Yale ERC030 AF/AG/BG, ERC040 AF/AG/BG Electric Forklift Truck A814 Series Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Yale Electric Forklift Truck Type A814, Models ERC030AF, ERC030AG, ERC030BG, ERC040AF, ERC040AG, ERC040BG

Original factory manuals for Yale Forklift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate and repair your truck. All Manuals Printable and contains Searchable Text

Covered models
   USA:
      ERC030AF
      ERC030AG
      ERC030BG
      ERC040AF
      ERC040AG
      ERC040BG
   Europe:
      ERC16AAF
      ERP16AAF
      ERC20AAF
      ERP20AAF

Language: English
Format: ZIP, Contained Set of PDF Manuals
Contents:
BRAKE SYSTEM.pdf; 32 pages
    General
    Description and Operation
    Service Brakes
    Master Cylinder
    Parking Brake
    Service Brakes Repair
    Remove and Disassemble
    Clean
    Inspect
    Assemble and Install
    Master Cylinder Repair
    Remove
    Disassemble
    Clean and Inspect
    Assemble
    Install
    Parking Brake Repair
    Remove and Dissemble
    Assemble and Install
    Parking Brake Switch Replacement
    Brake System Air Removal
    Service Brakes Adjustment
    Brake Pedal Adjustment
    Master Cylinder Adjustment
    Parking Brake Adjustment
    Parking Brake Switch Adjustment
    Parking Brake Not Applied Switch Test
    Seat Brake Assembly
    Seat Brake, Adjust
    Brake Switch, Adjust
    Torque Specifications
    Troubleshooting .
CAPACITIES AND SPECIFICATIONS.pdf; 24 pages
    Wheels and Tires
    Counterweights
    Hydraulic System
    Capacities
    Battery Specifications
    Battery Height Specifications (Hoods and Battery Types)
    Maximum Carriage and Tilt Creep Rates
    Mast Speeds
    ERC030AF, AG/BG-ERC040AF, AG/BG Mast Speeds (36 and 48 Volt) Americas
    ERC/P16-20AAF Mast Speeds (48 Volt) Europe
    ERC030AF, AG/BG-ERC040AF, AG/BG Mast Speeds Americas
    ERC/P16-20AAF Mast Speeds Europe
    Torque Specifications
    Frame
    Mast
    Drive Axle, Speed Reducer, and Differential
    Steering Axle
    Brake
    Adhesives and Sealants .
DC MOTOR MAINTENANCE.pdf; 30 pages
    General
    Brush and Commutator Inspection
    Hydraulic Pump Motor and Traction Motor
    Steering Pump Motor
    Normal Commutator Surface
    Commutator Problems
    Brush Replacement
    Stoning the Commutator
    Motors Repair
    Disassemble
    Traction Motor and Hydraulic Pump Motor
    Steering Pump Motor
    Assemble
    Traction Motor and Hydraulic Pump Motor
    Steering Pump Motor
    Brush Alignment, Traction and Hydraulic Motors
    Tests for Damaged Field and Armature
    Test for an Open Circuit in Armature
    Test for Short Circuit in One Armature Winding
    Test for Short Circuit to Armature Shaft
    Test for Open Circuit in Field Coil
    Test for Short Circuit in Field Coil
    Test for Short Circuit between Field and Motor Case
    Brush Holder Test
    Troubleshooting .
DISPLAY PANEL FOR SEM CONTROLS.pdf; 50 Pages
    General
    SEM Display Panel Features
    Descriptions of Common Features
    LED Symbol Indicators
    LCD Screen
    Battery Discharge Indicator (BDI)
    Service Reminder
    Status Codes
    Hourmeter
    Additional Features of Premium Display Panel
    Descriptions of Additional Features (Available With Premium Display)
    LCD Screen
    Operator Passwords
    Daily Check List and Service Items
    Performance Modes
    Status Code Lists
    Adjustment of BDI
    SEM Display Panel Indicators
    All Indicator Symbols
    Hourmeter Indicator Symbol
    Wrench Indicator Symbol
    Battery Indicator Symbol
    Battery State-of-Charge (BDI)
    Brake Fluid Too Low Symbol
    Parking Brake Symbol
    Fasten Seat Belt Symbol
    LCD Screen (Standard Display Panel)
    Additional Components of Premium Display Panel
    Alphanumeric Screen
    STAR Push Button
    Push Buttons 1 Through 5
    Adjustments With a Computer
    Computer System
    Connect PC to SEM Display Panel
    ITW Switches Windows Software Program (for SEM Display Panel)
    Description
    Getting Help
    Hardware and Software Requirements
    Install
    How to Start ITW SWITCHES Program
    Menus
    Sample Sessions
    Replacement
    SEM Display Panel
    Remove and Replace .
