ERC/ERP16-20AAF (A814)

SERVICE MANUAL CONTENTS

PART YRM REV
SECTION NUMBER NUMBER DATE
FRAME............................................................................................................................ 524179936 0100 YRM 0617 03/06
DC MOTOR MAINTENANCE.......................................................................................... 524158039 0620 YRM 0294 03/08
DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL............................................. 524179939 1400 YRM 0618 03/06
STEERING SYSTEM...................................................................................................... 524166836 1600 YRM 0485 07/03
STEERING HOUSING AND CONTROL UNIT (EARLY MODELS)................................ 524179941 1600 YRM 0512 07/03
STEERING AXLE............................................................................................................ 524179940 1600 YRM 0619 03/06
STEERING CONTROL UNIT.......................................................................................... 524158753 1600 YRM 0720 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
INSTRUMENT CLUSTER............................................................................................... 524158757 2200 YRM 0514 01/04
EV-100ZX SCR MOTOR CONTROLLER DESC/ADJ/TRBL/REPAIR AND THEORY.. 524179947 2200 YRM 0557 07/03
ELECTRICAL SYSTEM.................................................................................................. 524166840 2200 YRM 0560 07/05
EV-100ZX SCR MOTOR CONTROLLER PARAMETER TABLES................................ 524179950 2200 YRM 0624 07/03
SR/SP TRANSISTOR MOTOR CONTROLLERS DESCRIPTION, CHECKS AND
ADJUSTMENTS, TROUBLESHOOTING, REPAIRS, AND THEORY OF
OPERATON............................................................................................................... 524179951 2200 YRM 0724 04/05
DISPLAY PANEL FOR SEM CONTROLS (DOS VERSION)......................................... 524166842 2200 YRM 0725 07/02
SR/SP TRANSISTOR MOTOR CONTROLLER PARAMETER TABLES FOR FOUR-
WHEEL ELECTRIC RIDER LIFT TRUCKS............................................................... 524179952 2200 YRM 0739 04/05
DISPLAY PANEL FOR SEM CONTROLS..................................................................... 524166844 2200 YRM 0942 08/07
SR(SEM)/SP TROUBLESHOOTING AND ADJUSTMENTS WITH A COMPUTER
(WINDOWS VERSION).............................................................................................. 524167640 2200 YRM 0947 08/07
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
MAST - DESCRIPTION................................................................................................... 524158890 4000 YRM 0521 03/06
MAST - REPAIR.............................................................................................................. 524158891 4000 YRM 0522 07/10
FOUR STAGE MAST...................................................................................................... 524179953 4000 YRM 0563 04/05
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
PERIODIC MAINTENANCE............................................................................................ 524179957 8000 YRM 0552 07/03
CAPACITIES AND SPECIFICATIONS........................................................................... 524179959 8000 YRM 0621 01/05
DIAGRAMS..................................................................................................................... 524179955 8000 YRM 0622 07/03
DIAGRAMS (SEM).......................................................................................................... 524179956 8000 YRM 0742 06/04
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 524179928 (09/14)
100 YRM 617
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.
Description
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
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
100 YRM 617 Description

Legend for Figure 1

NOTE: OPTIONAL SIDE COVERS NOT SHOWN.

A. BATTERY COMPARTMENT
1. SPACER PLATE 5. FLOOR PLATES
2. ACCESS COVERS 6. FRAME
3. COWL 7. SIDE STEP AND FENDER WELDMENT
4. FLOOR MATS

3
Description 100 YRM 617

Figure 2. Lift Truck Frame Manual Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)

4
100 YRM 617 Description

Legend for Figure 2

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

5
Description 100 YRM 617

Figure 3. Lift Truck Frame E-Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)

6
100 YRM 617 Description

Legend for Figure 3

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

Figure 4. Spacers of Battery Compartment

7
Description 100 YRM 617

NOTE: OPTIONAL SIDE COVERS FOR BATTERY COMPARTMENT NOT SHOWN.

