Yale b888 erp15 vc lift truck service repair manual

ERP13-15VC (B888)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
OPERATOR'S CAB........................................................................................................ 550025937 0100 YRM 1446 09/14
FRAME............................................................................................................................ 550038795 0100 YRM 1514 12/13
AC MOTOR REPAIR...................................................................................................... 550038796 0620 YRM 1515 12/13
LOAD AXLE.................................................................................................................... 550038797 1300 YRM 1516 12/13
STEERING SYSTEM...................................................................................................... 550038798 1600 YRM 1517 12/13
BRAKE SYSTEM............................................................................................................ 550038799 1800 YRM 1518 12/13
HYDRAULIC SYSTEM.................................................................................................... 550038800 1900 YRM 1519 05/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVES............................................................................................. 550038801 2000 YRM 1520 05/14
CYLINDER REPAIR (MAST S/N A270, A271, A272, C661, C662, C663)..................... 550038802 2100 YRM 1521 05/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE SUPERVISOR................................................................................. 524319497 2200 YRM 1335 09/14
USER INTERFACE SERVICE TECHNICIAN................................................................. 524319498 2200 YRM 1336 09/14
ELECTRICAL SYSTEM.................................................................................................. 550038805 2200 YRM 1524 09/14
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
MAST REPAIR (S/N A270, A271, A272, C661, C662, AND C663)............................... 550038806 4000 YRM 1525 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
PERIODIC MAINTENANCE............................................................................................ 550038807 8000 YRM 1526 09/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550038808 8000 YRM 1527 05/14
DIAGRAMS..................................................................................................................... 550038809 8000 YRM 1528 09/14
DIAGNOSTIC 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. 550038790 (12/14)

General
This Service Manual describes how the cab operates
and includes replacement and repair instructions for
the following cab components (see Figure 1):
• Front, rear, and cab door window panels
• Windshield wipers
• Roof liner
• Roof top panel
• Cab doors
• Cab heater
• Weather panels
Some of the described components are options that
may not be present on each cab. The operation of the
various switches and controls can be found in the
Operating Manual.
1. FRONT WINDOW PANEL
2. DOOR WINDOW PANEL
3. WINDSHIELD WIPER
4. CAB DOOR
5. ROOF TOP PANEL
Figure 1. Operator's Cab
0100 YRM 1446 General
1

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.
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.
Before performing work on the cab, the capacitors
need to be discharged as described below:
1. Ensure the capacitors are discharged by
performing Step 2 through Step 6 below.
2. Turn the key or keyless switch to the OFF
position.
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 Emergency-
Disconnect switch is activated, rotate the switch
to the right until it pops up.
6. Press horn button. Wait 30 seconds to be sure
capacitors are fully discharged.
Window Replacement
FRONT PANEL
Remove, Lift Truck Models ERP22-35VL
(ERP045-070VL) (A976), ERP40-50VM,
ERP50-55VM6 (ERP080-120VM, ERP100VML)
(A985), ERP15-20VT (ERP030-040VT) (G807),
and ERP16-20VF (ERP30-40VF) (A955)
WARNING
All windows installed in the cab are made of
safety glass. All replacement windows must be
made of the correct material and must be made
the correct thickness. Failure to have the correct
material or thickness may cause the glass to
break easily when struck and may cause personal
injury.
WARNING
Disconnect the battery before doing any work on
the electrical system. Serious injury to personnel
and/or damage to lift truck components can occur
if battery is not disconnected.
Discharge capacitors as directed in the General
section of this manual.
Window Replacement 0100 YRM 1446
2

NOTE: In Step 1 and Step 2 note placement of com-
ponents during removal to aid in installation.
1. Remove nut, bolt, and six washers from upper
right hand corner of front window. See Figure 2.
2. Remove nut cover, nut, five washers, and screw
from front window in five places. Remove front
window from overhead guard. See Figure 3.
NOTE: OVERHEAD GUARD NOT SHOWN FOR
CLARITY. WIPER KIT SHOWN NOT THE SAME ON
ALL LIFT TRUCK MODELS.
1. FRONT WINDOW
2. INSERT
3. WASHER
4. SCREW
5. NUT COVER
6. WIRE HARNESS
7. WIPER KIT
8. SWITCH
9. CAPSCREW
10. BOLT
11. NUT
12. BRACKET
Figure 2. Front Panel and Wiper
3. Remove and discard seal from front window. See
Figure 3.
NOTE: Perform Step 4 for the following lift truck mod-
els
• ERP22-35VL (ERP045-070VL) (A976)
• ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
4. Remove light brackets from overhead guard, if
equipped. See manual Electrical System
2200YRM1369 for procedures.
NOTE: OVERHEAD GUARD NOT SHOWN FOR
CLARITY.
1. FRONT WINDOW
2. SEAL
3. SCREW
4. WASHER
5. BRACKET
6. NUT
7. NUT COVER
8. LIGHT BRACKET
Figure 3. Front Panel Assembly
0100 YRM 1446 Window Replacement
3