DRIVE AXLE, SPEED REDUCER AND DIFFERENTIAL.pdf; 24 Pages
    General
    Description
    Drive Unit Assembly Repair
    Remove Complete Drive Unit Assembly as a Unit
    Traction Motor, Remove
    Drive Unit and Speed Reducer, Remove
    Drive Axle, Disassemble
    Differential and Speed Reducer, Disassemble
    Clean
    Inspect
    Assembly of Drive Unit
    Find Correct Shim Set for Hypoid Gear
    Pinion, Assemble and Install
    Differential and Ring Gear, Assemble and Install
    Ring and Pinion Tooth Contact Adjustment
    Correct Tooth Contact
    Incorrect Tooth Contact
    Input Gear for Speed Reducer, Assemble
    Drive Axle and Hub Assembly, Assemble
    Installation of Drive Unit
    Drive Unit, Install
    Traction Motor, Install
    Torque Specifications
    Troubleshooting .
ELECTRICAL DIAGRAMS EV-100ZX.pdf; 50 pages
    Diagrams, Schematics, or Arrangements
    Figure 1. EV-100ZX SCR Control for Traction Motor Schematic Diagram
    Figure 2. EV-100ZX SCR Control for Lift Pump Motor Schematic Diagram
    Figure 3. Contactor Control for Lift Pump Motor Schematic Diagram
    Figure 4. Wiring Diagram
    Figure 5. Wiring Diagram
    Figure 6. Wiring Diagram
    Figure 7. Controller Panel-to-Panel Table of Wiring Connections
    Figure 8. Truck Wiring
    Figure 9. Truck Power Cables, North America Only
    Figure 10. Truck Power Cables, Europe Only
    Figure 11. EV-100ZX SCR Panel Wiring of Traction and Pump Motor Controllers
    Figure 12. EV-100ZX SCR Traction Motor Controller and Contactor Pump Control
    Figure 13. EV-100ZX SCR Panel Wiring of Traction Motor Controller and Contactor Pump Control
    Figure 14. EV-100ZX SCR Traction Motor and SCR Pump Motor Controllers
    Figure 15. EV-100ZX SCR Traction Motor Controller with Contactor Control of Pump Motor
    Figure 16. EV-100ZX SCR Traction Motor Controller with Contactor Control of Pump Motor
    Figure 17. EV-100ZX Contactor Panel
    Figure 18. Hydraulic Linkage Switch and Chassis Wiring Details
    Figure 19. Steering Column Wiring Detail
    Figure 20. Optional Basic Display Panel and Plug Connectors
    Figure 21. Standard Display Panel and Plug Connections
    Figure 22. Premium Display Panel and Plug Connector
    Figure 23. Lighting Schematic Diagram
    Figure 24. Lighting Wiring Diagram
    Figure 25. Detail of Battery Connector With +12-Volt Tap, Anderson SBE or SBX Connector .
ELECTRICAL DIAGRAMS SR-SP TRANSISTOR MOTOR CONTROLLERS (SEM).pdf; 56 pages
    Diagrams, Schematics, or Arrangements
    Figure 1. SR (SEM) Motor Controller for Traction Motor ERC/P16-20AAF (ERC030-040AG/BG), ERC20-30AGF (ERC040-065RG/ZG) Schematic Diagram
    Figure 2. SP Motor Controller for Pump Motor ERC/P16-20AAF (ERC030-040AG/BG), ERC20-30AGF (ERC040-065RG/ZG) Schematic Diagram
    Figure 3. Contactor Control for Pump Motor ERC/P16-20AAF (ERC030-040AG/BG), ERC20-30AGF (ERC040-065RG/ZG) Schematic Diagram
    Figure 4. Common Components ERC/P16-20AAF (ERC030-040AG/BG), ERC20-30AGF (ERC040-065RG/ZG) (SEM) Wiring Diagram
    Figure 5. SR (SEM) and SP Motor Controllers ERC/P16-20AAF (ERC030-040AG/BG), ERC20-30AGF (ERC040-065RG/ZG) Wiring Diagram
    Figure 6. SR (SRM) Motor Controller and Contactor Control for Pump Motor ERC/P16-20AAF (ERC030-040AG/BG), ERC20-30AGF (ERC040-065RG/ZG) Wiring Diagram
    Figure 7. Electrical Wiring Connectors ERC/P16-20AAF (ERC030-040AG/BG), ERC20-30AGF (ERC040-065RG/ZG)
    Figure 8. SR (SEM) Motor Controller for Traction Motor ERP20-30ALF Schematic Diagram
    Figure 9. SP Motor Controller for Pump Motor ERP20-30ALF Schematic Diagram
    Figure 10. Contactor Control for Pump Motor ERP20-30ALF Schematic Diagram
    Figure 11. Common Components ERP20-30ALF Wiring Diagram
    Figure 12. SR (SEM) and SP Motor Controllers ERP20-30ALF Wiring Diagram
    Figure 13. SR (SEM) Motor Controller and Contactor Control for Pump Motor ERP20-30ALF Wiring Diagram
    Figure 14. Electrical Wiring Connectors ERP20-30ALF
    Figure 15. Steering Column Wiring Detail ERC/P16-20AAF (ERC030-040AG/BG)
    Figure 16. Hydraulic Linkage Switch and Chassis Wiring Details ERC/P16-20AAF (ERC030-040AG/BG)
    Figure 17. Truck Wiring ERC/P16-20AAF (ERC030-040AG/BG)
    Figure 18. Truck Power Cables ERC/P16-20AAF (ERC030-040AG/BG)
    Figure 19. Steering Column Wiring Detail ERC20-30AGF (ERC040-065RG/ZG), and ERP20-30ALF
    Figure 20. Hydraulic Linkage Switch and Chassis Wiring Details ERC20-30AGF (ERC040-065RG/ZG), and ERP20-30ALF
