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

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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