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Yale Electric Forklift Truck Type A814: ERC030, ERC040 (AF, AG, BG); ERP/ERC 16AAF, 18AAF, 20AAF Workshop Service Manual

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31.5973 MB ZIP File - Platform: Indy

Original Illustrated Factory Workshop Service Manual for Yale Electric Forklift Truck Type A814.

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:
ERC030AF
ERC030AG
ERC030BG
ERC040AF
ERC040AG
ERC040BG
ERC16AAF
ERC18AAF
ERC20AAF
ERP16AAF
ERP18AAF
ERP20AAF

Language: English
Format: ZIP, Contained Set of PDF Manuals:

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


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