Yale Forklift A839 (ERC070_80_100_120HG) Service Manual – PDF DOWNLOAD

Yale Forklift A839 (ERC070_80_100_120HG) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A839 (ERC070_80_100_120HG) Service Manual – PDF DOWNLOAD

Language : English
Pages : 932
Downloadable : Yes
File Type : PDF
PART NO. 524150790

PART NO. 524150783

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A839 (ERC070_80_100_120HG) Service Manual – PDF DOWNLOAD

524150783-1600YRM0326-(03-2007)-UK-EN 1
toc 1
Steering Axle 1
Safety Precautions Maintenance and Repair 2
General 5
Description 5
Steering Axle Assembly Repair 10
Steering Axle GP/GLP/GDP070-110LG/MG (B813), GC/GLC070-120LG/MG 10
Remove 10
Install 10
Steering Axle GDP60-70CA (GP/GLP/GDP135-155CA) (A878, B878), GLP 11
Remove 11
Install 11
Wheels and Hubs Repair (All Units) 12
Remove and Disassemble 12
Clean 12
Inspect 12
Assemble and Install 12
Spindles and Bearings Repair (All Units) 14
Remove 14
Clean 14
Assemble and Install 15
Tie Rods Repair (All Units) 16
Remove 16
Clean 16
Install 16
Steering Cylinder Repair 19
Remove and Disassemble 19
Clean and Inspect 19
Assemble and Install 19
Troubleshooting 20
524150790-2100YRM0103-(03-2007)-UK-EN 25
toc 25
Tilt Cylinders 25
Safety Precautions Maintenance and Repair 26
General 29
Description 29
Tilt Cylinder Repair 29
Remove 29
Disassemble 29
Clean 29
Assemble 30
Tilt Cylinders With O-Ring or Single-Lip Seals 30
Tilt Cylinders 31
Install 32
Tilt Cylinder Leak Check 34
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 35
Torque Specifications 35
Piston Rod Nut 35
Retainer 35
Troubleshooting 36
tables 25
Table 1 Movement Rates (Maximum) for Tilt Cylinders 34
524150794-4000YRM0135-(03-2011)-UK-EN 41
toc 41
Lift Cylinders 41
Safety Precautions Maintenance and Repair 42
Safety Procedures When Working Near Mast 45
General 49
Description 49
Lowering Control Valve 49
Cylinders (General) 52
Lift Cylinder Repair 52
Lift Cylinder Removal Without Removing Mast 52
Standard Masts With Main Lift Cylinder Fastened to Crossmember o 52
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to 53
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift 54
Disassemble 54
Assemble 54
Lift Cylinder Installation in Mast 56
Standard Masts With Main Lift Cylinder Fastened to Crossmember o 56
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to 56
Chevron-Style Packing 57
Chevron-Style Packing Installation on Piston 57
Chevron-Style Packing Installation in Packing Gland 59
Lift Cylinders for HI VIS® Masts 61
Description 61
Lowering Control Valve 61
Remove 63
Disassemble 64
Assemble 64
Install 66
Main Lift Cylinders 66
Free-Lift Cylinder 66
Lift System Leak Check 66
Specifications 67
Troubleshooting 68
tables 41
Table 1 Cylinder Retainer Torque Specifications and Weight Guid 67
524150797-8000YRM0231-(02-2023)-UK-EN 73
General 79
Threaded Fasteners 79
Nomenclature, Threads 79
Strength Identification 80
Cotter (Split) Pins 81
Fastener Torque Tables 86
Conversion Table 88
524150797-8000YRM0231-(03-2020)-UK-EN 95
General 99
Threaded Fasteners 99
Nomenclature, Threads 99
Strength Identification 100
Cotter (Split) Pins 101
Fastener Torque Tables 106
Conversion Table 108
524153919-4000YRM0741-(03-2005)-UK-EN 115
toc 115
Lift Cylinders 115
Safety Precautions Maintenance and Repair 116
Safety Procedures When Working Near Mast 119
General 121
Description 121
Lowering Control Valve (Velocity Fuse) 121
Lift Cylinder Repair 124
Remove 124
Disassemble 125
Assemble 125
Install 125
Lift System Leak Check 126
Troubleshooting 127
