Yale Forklift D216 (ERP040-060DH) Service Manual – PDF DOWNLOAD

Yale Forklift D216 (ERP040-060DH) Service Manual – PDF DOWNLOAD

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Yale Forklift D216 (ERP040-060DH) Service Manual – PDF DOWNLOAD

Language : English
Pages : 870
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift D216 (ERP040-060DH) Service Manual – PDF DOWNLOAD

524150790-2100YRM0103-(03-2007)-UK-EN 1
toc 1
Tilt Cylinders 1
Safety Precautions Maintenance and Repair 2
General 5
Description 5
Tilt Cylinder Repair 5
Remove 5
Disassemble 5
Clean 5
Assemble 6
Tilt Cylinders With O-Ring or Single-Lip Seals 6
Tilt Cylinders 7
Install 8
Tilt Cylinder Leak Check 10
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 11
Torque Specifications 11
Piston Rod Nut 11
Retainer 11
Troubleshooting 12
tables 1
Table 1 Movement Rates (Maximum) for Tilt Cylinders 10
524150797-8000YRM0231-(03-2020)-UK-EN 17
General 21
Threaded Fasteners 21
Nomenclature, Threads 21
Strength Identification 22
Cotter (Split) Pins 23
Fastener Torque Tables 28
Conversion Table 30
524158039-0620YRM0294-(09-2016)-UK-EN 37
General 41
Brush and Commutator Inspection 42
Hydraulic Pump Motor and Traction Motor 42
Steering Pump Motor 45
Normal Commutator Surface 45
Commutator Problems 45
Brush Replacement 50
Stoning the Commutator 53
Motors Repair 54
Disassemble 55
Traction Motor and Hydraulic Pump Motor 55
Steering Pump Motor 56
Assemble 60
Traction Motor and Hydraulic Pump Motor 60
Steering Pump Motor 62
Brush Alignment, Traction and Hydraulic Motors 64
Tests for Damaged Field and Armature 65
Test for an Open Circuit in One Armature Winding 65
Test for Short Circuit in One Armature Winding 65
Test for Short Circuit to Armature Shaft 66
Test for Open Circuit in Field Coil 66
Test for Short Circuit in Field Coil 67
Test for Short Circuit Between Field and Motor Case 67
Brush Holder Test 67
Troubleshooting 68
524158040-2240YRM0001-(03-2020)-UK-EN 73
General 77
Battery Type 77
Lead-Acid Batteries 77
Lithium-Ion Batteries 78
Specific Gravity 78
Chemical Reaction in a Cell 78
Electrical Terms 80
Battery Selection 80
Battery Voltage 81
Battery as a Counterweight 82
Battery Ratings 82
Kilowatt-Hours 82
Battery Maintenance 82
Safety Procedures 82
Maintenance Records 83
New Battery 83
Cleaning Battery 83
Adding Water to Battery 85
Hydrometer 86
Battery Temperature 87
Charging Battery 88
Types of Battery Charges 88
Methods of Charging 90
Troubleshooting Charger 90
Knowing When Battery Is Fully Charged 91
Where to Charge Batteries 91
Equipment Needed 91
Battery Connectors 92
Battery Care 92
Troubleshooting 94
524158752-1600YRM0316-(08-2006)-UK-EN 99
toc 99
Steering Axle 99
Safety Precautions Maintenance and Repair 100
General 103
Description 103
Steering Axle Assembly Repair 104
Remove 104
Install 104
Wheels and Hubs Repair 105
Remove and Disassemble 105
Clean 105
Assemble and Install 105
Spindles, Bearings, and Tie Rods Repair 107
Remove 107
Install 107
Steering Cylinder Repair 108
Remove and Disassemble 108
Clean and Inspect 109
Assemble and Install 109
Torque Specifications 109
Troubleshooting 110
524158753-1600YRM0720-(11-2006)-UK-EN 115
toc 115
Steering Housing and Control Unit 115
Safety Precautions Maintenance and Repair 116
General 119
Description 119
Operation 120
Steering Wheel and Column Assembly Repair 121
Assembly Components, Remove 121
Steering Control Unit, Disassemble 126
Steering Control Unit, Clean 126
Steering Control Unit, Assemble 126
Assembly Components, Install 128
System Air Removal 130
Troubleshooting 130
524158890-4000YRM0521-(03-2006)-UK-EN 135
toc 135
Mast 135
Safety Precautions Maintenance and Repair 136
General 139
Description and Operation 139
Carriages 139
Mast Mounts 141
Two-Stage Mast, Limited Free-Lift (LFL) 142
Description and Operation 142
Two-Stage Mast, Full Free-Lift (FFL) 144