Remove, Lift Truck Models ERP13VC,
ERP15VC (B888)
WARNING
All windows installed in the cab are made of
safety glass. All replacement windows must be
made of the correct material and must be made
the correct thickness. Failure to have the correct
material or thickness may cause the glass to
break easily when struck and may cause personal
injury.
WARNING
Disconnect the battery before doing any work on
the electrical system. Serious injury to personnel
and/or damage to lift truck components can occur
if battery is not disconnected.
Discharge capacitors as directed in the General
section of this manual.
1. Move wiper blades away from front panel.
2. Remove inserts, wheel nuts, capscrews, and grab
handle from mounting bracket on front panel
frame. See Figure 4.
3. If equipped, remove light brackets from top of
front panel frame. See Electrical System
4. Remove top two capscrews used to mount steer-
ing column. See Figure 5.
5. Remove six capscrews, nuts, front panel and front
panel frame from lift truck. See Figure 5.
Clean
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
1. Using compressed air, blow dirt and debris from
components as needed.
2. Using a lint free cloth, wipe down front window
and other components as needed.
Inspect
1. Inspect front window for damage and cracks, re-
place if damaged.
2. For lift truck models ERP13VC, ERP15VC
(B888), inspect front panel and steel frame for
damage and cracks, replace if damaged.
3. Inspect components and hardware for cracks and
defects. Replace as needed.
1. INSERT
2. WHEEL NUT
3. CAPSCREW
4. GRAB HANDLE
5. MOUNTING BRACKET
6. FRONT PANEL FRAME
Figure 4. Grab Handle, Remove and Install, Lift
Truck Models ERP13VC, ERP15VC (B888)
4

1. CAPSCREW (FRONT PANEL AND FRAME)
2. NUT
3. CAPSCREW (STEERING COLUMN)
4. LIGHT BRACKET
5. FRONT PANEL
6. FRONT PANEL FRAME
Figure 5. Front Panel and Frame Components, Lift
Truck Models ERP13VC, ERP15VC (B888)
Install, Lift Truck Models ERP22-35VL
(ERP045-070VL) (A976), ERP40-50VM,
(A985), ERP15-20VT (ERP030-040VT) (G807),
1. Install seal on front window. See Figure 3.
els
• ERP22-35VL (ERP045-070VL) (A976)
(ERP080-120VM, ERP100VML) (A985)
2. Install light brackets on overhead guard, if equip-
ped. See section Electrical System
3. Install front window on overhead guard. Install two
washers, screw, two washers, bracket, washer,
nut, and nut cover on front window in five places.
See Figure 3.
4. Install two washers, bolt, four washers, and nut on
upper right hand corner of front window. See Fig-
ure 2.
Install, Lift Truck Models ERP13VC, ERP15VC
(B888)
1. Install grab handle to mounting bracket on front
panel frame using inserts, wheel nuts, and cap-
screws. See Figure 4.
NOTE: Apply liquid sealant, Yale P/N 501702902, to
capscrews prior to installation.
2. Install front panel and front panel frame to lift
truck with six capscrews and nuts. Tighten cap-
screws to 19 N•m (168 lbf in). See Figure 5.
3. Install top two capscrews for steering column.
See Figure 5.
4. If equipped, install light brackets from top of front
panel frame. See Electrical System
5. Push wiper blades into position on the front panel.
5