524153920-4000YRM0736-(07-2010)-UK-EN 131
toc 131
Masts 131
Safety Precautions Maintenance and Repair 132
General 135
Description and Operation 135
Carriages 135
Two-Stage Mast With Limited Free-Lift 135
Two-Stage Mast With Full Free-Lift 136
Three-Stage Mast With Full Free-Lift 137
Safety Procedures When Working Near Mast 139
Fork Replacement 141
Remove 142
Install 142
Carriage Repair 143
Remove 143
Sideshift Carriage Repair 145
Remove 145
Disassemble 145
Assemble 145
Install 145
Two-Stage Mast With Limited Free-Lift Repair 147
Remove, GLP/GDP3 5-5 5LJ/MJ (GP/GLP/GDP070-120LJ/MJ) Model Lift 147
Remove, GC070-120LJ/MJ, ERC070-120HG (A839), and ERC35-55HG (ERC 149
Disassemble 152
Clean and Inspect 152
Assemble 153
Install, GLP/GDP3 5-5 5LJ/MJ (GP/GLP/GDP070-120LJ/MJ) Lift Truck 154
Install, GC070-120LJ/MJ, ERC070-120HG (A839), and ERC35-55HG (ER 156
Two-Stage Mast With Full Free-Lift Repair 158
Remove 158
Disassemble 158
Clean and Inspect 160
Assemble 160
Install 160
Three-Stage Mast With Full Free-Lift Repair 162
Remove 162
Disassemble 162
Clean and Inspect 166
Assemble 166
Install 167
Mast Operation Check 173
Lift and Tilt System Leak Check 174
Lift System 174
Tilt System 175
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 176
Lift Chain Adjustments 178
Mast Adjustments 180
Carriage Adjustment 182
Troubleshooting 183
tables 131
Table 1 Tilt Cylinder Leak Check Specifications, GC070-120LJ/MJ 175
Table 2 Hook-Type Carriage Chain Adjustment 178
Table 3 Pin-Type Carriage Chain Adjustment 179
524158039-0620YRM0294-(09-2016)-UK-EN 189
General 193
Brush and Commutator Inspection 194
Hydraulic Pump Motor and Traction Motor 194
Steering Pump Motor 197
Normal Commutator Surface 197
Commutator Problems 197
Brush Replacement 202
Stoning the Commutator 205
Motors Repair 206
Disassemble 207
Traction Motor and Hydraulic Pump Motor 207
Steering Pump Motor 208
Assemble 212
Traction Motor and Hydraulic Pump Motor 212
Steering Pump Motor 214
Brush Alignment, Traction and Hydraulic Motors 216
Tests for Damaged Field and Armature 217
Test for an Open Circuit in One Armature Winding 217
Test for Short Circuit in One Armature Winding 217
Test for Short Circuit to Armature Shaft 218
Test for Open Circuit in Field Coil 218
Test for Short Circuit in Field Coil 219
Test for Short Circuit Between Field and Motor Case 219
Brush Holder Test 219
Troubleshooting 220
524158040-2240YRM0001-(01-2023)-UK-EN 225
General 231
Battery Type 231
Lead-Acid Batteries 231
Lithium-Ion Batteries 232
Specific Gravity 232
Chemical Reaction in a Cell 232
Electrical Terms 234
Battery Selection 235
Battery Voltage 236
Battery as a Counterweight 236
Battery Ratings 236
Kilowatt-Hours 236
Battery Maintenance 237
Safety Procedures 237
Maintenance Records 237
New Battery 237
Cleaning Battery 238
Adding Water to Battery 240
Hydrometer 240
Battery Temperature 241
Charging Battery 242
Types of Battery Charges 243
Methods of Charging 244
Troubleshooting Charger 245
Knowing When Battery Is Fully Charged 245
Where to Charge Batteries 245
Equipment Needed 245
Battery Connectors 246
Battery Care 246
Troubleshooting 248
524158040-2240YRM0001-(03-2020)-UK-EN 253
General 257
Battery Type 257
Lead-Acid Batteries 257
Lithium-Ion Batteries 258
Specific Gravity 258
Chemical Reaction in a Cell 258
Electrical Terms 260
Battery Selection 260
Battery Voltage 261
Battery as a Counterweight 262
Battery Ratings 262
Kilowatt-Hours 262
Battery Maintenance 262
Safety Procedures 262
Maintenance Records 263
New Battery 263
Cleaning Battery 263
Adding Water to Battery 265