Description and Operation 144
Three-Stage Mast, Full Free-Lift (FFL) 146
Description and Operation 146
Four-Stage Mast 148
Description and Operation 148
Cylinder Cushion During Lifting Sequence 152
Cylinder Cushion During Lowering Sequence 153
524158891-4000YRM0522-(07-2010)-UK-EN 157
toc 157
Mast 157
Safety Precautions Maintenance and Repair 158
General 161
Safety Procedures When Working Near Mast 162
Fork Repair 164
Remove 164
Install 164
Carriages Repair 166
Standard Carriage, Remove 166
Hang-On Sideshift Carriage, Remove 167
Standard Carriage and Hang-On Sideshift Carriage, Repair 168
Standard Carriage, Install 169
Hang-On Sideshift Carriage, Install 170
Integral Sideshift Carriage 170
Remove 170
Clean and Inspect 174
Repair 175
Install 176
Mast Repair 177
Remove 177
Two-Stage LFL and Two-Stage FFL Masts, Disassemble 179
Three-Stage FFL Mast 187
Disassemble 187
Mast and Chains, Clean and Inspect 190
Two-Stage LFL and Two-Stage FFL Mast, Assemble 191
Three-Stage FFL Mast, Assemble 192
Install 193
Lift Cylinders Repair 195
Main Lift Cylinders, Remove 195
Free-Lift Cylinder, Remove 195
Cylinders, Disassemble 196
Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder 196
Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder 198
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 198
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 199
Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas 200
Clean and Inspect 201
Cylinders, Assemble 201
Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder 201
Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder 202
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 203
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 203
Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas 204
Main Lift Cylinders, Install 205
Free-Lift Cylinder, Install 205
Header Hose Arrangements 206
Two-Stage LFL Mast, New Hose Install 206
Two-Stage LFL Mast, Adjust Hoses After Installation 211
Two-Stage FFL Mast, New Hose Install 211
Two-Stage FFL Mast, Adjust Hoses After Installation 219
Three-Stage FFL Mast, New Hose Install 219
Three-Stage FFL Mast, Adjust Hoses After Installation 230
Header Hose Arrangement 231
Two-Stage LFL Mast, New Hose Install 231
Two-Stage LFL Mast, Adjust Hoses After Installation 236
Two-Stage FFL Mast, New Hose Install 236
Two-Stage FFL Mast, Adjust Hoses After Installation 242
Three-Stage FFL Mast, New Hose Install 242
Three-Stage FFL Mast, Adjust Hoses After Install 251
Lift and Tilt System Leak Check 252
Lift Cylinders Leak Check 252
Tilt Cylinders Leak Check 252
Tilt Cylinders Adjustment 253
Lift Chains Adjustment 255
Mast Adjustment 257
Carriage Adjustment 259
Troubleshooting 260
tables 157
Table 1 Hook-Type Carriage Chain Adjustment 255
Table 2 Pin-Type Carriage Chain Adjustment 256
524179935-0100YRM0582-(07-2005)-UK-EN 263
toc 263
Frame 263
Safety Precautions Maintenance and Repair 264
General 267
Description 267
Main Frame 267
Other Frame Weldments 267
Overhead Guard 270
Battery and Operator Restraint, Hood, and Seat Assembly 275
Battery Restraint 275
Hood 276
Operator Restraint System and Seat Assembly 277
Overhead Guard Replacement 277
Remove 277
Install 277
Hood, Seat Assembly and Operator Restraint Replacement 281
Hood and Seat Assembly 281
Remove 281
Install 283
Operator Restraint System 285
Counterweight Replacement 285
Remove 285
Install, Early Model ERP20-30ALF (B216) Lift Trucks 287
Install, Later Model ERP20-30ALF (B216) Trucks and ERP20-30ALF ( 287
Traction Motor Replacement 288
Remove 288
Install 290
Hydraulic Tank Repair 290
Remove 290
Inspect 291
Clean 291
Steam Method 292
Chemical Solution Method 292
Additional Preparations for Tank Repair 292
Small Leaks, Repair 293
Large Leaks, Repair 293
Preparations for Usage After Repair 293
Install 293
Painting Instructions 293
