Yale Forklift ERC 070-120 HD (A839) Service Maintenance Manual PDF

Description

Yale Forklift ERC 070-120 HD (A839) Service Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift ERC 070-120 HD (A839) Service Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 507
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift ERC 070-120 HD (A839) Service Maintenance Manual – PDF DOWNLOAD

Section 1
SUPPORT INFORMATION
SERVICE PARTS ORDERING
INSTRUCTIONS
How То Order Service Parts
When Ordering Parts
SPECIAL TOOLS
TECHNICAL SERVICE PUBLICATIONS
OPERATOR TRAINING
DAILY OPERATOR CHECK-OFF LISTS
SERVICE TRAINING COURSES
SERVICE TRAINING MATERIALS
Section 2
GENERAL LIFT TRUCK MAINTENANCE
AND LUBRICATION SCHEDULE
GENERAL
HOW ТО MOVE А DISABLED LIFT TRUCK
How to Tow а Lift Truck
HOW ТО PUT А LIFT TRUCK ON BLOCKS
How То Raise the Drive Tires
How То Raise the Steering Tires
MAINTENANCE SCHEDULE
MAINTENANCE PROCEDURES
EVERY 8 HOURS OR DAILY
CHECKS WITH ТНЕ КЕУ “OFF”
Hydraulic System
Battery
Battery Restraint System
Operator Restraint System
lnspection Of The Mast, Forks And
Lift Chains
Tires And Wheels
Forks, Adjustment
Forks, Removal And lnstallation
SAFEТY LABELS
CHECKS WITH ТНЕ КЕУ “ON”
Gauges and Horn
Lift System Operation
Service Brakes
Parking Brake
Steering System
EVERY 350 HOURS OR ТWО MONTHS
HYDRAULIC TANK BREATHER
CONTENTS
1-1
1-1
1-1
1-1
1-1
1-1
1-1
1-1
1-1
1-1
2-1
2-1
2-1
2-1
2-1
2-2
2-2
2-4
2-9
2-9
2-9
2-9
2-10
2-11
2-11
2-12
2-13
2-13
2-13
2-14
2-14
2-14
2-14
2-14
2-15
2-15
2-15
DIFFERENTIALAND SPEED REDUCER 2-15
WHEEL NUT TORQUES 2-15
STEERING AXLE SPINDLES 2-15
MAST 2-15
LIFT CHAINS 2-16
Check for Wear 2-16
Lubrication 2-16
FORKS 2-17
BRAKE FLUID 2-17
OTHER LUBRICATION 2-17
SEAT BRAKE 2-17
ELECTRICAL INSPECTION 2-18
Contactors 2-19
Motor Brushes 2-19
EVERY 2000 HOURS OR YEARLY
HYDRAULIC SYSTEM
Change the Filter for the Hydraulic Oil
Change the Hydraulic Oil
DIFFERENTIAL AND SPEED REDUCER
SERVICE BRAKES
CONTACTORS
WHEEL BEARINGS
Steer Wheels, Lubrication
Drive Wheels, Lubrication
LIFT CHAINS
GENERAL PROCEDURES
HOW ТО CHARGE ТНЕ BATTERY
HOW ТО CHANGE ТНЕ BATTERY
SAFETY PROCEDURES WHEN WORКING
NEAR ТНЕ MAST
СНЕСК FOR LEAKS IN ТНЕ LIFT AND TILT
SYSTEM
Check the Lift Cylinders for Leaks
Check the Тilt Cylinders for Leaks
LIFT CHAIN ADJUSTMENTS
WELDING REPAIRS
CHANGES ТО ТНЕ OVERHEAD GUARD
SOLID RUBBER TIRES (PRESS-ON)
How То Change А Solid Rubber Tire
lnstall The Wheels
FRAME REPAIR
Overhead Guard, Removal
Overhead Guard, lnstallation
Battery Restraint And Seat AssemЫy
Counterweight
Removal
2-20
2-20
2-20
2-20
2-20
2-21
2-21
2-21
2-21
2-21
2-21
2-22
2-22
2-22
2-26