Hydrometer 266
Battery Temperature 267
Charging Battery 268
Types of Battery Charges 268
Methods of Charging 270
Troubleshooting Charger 270
Knowing When Battery Is Fully Charged 271
Where to Charge Batteries 271
Equipment Needed 271
Battery Connectors 272
Battery Care 272
Troubleshooting 274
524166809-0100YRM0284-(03-2003)-UK-EN 279
toc 279
Frame 279
Safety Precautions Maintenance and Repair 280
General 283
Description 283
Overhead Guard Repair 286
Remove 286
Install 286
Battery Restraint and Seat Assembly Repair 287
Seat Brake Assembly, Adjust 288
Counterweight Repair 290
Remove 290
Install 290
Traction Motor Repair 291
Remove 291
Install 292
Hydraulic Tank Repair 292
Inspect 292
Small Leaks, Repair 292
Large Leaks, Repair 293
Clean 293
Steam Method 293
Chemical Solution Method 294
Additional Preparations For Repair 294
Painting Instructions 294
Safety Label Replacement 295
tables 279
Table 1 Battery Specifications 284
Table 2 Seat Brake Adjustment 289
Table 3 Counterweights 290
524166834-1400YRM0413-(11-2006)-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
General 306
Traction Motor, Speed Reducer, and Differential 307
Motor, Speed Reducer, and Differential, Remove 307
Disassemble 310
Speed Reducer 310
Differential 311
Clean 312
Inspect 312
Assemble 312
Speed Reducer 312
Input Gear, Install 312
New Pinion, Install 312
Differential 315
Drive Axle Housing 318
Remove 318
Clean 319
Inspect 319
Assemble 319
Troubleshooting 322
tables 301
Table 1 Pinion Assembly Shims Adjustment 314
Table 2 Ring and Pinion Tooth Contact Adjustment 316
524166835-1600YRM0257-(05-2002)-UK-EN 325
toc 325
Steering Control Unit 325
Safety Precautions Maintenance and Repair 326
General 329
Description 329
Control Valve Section 329
Metering Section 329
Disassembly and Inspection 330
Disassemble and Inspect 334
Assembly 350
Assemble 350
Troubleshooting 373
524166836-1600YRM0485-(07-2003)-UK-EN 377
toc 377
Steering System for Electric Lift Trucks 377
Safety Precautions Maintenance and Repair 378
General 381
Description 383
Steering Wheel and Column Assembly Repair 384
Assembly Components, Remove 384
Assembly Components, Install 388
Power Steering Motor and Pump 389
Description 389
Remove and Disassemble, Models ERC 20-30AGF (ERC040-065RF/ZF, RG 390
Remove and Disassemble, Models ERC35-55HG (ERC70-120HD, ERC70-12 391
Remove and Disassemble, Models ERP20-30ALF 394
Remove and Disassemble, Models ERC/P16-20AAF (ERC040-065AF, AG/B 394
Assemble and Install, All Models With A Vertical Mount Except ER 395
Assemble and Install, Models ERP20-30ALF 395
Assemble and Install, Models ERC/P16-20AAF (ERC030-040AF, AG/BG) 396
Power Steering Pump, Repair 396
Seal, Replace 397
Hydraulic Steering Motor 398
Steering System Air Removal 398
Steering Pressure Check 398
Optical Encoder and Activator Circuits Check 399
Troubleshooting 401
524166837-1800YRM0338-(05-2009)-UK-EN 405
toc 405
Brake System 405
Safety Precautions Maintenance and Repair 406
General 409
Description and Operation 409
Brake Booster and Master Cylinder 409
Master Cylinder 409
Service Brake Assembly 409
Parking Brake 413
Seat Brake 414
Brake Shoe Assemblies Repair 415
Remove and Disassemble 415
Clean and Inspect 415
Assemble and Install 417
Master Cylinder Repair 421
Master Cylinder For Lift Truck Models GC/GLC70-120LG/MG (B818) a 421
Remove 421
Disassemble 421
Assemble 422
Install 422
Master Cylinder For Lift Truck Models ERC70-120HD, ERC70-120HG ( 423
Remove and Disassemble 423
Clean and Inspect 424
Assemble and Install 424
Brake Booster Repair 424
Remove 424