Safety Label Replacement 295
Battery Specifications 297
Early and Later ERP20-30ALF (B216) Model Trucks 297
ERP20-30ALF (ERP040-060DH) (D216) Model Trucks 297
tables 263
Table 1 Counterweights 286
524179938-1400YRM0575-(03-2003)-UK-EN 301
toc 301
Drive Axle, Speed Reducer, and Differential 301
Safety Precautions Maintenance and Repair 302
General 305
Description 305
Drive Axle, Speed Reducer, and Differential Repair 306
Remove 306
Disassemble 308
Clean 310
Inspect 311
Assemble 311
Install 314
Torque Specifications 315
Troubleshooting 316
524179943-1800YRM0566-(03-2003)-UK-EN 319
toc 319
Brake System 319
Safety Precautions Maintenance and Repair 320
General 323
Description and Operation 323
Service Brakes 323
Master Cylinder 323
Parking Brake 324
Service Brake Repairs 325
Remove and Disassemble 325
Clean 327
Inspect 328
Assemble and Install 328
Adjust 329
Parking Brake Repair 333
Remove and Disassemble 333
Assemble and Install 333
Adjust 333
Master Cylinder Repair 335
Remove 335
Clean and Inspect 336
Repair 336
Install 338
Service Brakes Adjustment 339
Brake Pedal Adjustment 339
Master Cylinder Adjustment 339
Brake System Air Removal 339
Parking Brake Not Applied Switch Test 340
Torque Specifications 340
Troubleshooting 340
524179945-1900YRM0559-(04-2009)-UK-EN 347
toc 347
Hydraulic System 347
Safety Precautions Maintenance and Repair 348
General 351
Description 351
Hydraulic System 351
Operation 359
Hydraulic System 359
Hydraulic Gear Pump 365
Steering Pump 365
Hydraulic Tank Repair 373
Tank, Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P1 373
Tank, Remove [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) 375
Tank, Remove [ERP20-32ALF (ERP040-065DH) (E216)] 376
Hydraulic Tank [ERC35-55HG (ERC70-120HH) (B839/C839)] 376
Inspect 377
Small Leaks, Repair 378
Large Leaks, Repair 378
Clean 378
Steam Method 378
Chemical Solution Method 379
Additional Methods for Tank Repair 379
Tank, Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P 379
Tank, Install [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) 380
Tank, Install [ERP20-32ALF (ERP040-065DH) (E216)] 380
Filter Replacement 381
All Lift Trucks Except [ERC35-55HG (ERC70-120HH) (B839/C839); ER 381
Remove 381
Install 382
Lift Truck Models [ERC35-55HG (ERC70-120HH) (B839/C839)] 382
Remove 382
Install 382
Lift truck Models [ERC20-32AGF (ERC040-065GH) (A908) and ERC/P16 383
Remove 383
Install 383
Lift Truck Models [ERP20-32ALF (ERP040-065DH) (E216)] 385
Remove 385
Install 385
Hydraulic Pump Repair 388
Hydraulic Pump, Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A81 388
Hydraulic Pump, Disassemble ERC/P16-20AAF (ERC030-040AF, AG/BG) 388
Inspect 390
Clean 390
Pump Seal Replace and Pump Assemble 390
Assemble Pump on Motor 390
Hydraulic Pump and Motor, Install [ERC/P16-20AAF (ERC030-040AF, 392
Hydraulic Pump, Remove [ERP20-30ALF (B216); ERP20-30ALF (ERP040- 393
Hydraulic Pump, Disassemble [ERC35-55HG (ERC70-120HH) (B839/C839 394
Hydraulic Pump, Inspect [ERC35-55HG (ERC70-120HH) (B839/C839) an 396
Hydraulic Pump, Clean [ERC35-55HG (ERC70-120HH) (B839/C839) and 396
Hydraulic Pump, Assemble [ERC35-55HG (ERC70-120HH) (B839/C839) a 396
Hydraulic Pump and Motor, Install [ERP20-30ALF (B216); ERP20-30A 396
Main Control Valve Repair 398
Steering Pump Repair 398
Pump, Remove and Disassemble [ERC/P16-20AAF (ERC030-040AF, ERC03 398
Pump, Remove and Disassemble [ERP20-30ALF (B216); ERP20-30ALF (E 400
Pump, Assemble and Install 402
Steering Control Unit Replacement 403
Remove 403
Install 403
Steering Cylinder Repair 409
Main Control Valve Check and Adjust 409
Steering Relief Valve Check and Adjust 410
Specifications 410
Relief Valve Pressures* 410
Hydraulic Tank Capacity (dipstick full mark) 411
Hydraulic Pump Capacities – All Models Except ERC35-55HG (ERC70- 411
Hydraulic Pump Capacities – Models ERC35-55HG (ERC70-120HH) (B83 411