REAR PANEL
Remove
1. Remove flange nut, cover, wiper arm, and wiper
blade from wiper motor. See Figure 6.
2. Disconnect wiring harness from wiper motor and
remove wiper motor from rear panel. See Fig-
ure 6.
3. Remove two screws and latch from overhead
guard legs in two places. See Figure 6.
4. Remove five capscrews and bracket from cab
body. See Figure 6.
5. Disconnect gas spring from lower ball stud in two
places. See Figure 7.
6. Remove cap, capscrew and washer from over-
head guard and rear panel in two places. Remove
rear panel from overhead guard. See Figure 6.
7. If damaged, remove ball stud from overhead
guard leg in two places. See Figure 7.
8. Remove nut cover, nut, four washers, and hinge
from rear panel in two places. See Figure 7.
9. Remove nut cover, nut, plate, washer, screw, and
cap from hinge. Repeat for second hinge. See
Figure 7.
10. Disconnect gas spring from upper ball stud on
knob in two places. See Figure 7.
11. Remove ball stud from knob in two places. See
Figure 7.
12. Remove screw, three washers, o-ring, and knob
from rear panel in two places. See Figure 7.
13. Remove nut cover, nut, and two washers from
connector on outside of rear panel. Repeat for op-
posite side. See Figure 7.
14. Remove plug, grip, nut, two washers, plug, con-
nector, and two washers from inside of rear panel.
Repeat for opposite side. See Figure 7.
15. Remove and discard seal from rear screen. See
Figure 7.
Clean
WARNING
2. Using a lint free cloth, wipe down rear screen and
other components as needed.
Inspect
1. Inspect components for cracks and defects. Re-
place as needed.
2. Inspect gas springs for proper travel and exten-
sion. Replace as necessary.
a. Extended length; 735 mm (28.9 in.).
b. Stroke length, 315 mm (12.4 in.).
c. Resistance, 150 N (33.7 lbf).
3. Inspect wiper blade for cracks and tearing. Re-
place as needed.
Install
1. Install seal on rear screen. See Figure 7.
2. Install two washers, connector, plug, two wash-
ers, nut, grip, and plug on inside of rear panel.
Repeat for opposite side. See Figure 7.
3. Install two washers, nut, and nut cover on con-
nector on outside of rear panel. Repeat for oppo-
site side. See Figure 7.
4. Install knob, O-ring, three washers, and screw on
rear screen in two places. See Figure 7.
5. Install ball stud on knob in two places. See Fig-
ure 7.
6. Connect gas spring to upper ball stud on knob in
two places. See Figure 7.
6

NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY.
1. REAR PANEL
2. CAP
3. CAPSCREW
4. WASHER
5. SCREW
6. WIRE HARNESS
7. SWITCH
8. WIPER MOTOR
9. WIPER BLADE
10. WIPER ARM
11. BRACKET
12. LATCH
13. COVER
14. FLANGE NUT
Figure 6. Rear Panel and Wiper Attachment
7

NOTE: OVERHEAD GUARD NOT SHOWN FOR CLARITY.
1. REAR PANEL
2. SEAL
3. NUT COVER
4. PLATE
5. WASHER
6. HINGE
7. SCREW
8. NUT
9. BALL STUD
10. GAS SPRING
11. KNOB
12. O-RING
13. PLUG
14. GRIP
15. LATCH
16. CONNECTOR
17. BRACKET
18. CAP
Figure 7. Rear Panel Assembly
8

7. Install plate, washer, screw, nut, nut cover, and
cap on hinge. Repeat for second hinge. See Fig-
ure 7.
8. Install washer, hinge, screw, three washers, nut,
and nut cover on rear panel in two places. See
Figure 7.
9. If removed, install ball stud on overhead guard leg
in two places. See Figure 7.
10. Install rear panel on overhead guard. Install
washer, capscrew, and cap on rear panel and
overhead guard in two places. See Figure 6.
11. Connect gas spring to two lower ball stud in two
places. See Figure 7.
12. Install bracket and five capscrews on cab body.
See Figure 6.
13. Install latch and two screws on overhead guard
legs in two places. See Figure 6.
14. Install rear wiper motor on rear panel and connect
wiring harness to rear wiper motor. See Figure 6.
15. If removed, install wiper blade on wiper arm. See
Figure 6.
16. Using a flange nut, install wiper arm and wiper
blade on wiper motor. See Figure 6.
DOOR WINDOW
Disassemble Window
NOTE: If repair to non-sliding window is necessary,
contact local glass repair shop.
NOTE: The following procedure applies to right and
left doors with sliding windows.
1. Remove window frame and window assembly
from door assembly. See Figure 8.
2. Remove two latches from two sliding windows.
See Figure 8.
3. Remove two sliding windows from window frame.
See Figure 8.
4. Remove and discard four guides from two sliding
windows. See Figure 8.
5. Remove and discard seal from rear of sliding win-
dow. See Figure 8.
6. Remove and discard five seals from window
7. Remove and discard strip seal from window
8. Remove and discard six clips from window frame.
See Figure 8.
9. Remove and discard edge protector from window
Clean
WARNING
2. Using a lint free cloth, wipe down windows on
both doors and other components as needed.
Inspect
1. Inspect all components and hardware for cracks
and defects. Replace as needed.
2. Inspect latch assembly and hardware. Ensure
proper operation.
3. Inspect windows for chips and cracks. Replace as
necessary.
Assemble Window
NOTE: The following procedure applies to right and
left doors.
1. Install edge protector and six clips on window
2. Install strip seal and five seals on window frame.
See Figure 8.
3. Install seal on rear of sliding window. See Fig-
ure 8.
4. Install four guides on two sliding windows. See
Figure 8.
9