Disassemble 424
Clean and Inspect 425
Assemble 426
Install 426
Brake System Air Removal 426
Brake Pedal Adjustment 426
Brake Pedal GP/GLP/GDP70-120LG/MG (B813) With Manual Transmissio 426
Brake Shoes Adjustment 428
Parking Brake Adjustment 428
Parking Brake Adjustment, Lift Truck Models GC/GLC70-120LG/MG (B 428
Parking Brake Lever and Switch Adjustment ERC70-120HD and ERC70- 429
Seat Brake Assembly 430
Remove 430
Clean and Inspect 430
Install 430
Adjustments 432
Solenoid Adjustment 432
Traction cutoff Switch Adjustment 432
Cable Adjustment 432
Brake Booster Relief Valve Check 435
Troubleshooting 435
524166838-1900YRM0286-(07-2002)-UK-EN 441
toc 441
Hydraulic System 441
Safety Precautions Maintenance and Repair 442
General 445
Description 445
Hydraulic System 445
Operation 446
Hydraulic System 446
Hydraulic Pump 447
Steering Pump 448
Hydraulic Pump Repair 448
Remove 448
Seal, Replace 449
Install 450
Main Control Valve Check and Adjust 450
Linkage and Switches 451
Relief Valve 451
Steering Relief Valve Check and Adjust 453
Specifications 453
Relief Valve Pressures 453
Capacities 453
Hydraulic Pump Capacities 453
Troubleshooting 454
524166839-2000YRM0077-(02-2009)-UK-EN 459
toc 459
Manual hydraulic Control Valve 459
Safety Precautions Maintenance and Repair 460
General 463
Description 463
Operation 465
Lift Section 467
Tilt Section 468
Tilt Backward 468
Tilt Forward 468
Relief Valve 470
Solenoid Valve for Auxiliary Function 471
Main Control Valve Repair 472
Remove and Disassemble – Control Valve Without OPS Solenoid 472
Remove and Disassemble – Control Valve With OPS Solenoid 472
Clean and Inspect 474
Assemble – Control Valve Without OPS 474
Assemble – Control Valve With OPS 474
Install 475
Solenoid Valve for Auxiliary Function Repair 475
Remove and Disassemble 475
Assemble and Install 477
Troubleshooting 477
Pressure Relief Valve Check and Adjustment 478
Primary Relief Valve 478
Secondary Relief Valve 478
Control Lever Arrangement and Adjustment 479
Specifications 481
Troubleshooting 481
524166840-2200YRM0560-(07-2005)-UK-EN 487
toc 487
Electrical System 487
Safety Precautions Maintenance and Repair 488
General 493
Description 494
ZX Series Display Panels 494
Optional Basic Display Panel 494
Features of the Optional Basic Display Panel 494
Description of Features on the Optional Basic Display Panel 494
Standard Display Panel 495
Features of the Standard Display Panel 495
Description of Features on the Standard Display Panel 495
Premium Display Panel 496
Features on the Premium Display Panel 496
Description of Features on the Premium Display Panel 497
Curtis 1215 Display Panel 499
Description and Features 499
Operation 499
SEM Display Panels – Features 500
Descriptions of Common Features 501
LED Symbol Indicators – SEM 501
LCD Screen 501
Battery Discharge Indicator (BDI) 501
Service Reminder 502
Status Codes 502
Hourmeter 502
Additional Features of Premium Display Panel 503
Descriptions of Additional Features 503
LCD Screen 503
Operator Passwords 503
Daily Checklist and Service Items 503
Performance Modes 503
Status Code Lists 504
Adjustment of BDI 504
SEM Display Panel Indicators 504
All Indicator Symbols 504
Hourmeter Indicator Symbol 504
Wrench Symbol 504
Battery Symbol 504
Battery Discharge Indicator (BDI) 504
Brake Fluid Too Low Symbol 504
Parking Brake Symbol 504
Fasten Seat Belt Symbol 505
LCD Screen (Standard Display Panel) 505
Additional Components of Premium Display Panel 505
Alpha Numerical Screen 505
STAR Push Button 505
Push Buttons ##1 Through ##5 – SEM 505
Other Control Components 505