Troubleshooting 411
Steering 411
Steering Housing and Steering Control Unit 412
Hydraulic System 413
524179946-2000YRM0562-(02-2009)-UK-EN 419
toc 419
Manual hydraulic Control Valve 419
Safety Precautions Maintenance and Repair 420
General 423
Description 423
Operation 426
ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P16-20AAF (ERC03 426
ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D216) and ERP20- 426
Lift Section 428
Tilt Section 428
Tilt Backward 428
Tilt Forward 428
Relief Valve 430
Main Control Valve Repair 431
Main Control Valve Without OPS Solenoid 431
Remove 431
Disassemble 431
Clean and Inspect 435
Assemble 435
Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P16-20A 436
Install [ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D216) a 436
Main Control Valve With OPS Solenoid 437
Remove 437
Disassemble 437
Clean and Inspect 439
Relief Valve Repair 441
Assemble 442
Install 443
Control Lever Linkage Repair 443
Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814),ERC/P16-20AAF 443
Disassemble [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814),ERC/P16- 443
Assemble and Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) 445
Control Valve Linkage Repair 445
Remove and Disassemble [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A81 445
Assemble and Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) 446
Control Lever Linkage Repair 446
Remove [ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D216) an 446
Disassemble [ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D21 448
Assemble and Install [ERP20-30ALF (B216), ERP20-30ALF (ERP040-06 448
Pressure Relief Valve Check and Adjustment 449
Primary Relief Valve 449
Secondary Relief Valve 450
Troubleshooting 451
524183080-0620YRM1053-(03-2010)-UK-EN 455
toc 455
AC Motor Repair 455
Safety Precautions Maintenance and Repair 456
General 459
AC Motor Repair 460
Disassemble 460
Assemble 462
Drive End Bearing, Replace 463
Disassemble, ERP20-32ALF (ERP040-065DH) (E216) Traction Motor 463
Assemble, ERP20-32ALF (ERP040-065DH) (E216) Traction Motor 465
Troubleshooting 466
524183081-1600YRM1054-(11-2006)-UK-EN 469
toc 469
Steering System for AC Electric Lift Trucks 469
Safety Precautions Maintenance and Repair 470
General 473
Description 474
Steering Wheel and Column Assembly Repair 475
General 475
Assembly Components, Remove 477
Assembly Components, Install 478
Power Steering Motor and Pump 479
Description 479
Remove 479
Disassemble 482
Install 482
Power Steering Pump, Repair 482
Seal, Replace 483
Steering System Air Removal 484
Steering Pressure Check 484
Steering Motor Circuits Check 485
Troubleshooting 486
524183082-2200YRM1055-(10-2009)-UK-EN 491
toc 491
Electrical System (Trucks With AC Controllers) 491
Safety Precautions Maintenance and Repair 492
General 495
Description 496
Features of the Display Panels 496
Other Control Components 497
Display Panel and Key Switch Replacement 498
Display Panel, Replace 498
Key Switch, Replace 500
Controller Replacement 500
Traction and Pump Motor Controller Replacement 500
Master Controller, Replace 506
Master Controller, Remove ERP20-30ALF (ERP040-060DH) (D216), ERP 506
Master Controller, Install ERP20-30ALF (ERP040-060DH) (D216), ER 506
Master Controller, Remove ERC/P16-20AAF (ERC030-040AH) (B814/C81 508
Master Controller, Install ERC/P16-20AAF (ERC030-040AH) (B814/C8 508
Master Controller, Remove ERC35-55HG (ERC070-120HH) (B839/C839) 510
Master Controller, Install ERC35-55HG (ERC070-120HH) (B839/C839) 510
Control Components Replacement 511
General 511
Start Switch, Replace 511
Brake Light Switch, Replace 512
Seat Switch, Replace 512
Parking Brake Switch, Replace 513
Foot Directional Control Pedal Direction Switches, Replace 515
Steering Column Direction Control Switches, Replace 518
Remove 518