1. INSTRUMENT PANEL COVER 3. CONTROL VALVE COVER
2. INNER COWL LINER 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 6. WASHER 11. COVER
2. DASH 7. LOCKWASHER 12. PLATE
3. NUT (FOLDOVER) 8. NUT 13. COVER
4. CAPSCREW 9. CATCH 14. TRIM
5. LINER 10. PLATE 15. SCREW

8
100 YRM 617 Description

Figure 6. Covers Manual Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)

9
Description 100 YRM 617

Figure 7. Covers E-Hydraulics ERC/P16-20AAF (ERC030, 040AH) (C814)

10
100 YRM 617 Description

Legend for Figure 7

1. MOUNTING PANEL 8. NUT
2. DASH 9. CATCH
3. NUT (FOLDOVER) 10. PLATE
4. CAPSCREW 11. COVER
5. LINER 12. PLATE
6. WASHER 13. COVER
7. LOCKWASHER

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
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 The overhead guard is a weldment that fastens to the

main frame and cowl to help protect the operator from
WARNING falling objects. See Figure 10, Figure 11, and Figure 12.
Do not operate the lift truck without the overhead
guard correctly fastened to the lift truck.

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 8. LATCH MECHANISM
2. STEERING WHEEL 9. OPTIONAL PREMIUM DISPLAY PANEL
3. ON-DEMAND STEERING COMPONENTS (NOT 10. OPTIONAL BASIC DISPLAY PANEL
ALL UNITS) 11. REGULAR DISPLAY PANEL*
4. HORN SWITCH CONNECTOR 12. HORN BUTTON
5. COLUMN COVER 13. STEERING COLUMN
6. COLUMN FRAME 14. STEERING COLUMN NUT
7. STEERING CONTROL UNIT

*CURTIS METER SHOWN. PANEL AVAILABLE WITH OPTIONAL GENERAL ELECTRIC METER.

12
100 YRM 617 Description

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

13
Description 100 YRM 617

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

14
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 10. CAPSCREW
2. SHIFT LEVER MECHANISM 11. WASHER
3. COLUMN COVER 12. NUT
4. LATCH MECHANISM 13. SCREW
5. STEERING CONTROL UNIT 14. OVERHEAD GUARD HANDLE
6. COLUMN FRAME 15. HORN SWITCH CONNECTOR
7. ON DEMAND STEERING COMPONENTS 16. HORN BUTTON
8. DISPLAY PANEL (PREMIUM DISPLAY PANEL 17. STEERING COLUMN
SHOWN) 18. STEERING COLUMN NUT
9. OVERHEAD GUARD

15
Description 100 YRM 617

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

16
100 YRM 617 Overhead Guard Replacement

Legend for Figure 12

NOTE: DISPLAY PANELS SHOWN ARE FOR LIFT TRUCKS WITH AC ELECTRIC CONTROLLERS AND CON-
TACTORS.

NOTE: OVERHEAD GUARD FOR LIFT TRUCK MODELS ERC030, 040AH (B814/C814) SHOWN. SEE FIGURE 13
FOR OVERHEAD GUARD USED ON ERC/P16-20AAF (B814/C814) LIFT TRUCKS.
1. ON-DEMAND STEERING COMPONENTS 12. LATCH MECHANISM
2. SHIFT LEVER MECHANISM 13. CAPSCREW
3. STEERING WHEEL 14. WASHER
4. DISPLAY PANEL 15. NUT
5. COLUMN COVER 16. SCREW
6. COLUMN FRAME 17. OVERHEAD GUARD HANDLE
7. STEERING CONTROL UNIT 18. HORN SWITCH CONNECTOR
8. COWL WELDMENT 19. HORN BUTTON
9. DASH 20. STEERING COLUMN
10. COLUMN MOUNT 21. STEERING COLUMN NUT
11. OVERHEAD GUARD

Overhead Guard Replacement

REMOVE

WARNING
Do not weld, drill, grind, or cut the overhead guard
for mounts for lights or accessories. The strength
of the overhead guard can be reduced.

