YALE (A985) ERP080VM LIFT TRUCK Service Repair Manual

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Text of YALE (A985) ERP080VM LIFT TRUCK Service Repair Manual

  • ERP080-1000VM (A985)SERVICE MANUAL CONTENTS

    SECTIONPART

    NUMBERYRM

    NUMBERREV

    DATEFRAME............................................................................................................................ 524319489 0100 YRM 1342 09/14OPERATOR'S CAB........................................................................................................ 550025937 0100 YRM 1446 09/14AC MOTOR REPAIR...................................................................................................... 524327049 0620 YRM 1385 09/14TRANSAXLE................................................................................................................... 550041580 1300 YRM 1539 09/14STEERING AXLE............................................................................................................ 524319491 1600 YRM 1360 09/14STEERING SYSTEM...................................................................................................... 524319492 1600 YRM 1363 09/14HYDRAULIC SYSTEM.................................................................................................... 524319494 1900 YRM 1367 09/14HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14MAIN CONTROL VALVES............................................................................................. 524319495 2000 YRM 1334 09/14CYLINDER 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).......................................................................................................................... 524319496 2100 YRM 1382 03/14

    WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14USER INTERFACE SUPERVISOR................................................................................. 524319497 2200 YRM 1335 09/14USER INTERFACE SERVICE TECHNICIAN................................................................. 524319498 2200 YRM 1336 09/14ELECTRICAL SYSTEM.................................................................................................. 524319499 2200 YRM 1369 09/14INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14MAST REPAIR (S/N A626-27, A751-52, B590-91, AND B749-54)................................ 550041581 4000 YRM 1540 09/14METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13DIAGRAMS..................................................................................................................... 524332383 8000 YRM 1384 09/14PERIODIC MAINTENANCE............................................................................................ 550041582 8000 YRM 1541 09/14CAPACITIES AND SPECIFICATIONS........................................................................... 550041583 8000 YRM 1542 09/14DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524319504 9000 YRM 1377 10/14

    Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.PART NO. 550041572 (12/14)

  • GeneralDESCRIPTION

    This section contains a description and serviceprocedures for the parts of the frame. These partsinclude the frame, counterweight assembly, overheadguard, hood and seat assembly, access panels, andlabels.

    Throughout this section, forward will refer to travel inthe direction of the forks and left and right will bedetermined by an operator sitting in the seat facingforward. See Figure 1.

    A. LEFT SIDEB. RIGHT SIDEC. FORWARD TRAVEL

    Figure 1. Truck Orientation

    If a torque value is not specified, go to Metric andInch (SAE) Fasteners 8000YRM0231 for torquevalues.

    FRAME

    The frame is a single weldment with mounts for: Counterweight Overhead guard Tilt cylinders Drive axle, or if equipped, transaxle Floor plate and pedals Side step and fender weldments Hood and seat assembly Front drop-in bulkhead for lift truck models

    ERC40-55VH, ERC50VHS (ERC80-120VH,ERC100VHS) (A938)

    See Figure 2 for lift truck models ERC22-35VG (ERC045-070VG) (A968)

    See Figure 3 for lift truck models ERC16-20VA (ERC030-040VA) (A969)

    See Figure 4 for lift truck models ERP22-35VL (ERP045-070VL) (A976)

    See Figure 5 for lift truck models ERP40-50VM, ERP50-55VM6

    (ERP080-120VM, ERP100VML) (A985)

    See Figure 6 for lift truck models ERC40-55VH, ERC50VHS (ERC80-120VH,

    ERC100VHS) (A938)

    0100 YRM 1342 General

    1

  • 1. FRONT OVERHEAD GUARD MOUNTINGBRACKET

    2. REAR OVERHEAD GUARD MOUNTINGBRACKET

    3. COUNTERWEIGHT MOUNTING PLATE4. FRONT BULKHEAD

    5. RIGHT FRAME CHANNEL6. LEFT FRAME CHANNEL7. REAR BULKHEAD8. TILT ANCHOR PLATE9. SIDE STEP MOUNTING BRACKET

    Figure 2. Frame Weldment for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

    General 0100 YRM 1342

    2

  • 1. FRONT OVERHEAD GUARD MOUNTINGBRACKET

    2. REAR OVERHEAD GUARD MOUNTINGBRACKET

    3. COUNTERWEIGHT MOUNTING PLATE4. FRONT BULKHEAD

    5. RIGHT FRAME CHANNEL6. LEFT FRAME CHANNEL7. REAR BULKHEAD8. TILT ANCHOR PLATE9. SIDE STEP MOUNTING BRACKET

    Figure 3. Frame Weldment for Lift Truck ERC16-20VA (ERC030-040VA) (A969)