Display Panel Components – ZX, and Curtis Replacement 506
ZX Panel Replacement 506
Curtis 1215 Display Panel Replacement 511
Remove 511
Install 511
SEM Display Panel Replacement 512
Motor Controller (SR or SP) Replacement 512
Remove 512
Install 512
Control Components Replacement 514
Start Switch, Replace 514
Brake Light Switch, Replace 515
Seat Switch, Replace 515
External Seat Switch, Adjust 516
Switch for Optional Seat Brake, Replace 517
Parking Brake Switch, Replace 517
Direction Switches Foot Directional Control Replace 518
Direction Control Switches (Steering Column), Replace 519
Direction Control Switches, ERC070-120HG (Steering Column), Repl 520
Brake Fluid Switch, Replace 520
Brush Wear and Overtemperature Sensors 520
Rocker Switches for Lights 521
Accelerator Position Sensor, Replace 521
On-Demand Steering Components 523
Lights, Converter, Relay, and Reverse Alarm 525
Incandescent Brake, Tail, and Reverse Light Assembly, Replace 525
LED Brake, Tail, and Reverse Light Assembly, Replace 527
Remove 527
Install 527
Flashing Light Assembly, Replace 527
Front, Rear Driving Light, or Spot Light Assemblies, Replace 529
Operator Compartment Light Assembly, Replace 529
Converter, Replace 530
Relay, Replace 530
Reverse Alarm, Replace 530
Horn and Horn Button 530
Horn Switch and Cover 531
Hydraulic Pump Switches 531
Control and Power Fuses Check 532
ZX Motor Controllers 532
SEM Motor Controllers 532
SEM Controller Field Diagnostic Procedure 537
Armature FET Test 537
Field FET Test 537
Brush Wear and Overtemperature Sensors Check – ZX Motor Controll 541
Thermal Sensors – SEM Motor Controllers Check 542
Start Switch Adjustment 543
Accelerator Potentiometer and Start Switch, ERC070-120HG Lift Tr 544
ERC070-120HG 544
Direction Switches Foot Directional Control Pedal 545
Brake Light Switch Adjustment 546
Seat Switch Check 547
Optional Seat Brake Switch Adjustment 547
Parking Brake Switch Adjustment 548
Direction Switches Check 548
Foot Directional Control Pedal 548
Steering Column 549
Hydraulic Pump Switch Adjustment 549
Foot Directional Control or Accelerator Pedal Adjustment 549
Accelerator Position Sensor Adjustment 550
524166842-2200YRM0725-(07-2002)-UK-EN 555
toc 555
SEM Display Panel 555
Safety Precautions Maintenance and Repair 556
General 559
SEM Display Panel Features 559
Common Features Descriptions 559
LED Symbol Indicators 559
LCD Screen 559
Battery Discharge Indicator (BDI) 559
Service Reminder 560
Status Codes 560
Hourmeter 560
Premium Display Panel Additional Features 561
Additional Features Descriptions (Available With Premium Display 561
LCD Screen 561
Operator Passwords 562
Daily Check List and Service Items 562
Performance Modes 562
Status Code Lists 562
BDI, Adjust 562
SEM Display Panel Indicators 563
All Indicator Symbols 563
Hourmeter Indicator Symbol 563
Wrench Indicator Symbol 563
Battery Indicator Symbol 563
Battery State-of-Charge (BDI) 563
Brake Fluid Low Symbol 563
Parking Brake Symbol 563
Fasten Seat Belt Symbol 563
LCD Screen (Standard Display Panel) 563
Premium Display Panel Additional Components 564
Alpha Numerical Screen 564
STAR Push Button 564
Push Buttons ##1 Through ##5 564
Computer Adjustments 564
Computer System 564
Connect PC to SEM Display Panel 565
ITW Switches Software Program (for SEM Display Panel) 565
Description 565
Where to Get Help 566
Hardware and Software Requirements 566
How to Start ITW Switches Program 566
Menus 567
Create a Setup File 572
SEM Display Panel Replacement 589
General 589
Remove and Replace 589
tables 555