1. Remove the battery as described in the section

Periodic Maintenance 8000 YRM 552 for lift
truck models ERC/P16-20AAF (ERC030-40AF,
AG/BG) (A814), and Periodic Maintenance 8000
YRM 1060 for lift truck models ERC/P16-20AAF
(ERC030, 040AH) (B814/C814), or your vehicle’s
Operating Manual.

2. Access to the capscrews that hold the rear legs of

the overhead guard to the frame is from the battery
compartment. Remove the, capscrews, washers,
and nuts that fasten each leg. See Figure 10, Fig-
ure 11, Figure 12, Figure 13, and Figure 14.

3. Remove the capscrews, washers, and nuts that

hold each front leg of the overhead guard to the
cowl. Disconnect any electric wires from under the
cowl that go through the front legs of the overhead
guard. When the overhead guard is lifted from the 1. CAPSCREW
frame, make sure these electric wires move through 2. WASHER
3. NUT
the holes in the frame at the front and rear so that 4. OVERHEAD GUARD HANDLE
they are not damaged. 5. OVERHEAD GUARD
4. Use a lifting device or another person to help lift the Figure 13. Overhead Guard, Lift Truck Models
overhead guard from the lift truck. ERC/P16-20AAF (ERC030, 040AH) (B814/C814)

17
Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 617

INSTALL capscrews to 55 N•m (41 lbf ft). Install the capscrews,

Put the overhead guard on the lift truck. Install any
electric wires from the overhead guard legs through the
holes in the frame. Install the capscrews, washers, and
nuts that hold each front leg to the frame. Tighten the
washers, and nuts that hold the rear legs to the frame.
Tighten the capscrews to 68 N•m (50 lbf ft). Install the
battery.

1. FRONT LEG, OVERHEAD GUARD 5. COUNTERWEIGHT

2. SETSCREW 6. TOW PIN
3. ATTACHMENT PLATE 7. BOLT
4. REAR LEG, OVERHEAD GUARD

Figure 14. Overhead Guard and Counterweight

Battery and Operator Restraint System, Hood and Seat

Brake, and Seat Assembly Replacement
BATTERY RESTRAINT SYSTEM
WARNING
On units with a shorter frame, the gas spring for the
hood can raise the hood at a rapid rate and cause an
injury. DO NOT bend over hood when raising hood.
NOTE: The steering column must be all the way for-
ward before unlocking and raising the battery restraint
system.
A battery restraint system is installed as a safety de-
vice. See Figure 15. The function of the battery re-
straint system, when correctly locked in the down posi-
tion, is to hold the battery in the battery compartment

18
100 YRM 617 Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement
if an accident causes the lift truck to tip over. The bat-
tery restraint is a steel weldment that is connected to the
frame with a hinge. A sliding latch mechanism (see Fig-
ure 15) locks the battery restraint in the down position
for operation. The latch, at the top center of the coun-
terweight, unlocks the battery restraint from the frame
so that the battery restraint can be raised to the up po-
sition for access to the battery. The battery restraint is
also the support for the hood. A gas spring helps lift
the hood assembly. A rod is used to hold the hood in
the up position on units with a longer frame. The oper-
ator must hold the hood assembly with one hand. Use
the other hand to move the rod to the storage position.
Lower the hood and battery restraint assembly to the
operating position. Make sure that the battery restraint
is correctly locked to the frame for operation of the lift
truck.
WARNING
Correct operation of the battery restraint system re-
quires that the battery does not move more than
1. HOOD
2. SEAT
3. LATCH ASSEMBLY
4. BATTERY RESTRAINT AND HOOD FRAME
5. GAS SPRING
6. HINGE
Figure 15. Hood, Latch, and Battery Restraint System
13 mm (0.5 in.) horizontally. Make sure that the bat-
tery spacer plate is correctly adjusted.
WARNING
The battery restraint and its latch mechanisms must
operate correctly before a lift truck is operated.
To operate correctly, the battery restraint must be locked
in the down position. The battery must have the spacers
correctly adjusted to prevent movement in any one hor-
izontal direction of 13 mm (0.5 in.) maximum. See Fig-
ure 4. Raise the seat. Use the latch handle to release
the battery restraint. See Figure 15. Use the handle on
the hood to raise the battery restraint and hood. Make
sure that the battery cannot move more than a total of
13 mm (0.5 in.) in any one horizontal direction. Make
sure the spacer plate is correctly adjusted to prevent
the movement. Push the hood and the battery restraint
down until the latch locks. Make sure the battery re-
straint is locked securely. Lift on the handle to make
sure it is latched and will not move.
7. STOP ROD
8. RELEASE LABEL FOR STOP ROD
9. COUNTERWEIGHT
10. LATCH HANDLE
11. LIFT HANDLE
12. LATCH WARNING LABEL
19
Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 617

