ERP25-30VC (B888)

SERVICE MANUAL CONTENTS

PART YRM REV
SECTION NUMBER NUMBER DATE
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............................................................................................ 550087451 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. 550087448 (12/14)
0100 YRM 1514 Introduction

Introduction
GENERAL
This service manual contains a description of, and
service procedures for parts of the frame. These parts
include the frame, counterweight assembly, overhead
guard, hood and seat assembly, side panels, master
drive unit (MDU), 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.

A. LEFT SIDE C. FORWARD TRAVEL

B. RIGHT SIDE

Figure 1. Lift Truck Orientation

1
Introduction 0100 YRM 1514

DESCRIPTION The hydraulic pump and motor assembly and

The frame is a welded assembly with mounts for the
counterweight, overhead guard, mast, steering
system, step plate, hydraulic system, side covers,
hood, cowl, transaxle and master drive unit. See
Figure 2. 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 battery without removing the overhead
guard.
Each lift truck has a cast-iron counterweight
appropriately weighted for the indicated capacity on
the Nameplate. See Figure 2.
hydraulic tank are located under the floor mat and
floor plate, in the front of the lift truck between the
load axles. See Figure 3. Floor plates are held in
position by tabs and can be removed to provide
access to components underneath.
The traction motor is in the counterweight. See
Figure 3. Access to the traction motor is through
removal of counterweight cover. The lift trucks
covered in this Service Manual can be equipped with
either a manual control valve or an E-Hydraulic
control valve. Both are fastened to the front of the
battery compartment. Both control valve types have
covers to protect the control valve. The manual
control valve also has covers to protect the control
linkages.

A. FRONT VIEW B. BACK VIEW

1. OVERHEAD GUARD 6. STEP PLATE, FLOOR PLATE, FLOOR MAT
2. MAST MOUNTS 7. SIDE COVER
3. TRANSAXLE 8. HOOD
4. HYDRAULIC TANK 9. COUNTERWEIGHT
5. COWL 10. STEERING SYSTEM

Figure 2. Frame Components

2
0100 YRM 1514
1. TRACTION MOTOR
2. HYDRAULIC CONTROL VALVE
3. HYDRAULIC TANK
Figure 3. Motor Locations
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.
Introduction
4. HYDRAULIC PUMP AND MOTOR
5. COUNTERWEIGHT COVER
6. LOAD AXLE
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 capacitors 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.
3
Covers and Floor Plate 0100 YRM 1514

1. Ensure capacitors are discharged by performing
Step 2 through Step 6 below.
2. Turn key or keyless switch to OFF position.
3. Disconnect battery by separating the connectors.
4. Block drive wheels to prevent lift truck from
moving.
5. Make sure the Emergency-Disconnect switch
HAS NOT been activated. If Emergency-
Disconnect switch is activated, rotate switch to
the right until it pops up.
6. Press horn button. Wait 30 seconds to be sure
capacitors are fully discharged.

Covers and Floor Plate

Various covers and floor plates provide access to
components during service and securely cover areas
during normal operation. Covers in the floor of the op-
erator compartment allow access to the hydraulic
tank, hydraulic pump and motor assembly, and Vehi-
cle Systems Manager (VSM). A cover on top of the
counterweight provides access to the traction motor
and motor controllers.

See Figure 4 for lift trucks manufactured before Janu-

ary, 2013.

See Figure 5 for lift trucks manufactured after Janu-

ary, 2013 and equipped with manual main control
valve.

See Figure 6 for lift trucks manufactured after Janu-

ary, 2013 and equipped with E-Hydraulic main control
valve.

1. FLOOR MAT
2. FLOOR PLATE
3. COUNTERWEIGHT COVER
4. STEERING COLUMN COVER
5. DASH PANEL COVER
6. MANUAL HYDRAULIC CONTROLS COVER
7. PARKING BRAKE COVER
8. RIGHT HOSE COVER
9. STEP PLATE

Figure 4. Floor Plates and Covers, Lift Trucks

Manufactured Before January, 2013

4
0100 YRM 1514 Covers and Floor Plate

1. FLOOR MAT 1. FLOOR MAT

2. FLOOR PLATE 2. FLOOR PLATE
3. COUNTERWEIGHT COVER 3. COUNTERWEIGHT COVER
4. STEERING COLUMN COVER 4. STEERING COLUMN COVER
5. DASH PANEL COVER 5. DASH PANEL COVER
6. MANUAL HYDRAULIC CONTROLS COVER 6. STEP PLATE
7. PARKING BRAKE COVER 7. PARKING BRAKE COVER
8. RIGHT HOSE COVER 8. RIGHT HOSE COVER
9. STEP PLATE
Figure 6. Floor Plates and Covers, Lift Trucks
Figure 5. Floor Plates and Covers, Lift Trucks Manufactured After January, 2013 With E-
Manufactured After January, 2013 With Manual Hydraulic Control Valve
Hydraulic Control Valve