    Figure 21. Truck Wiring ERC20-30AGF (ERC040-065RG/ZG), and ERP20-30ALF
    Figure 22. Truck Power Cables ERC20-30AGF (ERC040-065RG/ZG), and ERP20-30ALF
    Figure 23. Panel Wiring With SR (SEM) and SP Motor Controllers
    Figure 24. Panel Wiring With SR (SEM) Motor Controller and Contactor Pump Control
    Figure 25. SR (SEM) and SP Motor Controllers
    Figure 26. SR (SEM) Motor Controller and Contactor Control of Pump Motor
    Figure 27. SEM Display Panels
    Figure 28. SEM Display Panel Connections and Mounting (Standard Display Panel Shown)
    Figure 29. Lighting Schematic Diagram ERC/P16-20AAF (ERC030-040AG/BG), ERC20-30AGF (ERC040-065RG/ZG), AND ERP20-30ALF
    Figure 30. Light Wiring Diagram ERC/P16-20AAF (ERC030-040AG/BG)
    Figure 31. Light Wiring Diagram ERC20-30AGF (ERC040-065RG/ZG)
ELECTRICAL SYSTEM.pdf; 66 pages
    General
    Description
    ZX Series Display Panels
    Optional Basic Display Panel
    Features of the Optional Basic Display Panel
    Description of Features on the Optional Basic Display Panel
    Standard Display Panel
    Features of the Standard Display Panel
    Description of Features on the Standard Display Panel
    Premium Display Panel
    Features on the Premium Display Panel
    Description of Features on the Premium Display Panel
    Curtis 1215 Display Panel
    Description and Features
    Operation
    SEM Display Panels - Features
    Descriptions of Common Features
    LED Symbol Indicators - SEM
    LCD Screen
    Battery Discharge Indicator (BDI)
    Service Reminder
    Status Codes
    Hourmeter
    Additional Features of Premium Display Panel
    Descriptions of Additional Features
    LCD Screen
    Operator Passwords
    Daily Checklist and Service Items
    Performance Modes
    Status Code Lists
    Adjustment of BDI
    SEM Display Panel Indicators
    All Indicator Symbols
    Hourmeter Indicator Symbol
    Wrench Symbol
    Battery Symbol
    Battery Discharge Indicator (BDI)
    Brake Fluid Too Low Symbol
    Parking Brake Symbol
    Fasten Seat Belt Symbol
    LCD Screen (Standard Display Panel)
    Additional Components of Premium Display Panel
    Alpha Numerical Screen
    STAR Push Button
    Push Buttons #1 Through #5 - SEM
    Other Control Components
    Display Panel Components - ZX, and Curtis Replacement
    ZX Panel Replacement
    Curtis 1215 Display Panel Replacement
    Remove
    Install .
    SEM Display Panel Replacement
    Motor Controller (SR or SP) Replacement
    Control Components Replacement
    Start Switch, Replace
    Brake Light Switch, Replace
    Seat Switch, Replace
    External Seat Switch, Adjust
    Switch for Optional Seat Brake, Replace
    Parking Brake Switch, Replace
    Direction Switches (Foot Directional Control Pedal), Replace
    Direction Control Switches (Steering Column), Replace
    Direction Control Switches, ERC070-120HG (Steering Column), Replace
    Brake Fluid Switch, Replace
    Brush Wear and Overtemperature Sensors
    Rocker Switches for Lights
    Accelerator Position Sensor, Replace
    On-Demand Steering Components
    Lights, Converter, Relay, and Reverse Alarm
    Brake, Tail, and Reverse Light Assembly, Replace
    Flashing Light Assembly, Replace
    Front, Rear Driving Light, or Spot Light Assemblies, Replace
    Operator Compartment Light Assembly, Replace
    Converter, Replace
    Relay, Replace
    Reverse Alarm, Replace
    Horn and Horn Button
    Horn Switch and Cover
    Hydraulic Pump Switches
    Control and Power Fuses Check
    ZX Motor Controllers
    SEM Motor Controllers
    Brush Wear and Overtemperature Sensors Check - ZX Motor Controllers
    Thermal Sensors - SEM Motor Controllers Check
    Start Switch Adjustment
    Accelerator Potentiometer and Start Switch, ERC070-120HG Lift Trucks
    ERC070-120HG
    Direction Switches Foot Directional Control Pedal
    Brake Light Switch Adjustment
    Seat Switch Check
    Optional Seat Brake Switch Adjustment
    Parking Brake Switch Adjustment
    Direction Switches Check
    Foot Directional Control Pedal
    Steering Column
    Hydraulic Pump Switch Adjustment
    Foot Directional Control or Accelerator Pedal Adjustment
    Accelerator Position Sensor Adjustment .
EV-100ZX SCR MOTOR CONTROLLER 2.pdf; 34 pages
    Register Parameters
    General
    Function Numbers
    Control Card Checks and Adjustments
    Register Parameter Tables .