HOOD AND SEAT BRAKE

NOTE: The steering column must be all the way forward
before raising the hood.

The hood must be locked in the down position during

operation. The battery must have the spacers correctly
adjusted to prevent movement of 13 mm (0.5 in.) maxi-
mum. On lift trucks ERC/P16-20AAF (ERC030-040AF,
AG/BG) (A814), if the unit has a seat brake, raise the
seat and seat plate assembly. Use the latch handle at
the rear of the hood (see Figure 16) to release the hood
frame and battery restraint. Raise the latch handle and
slide the handle toward the right side of the truck. A
spring moves the handle back to the left.

1. HINGE
2. SEAT PLATE
3. HOOD
4. LATCH HANDLE

Figure 17. Seat Brake Assembly, E-Hydraulics,

Lift Truck Models ERC/P16-20AAF (ERC030,
040AH)(C814)

Use the lift handle by the seat to raise the hood (see
Figure 16) or Figure 17. A gas spring and stop rod will
hold the assembly in the up position. Make sure that
the battery cannot move more than a total of 13 mm
1. HINGE 4. LATCH HANDLE (0.5 in.) in any one horizontal direction. If necessary,
2. LIFT HANDLE 5. SEAT PLATE (WITH adjust the battery spacers as shown in Figure 4.
3. HOOD SEAT BRAKE*)
Release the stop rod by moving it to the right before low-
* THE SEAT PLATE (WITH SEAT BRAKE) IS USED ering hood. See the label in Figure 15. Make sure the
ON ERC/P16-20AAF (ERC030-40AF, AG/BG) (A814) latch handle is fully to the right when closing the hood
ONLY. so that the latch can engage the latch plate. Make sure
Figure 16. Seat Brake Assembly, Manual the hood is locked securely. Try to raise the hood using
Hydraulics, Lift Truck Models ERC/P16-20AAF only the lift handle to make sure the hood is latched and
(ERC030-040AF, AG/BG) (A814) ERC/P16-20AAF will not move.
(ERC030, 040AH)(B814)

20
100 YRM 617 Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement

On ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814)

units with a seat brake, there is a separate plate with a
hinge fastened to the front of the battery compartment
(see Figure 16). The seat is fastened to this plate in-
stead of the hood on these units. The linkage for the
seat plate has a spring that holds the plate up and ap-
plies the brake on the rear of the traction motor. The
weight of the operator compresses the spring and ap-
plies the brake. On these units, push the seat and seat
plate into position over the hood.

HOOD WITH E-HYDRAULICS

WARNING
The gas spring for the hood can raise the hood at
a rapid rate and cause an injury. DO NOT lean over
hood when raising hood.