2-27
2-27
2-28
2-28
2-29
2-29
2-29
2-29
2-29
2-30
2-31
2-31
2-31
2-34
2-34
lnstallation
TRACTION MOTOR
Removal
lnstallation
HYDRAULIC TANK
lnspection
Repairs, Small Leaks
Repairs, Large Leaks
Cleaning
Steam Method Of Cleaning
Chemical Solution Method of Cleaning
Additional Preparations For Repair
PAINT INSTRUCTIONS
LABEL REPLACEMENT
Section З
ELECTRICAL SYSTEM
DC MOTOR MAINTENANCE, GENERAL
BRUSH AND COMMUTATOR INSPECTION
Hydraulic Pump Motor And Traction Motor
Steering Pump Motor
Commutator ProЫems
BRUSH REPLACEMENT
DISASSEMBLY OF MOTORS
Traction Motor And Hydraulic Pump Motor
Steering Pump Motor
ASSEMBLY OF MOTORS
Traction Motor And Hydraulic Pump Motor
Steering Pump Motor
BRUSH ALIGNMENT, TRACTION AND
HYDRAULIC MOTORS
TESTS FOR А DAMAGED FIELD AND
ARMATURE
Test For An Open Circuit ln The Armature
Test For А Short-Circuit ln
One Armature Winding
Test For А Short-Circuit То Armature Shaft
Test For An Open Circuit ln А Field Coil
Test For А Short-Circuit ln А Field Coil
Test For А Short-Circuit Between
The Field And The Motor Case
Brush Holder Test
2-34
2-35
2-35
2-36
2-36
2-36
2-36
2-36
2-37
2-37
2-37
2-37
2-37
2-38
3-1
3-1
3-1
3-1
3-2
3-3
3-6
3-8
3-8
3-9
3-12
3-12
3-12
3-12
3-12
3-13
3-13
3-13
3-14
3-14
3-14
3-14
EV-100/200 LX MOTOR CONTROLLER
EV-100LX AND EV-200LX MOTOR
CONTROLLERS, GENERAL 3-15
ELECTRONIC SPEED CONTROLS 3-16
Yale lndustria/ Тrucks
The Silicon Controlled Rectifier (SCR)
А Motor Circuit That Operates With Pulses
Traction Circuit
Hydraulic Pump Motor
The SCR 1 “OFF” Circuit
INDUCTION CURRENT FROM ТНЕ MOTOR
ТНЕ CONTROL CARD
Pulse Monitor Trip (РМТ)
(Тraction Circuit Only)
SRO Circuit (Traction Circuit Only)
Control Card Adjustments (Тraction Circuit)
Accelerator Control
SCR CONTROL, DUAL HYDRAULIC
PUMP MOTORS
VOLTAGE ADJUSTMENTS, SCR
CONTROL FOR HYDRAULIC PUMP
3-16
3-17
3-18
3-18
3-18
3-21
3-21
3-22
3-23
3-23
3-26
3-26
3-27
CONTACTORS 3-27
CIRCUIT PROTECTION
Traction Circuit Fuse
Current Limit
Thermal Protection
Suppressors
SEQUENCE OF OPERATION
CONTROL CARD, CHECKS AND
ADJUSTMENTS
Status Codes
HAND SET
INSTRUMENT PANEL DISPLAY
Battery Gauge With Lift lnterrupt
(Curtis 933/1 or
Curtis 933/4 Lift lnterrupt Controller)
Battery Gauge With Lift lnterrupt And
Brush Wear lndicator (General Electric)
lnstrument Panel Display (I T W Controller)
Motor Temperature lndicators
Brush Wear lndicators
CONTROL CARD CONNECTIONS
CHECKS AND ADJUSTMENTS,
CONTROL CARD
Function Codes
Checks And Adjustments Оп The Bench
When The Hand Set Is Connected То А
Control Card lnstalled ln А Lift Truck
3-28
3-28
3-28
3-28
3-28
3-28
3-29
3-29
3-30
3-31
3-31
3-32
3-33
3-34
3-34
3-35