EV-100ZX SCR MOTOR CONTROLLER.pdf; 126 pages
    General
    Model Number Data For EV-100ZX Controller
    Register Parameters
    General
    Function Numbers
    Control Card, Checks and Adjustments
    Handset
    How to Check and Adjust Registers
    How to Scroll through Fault Codes and Clear Them
    Checks and Adjustments on Workbench
    When Handset Is Connected to Control Card Installed In Lift Truck
    Function Numbers 1 through 15
    Function Numbers 16 through 30
    Function Numbers 48 through 62
    Control Cards
    Function Number Descriptions
    Traction Control Cards (Label Letters - ZH and ZY)
    Function Number 1 STORED STATUS CODE
    Function Number 2 CREEP SPEED
    Function Number 3 CONTROLLED ACCELERATION AND 1A TIME
    Function Number 4 CURRENT LIMIT
    Function Number 5 PLUGGING DISTANCE (CURRENT)
    Function Number 6 1A DROP OUT CURRENT
    Function Number 7 FIELD WEAKENING PICK UP
    Function Number 8 FIELD WEAKENING DROP OUT
    Function Number 9 REGENERATIVE BRAKING CURRENT LIMIT
    Function Number 10 REGENERATIVE BRAKING START
    Function Number 13 SPEED LIMIT 3 (SL3)
    Function Number 14 INTERNAL RESISTANCE COMPENSATION
    Function Number 15 BATTERY VOLTS
    Function Numbers GREATER THAN 15
    Function Number 16 PEDAL POSITION PLUG
    Function Number 17 CARD TYPE SELECTION
    Function Number 18 STEERING PUMP TIME DELAY
    Function Number 19 MAINTENANCE ALERT (Tens/Units)
    Function Number 20 MAINTENANCE ALERT (Thousands/Hundreds)
    Function Number 21 MAINTENANCE SPEED LIMIT
    Function Numbers 22 Through 28 TEMPORARY DATA REGISTERS
    Function Number 29 HOURMETER (Tens/Units)
    Function Number 30 HOURMETER (Thousands/Hundreds)
    Function Number 48 Through 62 SET LIFT TRUCK PERFORMANCE
    Function Number 48 CONTROLLED ACCELERATION AND 1A TIME
    Function Number 49 FIELD WEAKENING PICK UP
    Function Number 50 SPEED LIMIT 1
    Function Number 52 CONTROLLED ACCELERATION AND 1A TIME
    Function Number 53 FIELD WEAKENING PICK UP
    Function Number 54 SPEED LIMIT 1
    Function Number 56 CONTROLLED ACCELERATION AND 1A TIME
    Function Number 57 FIELD WEAKENING PICK UP
    Function Number 58 SPEED LIMIT 1
    Function Number 60 CONTROLLED ACCELERATION AND 1A TIME.
    Function Number 61 FIELD WEAKENING PICK UP
    Pump Control Card (Label Letter ZP)
    Function Number 1 STORED STATUS CODE
    Function Number 2 INTERNAL RESISTANCE COMPENSATION START
    Function Number 3 CONTROLLED ACCELERATION
    Function Number 4 CURRENT LIMIT
    Function Number 7 CONTROLLED ACCELERATION COMPENSATION
    Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and Slow Auxiliary (Auxiliary and
    Slow Rotate for N30XMH)
    Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lift and Medium Auxiliary
    (Slow Lift And Fast Rotate for N30XMH)
    Function Number 13 SPEED LIMIT 3 (SL3)
    Function Number 14 SPEED LIMIT 4 (SL4) Fast Lift
    Function Numbers Greater Than 15
    Function Number 16 INTERNAL RESISTANCE COMPENSATION
    Function Number 17 CARD TYPE SELECTION
    Function Numbers 18 through 28 TEMPORARY DATA REGISTERS
    Function Number 29 HOURMETER (Tens/Units)
    Function Number 30 HOURMETER (Thousands/Hundreds)
    Function Number 48 CONTROLLED ACCELERATION
    Function Number 49 SPEED LIMIT 2
    Function Number 50 SPEED LIMIT 3
    Function Number 52 CONTROLLED ACCELERATION
    Function Number 53 SPEED LIMIT 2
    Function Number 54 SPEED LIMIT 3
    Function Number 56 CONTROLLED ACCELERATION
    Function Number 57 SPEED LIMIT 2
    Function Number 58 SPEED LIMIT 3
    Function Number 60 CONTROLLED ACCELERATION
    Function Number 61 SPEED LIMIT 2
    Function Number 62 SPEED LIMIT 3
    Register Parameters
    Troubleshooting
    General
    Status Codes
    Register Maps
    Status Code Charts
    V-100ZX SCR Motor Controller Repair
    Fuses
    SCR, Check
    SCR Assembly
    Thermal Protector
    SCR 1 Assembly, Replace
    OFF Circuit for SCR 1
    Reactor Assembly, Check
    Suppressors for SCR 2 and SCR 5, Check
    SCR 2 and SCR 5, Check
    SCR 2 and SCR 5, Replace
    Capacitor C1, Check
    Diodes D3 and D4
    Diodes D3 and D4, Check
    Diodes D3 and D4, Replace
    Motor Current Sensor
    Contactors
    Contactor, Repair
    Control Card
    Control Card Plugs
    Brush Wear Indicators
    Theory of Operation
    Electronic Speed Controls
    Silicon Controlled Rectifier (SCR)
    Motor Circuit That Operates With Pulses
    Traction Circuit
    Hydraulic Pump Motor
    SCR 1 OFF Circuit
    SCR 1 OFF Operation
    Induction Current from Motor
    Control Cards
    Pulse Monitor Trip (PMT) (Traction Circuit Only)
    SRO Circuit (Traction Circuit Only)
    Sequence of Operation
    Control Card Adjustments (Traction Circuit)
    Accelerator Control
    SCR Control (Hydraulic Pump Motor)
    Contactors
    Circuit Protection
    Traction Circuit Fuse
    Current Limit
    Thermal Protection
    Suppressors
    Truck Management Module (TMM1)
    Display Panels
    Display Panel
    Optional Basic Display Panel
    Features of the Optional Basic Display Panel
    Description of Features on the Optional Basic Display Panel
    Standard Display Panel
    Features of the Standard Display Panel
    Description of Features on the Standard Display Panel
    Premium Display Panel
    Features on the Premium Display Panel
    Description of Features on the Premium Display Panel
    Curtis 1215 Display Panel
    Description and Features
    Operation .