WARNING
The batteries for these lift trucks must fit the battery
compartment width with a maximum of 13 mm (0.5
in.) clearance. The Battery Specifications, at the
back of this manual, shows the minimum sizes of
the battery compartment.
Another important part of the battery restraint system
is the steel weldment that is also the hood frame. This
hood frame is connected to the lift truck frame with
hinges at the rear of the hood. Gas springs help lift the
hood assembly. The seat and other parts of the opera-
tor restraint system fasten to the hood assembly.
NOTE: Before raising the hood, move the steering col-
umn to the forward position and slide the seat all the
way back, and If necessary, move the armrest all the
way back. See Figure 18.
The latch that secures the cover for the hood release
handle can be either a locking or non locking latch. If
the latch is a locking latch, unlock latch with key first.
The cover, latch and hood release handle are located
on the right side of the hood. See Figure 19.
1. ARMREST ADJUSTMENT HANDLE
Figure 18. Armrest Latch Location
Pull the latch handle, located on the top of the latch, to
the up position and then pull on latch handle to move
cover away from hood release handle. Pull hood re-
lease handle up to release hood latch mechanism. See
Figure 19. Use handle on the hood to place hood in the
raised position.
Before lowering the hood, make sure the battery re-
straint rod is over the battery. Lower the hood and push
hood release handle down to secure hood to frame.
Move cover over hood release handle and push latch
handle down to secure cover to hood. If latch is a lock-
ing latch, lock latch with key.

21
Battery and Operator Restraint System, Hood and Seat Brake, and Seat Assembly Replacement 100 YRM 617

1. LATCH 6. PIN
2. COVER 7. SCREW
3. HOOD RELEASE 8. CAPSCREW
HANDLE 9. NUT
4. HOOD LATCH 10. LOCKWASHER
MECHANISM 11. WASHER
5. COMPRESSION 12. LATCH HANDLE 1. SEAT 4. HOOD
SPRING 2. HIP RESTRAINT 5. SEAT RAILS
3. SEAT BELT AND 6. SEAT PLATE (WITH
Figure 19. Latch and Cover With E-Hydraulics MOUNT SEAT BRAKE)*

* THE SEAT PLATE (WITH SEAT BRAKE) IS USED

OPERATOR RESTRAINT SYSTEM AND
SEAT ASSEMBLY
The seat belt, hip restraint brackets, seat and mounting,
hood, and latches are all part of the operator restraint
system. Each item must be checked to make sure it
is attached securely, functions correctly, and is in good
condition. See Figure 20.
Automatic Locking Retractor (ALR)
NOTE: ERC/P16-20AAF (ERC030-40AF, AG/BG)
(A814), ERC/P16-20AAF (ERC030, 040AH) (B814) lift
trucks produced before November 2005 are equipped
with the ALR type seat belts.
The seat belt must fasten securely. Make sure the seat
belt extends and retracts smoothly and is not frayed or
torn. If the seat belt is damaged or does not operate
properly, it must be replaced. See Figure 20.
ON ERC/P16-20AAF (ERC030-40AF, AG/BG) (A814)
ONLY.
Figure 20. Seat Assembly
Emergency Locking Retractor (ELR)
NOTE: Lift trucks produced after November 2005 are
equipped with the Emergency Locking Retractor (ELR)
style seat belt.
When the ELR style seat belt is properly buckled across
the operator, the belt will permit slight operator reposi-
tioning without activating the locking mechanism. If the
truck tips, travels off a dock, or comes to a sudden stop,
the locking mechanism will be activated and hold the
operator’s lower torso in the seat.
A seat belt that is damaged worn or does not operate
properly will not give protection when it is needed. The
end of the belt must fasten correctly in the latch. The
seat belt must be in good condition. Replace the seat
belt if damage or wear is seen. See Figure 21.

22
100 YRM 617 Counterweight Replacement

The following seat belt operation checks must be per- replaced. See the section Hood Repair in this manual
formed: for the adjustment procedures for the hood.
• With the hood closed and in the locked position, pull
the seat belt slowly from the retractor assembly. Make
sure the seat belt pulls out and retracts smoothly. if
the seat belt cannot be pulled from the retractor as-
sembly or the belt will not retract, replace the seat belt
assembly.
• With the hood closed and in the locked position, pull
the seat belt with a sudden jerk. Make sure the seat
belt will not pull from the retractor assembly. If the
seat belt can be pulled from the retractor, when it is
pulled with a sudden jerk, replace the seat belt as-
sembly.
• With the hood in the open position, make sure the
seat belt will not pull from the retractor assembly. If
the seat belt can be pulled from the retractor, with
the hood in the open position, replace the seat belt
assembly.

