. 3. 4. 5. 6. 7.
8. OPTIONAL BASIC DISPLAY PANEL 9. STANDARD DISPLAY PANEL (WITH CURTIS OR GE METER) 10. PREMIUM DISPLAY PANEL 11. HORN BUTTON 12. STEERING COLUMN 13. STEERING COLUMN NUT
STEERING WHEEL STEERING CONTROL UNIT LATCH MECHANISM COLUMN COVER COLUMN FRAME HORN SWITCH CONNECTOR ON-DEMAND STEERING COMPONENTS (NOT ALL UNITS)
Figure 4. Steering Column and Instrument Panel Early Model ERP20-30ALF (B216) Lift Trucks
6
100 YRM 582
1. 2. 3. 4. 5. 6. 7.
STEERING WHEEL SHIFT LEVER MECHANISM COLUMN COVER STEERING CONTROL UNIT COLUMN FRAME ON-DEMAND STEERING COMPONENTS DISPLAY PANEL (PREMIUM DISPLAY PANEL SHOWN)
Description
8. 9. 10. 11. 12.
LATCH MECHANISM HORN SWITCH CONNECTOR HORN BUTTON STEERING COLUMN STEERING COLUMN NUT
Figure 5. Steering Column and Display Panel, Later Model ERP20-30ALF (B216) Trucks
7
Description
100 YRM 582
Figure 6. Steering Column and Display Panel, ERP20-30ALF (ERP040-060DH) (D216) Trucks
8
100 YRM 582
Description Legend for Figure 6
1. 2. 3. 4. 5. 6. 7. 8.
ON-DEMAND STEERING COMPONENTS SHIFT LEVER MECHANISM STEERING WHEEL DISPLAY PANEL COLUMN COVER COLUMN FRAME STEERING CONTROL UNIT COWL WELDMENT
BATTERY AND OPERATOR RESTRAINT, HOOD, AND SEAT ASSEMBLY Battery Restraint WARNING The hood and battery restraint, as well as the latch for the hand lever assembly, must operate correctly before a lift truck is operated. These parts are part of the battery restraint system. The battery restraint system must operate correctly to help provide reasonable protection to the operator if the lift truck tips over.
9. 10. 11. 12. 13. 14. 15.
DASH COLUMN MOUNT LATCH MECHANISM HORN SWITCH CONNECTOR HORN BUTTON STEERING COLUMN STEERING COLUMN NUT
movement of the battery. See Figure 8. The adjustable spacer plate is used inside the battery compartment. See Figure 8. The spacer plate must be adjusted for a maximum clearance of 13 mm (0.5 in.) with the battery against the rear bulkhead. There must be some clearance to allow battery removal. See the section Periodic Maintenance 8000 YRM 552 for both early and later model ERP20-30ALF (B216) trucks and Periodic Maintenance 8000 YRM 1060, for ERP20-30ALF (ERP040-060DH) (D216) models, to remove the battery and adjust the spacer plate.
A battery restraint system is installed as a safety device. See Figure 7. The function on the battery restraint system is to hold the battery in the battery compartment in case of a tip over. Part of the battery restraint system is a battery restraint rod at the rear of the battery compartment. See Figure 7. This restraint rod extends over the rear edge of the battery case to help hold the battery within the battery compartment during a tip over. A handle is used to move the restraint rod. The handle of the battery restraint must be in the DOWN position to close the hood. The handle can be moved to the DOWN position only after the restraint rod is extended over the battery. The restraint rod can only be retracted when the hood is in the UP position.
WARNING The battery must fit the battery compartment so that the battery restraint will operate correctly. A loose battery can cause serious injury and property damage if the lift truck overturns. The battery must not be able to move more than 13 mm (0.5 in.) forward, backward, or side to side. An adjustable spacer plate is used at the front of the battery compartment to prevent forward and backward
A. RETRACTED 1. 2. 3. 4. 5.
B. EXTENDED
BATTERY RESTRAINT WARNING LABEL HOOD BATTERY RESTRAINT HANDLE BATTERY STEEL WELDMENT Figure 7. Battery Restraint Rod
9
Description
100 YRM 582
Hood WARNING The gas springs for the hood can raise the hood at a rapid rate and cause an injury. DO NOT get over hood when raising hood.
WARNING The batteries for these lift trucks must fit the battery compartment width with a maximum of 13 mm (0.5 in.) clearance. The Battery Specifications at the back of this manual, shows the minimum sizes of the battery compartments.