Table 1 Adapter Pins (DB25F to DB9) 564
524166843-2200YRM0808-(06-2005)-UK-EN 595
toc 595
Transistor Motor Controllers (SR and SP) 595
Safety Precautions Maintenance and Repair 596
Description 599
Model Number Data for Transistor Motor Controllers (SR and SP) 600
Motor Controller Checks and Adjustments 603
Checks and Adjustments Using a Handset 603
General 603
Connect Handset 604
Start Sequence 604
Check or Delete Stored Status Codes 605
Returning Lift Truck to Normal Operation 606
Checks and Adjustments on Workbench 606
How to Check and Adjust Registers 606
Function Parameters Adjustments 608
General 608
Function Numbers 609
When Handset is Connected to Motor Controller in Lift Truck 609
Function Numbers 1 through 15 609
Function Numbers 16 through 30 609
Function Numbers 48 through 63 610
Function Number Descriptions 610
Traction Motor Controller (Label Letter – SR) 610
Functions with Premium Display Panel Only 615
Pump Motor Controller (Label Letter – SP) 617
Functions With Premium Display Panel Only 619
Troubleshooting 625
General 625
Status Codes 625
Status Code Charts 628
Transistor Motor Controllers Repairs 660
General 660
General Maintenance Instructions 663
Special Precautions 663
Fuses 663
Contactors 664
Repair 664
Contactor Driver Module 664
Contactor Driver, Replace 664
Motor Controller Plug 667
Brush Wear Indicators 668
Thermal Sensors 669
Motor Controller, Replace 669
Parameter Tables 672
General 672
Function Numbers 672
Motor Controller Checks and Adjustments 672
Parameter Tables 673
Theory of Operation 680
General 680
SEM System Description 681
SEM System Operation (SR Motor Controller) 681
Reverse Circuit 681
Performance and Efficiency 682
Field Weakening 682
Regenerative Braking 682
Creep Speed 683
Controlled Acceleration 683
Current Limit 683
Braking 683
Regenerative Braking to Zero Speed 683
Pedal Position Braking 683
Auto Braking 683
Auxiliary Speed Control 684
Field Weakening 684
Speed Limits 684
Ramp Operation 684
Ramp Start 684
Anti-Rollback 684
Steer Pump Contactor Time Delay 684
Coil Drivers and Internal Coil Suppression 684
System Protective Override 684
SRO (Static Return to Off) 684
Accelerator Volts Hold Off 684
Pulse Monitor Trip (PMT) 684
Thermal Protector (TP) 685
Low Voltage 685
SP Pump Motor Controllers 685
Contactor Driver Module 685
Diagnostics 685
Systems Diagnostics 685
Standard Status Codes 686
Stored Status Codes 686
Hourmeter Readings 686
Maintenance Management Capability 686
tables 595
Table 1 Speed/Torque Compensation 619
Table 2 Function Map for Motor Controllers SR (Traction) 621
Table 3 Function Map for Motor Controllers SP (Lift Pump Motor) 623
Table 4 List of Status Codes 626
Table 5 Large (P) Plug (23-Pin) Connections/Descriptions for Mo 667
Table 6 Small Plug (12-Pin) Connections/Descriptions for Motor 668
Table 7 Traction Control – SR Transistor Control Settings, 11-I 673
Table 8 Traction Control – SR Transistor Control Settings, 13-I 675
Table 9 Traction Control – SR Transistor Control Settings, 13-I 677
Table 10 Hydraulic Pump – SR Transistor Control Settings (36/48 678
524166844-2200YRM0942-(08-2007)-UK-EN 689
toc 689
Display Panel for SEM Controls 689
Safety Precautions Maintenance and Repair 690
General 693
SEM Display Panel Features 693
Descriptions of Common Features 693
LED Symbol Indicators 693
LCD Screen 693
Battery Discharge Indicator (BDI) 694
Service Reminder 694
Status Codes 694
Hourmeter 694
Additional Features of Premium Display Panel 694
Descriptions of Additional Features (Available With Premium Disp 694
LCD Screen 694
