service repair manual

1. ERC/P16-20AAF (B814)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524179936 0100 YRM 0617 03/06
DC MOTOR MAINTENANCE.......................................................................................... 524158039 0620 YRM 0294 03/08
AC MOTOR REPAIR...................................................................................................... 524205680 0620 YRM 1098 03/10
DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL............................................. 524179939 1400 YRM 0618 03/06
STEERING AXLE............................................................................................................ 524179940 1600 YRM 0619 03/06
STEERING CONTROL UNIT.......................................................................................... 524158753 1600 YRM 0720 11/06
STEERING SYSTEM...................................................................................................... 524183081 1600 YRM 1054 11/06
BRAKE SYSTEM............................................................................................................ 524179944 1800 YRM 0620 03/08
HYDRAULIC SYSTEM.................................................................................................... 524179945 1900 YRM 0559 04/09
MAIN CONTROL VALVE................................................................................................ 524179946 2000 YRM 0562 02/09
TILT CYLINDERS........................................................................................................... 524150790 2100 YRM 0103 03/07
CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507,
B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515,
C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND
E564).......................................................................................................................... 524223768 2100 YRM 1139 02/14
ELECTRICAL SYSTEM.................................................................................................. 524183082 2200 YRM 1055 10/09
AC MOTOR CONTROLLER DESC/CHKS/ADJ/TRBSHT/REP&THEORY OF
OPERATION/DISPLAY PANEL................................................................................. 524183083 2200 YRM 1056 03/09
TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS
PROGRAM................................................................................................................. 524183085 2200 YRM 1058 04/11
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
MAST - DESCRIPTION................................................................................................... 524158890 4000 YRM 0521 03/06
MAST - REPAIR.............................................................................................................. 524158891 4000 YRM 0522 07/10
MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508,
B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551,
C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ 524223776 4000 YRM 1148 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
DIAGRAMS..................................................................................................................... 524183086 8000 YRM 1059 08/12
PERIODIC MAINTENANCE............................................................................................ 524183087 8000 YRM 1060 02/10
CAPACITIES AND SPECIFICATIONS........................................................................... 524213865 8000 YRM 1113 11/06
PART NO. 524201842 (09/14)

2. 100 YRM 617 Description
General
This section has a description and the service procedures for the parts of the frame. These parts include the frame,
counterweight assembly, overhead guard, hood and seat assembly, access panels, and label positions. The proce-
dure for removing the traction motor is also described in this section.
Description
MAIN FRAME
The main frame is a single weldment. See Figure 1,
Figure 2 and Figure 3. The main frame has mounts for
the following:
• Counterweight
• Overhead guard
• Battery restraint and hood
• Seat plate (with optional seat brake)
• Tilt cylinders
• Steering axle
• Drive axle assembly
• Cowl assembly
• Floor pedals and floor plates
• Side step and fender weldments
• Hydraulic tank, pump, and motor assembly
• Control valves and levers
The hood is part of the operator and battery restraint
system. The seat is also part of the operator restraint
system. The floor plates can be removed for access
to the traction motor. A panel in the bottom of the bat-
tery compartment can be removed for access to the hy-
draulic pump motor and the steering pump motor. The
electronic controller and contactors are attached to the
lift truck frame and surrounded by the counterweight. A
panel in the counterweight can be removed for access
to the controller and contactors.
WARNING
The battery must fit the battery compartment so
that the battery restraint will operate correctly. A
loose battery can cause serious injury and property
damage if the lift truck overturns. Adjust the spac-
ers to prevent the battery from moving more than
13 mm (0.5 in.) in any horizontal direction. See Fig-
ure 4.
WARNING
Maximum clearance between the battery and bat-
tery compartment width is 13 mm (0.5 in.). Maxi-
mum clearance between the battery and the spacer
plate is also 13 mm (0.5 in.). The Battery Specifica-
tions chart shows the minimum size compartment
allowed.
The weight of the battery is a large part of the coun-
terweight system on an electric lift truck. Make sure
that the battery is within the weight limits indicated on
the nameplate. Each model of lift truck has a cast-iron
counterweight that provides the additional weight nec-
essary for the indicated capacity. A slot in the overhead
guard permits removal of the battery without removing
the overhead guard.
Figure 5, Figure 6, and Figure 7 shows covers for in-
strument panel and control valve.
1

3. Description 100 YRM 617
Figure 1. Lift Truck Frame Manual Hydraulics ERC/P16-20AAF ([ERC030-040AF]; ERC030-040AG/BG)
(A814); ERC/P16-20AAF (ERC030-040AH) B814
2

4. 100 YRM 617 Description
Legend for Figure 1
NOTE: OPTIONAL SIDE COVERS NOT SHOWN.
A. BATTERY COMPARTMENT
1. SPACER PLATE
2. ACCESS COVERS
3. COWL
4. FLOOR MATS
5. FLOOR PLATES
6. FRAME
7. SIDE STEP AND FENDER WELDMENT
3

5. Description 100 YRM 617
Figure 2. Lift Truck Frame Manual Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)
4

6. 100 YRM 617 Description
Legend for Figure 2
1. COWL
2. NUT
3. CAPSCREW
4. LOCKWASHER
5. PLATE
6. SPACER
7. FOAM RUBBER
8. WASHER
9. COVER
10. PLATE
11. PLATE
12. FENDER
13. PLUG
14. BOLT
15. FLOORPLATE
5