Install 518
Brake Fluid Switch, Replace 520
Brush Wear and Over Temperature Sensors (DC Pump Motor Only) 520
Rocker Switches for Lights, Replace 520
Accelerator Position Sensor, Replace 521
On-Demand Steering Sensor, Replace 522
Lights, Converter, Relay, and Reverse Alarm 522
Brake, Tail, and Reverse Light Assembly, Replace 523
Incandescent Assembly 523
LED Assembly – Remove 525
LED Assembly – Install 525
Strobe Light Assembly, Replace 528
Wire Harness Repair 529
Del-City Crimp-Solder-Shrink Splice 529
Front, Rear Driving Light or Spot Light Assemblies, Replace 530
Converter, Replace 530
Remove, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216), ERP 530
Install, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216), ER 532
Remove, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) and 532
Install, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) and 532
Remove, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839) 534
Install, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839) 534
Reverse Relay, Replace 535
Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908), ERC/P16-20A 535
Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839) 535
Backup Alarm, Replace 537
Horn and Horn Button, Replace 537
Horn Replacement for Lift Trucks ERP20-30ALF (ERP040-060DH) (D21 537
Horn Replacement for Lift Trucks ERC35-55HG (ERC70-120HH) (B839/ 539
Horn Switch and Cover, Replace 540
Hydraulic Pump Switches 541
Fan Power Supply, Replace 541
Remove, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839) 541
Install, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839) 541
Remove, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216) and 542
Install, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216) and 543
Remove, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) 543
Install, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) 543
Control and Power Fuse Check 544
Fuse Locations 544
Brake Light Switch Adjustment 550
Seat Switch Check 551
Seat Brake Adjustment 551
Parking Brake Switch Adjustment 552
Direction Switches Check 552
Foot Directional Control Pedal 552
Steering Column 553
Foot Directional Control Pedal or Accelerator Pedal Adjustment 553
Accelerator Position Sensor Adjustment and Start Switch Adjustme 554
Acceleration Position Sensor, Adjust 554
Start Switch, Adjust 556
tables 491
Table 1 Wire Splice Size 529
524183083-2200YRM1056-(03-2009)-UK-EN 559
toc 559
AC Motor Controllers/Display Panel 559
Safety Precautions Maintenance and Repair 560
Description 563
General 563
AC Motors 563
Motor Controllers 563
Master Controller 563
Dash Display 563
Controller Area Network Bus (CANbus) 563
Master Controller Checks and Adjustments 564
Function Settings 565
General 565
Function Numbers 565
Function Descriptions 568
General 568
Function Number 1 BATTERY VOLTAGE 568
Function Number 2 EXTENDED SHIFT 568
Function Number 3 ACCELERATION 1 568
Function Number 4 ACCELERATION 2 568
Function Number 5 TOP SPEED LIMIT 568
Function Number 6 REGEN BRAKING 568
Function Number 7 AUTO DECELERATION 569
Function Number 8 BDI ADJUSTMENT 569
Function Number 9 LIFT INTERRUPT 569
Function Number 10 POWER STEERING TIME DELAY 569
Function Number 11 SERVICE REMINDER 569
Function Number 12 CUSTOM 569
Function Number 13 PUMP SPEED 1 569
Function Number 14 PUMP SPEED 2 570
Function Number 15 PUMP SPEED 3 570
Function Number 16 PUMP ACCELERATION 570
Troubleshooting 570
General 570
Controller Status Light Emitting Diodes (LEDs) 571
Master Controller 571
AC Motor Controllers 571
Status Codes 577
AC Motor Controllers Status Code Charts 579
Troubleshooting When Dash and/or Lift Truck is not Operational 600
Typical Symptoms 600
Truck Runs but Dash Display is not Operational, or Only Displays 600
Truck Does Not Run and Dash is Not Operational or Only Displays 601