FOUR STAGE MAST.pdf; 46 Pages
    General
    Description
    Carriages
    Mast Mounts
    Mast
    Description
    Operation
    Forks Repair
    Remove
    Install
    Safety Procedures When Working Near Mast
    Carriage Repair
    Remove
    Standard Carriage
    Sideshift Carriage
    Repairs
    Install
    Standard Carriage
    Sideshift Carriage
    Mast Repair
    Remove
    Disassemble
    Clean and Inspect
    Assemble
    Install
    Lift Cylinders Repair
    Remove
    Main Lift Cylinders
    Free-Lift Cylinders
    Disassemble
    Assemble
    Install
    Main Lift Cylinder
    Free-Lift Cylinder
    Header Hose Arrangements
    Header Hoses, Install
    Lift and Tilt System Leaks Check
    Lift Cylinders Leaks Check
    Tilt Cylinders Leaks Check
    Tilt Cylinders Adjustment
    Lift Chain Adjustments
    Mast Adjustments
    Carriage Adjustments
    Troubleshooting .
FRAME.pdf; 26 Pages
    General
    Description
    Main Frame
    Other Frame Weldments
    Battery Restraint and Hood Frame
    Overhead Guard
    Overhead Guard Repair
    Remove
    Install
    Battery Restraint and Seat Assembly
    Counterweight Repair
    Remove
    Install
    Traction Motor Repair
    Remove
    Install
    Hydraulic Tank Repair
    Inspect
    Small Leaks, Repair
    Large Leaks, Repair
    Clean
    Steam Method
    Chemical Solution Method
    Additional Preparations for Repair
    Painting Instructions
    Safety Label Replacement
    Battery Specifications.
HYDRAULIC SYSTEM.pdf; 44 Pages
    General
    Description .
    Hydraulic System .
    Operation.
    Hydraulic System .
    Hydraulic Gear Pump.
    Steering Pump .
    Hydraulic Tank Repair .
    ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG) Tank,
    Remove .
    ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216) Tank, Remove .
    Inspect.
    Small Leaks, Repair .
    Large Leaks, Repair .
    Clean.
    Steam Method .
    Chemical Solution Method.
    Additional Methods for Tank Repair .
    ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG) Tank,
    Install.
    ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216) Tank, Install.
    Filter Replacement .
    Hydraulic Pump Repair.
    ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG)
    Hydraulic Pump, Remove.
    ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216) Hydraulic Pump, Remove .
    Pump Seal, Replace and Pump, Assemble .
    Assemble Pump on Motor .
    ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG)
    Hydraulic Pump and Motor Assembly, Install .
    ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216) Hydraulic Pump and Motor
    Assembly, Install.
    Main Control Valve Repair .
    Steering Pump Repair .
    Pump, Remove and Disassemble .
    ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216) Pump, Remove and
    Disassemble.
    Pump, Assemble and Install.
    Steering Control Unit Repair .
    Remove .
    Install.
    Steering Cylinder Repair .
    Main Control Valve Check and Adjust .
    Steering Relief Valve Check and Adjust .
    Specifications .
    Relief Valve Pressures*.
    Hydraulic Tank Capacity (dipstick full mark).
    Hydraulic Pump Capacities .
    Troubleshooting .
    Steam Method
INDUSTRIAL BATTERY.pdf; 22 Pages
    General
    Lead-Acid Batteries
    Specific Gravity
    Chemical Reaction in a Cell
    Electrical Terms
    Battery Selection
    Battery Voltage
    Battery as a Counterweight
    Battery Ratings
    Kilowatt-Hours
    Battery Maintenance
    Safety Procedures
    Maintenance Records
    New Battery
    Cleaning Battery
    Adding Water to Battery
    Hydrometer
    Battery Temperature
    Charging Battery
    Types of Battery Charges
    Methods of Charging
    Troubleshooting Charger
    Knowing When Battery Is Fully Charged
    Where to Charge Batteries
    Equipment Needed
    Battery Connectors
    Battery Care.