Operator Passwords 695
Daily Check List and Service Items 695
Performance Modes 695
Status Code Lists 695
Adjustment of BDI 695
SEM Display Panel Indicators 696
All Indicator Symbols 696
Hourmeter Indicator Symbol 696
Wrench Indicator Symbol 696
Battery Indicator Symbol 696
Battery State-of-Charge (BDI) 696
Brake Fluid Too Low Symbol 697
Parking Brake Symbol 697
Fasten Seat Belt Symbol 697
LCD Screen (Standard Display Panel) 698
Additional Components of Premium Display Panel 698
Alphanumeric Screen 698
STAR Push Button 698
Push Buttons 1 Through 5 698
Adjustments With a Computer 698
Computer System 698
Connect PC to SEM Display Panel 699
ITW Switches Windows Software Program (for SEM Display Panel) 700
Description 700
Getting Help 700
Hardware and Software Requirements 700
Install 700
How to Start ITW Switches Program 700
Menus 704
Sample Sessions 713
Replacement 735
SEM Display Panel 735
Remove and Replace 735
tables 689
Table 1 Adapter Pins (DB25F to DB9) 699
524166845-4000YRM0340-(09-2002)-UK-EN 741
toc 741
Masts 741
Safety Precautions Maintenance and Repair 742
General 745
Description and Operation 745
Carriages 745
Two-Stage Mast With Limited Free-Lift 745
Two-Stage Mast With Full Free-Lift Mast 746
Three-Stage Mast With Full Free-Lift 747
Safety Procedures When Working Near Mast 749
Forks Replacement 751
Remove and Install 751
Hook Fork 751
Remove 751
Install 751
Pin Fork 752
Remove 752
Install 752
Carriage Repair 752
Remove 752
Sideshift Carriage Repair 754
Sideshift Carriage (Earlier Designs) 754
Disassemble 754
Assemble 755
Install 758
Sideshift Carriage (1993 and Later Design) 758
Remove 758
Repairs 758
Install 758
Weight of Mast Parts 761
Two-Stage Mast With Limited Free-Lift Repair 761
Remove 761
Disassemble 763
Clean and Inspect 763
Assemble 763
Install 765
Two-Stage Mast With Full Free-Lift Repair 765
Remove 765
Disassemble 765
Clean and Inspect 767
Assemble 767
Install 767
Three-Stage Mast With Full Free-Lift 768
Remove 768
Disassemble 768
Clean and Inspect 768
Assemble 768
Install 770
Mast Operation Check 772
Lift and Tilt System Leak Check 773
Lift System 773
Tilt System 773
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 774
Lift Chain Adjustments 774
Mast Adjustments 775
Carriage Adjustment 777
Troubleshooting 778
524166846-8000YRM0915-(07-2002)-UK-EN 783
toc 783
Periodic Maintenance 783
Safety Precautions Maintenance and Repair 784
General 787
Serial Number Data 787
How to Move Disabled Lift Truck 787
How to Tow Lift Truck 787
How to Put Lift Truck on Blocks 788
How to Raise Drive Tires 788
How to Raise Steering Tires 789
Maintenance Schedule 789
Maintenance Procedures Every 8 Hours or Daily 792
How to Make Checks with Key Switch OFF 792
Tires and Wheels 792
Forks 792
Adjust 792
Remove 792
Install 794
Inspect Mast, Forks, and Lift Chains 794
Safety Labels 795
Steering Column Latch 795
Operator Restraint System 795
Battery Restraint System 796
Battery 797
Hydraulic System 797
How to Make Checks with Key Switch ON 798
Gauges, Horn, and Fuses 798
Steering System 798
Service Brakes 798
Parking Brake 798
Control Levers and Pedals 798
Lift System Operation 799
Maintenance Procedures Every 500 Hours or 3 Months 799
Differential and Speed Reducer 799
Wheel Nuts 799
Steering Axle Spindles 799
Mast 800
Brake Fluid 800
Other Lubrication 801
Seat Brake 801
Electrical Inspection 801
Contactors 801
Motor Brushes 801
Maintenance Procedures Every 1000 Hours or 6 Months 803
Lift Chains 803
Wear Check 803
Lubrication 803
Forks 803
Maintenance Procedures Every 2000 Hours or Yearly 804