Make sure the seat rails and latch striker are not loose.
The seat rails must lock securely in position but move
1. OPERATOR WEIGHT ADJUSTMENT
freely when unlocked. The seat rails must be securely 2. FORWARD/BACKWARD ADJUSTMENT
attached to the mounting surface. The hood must be 3. SEAT BELT
fully closed. Lift the hood to make sure it is closed and 4. HIP RESTRAINT
will not move. 5. SEAT
6. SEAT RAIL
Adjust hood, hood latch, and latch striker when any of
the parts of the operator restraint system are installed or Figure 21. Hood and Seat Check

Counterweight Replacement
If the lift truck must be put on blocks for maintenance
or repair, see How to Put Lift Truck on Blocks in the
Operating Manual or Periodic Maintenance section
for your vehicle.
WARNING
The counterweight is very heavy. Make sure that the
crane and lifting devices have enough lifting capac-
ity to safely lift the counterweight. The weights of
the counterweights are shown in Table 1.
The counterweight normally is not removed for most re-
pairs. Replacement of the SCR Electronic Controllers
is easier with the counterweight removed. Replace-
ment of the SEM, and AC Controllers is accomplished
by removing the cover from the counterweight. See Fig-
ure 22. The counterweight is fastened to the frame with
four capscrews. The weights for the counterweights are
in Table 1.
REMOVE
1. Remove the battery from the truck. See How to
Change Battery in your vehicle’s Periodic Main-
tenance section or Operating Manual for the pro-
cedures.
2. Install the counterweight lifting tool to the counter-
weight with a 1 UNC × 2 in. (50 mm) bolt. See
Figure 23 and Figure 24. Connect a clevis to the
counterweight lifting tool. The clevis must have a
pin diameter of 16.0 to 19.0 mm (0.625 to 0.750 in.).
Fasten a chain or sling to the clevis. Make sure the
chain or sling and crane has the capacity to lift the
counterweight. See Table 1. Use the crane to hold
the weight of the counterweight.

23
Counterweight Replacement 100 YRM 617

1. SEAL
2. COUNTERWEIGHT
3. TOW PIN
4. ACCESS COVER
5. UPPER CAPSCREW AND WASHER
6. LOWER CAPSCREW AND WASHER
7. COVER CAPSCREW AND WASHERS

Figure 22. Counterweight Assembly

Table 1. Counterweights

+30 kg (66 lb)

Model Weight
0 kg (0 lb)
ERC030AF, 467 kg (1030 lb)
AG/BG (A814),
and ERC030AH
(B814/C814)
1. LIFT CHAIN 3. CLEVIS
ERC/P16-18AAF 563 kg (1240 lb) 2. LIFTING TOOL 4. COUNTERWEIGHT
(A814), and
ERC/P16-18AAF Figure 23. Lift Counterweight
(B814/C814)
3. From inside the battery compartment near the
ERC/P20AAF 738 kg (1630 lb) bottom, remove the two top capscrews that hold
(ERC040AF, the counterweight to the frame. Remove the cap-
AG/BG) (A814) and screws, nuts, and washers from the tow pin area
ERC/P20AAF of the counterweight. Use the crane to lift the
(ERC040AH) counterweight away from the frame. Make sure
(B814/C814) that you do not damage the electronic controller.