INSTRUMENT CLUSTER.pdf; 30 Pages
    General
    Description
    Instrument Cluster Display Panel, Internal Combustion Lift Truck Models
    Instrument Cluster Display Panel, Electric Lift Truck Models
    Optional Basic Display Panel
    Features of the Optional Basic Display Panel
    Description of Features on the Optional Basic Display Panel
    Standard Display Panel
    Features of the Standard Display Panel
    Description of Features on the Standard Display Panel
    Premium Display Panel
    Features on the Premium Display Panel
    Description of Features on the Premium Display Panel
    Curtis 1215 Display Panel
    Description and Features
    Operation
    Cluster-Type Display Panel (Internal Combustion) Replacement
    Remove
    Install
    Cluster Display Panel (Electric Lift Truck) Replacement
    Curtis 1215 Display Panel Replacement
    Remove
    Install.
MAIN CONTROL VALVE.pdf; 26 pages
    General
    Description
    Operation
    ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG)
    ERP20-30ALF and ERP20-30ALF (ERP040-060DH)
    Lift Section
    Tilt Section
    Tilt Backward
    Tilt Forward
    Relief Valve
    Main Control Valve Repair
    Remove
    Disassemble
    Clean and Inspect
    Assemble
    Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG)]
    Install [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216)]
    Control Lever Linkage Repair
    Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG)]
    Disassemble [ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG)]
    Assemble and Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG)]
    Control Valve Linkage Repair
    Remove and Disassemble [ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG)]
    Assemble and Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) and ERC20-30AGF (ERC040-065RF/ZF, RG/ZG)]
    Control Lever Linkage Repair
    Remove [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216)]
    Disassemble [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216)]
    Assemble and Install [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) (D216)]
    Pressure Relief Valve Check and Adjustment
    Primary Relief Valve
    Secondary Relief Valve
MAST REPAIR.pdf; 86 Pages
    General
    Safety Procedures When Working Near Mast
    Forks Repair
    Remove
    Install
    Carriages Repair
    Standard Carriage, Remove
    Hang-On Sideshift Carriage, Remove
    Standard Carriage and Hang-On Sideshift Carriage, Repair
    Standard Carriage, Install
    Hang-On Sideshift Carriage, Install
    Integral Sideshift Carriage
    Remove
    Clean and Inspect
    Repair
    Install
    Mast Repair
    Remove
    Two-Stage LFL and Two-Stage FFL Masts, Disassemble
    Three-Stage FFL Mast
    Disassemble
    Mast and Chains, Clean and Inspect
    Two-Stage LFL and Two-Stage FFL Mast, Assemble
    Three-Stage FFL Mast, Assemble
    Install
    Lift Cylinders Repair
    Main Lift Cylinders, Remove
    Free-Lift Cylinder, Remove
    Lift Cylinders, Disassemble
    Lift Cylinders, Assemble
    Main Lift Cylinders, Install
    Free-Lift Cylinder, Install
    Header Hose Arrangements
    Two-Stage LFL Mast, New Hose Install
    Two-Stage LFL Mast, Adjust Hoses After Installation
    Two-Stage FFL Mast, New Hose Install
    Two-Stage FFL Mast, Adjust Hoses After Installation
    Three-Stage FFL Mast, New Hose Install
    Three-Stage FFL Mast, Adjust Hoses After Installation
    Header Hose Arrangement
    Two-Stage LFL Mast, New Hose Install
    Two-Stage LFL Mast, Adjust Hoses After Installation
    Two-Stage FFL Mast, New Hose Install
    Two-Stage FFL Mast, Adjust Hoses After Installation
    Three-Stage FFL Mast, New Hose Install
    Three-Stage FFL Mast, Adjust Hoses After Install
    Lift and Tilt System Leak Check
    Lift Cylinders Leak Check
    Tilt Cylinders Leak Check
    Tilt Cylinders Adjustment
    Lift Chains Adjustment.
MAST.pdf; 18 Pages
    General
    Description and Operation
    Carriages
    Mast Mounts
    Two-Stage Mast, Limited Free-Lift (LFL)
    Description and Operation
    Two-Stage Mast, Full Free-Lift (FFL)
    Description and Operation
    Three-Stage Mast, Full Free-Lift (FFL)
    Description and Operation
    Cylinder Cushion During Lifting Sequence
    Cylinder Cushion During Lowering Sequence.