Hydraulic System 804
Hydraulic Tank Breather 804
Change Filter for Hydraulic Oil 804
Change Hydraulic Oil 804
Differential and Speed Reducer 804
Service Brakes 805
Contactors 805
Wheel Bearings 805
Steer Wheels, Lubrication 805
Drive Wheels, Lubrication 805
Lift Chains 805
Battery Maintenance 806
How to Charge Battery 806
How to Change Battery 807
Safety Procedures When Working Near Mast 810
Lift and Tilt System Leaks Check 812
Check Lift Cylinders for Leaks 812
Check Tilt Cylinders for Leaks 812
Lift Chain Adjustments 813
How to Check PMT Circuit 815
Welding Repairs 816
Overhead Guard Changes 816
Tires and Wheels 816
General 816
Remove Wheels from Lift Truck 817
Remove Tire from Wheel and Install Tire on Wheel 817
Install Wheels 817
Battery Specifications 818
tables 783
Table 1 Maintenance Schedule 790
Table 2 Hook-Type Carriage Chain Adjustment 813
Table 3 Pin-Type Carriage Chain Adjustment 814
524166847-8000YRM0916-(07-2002)-UK-EN 821
toc 821
Capacities and Specifications 821
Safety Precautions Maintenance and Repair 822
Lift Truck Weights 825
Tire Sizes 825
Capacities 825
Hydraulic System 825
Mast Speeds 826
Mast Creep Speeds 827
Battery Specifications 827
Traction Speed and Traction Motor Current 828
Hoist Motor Current 829
Torque Specifications 829
Brake System 829
Differential 829
Drive Axle 829
Frame 829
Mast 829
Main Control Valve 829
Steering System 830
Tilt Cylinders 830
524166848-8000YRM0917-(01-2004)-UK-EN 833
toc 833
Diagrams 833
Safety Precautions Maintenance and Repair 834
524167640-2200YRM0947-(08-2007)-UK-EN 859
toc 859
Troubleshooting and Adjustments With a Computer 859
Safety Precautions Maintenance and Repair 860
Computer System 863
Connect a PC to a Control Card 864
Installation 865
SMARTSET™ Windows Software Program 865
How to Start the Program 865
DEMO Mode 866
Selecting the Communications Port 868
Verification of Controller and Lift Truck 869
Select Lift Truck Series 871
Controller Card Register Parameter List 872
How to Change a Parameter 873
How to Save a Changed Parameter File 874
How to Load a Saved Parameter File 876
How to Show and Remove Saved Parameter Files 876
How to Return to Factory Default Settings 877
How to Save Changes to Control Card 878
How to View Status Codes 879
Saving Status Codes 880
How to Show and Remove Saved Status Code Files 881
Closing and Clearing Status Code List 882
How to View Saved Register Data and Saved Status Data 883
How to Save Register Data and Status Code Data In RTF and TXT 885
GE Sentry™ Software Program 886
Installation 886
Description 886
How to Start GE SENTRY Program 886
How to Reset MIN and MAX Display 891
Graphing Mode 892
How to Exit GE SENTRY Program 893
tables 859
Table 1 Cable Connections – Computer to Control 863
Table 2 Adapter Pins (DB25F to DB9) 864
Table 3 Plug-Z Connection 865
524179949-2200YRM0595-(07-2003)-UK-EN 897
toc 897
EV-100ZX™ SCR Motor Controller 897
Safety Precautions Maintenance and Repair 898
Register Parameters 901
General 901
Function Numbers 901
Control Card Checks and Adjustments 902
Register Parameter Tables 902
tables 897
Table 1 EV-100ZX Parameters – ERC040-065RF/ZF, and ERP20-30ALF 903
Table 2 EV-100ZX Parameters – ERC040-065RF/ZF (36 to 48V) (Trac 907
Table 3 EV-100ZX Parameters – ERC20-30AGF, and ERP20-30ALF (72 911
Table 4 EV-100ZX Parameters – ERC20-30AGF (72 to 80V) (Traction 915
Table 5 EV-100ZX Parameters – ERC20-30AGF (72 to 80V) (Low Ener 919
Table 6 EV-100ZX Parameters – ERC70-120HD, ERC040-065RF/ZF, and 923
Table 7 EV-100ZX Parameters – ERC35-55HG, ERC20-30AGF, and ERP2 927