24
100 YRM 617
NOTE: THE MATERIAL IS ASTM A36 STEEL 12.7 mm
(0.50 in.) THICK.
Figure 24. Counterweight Lifting Tool
Counterweight Replacement
INSTALL
NOTE: The access panel to the electronic controller can
be removed from the counterweight to make checks and
adjustments on the controller. Before installing access
panel, check the seal to make sure it fully seals the con-
trols compartment and that there are no gaps between
the seal, seal blocks, wire harness, battery bulkhead
covers, or counterweight. Make sure the lugs are cor-
rectly engaged when the access panel is installed again
or the panel will fall from the counterweight during op-
eration.
1. Use a crane and the lifting tool, as during removal,
to lift the counterweight into position. Make sure
that you do not damage the electronic controller
during installation. Install the two upper capscrews
near the bottom of the battery compartment that
hold the counterweight to the frame. Install the
lower capscrews, washers, and nuts in the tow pin
area of the counterweight. Tighten the upper cap-
screws to 380 N•m (280 lbf ft). Tighten the lower
(tow pin) capscrews and nuts to 66 N•m (49 lbf ft).
If removed, tighten the cover capscrews to 52 N•m
(38 lbf ft).
2. Disconnect the sling or chain. Remove the lifting
tool from the counterweight.
3. Install the battery. See the secton Periodic Main-
tenance 8000 YRM 552 for the ERC/P16-20AAF
(ERC030-40AF, AG/BG) (A814), and Peri-
odic Maintenance 8000 YRM 1060 for the
ERC/P16-20AAF (ERC030, 040AH) (B814/C814),
or your vehicle’s Operating Manual.
25
Traction Motor Replacement
Traction Motor Replacement
REMOVE
This procedure describes the removal of the trac-
tion motor through the battery compartment. See
Figure 25. Some lift trucks have a seat brake that
actuates a brake on the armature shaft of the traction
motor. See Figure 26 and Figure 27. A lifting de-
vice can be fastened to the overhead guard to lift the
motor. If a crane will be used, remove the overhead
guard for crane access. The steering pump and motor
must be removed for clearance. See Steering Sys-
tem for Electric Lift Trucks 1600 YRM 485 for the
ERC/P16-20AAF (ERC030-40AF, AG/BG) (A814), and
Steering System for AC Electric Lift Trucks 1600
YRM 1054 for the ERC/P16-20AAF (ERC030, 040AH)
(B814/C814) removal procedures.
NOTE: TRACTION MOTOR FOR MODELS
ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814)
SHOWN. TRACTION MOTOR FOR ERC/P16-20AAF
(ERC030,040AH) (B814/C814) IS SIMILAR.
Figure 25. Traction Motor for Lift Truck Models
NOTE: The traction motor can also be removed from
under the lift truck with the use of a floor jack, but is
more difficult. If the traction motor is removed from un-
der the lift truck, the lift truck must be on blocks with
enough clearance for the jack and traction motor. Some
lift trucks require removal of hydraulic lines to remove
the traction motor from under the lift truck.
1. See How to Change Battery in your vehicle’s Peri-
odic Maintenance or Operating Manual. Remove
26
100 YRM 617
the battery from the truck. Then remove the floor
plates and the access panel in the bottom of the
battery compartment.
2. For the ERC/P16-20AAF (ERC030-40AF, AG/BG)
(A814) trucks, if there is a seat brake, put a weight
on the seat that will hold the seat in the down po-
sition. See Figure 26. Remove the nut, capscrew,
washers, and bushing at the pivot of the brake link-
age. Make a note of the arrangement of the parts
for correct assembly during installation. Disconnect
the spring between the linkage and the brake as-
sembly.
1. TRACTION MOTOR
2. LEVER OF SEAT BRAKE LINKAGE
3. NUT, CAPSCREW, WASHERS, AND BUSHING
4. SPRING
Figure 26. Traction Motor With Seat Brake, Lift
Trucks ERC/P16-20AAF (ERC030-040AF, AG/BG)
(A814)
3. On lift truck models ERC/P16-20AAF
(ERC030,040AH) (B814/C814) the guide
pipe and electrical connections for the seat brake
must be disconnected from the traction motor
before motor is removed. See Figure 27.
4. Disconnect the power cables from the traction mo-
tor. Make an identification of which cable is con-
nected to each terminal. Disconnect the wires to
the brush wear indicator and the thermal switch, if
installed.
100 YRM 617 Traction Motor Replacement

the sling as shown in Figure 28 to control the trac-

tion motor during removal. Use the crane to hold
the weight of the traction motor.