5
Overhead Guard Replacement
Overhead Guard Replacement
WARNING
The overhead guard is part of the operator protec-
tion 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 unob-
structed 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, eyebolts, and crane or lifting device has the
capacity to lift the overhead guard.
1. Remove hood and seat assembly. See Hood and
Seat Assembly.
2. Remove battery. See the Operating Manual or
service manual Periodic Maintenance
8000YRM1526.
3. Remove parking brake and hose covers from
cowl plate. See Figure 7.
4. Remove parking brake from cowl plate. See
Brake System 1800YRM1518.
5. Remove steering column upper cover. See Fig-
ure 7.
NOTE: Tag electrical wiring and hydraulic hoses and
note routing during removal to aid in installation.
6
0100 YRM 1514
6. Tag and disconnect electrical wiring and hydraulic
hoses from steering column and steering control
unit. See Figure 7.
7. Remove four capscrews and nuts from steering
column. See Figure 8.
8. Remove two inserts and two capscrews from
each end of dash panel. See Figure 8.
9. Remove dash panel and steering column from
cowl plate.
10. Access to rear capscrews and nuts is from the
battery compartment. Remove rear capscrews
and nuts from rear overhead guard legs and
plates. See Figure 9.
11. Remove two bolts, washers, and nuts from cowl
plate that connect front legs of overhead guard to
frame. See Figure 9.
NOTE: Note routing of electrical wires prior to discon-
necting.
NOTE: Tag electrical connectors during removal to
aid in installation.
12. Tag and disconnect any electrical wires that go
through legs of overhead guard.
NOTE: When overhead guard is lifted from frame as-
sembly, make sure electrical wires move through
holes in frame at the front and rear so that they are
not damaged.
13. Using a lifting device, remove overhead guard
from frame assembly.
14. Remove capscrews, inserts, and handle from
overhead guard. See Figure 9.
0100 YRM 1514 Overhead Guard Replacement

NOTE: REAR RIGHT OVERHEAD GUARD LEG OMITTED FOR CLARITY.

1. CAPSCREW 6. UPPER STEERING COLUMN COVER

2. PARK BRAKE COVER 7. HOSE COVER
3. CLIP NUT 8. COWL PLATE
4. PARK BRAKE 9. DASH PANEL
5. STEERING HOSES

Figure 7. Overhead Guard Removal

7
Overhead Guard Replacement 0100 YRM 1514

1. CAPSCREW 4. DASH PANEL

2. INSERT 5. GAS SPRING MOUNTING PLATE
3. COWL PLATE

Figure 8. Dash Panel Removal

8
0100 YRM 1514 Hood and Seat Assembly

INSTALL

WARNING
The overhead guard is heavy. Make sure the sling,
chain, eyebolts, and crane or lifting device has the
capacity to lift the overhead guard.

NOTE: Make sure electrical wires are routed as no-

ted during removal to assure that wires do not get
pinched.

1. Using a lifting device, install overhead guard onto

frame assembly.

2. Connect electrical wires, as tagged during re-

moval.

3. Install two bolts, washers, and nuts to cowl plate

and install overhead guard front legs to frame.
See Figure 9.

4. Install rear capscrews and nuts into rear overhead

guard legs and plates. See Figure 9.

5. Place dash panel and steering column onto cowl

plate. Secure dash panel to cowl plate using two
capscrews and inserts. Attach steering column to
cowl plate with four bolts, washers, and nuts. See
Figure 9.

6. Connect steering hoses and electrical connec-

tions as noted during removal.
1. OVERHEAD GUARD 5. HANDLE
2. NUT 6. WASHER 7. Install steering column upper cover.
3. CAPSCREW 7. BOLT
4. INSERT 8. FRAME 8. Install parking brake to cowl plate. See service
manual Brake System 1800YRM1518 for proce-
Figure 9. Overhead Guard Components dures.

9. Install parking brake and hose covers using cap-

screws and clip nuts. Tighten capscrews to 2.55
to 2.75 N•m (23 to 24 lbf in).

10. Install battery. See the Operating Manual or

service manual Periodic Maintenance
8000YRM1526.

11. Install hood and seat assembly. See Hood and

Seat Assembly.