7. Description 100 YRM 617
Figure 3. Lift Truck Frame E-Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)
6

8. 100 YRM 617 Description
Legend for Figure 3
1. COWL
2. NUT
3. CAPSCREW
4. LOCKWASHER
5. PLATE
6. SPACER
7. FOAM RUBBER
8. WASHER
9. COVER
10. PLATE
11. PLATE
12. FENDER
13. PLUG
14. BOLT
15. FLOORPLATE
Figure 4. Spacers of Battery Compartment
Legend for Figure 4
1. BATTERY COMPARTMENT
2. BATTERY
3. BULKHEAD
4. SPACER PLATES
5. ADJUSTMENT CAPSCREWS
6. JAM NUTS
A + B = 13 mm (0.5 in.) MAXIMUM
7

9. Description 100 YRM 617
NOTE: OPTIONAL SIDE COVERS FOR BATTERY COMPARTMENT NOT SHOWN.
1. INSTRUMENT PANEL COVER
2. INNER COWL LINER
3. CONTROL VALVE COVER
4. BATTERY COMPARTMENT
Figure 5. Covers Manual Hydraulics ERC/P16-20AAF ([ERC030-040AF]; ERC030-040AG/BG) (A814);
ERC/P16-20AAF (ERC030-040AH) B814
Legend for Figure 6
1. MOUNTING PANEL
2. DASH
3. NUT (FOLDOVER)
4. CAPSCREW
5. LINER
6. WASHER
7. LOCKWASHER
8. NUT
9. CATCH
10. PLATE
11. COVER
12. PLATE
13. COVER
14. TRIM
15. SCREW
8

10. 100 YRM 617 Description
Figure 6. Covers Manual Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)
9

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12. Description 100 YRM 617
Figure 7. Covers E-Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)
10

13. 100 YRM 617 Description
Legend for Figure 7
1. MOUNTING PANEL
2. DASH
3. NUT (FOLDOVER)
4. CAPSCREW
5. LINER
6. WASHER
7. LOCKWASHER
8. NUT
9. CATCH
10. PLATE
11. COVER
12. PLATE
13. COVER
OTHER FRAME WELDMENTS
These frame parts are the right-hand and left-hand side
step and fender weldments and the cowl weldment (see
Figure 1 and Figure 2.) Each part is a weldment fas-
tened to the main frame to make the frame assembly.
The cowl weldment is a mount for the front of the over-
head guard, the steering column assembly, the release
linkage of the parking brake and the instrument panel
with light switches. The display panel is on the right side
of the steering column and attached to the instrument
panel for lift truck models with SEM (Separately Excited
Motor), SCR (Silicon Controlled Rectifier), Alternating
Current (AC) and electronic controllers and contactors.
See Figure 5, Figure 8, Figure 9, Figure 10, Figure 11,
and Figure 12.
A. STANDARD SEM DISPLAY PANEL B. PREMIUM SEM DISPLAY PANEL
Figure 8. SEM Display Panel
11

14. Description 100 YRM 617
NOTE: FOR LIFT TRUCKS MODELS WITH AC ELECTRONIC CONTROLLERS AND CONTACTORS, BOTH THE
STANDARD AND PREMIUM DISPLAY PANELS LOOK IDENTICAL. THE ONLY DIFFERENCE IS IN THE DISPLAY
SOFTWARE AND THE RESULTING FUNCTIONALITY.
Figure 9. AC Display Panel
OVERHEAD GUARD
WARNING
Do not operate the lift truck without the overhead
guard correctly fastened to the lift truck.
The overhead guard is a weldment that fastens to the
main frame and cowl to help protect the operator from
falling objects. See Figure 10, Figure 11, and Figure 12.
Legend for Figure 10
NOTE: THE DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH SCR ELECTRONIC CONTROLLERS AND
CONTACTORS.
A. STEERING CONTROL UNIT USED ON EARLY MODEL LIFT TRUCKS
B. STEERING CONTROL UNIT USED ON LATER MODEL LIFT TRUCKS
1. OVERHEAD GUARD
2. STEERING WHEEL
3. ON-DEMAND STEERING COMPONENTS (NOT
ALL UNITS)
4. HORN SWITCH CONNECTOR
5. COLUMN COVER
6. COLUMN FRAME
7. STEERING CONTROL UNIT
8. LATCH MECHANISM
9. OPTIONAL PREMIUM DISPLAY PANEL
10. OPTIONAL BASIC DISPLAY PANEL
11. REGULAR DISPLAY PANEL*
12. HORN BUTTON
13. STEERING COLUMN
14. STEERING COLUMN NUT
*CURTIS METER SHOWN. PANEL AVAILABLE WITH OPTIONAL GENERAL ELECTRIC METER.
12

15. 100 YRM 617 Description
Figure 10. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF
(ERC030-40AF) (A814)
13

16. Description 100 YRM 617
Figure 11. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF
(ERC030-40AG/BG) (A814)
14

17. 100 YRM 617 Description
Legend for Figure 11
NOTE: THE DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH SEM ELECTRONIC CONTROLLERS AND
CONTACTORS.
1. STEERING WHEEL
2. SHIFT LEVER MECHANISM
3. COLUMN COVER
4. LATCH MECHANISM
5. STEERING CONTROL UNIT
6. COLUMN FRAME
7. ON DEMAND STEERING COMPONENTS
8. DISPLAY PANEL (PREMIUM DISPLAY PANEL
SHOWN)
9. OVERHEAD GUARD
10. CAPSCREW
11. WASHER
12. NUT
13. SCREW
14. OVERHEAD GUARD HANDLE
15. HORN SWITCH CONNECTOR
16. HORN BUTTON
17. STEERING COLUMN
18. STEERING COLUMN NUT
15

18. Description 100 YRM 617
Figure 12. Overhead Guard, Steering Column, and Instrument Panel, Truck Models ERC/P16-20AAF
(ERC030, 040AH) (B814/C814)
16