PERIODIC MAINTENANCE.pdf; 74 Pages
    General
    Serial Number Data
    How to Move Disabled Lift Truck
    How to Tow Lift Truck
    How to Put Lift Truck on Blocks
    How to Raise Drive Tires
    How to Raise Steering Tires
    Maintenance Schedule
    Maintenance Procedures Every 8 Hours or Daily
    How to Make Checks With Key OFF
    Tires and Wheels
    Forks
    Adjust
    Remove
    Install
    Forks, Mast, and Lift Chains, Inspect
    Safety Labels
    Steering Column Latch
    Operator Restraint System
    Battery Restraint System ERC/P16-20AAF (ERC030-040AF - AG/BG), ERC20-30AGF
    (ERC040-065RF/ZF - RG/ZG) Lift Truck Models
    Battery Restraint System ERP20-30ALF
    Battery
    Hydraulic System
    How to Make Checks With Key ON
    Gauges, Horn, and Fuses
    Steering System
    Service Brakes
    Parking Brake
    Control Levers and Pedals
    Direction and Speed Control Pedals
    Lift System Operation
    Maintenance Procedures Every 250 Hours or 6 Weeks
    Steering Tie Rods
    Maintenance Procedures Every 500 Hours or 3 Months
    Hydraulic Tank Breather
    Differential and Speed Reducer
    Wheel Nut Torques
    Steering Axle Spindles
    Steering Tie Rods
    Mast
    Lift Chains
    Wear Check
    Forks
    Brake Fluid
    Other Lubrication
    Seat Brake, ERC/P16-20AAF (ERC030-040AF - AG/BG), ERC20-30AGF (ERC040-065RF/ZF -
    RG/ZG) Only
    Electrical Inspection
    Contactors
    Motor Brushes
    Motor Brushes, General
    Maintenance Procedures Every 1000 Hours or 6 Months
    Lift Chains
    Forks
    Check Upper and Lower Bearings, Integral Sideshift Carriage
    Maintenance Procedures Every 2000 Hours or Yearly
    Hydraulic System
    Change Filter for Hydraulic Oil
    Change Hydraulic Oil
    Differential and Speed Reducer
    Service Brakes
    Contactors
    Wheel Bearings
    Steer Wheels, Lubrication
    Drive Wheels, Lubrication
    Lift Chains
    Replace Upper and Lower Bearings, Integral Sideshift Carriage
    Steering Axle
    King Pins and Rod Ends (Steering Cylinders)
    Other Lubrication
    Battery Maintenance
    How to Charge Battery
    How to Change Battery
    General
    Change Battery, ERC/P16-20AAF (ERC030-040AF - AG/BG) and ERC20-30AGF (ERC040-065RF/ZF - RG/ZG) Models Only
    Change ERP20-30ALF Battery
    Lift and Tilt System Leak Check
    Lift Cylinders Leak Check
    Tilt Cylinders Leak Check
    Safety Procedures When Working Near Mast
    Lift Chain Adjustments
    PMT Circuit Check
    Welding Repairs
    Overhead Guard Changes
    Wheels and Tire Maintenance
    Tires and Wheels, ERC/P16-20AAF (ERC030-040AF - AG/BG), ERC20-30AGF (ERC040-065RF/ZF - RG/ZG)
    Remove Wheels From Lift Truck
    Remove and Install Tire on Wheel
    Pneumatic Tires and Wheels ERP20-30ALF
    Remove Wheels From Lift Truck
    Remove Wheel From Pneumatic Tire
    Install Wheel in Pneumatic Tire
    Install Three- or Four-Piece Wheel in Pneumatic Tire
    Add Air to Tires
    Wheels, Install
    Solid Rubber Tires on Pneumatic Wheels
    Remove Wheels From Lift Truck
    Remove Solid Rubber Tire From Pneumatic Wheel
    Install Solid Rubber Tire on Pneumatic Wheel
SR-SP TRANSISTOR MORTOR CONTROLLERS.pdf; 94 Pages
    Description
    General
    Model Number Data for SR/SP Transistor Motor Controllers
    Motor Controller Checks and Adjustments
    Checks and Adjustments Using Handset
    General
    Connect Handset
    Start Sequence
    Check or Delete Stored Status Codes
    Returning Lift Truck to Normal Operation
    Workbench Checks and Adjustments
    How to Check and Adjust Registers
    Function Parameters Adjustments
    General
    Function Numbers
    When Handset is Connected to Motor Controller in Lift Truck
    Function Numbers 1 through 15
    Function Numbers 16 through 30
    Function Numbers 48 through 63
    Function Number Descriptions
    Traction Motor Controller (Label Letter - SR)
    Function Number 01 AUTO REGEN ENABLE SPEED
    Function Number 02 CREEP SPEED
    Function Number 03 CONTROLLED ACCELERATION
    Function Number 04 ARMATURE CURRENT LIMIT
    Function Number 05 REGEN RAMP RATE
    Function Number 06 FIELD WEAKENING (FW) RATIO
    Function Number 07 MINIMUM FIELD CURRENT
    Function Number 08 MAXIMUM FIELD CURRENT
    Function Number 09 REGENERATIVE BRAKING CURRENT LIMIT (C/L)
    Function Number 10 FIELD CURRENT FOR REGENERATIVE BRAKING
    Function Number 12 MAXIMUM ARMATURE % ON TIME (Travel Speed Limit)
    Function Number 13 SPEED LIMIT 3
    Function Number 14 INTERNAL RESISTANCE COMPENSATION
    Function Number 15 BATTERY VOLTAGE SELECTION