9
Hood and Seat Assembly 0100 YRM 1514

Hood and Seat Assembly

GENERAL
The hood is the platform for the seat assembly and is
located above the battery. It functions as a battery re-
straint that completely covers the battery compart-
ment. See Figure 12. When correctly locked to the
frame, it will hold the battery in the battery compart-
ment if an accident causes the lift truck to tip over.
The hood is a stamped steel cover. Two hinges at the
back attach to overhead guard. A rotor lock latch as-
sembly on the front of hood locks hood closed during
operation. A gas-controlled spring holds hood in open
position.
Opening hood latch assembly unlocks hood from
frame so hood can be raised to access the battery.
See Figure 12. The hood latch assembly must be in
good condition and properly secured before lift truck
can be operated.
If lift truck is equipped with manual hydraulic control
levers, the levers and linkage assembly must be
moved to raise the hood. Pull latch handle under
manual hydraulic cover toward seat, allowing lever
and linkage assembly to drop forward and out of the
way. See Figure 10. If lift truck is equipped with E-Hy-
draulic mini-levers, pull up on the smaller adjustment
handle, located on right side of armrest, and move
armrest all the way back before raising hood. See Fig-
ure 11.
The seat assembly slides on seat rails that are fas-
tened 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. See
Figure 12. Optional seats are available in cloth or vi-
nyl with features such as non-suspension, full suspen-
sion, and limited swivel.
All seats have a seat switch installed in the bottom
cushion that senses operator presence. When opera-
tor is not on 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.
The hood, seat belt, arm rest, 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 in the follow-
ing service manual, Periodic Maintenance
8000YRM1526.

If rotor lock latch assembly does not lock hood in

closed position, the lever and linkage assembly will
not lock into position and lift truck will not operate.

On lift trucks equipped with manual hydraulic control

levers, a large, red push-button switch is mounted on
the levers and linkage assembly. See Figure 10. On
lift trucks equipped with E-Hydraulic mini-levers, the
large, red push-button switch is located on right side
of armrest. See Figure 11. This switch is an emer-
gency battery disconnect switch and it allows operator
to quickly disconnect the battery while seated on lift 1. LATCH HANDLE
2. MANUAL HYDRAULIC LEVER ASSEMBLY
truck in case of an emergency. 3. EMERGENCY BATTERY DISCONNECT
SWITCH

Figure 10. Latch Handle, Manual Hydraulic Control

Levers

10
0100 YRM 1514 Hood and Seat Assembly

Legend for Figure 11

1. EMERGENCY BATTERY DISCONNECT

SWITCH
2. SMALL ADJUSTMENT HANDLE
3. LARGE ADJUSTMENT HANDLE

Figure 11. Armrest Adjustment Handle, E-

Hydraulic Mini-Levers

NOTE: FULL SUSPENSION SEAT SHOWN. ARMREST FOR MANUAL HYDRAULIC CONTROL LEVERS
SHOWN.

1. COUNTERWEIGHT COVER 8. SEAT RAIL

2. HOOD 9. SEAT BELT
3. SEAT SWITCH CONNECTOR 10. ARM REST
4. HOOD HINGE 11. SEAT
5. HOOD LATCH 12. FORWARD/BACKWARD ADJUSTMENT LEVER
6. HOOD LATCH HANDLE 13. WEIGHT ADJUSTMENT KNOB
7. HOOD HANDLE
Figure 12. Hood and Seat Assembly Components

11
Hood and Seat Assembly
To raise hood and seat assembly, perform the follow-
ing:
1. Use tilt memory lever and tilt steering column all
the way up. See Figure 13.
2. Slide seat all the way back.
3. If lift truck is equipped with manual hydraulic con-
trol levers, pull latch handle for manual hydraulic
lever assembly and move manual hydraulic lever
assembly to forward position before raising hood.
See Figure 10.
4. If lift truck is equipped with E-Hydraulic mini-lev-
ers, pull up on the smaller adjustment handle, lo-
cated on right side of armrest, and move armrest
all the way back. See Figure 11.
NOTE: OPTIONAL TELESCOPIC STEERING COL-
UMN SHOWN.
1. TILT POSITION LEVER
2. TILT MEMORY LEVER
3. TELESCOPIC COLUMN LOCKING HANDLE
Figure 13. Steering Column Tilt Memory Lever
12
0100 YRM 1514
NOTE: The hood can be raised from either side of lift
truck. The hood latch handle is spring loaded.
5. To raise the hood, lift hood latch handle upwards
to unlatch hood. See Figure 12. Place hand in
hood handle provided and raise hood to UP posi-
tion.
To close hood, place hand in hood handle and pull
hood down until hood latch clicks. Try to lift hood to
make sure hood is locked down.
REMOVE
1. Disconnect battery connector.
2. Tag and disconnect the electrical connectors to
the emergency battery disconnect switch. See
Electrical System 2200YRM1524 for proce-
dures.
3. Tag and disconnect seat switch. See Figure 12.
Remove seat harness from hood.
NOTE: The seat assembly does not have to be re-
moved from hood for hood to be removed from lift
truck. Perform Step 4 if removing seat assembly.
4. To remove seat assembly, disconnect electrical
connectors if not already done. See Step 2 and
Step 3. Remove four screws, washers, spacers if
required, and seat assembly from hood.
5. Raise hood.
6. Remove gas spring:
a. Remove two clips and pins from gas spring.
See Figure 14.
b. Slide gas spring off mounting plates and re-
move from lift truck. See Figure 8 and Fig-
ure 14.
7. Lower the hood.
8. Remove two capscrews, standoffs, and tow pin
from counterweight cover and remove cover from
counterweight. See Figure 15.
9. Remove two capscrews, spacers, and washers
from hood hinges and hood mounting plates. See
Figure 15.
10. Release hood latch and lift hood off of lift truck.
0100 YRM 1514 Hood and Seat Assembly