1. BATTERY COMPARTMENT 2. BATTERY 3. BULKHEAD
4. SPACER PLATE 5. ADJUSTMENT CAPSCREW 6. JAM NUTS
Figure 8. Battery Spacer Plate
Another important part of the battery restraint system is the steel weldment that is also the hood frame. See Figure 7. This hood frame is connected to the lift truck frame with hinges at the rear of the hood (see Figure 13). The front of the hood and frame is locked in the closed position by the assembly for the hydraulic hand levers. A latch releases the assembly to tilt forward and allow the hood to raise. See Figure 9. Gas springs help lift the hood assembly. The seat and other parts of the operator restraint system fasten to the hood assembly.
A. CLOSED OVER HOOD
B. OPEN
1. HAND LEVER ASSEMBLY 2. HOOD 3. SEAT
4. LATCH HANDLE 5. LATCH
Figure 9. Hood and Hand Lever Assembly with Latch
10
100 YRM 582
Overhead Guard Replacement
Operator Restraint System and Seat Assembly The operator restraint system has the seat, hip restraints, and the seat belt. The system helps the operator stay within the lift truck in case of a tip over. See Figure 10. Make sure that the seat is not loose on the rails. Make sure the seat rails are not loose. The seat rails must lock securely in position, but move freely when unlocked. The seat rails must be securely attached to the mounting surface. Legend for Figure 10 1. 2. 3. 4. 5.
SEAT HIP RESTRAINT SEAT BELT AND MOUNT SEAT RAILS CAPSCREW
Figure 10. Seat Assembly and Operator Restraint
Overhead Guard Replacement REMOVE WARNING Do not weld, drill, grind, or cut the overhead guard for mounts of lights or accessories. The strength of the overhead guard can be reduced. 1. Remove the battery as described in the section Periodic Maintenance 8000 YRM 552 for both early and later ERP20-30ALF (B216) model lift trucks and Periodic Maintenance 8000 YRM 1060 for ERP20-30ALF (ERP040-060DH) (D216) lift truck models. 2. Access to the capscrews that hold the rear legs of the overhead guard to the frame is from the battery compartment. See Figure 11 and Figure 12. Remove the capscrews, washers, and nuts that fasten each leg. 3. Remove the capscrews, washers, and nuts that hold each front leg of the overhead guard to the cowl. Disconnect any electric wires from under the cowl that go through the front legs of the overhead
guard. When the overhead guard is lifted from the frame, make sure these electric wires move through the holes in the frame at the front and rear so that they are not damaged. 4. Use a lifting device or another person to help lift the overhead guard from the lift truck.
INSTALL Put the overhead guard on the lift truck. Install any electric wires from the overhead guard legs through the holes in the frame. Install the capscrews, washers, and nuts that hold each front leg to the frame. See Figure 11 and Figure 12. Tighten the capscrews to 102 N•m (75 lbf ft). Install the capscrews, washers, and nuts that hold the rear legs to the frame. Tighten the capscrews to 102 N•m (75 lbf ft). Install the battery as described in the section Periodic Maintenance 8000 YRM 552 for both early and later ERP20-30ALF (B216) model lift trucks and Periodic Maintenance 8000 YRM 1060 for ERP20-30ALF (ERP040-060DH) (D216) lift truck models.
11
Overhead Guard Replacement
100 YRM 582
Figure 11. Overhead Guard and Counterweight Early Model ERP20-30ALF (B216) Trucks
12
100 YRM 582
Overhead Guard Replacement Legend for Figure 11
1. 2. 3. 4. 5. 6.
OVERHEAD GUARD COVER OF ELECTRONICS COMPARTMENT COUNTERWEIGHT TOW PIN AND HANDLE CAPSCREW LOCKWASHER
7. 8. 9. 10. 11. 12.
WASHER HANDLE SCREW NUT NUT FOAM TAPE
13
Overhead Guard Replacement
100 YRM 582
Figure 12. Overhead Guard and Counterweight Later Model ERP20-30ALF (B216) Trucks and ERP20-30ALF (ERP040-060DH) (D216) Trucks
14
100 YRM 582
Hood, Seat Assembly and Operator Restraint Replacement Legend for Figure 12
A. OVERHEAD GUARD USED ON LATER MODEL ERP20-30ALF (B216) TRUCKS B. OVERHEAD GUARD USED ON ERP20-30ALF (ERP040-060DH) (D216) TRUCKS 1. 2. 3. 4. 5. 6. 7. 8. 9.