Hydraulics Operate Normally, Traction Does Not Operate Correctly 602
Traction Operates Normally, Hydraulics do Not Operate Correctly, 602
AC Transistor Motor Controller Replacement 602
General 602
General Maintenance Instructions 608
Special Precautions 608
Fuses 609
Fan Test 609
Contactors 609
Repair 609
Thermal Sensors 613
Motor Controller, Replace 613
Display Panel 614
General 614
Premium Display Panel 614
Standard Display Panel 614
Display Functions and Features 615
Key-On Initialization 615
Standard Display 616
Premium Display 616
Lift Truck Inspection Function 617
Access to Service Functions 617
Service Functions 617
Service Functions 618
Performance Modes 620
Battery Discharge Indicator (BDI) 620
Hourmeter 621
Dash Display Service Menu Navigation 627
General 627
Moving Through Menu Selections 627
Editing and Adding Information 627
tables 559
Table 1 Factory Parameters for ERP20-30ALF (ERP040-060DH) (D216 565
Table 2 Factory Setting for ERC020-032AGF (ERC40-65GH) (A908) 566
Table 3 Factory Setting for ERC/P16-20AAF (ERC030-040AH) (B814/ 566
Table 4 Factory Parameters for ERC35-55HG (ERC70-120HH) (B839/C 567
Table 5 List of Status Codes 577
Table 6 42-Pin Connections/Descriptions for Master Controller 610
Table 7 Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo 612
Table 8 Pin Connections/Descriptions for 36/48 and 72v/80v (Gen 612
524183085-2200YRM1058-(04-2011)-UK-EN 631
toc 631
Troubleshooting and Adjustments Using the AC Controls Program (E 631
Safety Precautions Maintenance and Repair 632
General 635
Computer Requirements 635
Software, Install 635
Language Selection 635
Demo Mode 636
Connect PC to Lift Truck 640
Starting AC Controls Program 642
Lift Truck Control Setup 647
Change Lift Truck Serial Number or Hourmeter 647
Setting Factory Default Values or Changing Lift Truck Parameters 648
Create New Custom Lift Truck Configuration 654
Lift Truck Configuration Properties 657
Import New Lift Truck Configuration From Disk 660
Delete Custom Lift Truck Configuration or Password File 662
Dash Display 665
Custom Display Languages 665
Download Display Language 667
Clear Operator Log 667
Password Functions 670
Enable/Disable Password and Lift Truck Inspection Functions 670
Truck Inspection Checklist 670
Password 670
Password Properties 670
Create New Password File 675
Download Passwords 676
Upload Passwords 678
Reports Menu 680
Devices Report 680
Custom Report 680
Password Report 680
Operator Report 687
Current Settings Report 690
Status Code Report 694
Status Codes Log 697
Troubleshooting 699
Diagnostics 699
Help Menu 702
General 702
Contents 702
Technical Support 702
About Electric Truck AC Controls Program 702
524183086-8000YRM1059-(08-2012)-UK-EN 709
toc 709
Electrical Diagrams 709
Safety Precautions Maintenance and Repair 710
524183087-8000YRM1060-(02-2010)-UK-EN 785
toc 785
Periodic Maintenance 785
Safety Precautions Maintenance and Repair 786
General 791
Serial Number Data 791
How to Move Disabled Lift Truck 791
How to Tow Lift Truck 791
How to Put Lift Truck on Blocks 792
How to Raise Drive Tires 792
How to Raise Steering Tires 792
How to Clean a Lift Truck 792
Maintenance Schedule 794
Maintenance Procedures Every 8 Hours or Daily 801
How to Make Checks With Key OFF 801
Tires and Wheels 801
Forks 802
Inspect 802
Mast and Lift Chains, Inspect 803
Safety Labels 803
Steering Column Latch 803
Operator Restraint System 804
Automatic Locking Retractor (ALR) 804
Emergency Locking Retractor (ELR) 804
Battery Restraint System ERC20-32AGF (ERC040-065GH) (A908) and E 805
Battery Restraint System ERP20-30ALF (ERP040-060DH) (D216) Lift 806
Battery 806
Attachment 807
Hydraulic System 807
How to Make Checks With Key ON 808
Horn, Lights, and Alarm 808
Steering System 808
Service Brakes 808
Parking Brake 808
Control Levers and Pedals 809
Direction and Speed Control Pedals 809