NOTE: TRACTION MOTOR FOR MODELS

ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814)
SHOWN. TRACTION MOTOR FOR ERC/P16-20AAF
1. GUIDE PIPE CONNECTION (ERC030,040AH) (B814C814) IS SIMILAR.
2. ELECTRICAL CONNECTION
3. SEAT BRAKE 1. SLING
4. SPRING 2. USE A WOOD BLOCK AND BOARD UNDER
5. TRACTION MOTOR SLING FOR A LEVER
3. TRACTION MOTOR
Figure 27. Traction Motor With Seat Brake,
Lift Trucks ERC/P16-20AAF (ERC030,040AH) Figure 28. Install Sling to Lift Traction Motor, Lift
(B814/C814) Truck Models

6. Disconnect the motor mount. Remove the bolts be-

WARNING
The motor is heavy. Make sure that any lifting de-
vice has enough capacity to lift the weight. The mo-
tor can weigh approximately 90 to 140 kg (200 to
310 lb).
5. Put the lift truck on blocks for maintenance or repair,
see How to Put Lift Truck on Blocks in the Oper-
ating Manual or Periodic Maintenance of your ve-
hicle. Raising the lift truck will allow easier access
to the bottom bolts between the traction motor and
the speed reducer. Install a sling to hold the trac-
tion motor. Use a wood block and a board under
tween the speed reducer housing and the motor.
NOTE: The traction motors are in different configura-
tions for different applications of the lift trucks. Trac-
tion motors weigh approximately 90 to 140 kg (200 to
310 lb). Make sure that the sling cannot slide and per-
mit the traction motor to fall.
7. Use the crane or special lifting device to move the
traction motor to a work space to make repairs as
shown in Figure 29.

27
Traction Motor Replacement
NOTE: TRACTION MOTOR FOR MODELS
ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814)
SHOWN. TRACTION MOTOR FOR ERC/P16-20AAF
(ERC030,040AH) (B814/C814) IS SIMILAR.
Figure 29. Use Crane to Lift Traction Motor
INSTALL
WARNING
The motor is heavy. Make sure that any lifting de-
vice has enough capacity to lift the weight. The mo-
tor can weigh approximately 90 to 140 kg (200 to
310 lb).
1. Make sure the mount surfaces of the motor and
speed reducer housing are clean with no old ad-
hesive.
2. Install a sling to lift the traction motor. Use a wood
block and a board under the sling as shown in Fig-
ure 28 to control the traction motor during installa-
tion.
CAUTION
There must be 0 to 0.15 mm (0 to 0.006 in.) clear-
ance between the bearing for the input gear of the
speed reducer and the traction motor housing.
Shims must be installed, if necessary, for this
clearance.
NOTE: If the motor, bearing, or speed reducer are dif-
ferent than when the motor was removed, a new shim
set is required. See the Drive Axle, Speed Reducer,
and Differential 1400 YRM 618 to select the correct
shim set before doing Step 3.
28
100 YRM 617
3. Lower the traction motor into position. Align the
traction motor with the speed reducer. See Fig-
ure 30. Make sure the spacer and correct shims
are installed in the speed reducer housing.
NOTE: TRACTION MOTOR FOR MODELS
ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814)
SHOWN. TRACTION MOTOR FOR ERC/P16-20AAF
(ERC030,040AH) (B814/C814) IS SIMILAR.
1. SLING
2. BOARD AND BLOCK
3. TRACTION MOTOR
Figure 30. Align Traction Motor With Speed
Reducer
4. Make sure the surface of the speed reducer and
motor housings are clean with no adhesive. Apply
liquid adhesive (Yale part number 520042831) to
seal the motor to the speed reducer housing.
5. Use a board or pry bar as necessary to carefully
push the traction motor into the speed reducer.
6. Align the bolt holes in the speed reducer and the
motor housing. Install the six bolts that hold the
traction motor to the speed reducer. Tighten the
bolts to 71 to 83 N•m (52 to 61 lbf ft).
NOTE: If the drive unit assembly is in the lift truck, con-
tinue with this procedure. If the drive unit assembly is
out of the lift truck, install the drive unit assembly. See
the section Drive Axle, Speed Reducer, and Differen-
tial 1400 YRM 618.
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