    0100 YRM 1342 General

    3

  • 1. FRONT OVERHEAD GUARD MOUNTINGBRACKET

    2. OPERATOR MODULE PLATE3. FRONT BULKHEAD4. REAR BULKHEAD5. COUNTERWEIGHT MOUNTING PLATE6. LEFT FENDER

    7. RIGHT FENDER8. RIGHT FRAME CHANNEL9. LEFT FRAME CHANNEL10. TILT ANCHOR PION11. DRIVE AXLE MOUNTS12. SIDE STEP MOUNTING BRACKET

    Figure 4. Frame Weldment for Lift Truck ERP22-35VL (ERP045-070VL) (A976)

    General 0100 YRM 1342

    4

  • 1. FRONT OVERHEAD GUARD MOUNTINGBRACKET

    2. OPERATOR MODULE PLATE3. FRONT BULKHEAD4. REAR BULKHEAD5. COUNTERWEIGHT MOUNTING PLATE6. LEFT FENDER

    7. RIGHT FENDER8. RIGHT FRAME CHANNEL9. LEFT FRAME CHANNEL10. TILT ANCHOR PION11. DRIVE AXLE MOUNTS12. SIDE STEP MOUNTING BRACKET

    Figure 5. Frame Weldment for Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML)(A985)

    0100 YRM 1342 General

    5

  • 1. FRONT OVERHEAD GUARD MOUNTINGBRACKET

    2. REAR OVERHEAD GUARD MOUNTINGBRACKET

    3. COUNTERWEIGHT MOUNTING PLATE4. FRONT BULKHEAD

    5. RIGHT FRAME CHANNEL6. LEFT FRAME CHANNEL7. REAR BULKHEAD8. TILT ANCHOR PLATE9. SIDE STEP MOUNTING BRACKET

    Figure 6. Frame Weldment for Lift Trucks ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)

    The hydraulic and traction motor electronic controllersand contactors are located in the counterweight cavityfor the following lift truck models

    ERC22-35VG (ERC045-070VG) (A968) ERC16-20VA (ERC030-040VA) (A969) ERC40-55VH, ERC50VHS (ERC80-120VH,

    ERC100VHS) (A938)

    The hydraulic motor electronic controller andcontactor are located in the counterweight cavity andthe traction motor controller is attached to the frontbulkhead for the following lift truck models

    ERP22-35VL (ERP045-070VL) (A976) ERP40-50VM, ERP50-55VM6

    (ERP080-120VM, ERP100VML) (A985)

    NOTE: Lift truck models ERC22-35VG(ERC045-070VG) (A968) manufactured after June,2012 are equipped with a removable floor plate thatrequires no tools to remove.

    For all lift truck models covered in this ServiceManual, the Vehicle Systems Manager (VSM) iseither mounted on or near the front bulkheadunderneath the floor mat and floor plate.

    General 0100 YRM 1342

    6

  • DISCHARGING THE CAPACITORS

    WARNING DO NOT make repairs or adjustments unless youhave been properly trained and authorized to doso. Improper repairs and adjustments can createdangerous operating conditions. DO NOT operatea lift truck that needs repairs. Report the need forrepairs to your supervisor immediately. If repair isnecessary, attach a DO NOT OPERATE tag on thesteering wheel and disconnect the battery.

    Disconnect the battery and allow the capacitors todischarge before opening any compartmentcovers or inspecting or repairing the electricalsystem. DO NOT place tools on top of the battery.If a tool causes a short circuit, the high currentflow from the battery can cause personal injury orproperty damage.

    Some checks and adjustments are performed withthe battery connected. DO NOT connect thebattery until the procedure instructs you to do so.Never wear any metallic items on your fingers,arms, or neck. Metal items can accidentally makean electrical connection and cause injury.

    Before performing any tests or adjustments, blockthe lift truck to prevent unexpected movement.

    The capacitor in the transistor controller(s) canhold an electrical charge for about 10 secondsafter the battery is disconnected. To prevent anelectrical shock and personal injury, dischargethe capacitor(s) before inspecting or repairing anycomponent in the drive unit compartment. Makecertain that the battery has been disconnected.

    DO NOT short across the motor controllerterminals with a screwdriver or jumper wire.

    Make certain the Emergency-Disconnect switchhas not been activated. This will isolate thecontroller and prevent the capacitors fromdischarging properly. The proper way todisconnect the battery is by separating the batteryconnectors.

    1. Ensure the capacitors are discharged byperforming Step 2 through Step 6 below.

    2. Turn the key or keyless switch to the OFFposition.

    3. Disconnect the battery by separating theconnectors.

    4. Block the drive wheels to prevent the lift truckfrom moving.

    5. Make sure the Emergency-Disconnect switchHAS NOT been activated. If the Emergency-Disconnect switch is acti