Lift System Operation 809
Oil Leaks 809
First Service After First 100 Hours of Operation 809
Change Filter for Hydraulic Oil 809
Maintenance Procedures Every 250 Hours or 6 Weeks 811
Steering King Pins ERC/P16-20AAF (B814/C814) Trucks Only 811
Steering Tie Rods and Spindles 811
Maintenance Procedures Every 500 Hours or 3 Months 811
Differential and Speed Reducer ERC20-32AGF (ERC040-065GH) (A908) 811
Wheel Nut Torques 812
Header Hose Checks 812
Mast Lubrication 812
Forks 816
Remove 816
Inspect 816
Install 816
Adjust 817
Brake Fluid ERC/P16-20AAF (ERC030-040AH) (B814/C814) and ERC20-3 817
Parking Brake Adjustment 817
Seat Brake Operations Check 818
Maintenance Procedures Every 1000 Hours or 6 Months 818
Lift Chains 818
Wear Check 818
Lift Chain Lubrication 819
Forks 819
Check Upper and Lower Bearings, Integral Sideshift Carriage 819
Steering King Pins ERC20-32AGF (ERC040-065GH) (A908) Lift Truck 820
Steering Tie Rods ERP20-30ALF (ERP040-060DH) (D216) Lift Truck M 820
Steering Axle Spindles 820
King Pins ERP20-30ALF (ERP040-060DH) (D216) 820
Hydraulic Tank Breather 820
ERP20-30ALF (ERP040-060DH) (D216) 820
ERC20-32AGF (ERC040-065GH) (A908) 821
ERC/P16-20AAF (ERC030-040AH) (B814/C814) 821
Differential and Speed Reducer ERP20-30ALF (ERP040-060DH) (D216) 821
Brake Fluid ERP20-30ALF (ERP040-060DH) (D216) Lift Truck Models 822
Other Lubrication 822
Electrical Inspection 822
Contactors 822
Motor Brushes (DC Pump) 822
Motor Brushes, General 822
Maintenance Procedures Every 2000 Hours or Yearly 826
Hydraulic System 826
Change Filter for Hydraulic Oil 826
Change Hydraulic Oil 827
Differential and Speed Reducer 827
Brake Fluid Replacement 828
Service Brakes 828
Steering Tie Rods and Spindle Lift Truck Models ERC030-040AH (B8 828
Wheel Bearings 829
Steer Wheels, Lubrication 829
Drive Wheels, Lubrication 829
Lift Chains 829
Forks 829
Replace Upper and Lower Bearings, Integral Sideshift Carriage 829
Other Lubrication 829
Battery Maintenance 830
How to Charge Battery 830
How to Change Battery for ERP20-30ALF (ERP040-060DH) (D216) and 831
General 831
How to Change Battery for ERC20-32AGF (ERC040-065GH) (A908) and 833
General 833
Lift and Tilt System Leak Check 836
Lift Cylinders Leak Check 836
Tilt Cylinders Leak Check 837
Safety Procedures When Working Near Mast 837
WHEN WORKING NEAR THE MAST ALWAYS: 837
Lift Chain Adjustments 840
Welding Repairs 841
Overhead Guard Changes 841
Wheels and Tire Maintenance 842
Solid Rubber Tires ERC20-32AGF (ERC040-065GH) (A908) and ERC/P16 842
Remove Wheels From Lift Truck 842
Remove and Install Tire on Wheel 842
Pneumatic Tires and Wheels ERP20-30ALF (ERP040-060DH) (D216) 843
Remove Wheels From Lift Truck 843
Remove Wheel From Pneumatic Tire 844
Install Three- or Four-Piece Wheel in Pneumatic Tire 845
Add Air to Tires 846
Wheels, Install 846
Solid Rubber Tires on Pneumatic Wheels 847
Remove Wheels From Lift Truck 847
Remove Solid Rubber Tire From Pneumatic Wheel 847
Install Solid Rubber Tire on Pneumatic Wheel 849
Wheels, Install 850
Snap-On Tire, Change 850
Remove Snap-On Solid Tire From Wheel 851
Install Snap-On Solid Tire on Wheel 852
Adhesives and Sealants 853
tables 785
Table 1 Maintenance Schedule 796
524183088-8000YRM1061-(01-2005)-UK-EN 857
toc 857
Capacities and Specifications 857
Safety Precautions Maintenance and Repair 858
Counterweights 861
Hydraulic System 861
Wheels and Tires 861
Battery Specifications 862
Capacities 862
Movement Rates (Maximum) for Tilt Cylinders 863
Mast Speeds 863
Mast Speeds – ERP20-30ALF (72 or 80 Volt) Europe 863
Mast Speeds – ERP040-060DH (72 or 80 Volt) Americas 864
Mast Speeds – ERP20-30ALF (72 or 80 Volt) Europe 865
Mast Speeds – ERP040-060DH (72 or 80 Volt) Americas 866
Torque Specifications 867
Frame 867
Drive Axle, Speed Reducer, and Differential 867
Masts 868
Adhesives and Sealants 868