11. If hood latch needs to be removed, remove four

capscrews from hood latch assembly and remove
hood latch assembly from mounting plate and
front bulkhead. See Figure 16.

NOTE: SOME COMPONENTS OF HOOD RE-

MOVED FOR CLARITY.

1. PIN
2. CLIP
3. GAS SPRING
4. HOOD
5. GAS SPRING MOUNTING PLATE

Figure 14. Remove Gas Spring

1. OVERHEAD GUARD
2. HOOD MOUNTING PLATE
3. HOOD
4. HOOD HINGE
5. WASHER
6. SPACER
7. CAPSCREW
8. STANDOFF
9. COUNTERWEIGHT COVER

Figure 15. Hood Removal

13
Hood and Seat Assembly
NOTE: HOOD OMITTED FOR CLARITY.
1. CAPSCREW
2. HOOD LATCH
3. FRONT BULKHEAD
Figure 16. Hood Latch Assembly
INSTALL
1. If hood latch assembly was removed from hood,
install by doing the following:
a. Place hood latch assembly onto mounting plate
on front bulkhead.
b. Install four capscrews to secure hood latch as-
sembly to mounting plate. See Figure 16.
2. Place hood onto lift truck frame. Be sure holes on
hood hinges line up with holes on mounting plates
on overhead guard.
3. Install two capscrews, spacers, and washers in
hood hinges. See Figure 15. DO NOT tighten
capscrews.
4. Allow hood to engage latch and adjust hood for
adequate latch engagement with hood striker. Ad-
equate engagement is when the latch completely
14
0100 YRM 1514
4. HOOD LATCH HANDLE
5. LATCH STRIKER
6. MOUNTING PLATE
clears the 90 degree bend of the hood striker. Af-
ter adjustment is complete, tighten capscrews to
secure hood to hood mounting plates.
5. Raise hood.
NOTE: When installing gas spring, be sure rod end is
mounted to frame and shell end is mounted to hood.
6. Align gas spring to holes in mounting plates. In-
stall pins and clips and secure gas spring to
mounting plates. See Figure 8 and Figure 14.
7. Reinstall seat, if removed, and route seat harness
through hood and connect to seat.
8. Connect electrical wiring harness to seat switch.
See Figure 12.
9. Close hood. Make certain that latch is properly
engaged.
0100 YRM 1514 Counterweight Replacement

10. Install counterweight cover, capscrews, standoffs

and tow pin onto counterweight. Tighten cap-
screws to 10 N•m (89 lbf in) and standoffs to
30 N•m (266 lbf in).

11. Connect the emergency battery disconnect

switch. See Electrical System 2200YRM1524 for
procedures.

12. If lift truck is equipped with manual hydraulic lev-

ers, move manual hydraulic lever and linkage as-
sembly back to upright position and lock in place.

13. Connect battery connector.

GROUND TEST
NOTE: If the static discharge ground connection is
not secured properly it could lead to possible failure of
traction and/or pump motor controllers.

To ensure proper installation of seat assembly and

associated brackets, perform continuity test as descri-
bed below.

1. Using an ohm meter, place a test lead at the arm-

rest mounting bolt and another at the truck frame.
The resistance needs to read 5 Ohms or less.
See Figure 17.

2. 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.

A. ARMREST FOR LIFT TRUCK MODELS

ERP25VC, ERP30VC (B888)
B. ARMREST FOR LIFT TRUCK MODELS
ERP13VC, ERP15VC (B888)
1. ARMREST BOLT
2. FRAME

Figure 17. Ground Test

15
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