5. Install two sliding windows on window frame. See
Figure 8.
6. Install two latches to sliding windows. See Fig-
ure 8.
7. Install window frame and window assembly to
door assembly. See Figure 8.
NOTE: RIGHT-HAND SIDE SHOWN.
1. SLIDING WINDOW
2. SEAL
3. LATCH
4. STRIP SEAL
5. CLIP
6. WINDOW FRAME
7. EDGE PROTECTOR
8. GUIDE
Figure 8. Window Components
10

Window Wipers Replacement
FRONT WIPER ASSEMBLY
NOTE: Lift truck models ERC22-35VG
(ERC045-070VG) (A968) are not equipped with wind-
shield wiper and motor.
Remove, Lift Truck Models ERP22-35VL
(ERP045-070VL) (A976), ERP40-50VM,
(A985), ERP15-20VT (ERP030-040VT) (G807),
1. Disconnect wire harness from wiper motor con-
nector.
See Figure 9 for lift truck models
• ERP22-35VL (ERP045-070VL) (A976)
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
(ERP080-120VM, ERP100VML) (A985)
2. Disconnect wire harness from washer pump con-
nector.
• ERP22-35VL (ERP045-070VL) (A976)
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
(ERP080-120VM, ERP100VML) (A985)
NOTE: Perform Step 3 and Step 4 for lift truck mod-
els ERP22-35VL (ERP045-070VL) (A976).
3. Disconnect hose (6) from connector (7). See Fig-
ure 9.
4. Remove two clamps (5), hose (6), and nozzle (4)
from wiper arm. Set aside for installation. See Fig-
ure 9.
els
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
5. Disconnect hose (15) from connector (11). See
Figure 10.
NOTE: Perform Step 6 and Step 7 for lift truck mod-
els ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985).
6. Disconnect hose (17) from connector (7). See
Figure 11.
7. Disconnect hose from nozzle clip. Remove nozzle
clip and nozzle from wiper arm. See Figure 11.
8. Remove two flange nuts, wiper arms, and wiper
blade from wiper motor. See Figure 12.
9. Remove wiper blade from wiper arm.
• ERP22-35VL (ERP045-070VL) (A976)
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
(ERP080-120VM, ERP100VML) (A985)
10. Remove two nut covers, two nuts, two washers,
and wiper motor from lift truck. See Figure 12.
11. Disconnect hose from reservoir.
• ERP22-35VL (ERP045-070VL) (A976)
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955)
(ERP080-120VM, ERP100VML) (A985)
0100 YRM 1446 Window Wipers Replacement
11

1. WIPER MOTOR
2. WIPER ARM
3. WIPER BLADE
4. NOZZLE (CLIP)
5. CLAMP
6. HOSE
7. CONNECTOR (SPRAY NOZZLE)
8. HOSE
9. CHECK VALVE
10. BRACKET
11. RESERVOIR
12. WASHER
13. CAPSCREW
14. WASHER PUMP CONNECTOR
15. WIPER MOTOR CONNECTOR
Figure 9. Front Wiper Assembly for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)
Window Wipers Replacement 0100 YRM 1446
12

1. WIPER MOTOR
2. WIPER ARM
3. WIPER BLADE
4. RESERVOIR
5. CAP
6. CAPSCREW
7. WASHER
8. BRACKET
9. NUT
10. CHECK VALVE
11. CONNECTOR
12. CHECK VALVE CONNECTOR
13. HOSE
14. HOSE
15. HOSE
16. WIRING CONNECTOR
Figure 10. Front Wiper Assembly for Lift Truck Models ERP15-20VT (ERP030-040VT) (G807) and
ERP16-20VF (ERP30-40VF) (A955)
13

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Figure 11. Front Wiper Assembly for Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) (A985)
Window Wipers Replacement 0100 YRM 1446
14

Legend for Figure 11
1. CAPSCREW
2. WASHER
3. NUT
4. WIPER ARM
5. WIPER BLADE
6. WIPER MOTOR
7. CONNECTOR (SPRAY NOZZLE)
8. CAP
9. RESERVOIR BRACKET
10. WASHER RESERVOIR
11. CHECK VALVE
12. INSERT
13. SWITCH
14. FUSES
15. FUSES MOUNTING BRACKET
16. WIRE HARNESS
17. HOSE
18. NOZZLE CLIP
19. HOSE
20. WASHER PUMP CONNECTOR
1. WIPER MOTOR
2. WASHER
3. NUT
4. NUT COVER
5. WIPER ARM
6. FLANGE NUTS
7. WIPER BLADE
Figure 12. Wiper Attachment
15

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