OVERHEAD GUARD HANDLE ROLLING THREAD SCREW NUT WASHER CAPSCREW COVER TOW PIN TAPE
10. 11. 12. 13. 14. 15. 16. 17.
COVER SOCKET CAPSCREW LOCKWASHER COUNTERWEIGHT FOAM TAPE SPACER BRACKET SELF RETAINING NUT
Hood, Seat Assembly and Operator Restraint Replacement HOOD AND SEAT ASSEMBLY Remove WARNING The gas spring for the hood can raise the hood at a rapid rate and cause an injury. DO NOT get over hood when raising hood. NOTE: The hood and seat assembly can be removed as a unit or the seat assembly can be removed with the hood assembly installed on the truck frame. Do only the steps necessary. If the hood and seat assembly will be removed as a unit, do Step 1 through Step 4. To remove the seat assembly from the hood assembly, do Step 1 through Step 3 and Step 5 through Step 7. Remove the hood and seat assembly as follows (see Figure 13): 1. Turn the key to the OFF position and remove the key.
WARNING Never put tools or other metal on the battery. Metal on the battery can cause a short circuit and possible damage or injury.
3. Disconnect the connector for the seat switch wires near the rear of the hood frame. If the hood will be removed, remove the Emergency Stop knob and the power disconnect assembly from the hood. 4. Fasten the hood assembly so that it cannot lower and carefully remove the gas springs from the hood. Have an assistant help hold the hood assembly. Remove the screws that fasten the hood assembly to the lift truck frame. See Figure 13 and Figure 14. Carefully remove the hood assembly. 5. Push the connector of the seat switch wire through the grommet in the hood. It can be necessary to remove the grommet from the hole in the hood for enough clearance to get the connector through the grommet. Inspect seat switch and replace if worn or damaged. See Figure 13 6. Remove the screws that fasten the seat to the hood and hood frame. Close and latch the hood and put the seat on its side for access to the seat switch. 7. Use a flat blade screwdriver or other tool with a flat blade to carefully lift the switch free of the seat pan. Slide the switch out of the seat cushion.
2. Open the hood and disconnect the battery connector. Install a cardboard or plywood cover on the top of the battery to prevent accidental short circuits.
15
Hood, Seat Assembly and Operator Restraint Replacement
Figure 13. Hood Remove
16
100 YRM 582
100 YRM 582
Hood, Seat Assembly and Operator Restraint Replacement Legend for Figure 13
A. TOP VIEW B. SIDE VIEW
C. HOOD IN OPEN POSITION
1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11. 12.
HOOD HANDLE EMERGENCY STOP BUTTON HOOD SEAT SWITCH GAS SPRING SEAT
Install NOTE: If just the seat assembly was removed, install seat assembly onto hood by performing Step 1, Step 2, Step 4, and Step 5. If the hood and seat assembly were removed, install hood and seat assembly by performing Step 3 through Step 5. 1. Carefully slide the seat switch into the cavity of the seat cushion until the end of the switch with the wires is aligned over the hole in the pan. Push on the switch until the clips of the switch are fastened to the seat. See Figure 13. 2. Carefully install the grommet over the wire connector (see Figure 14.) Install the seat on the hood and
SEAT RAILS HOOD BRACKET SPRING CAPSCREW, WASHER, AND NUT WASHER, NUT, AND BOLT BATTERY COVER OVERHEAD GUARD tighten the nuts. Install the grommet in the hole of the hood, connect the wire connector, and push the connector back inside the hood frame.
3. If the hood assembly was removed, have an assistant help align the hood assembly in the correct position. Install the screws that fasten the hood assembly to the lift truck frame. See Figure 13. Hold the hood assembly in the open position and carefully install the gas springs. 4. Install the power disconnect assembly on the hood. Install the Emergency Stop knob. 5. Remove cardboard or plywood from top of battery.
17
Hood, Seat Assembly and Operator Restraint Replacement
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
HOOD STEEL WELDMENT PLATE WASHER LOCKWASHER NUT GAS SPRING FOAM TAPE SPACER BRACKET
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
100 YRM 582
CAPSCREW TRIM COVER RIVET HANDLE STRAP CLAMP CLIP INSULATION BOLT GROMMET
Figure 14. Hood Assembly
18
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