    Function Number 16 STALL TRIP POINT % ON TIME
    Function Number 17 CONTROL TYPE SELECTION
    Function Number 18 STEERING PUMP TIME DELAY
    Function Number 19 MAINTENANCE CODE TENS AND UNITS
    Function Number 20 MAINTENANCE CODE THOUSANDS AND HUNDREDS
    Function Number 21 AUTO REGEN BRAKING CURRENT LIMIT
    Function Number 23 FOR SPECIAL FUNCTIONS
    Function Number 24 FIELD WEAKENING START
    Function Number 25 MONITOR
    Function Number 26 BASE RATIO
    Function Number 28 STORED STATUS CODE COUNT POINTER
    Functions with Premium Display Panel Only
    Function Number 48 MODE 1 - CONTROLLED ACCELERATION
    Function Number 49 MODE 1 FIELD WEAKENING (FW) START
    Function Number 50 MODE 1 - FIELD WEAKENING (FW) RATIO
    Function 51 MODE 1 - MAXIMUM ARMATURE % ON TIME (MODE 1 - TRAVEL SPEED LIMIT)
    Function 52 MODE 2 - CONTROLLED ACCELERATION
    Function Number 53 MODE 2 - FIELD WEAKENING (FW) START
    Function Number 54 MODE 2 - FIELD WEAKENING (FW) RATIO
    Function Number 55 MODE 2 - MAXIMUM ARMATURE % ON TIME (MODE 2 - TRAVEL SPEED LIMIT)
    Function Number 56 MODE 3 - CONTROLLED ACCELERATION
    Function Number 57 MODE 3 - FIELD WEAKENING (FW) START
    Function Number 58 MODE 3 - FIELD WEAKENING (FW) RATIO
    Function Number 59 MODE 3 - MAXIMUM ARMATURE % ON TIME (MODE 3 - TRAVEL SPEED LIMIT)
    Function Number 60 MODE 4 - CONTROLLED ACCELERATION
    Function Number 61 MODE 4 - FIELD WEAKENING (FW) START
    Function Number 62 MODE 4 - FIELD WEAKENING (FW) RATIO
    Function Number 63 MODE 4 - MAXIMUM ARMATURE % ON TIME (MODE 4 - TRAVEL SPEED LIMIT)
    Pump Motor Controller (Label Letter - SP)
    Function Number 01 STORED STATUS CODE
    Function Number 02 INTERNAL RESISTANCE COMPENSATION START
    Function Number 03 CONTROLLED ACCELERATION
    Function Number 04 CURRENT LIMIT
    Function Number 07 INTERNAL RESISTANCE COMPENSATION RATE
    Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) - Tilt and Slow Auxiliary
    Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) - Slow Lift and Medium Auxiliary
    Function Number 13 SPEED LIMIT 3 (SL3) Fast Lift
    Function Number 16 SPEED/TORQUE COMPENSATION
    Function Number 17 CONTROL TYPE SELECTION
    Function Numbers 18 through 27 TEMPORARY DATA REGISTERS
    Function Number 28 STORED STATUS CODE COUNT POINTER
    Functions with Premium Display Panel Only
    Function Number 48 MODE 1 - CONTROLLED ACCELERATION
    Function Number 49 MODE 1 - SPEED LIMIT 2
    Function Number 50 MODE 1 - SPEED LIMIT 3
    Function Number 52 MODE 2 - CONTROLLED ACCELERATION
    Function Number 53 MODE 2 - SPEED LIMIT 2
    Function Number 54 MODE 2 - SPEED LIMIT 3
    Function Number 56 MODE 3 - CONTROLLED ACCELERATION
    Function Number 57 MODE 3 - SPEED LIMIT 2
    Function Number 58 MODE 3 - SPEED LIMIT 3
    Function Number 60 MODE 4 - CONTROLLED ACCELERATION
    Function Number 61 MODE 4 - SPEED LIMIT 2
    Function Number 62 MODE 4 - SPEED LIMIT 3
    Troubleshooting
    General
    Status Codes
    SR (SEM) and SP Status Code Charts
    SR/SP Transistor Motor Controller Repair
    General
    General Maintenance Instructions
    Special Precautions
    Fuses
    Contactors
    Repair
    Contactor Driver Module
    Contactor Driver, Replace
    Motor Controller Plug
    Brush Wear Indicators
    Thermal Sensors
    Motor Controller, Replace
    Theory of Operation
    General
    SEM System Description
    SEM System Operation (SR Motor Controller)
    Reverse Circuit
    Performance and Efficiency
    Field Weakening
    Regenerative Braking
    SEM System Operation (SP Motor Controller)
    Creep Speed
    Controlled Acceleration
    Current Limit (CL)
    Braking
    Regenerative Braking to Zero Speed
    Pedal Position Braking
    Auto Braking
    Auxiliary Speed Control
    Field Weakening
    Speed Limits
    Ramp Operation
    Ramp Start
    Anti-rollback
    Steer Pump Contactor Time Delay
    Coil Drivers and Internal Coil Suppression
    System Protective Override
    Static Return to Off (SRO)
    Accelerator Volts Hold Off
    Pulse Monitor Trip (PMT)
    Thermal Protector (TP)
    Low Voltage
    SP Pump Motor Controllers
    Contactor Driver Module
    Diagnostics
    Systems Diagnostics
    Standard Status Codes
    Stored Status Codes
    Hourmeter Readings
    Maintenance Management Capability
STEERING AXLE.pdf; 16 Pages
STEERING HOUSING AND CONTROL UNIT 2.pdf
STEERING HOUSING AND CONTROL UNIT.pdf
STEERING SYSTEM.pdf
TILT CYLINDERS.pdf
TRANSISTOR MOTOR CONTROLLERS.pdf
TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER.pdf