3-39
3-39
3-40
3-40
FUNCTION SETTINGS, CHECKS AND
ADJUSTMENTS 3-41
General 3-41
How То Connect, Disconnect, And
Check The Hand Set 3-41
Yale lndustria/ Тrucks
How То Check And Adjust Functions
FUNCTION DESCRIPTIONS
Traction Control Cards
(label letters – LX, LХТ and LXM)
Pump Control Card (label letter РХ)
ТаЫеs for the Function Value Settings
TROUBLESHOOTING
REPAIRS
FUSES
СНЕСК AN SCR
The SCR 1 AssemЫy
Thermal Protector
Replace The SCR 1 AssemЫy
ТНЕ “OFF” CIRCUIT FOR SCR 1
Check The Reactor AssemЫy
Check Suppressors For SCR 2 And SCR 5
Check SCR 2 And SCR 5
REPLACE ТНЕ SCR 2 AND SCR 5
3-41
3-42
3-42
3-45
3-46
3-50
3-81
3-82
3-83
3-84
3-84
3-84
3-84
3-84
3-85
3-85
3-86
Check Capacitor С1 3-86
DIODES D3 AND D4 3-86
Check The Diodes D3 And D4 3-86
Replacement, Diodes D3 and D4 3-86
MOTOR CURRENT SENSOR 3-86
CONTACTORS
Contactor Repair
CONTROL CARD
CONTROL CARD PLUGS
CONTROL SWITCHES
Seat Switch
Кеу Switch
Direction Control Switch (Steering Column)
Parking Brake Switch And Buzzer Alarm
Start Switch
3-86
3-87
3-88
3-89
3-89
3-89
3-89
3-89
3-90
3-90
Accelerator Circuit 3-90
DIAGRAMS FOR ТНЕ EV-100/200 LX MOTOR
CONTROLLER 3-95
Figure 3-60 Schematic Diagram, EV-100LX Or
EV-200LX SCR Traction Motor
Control, 36-48 Volts 3-96
Figure 3-61 Hydraulic Pump Moto
r Controls 3-97
Figure 3-62 Hydraulic Pump Motor
Controls 3-98
Figure 3-63 Hydraulic Pump Motor
Controls 3-99
Figure 3-64 Hydraulic Pump Motor
Controls 3-100
Figure 3-65 Wiring Diagram, EV-100LX SCR
Traction Motor Control With Single Or Dual
Hydraulic Pump Motor Contactor Control 3-102
Figure 3-66 Wiring Diagram, EV-200LX SCR
Traction Motor Control With EV-100LX SCR
Hydraulic Pump Motor Control 3-104
Figure 3-67 Control Switches 3-106
Figure 3-68 Wiring Diagram, Control Switches
Without On-Demand Power Steering 3-108
Figure 3-69 Wiring Diagram, Control
Switches, On-Demand Power Steering 3-110
Figure 3-70 Hydraulic Pump Motor
Controls 3-112
Figure 3-71 Hydraulic Pump Motor
Controls 3-114
Figure 3-72 EV-100 “LX” Series GE Or IТW
Display With Lift lnterrupt – Without
Pump Motor SCR Control Schematic 3-115
Figure 3-73 Battery lndicators 3-116
Figure 3-74 Battery lndicators 3-117
Figure 3-75 “LX” SCR Hydraulics
Wiring Diagram 3-118
Figure 3-76 Contactor Hydraulics
Wiring Diagram 3-119
EV-100/200 ZX MOTOR CONTROLLER
EV-100ZXAND EV-200ZX MOTOR
CONTROLLERS, GENERAL 3-121
ELECTRONIC SPEED CONTROLLERS 3-122
The Silicon Controlled Rectifier (SCR) 3-123
А Motor Circuit That Operates With Pulses 3-123
Traction Circuit 3-124
Hydraulic Pump Motor 3-124
The SCR 1 “OFF” Circuit 3-125
lnduction Current From The Motor 3-127
The Control Card 3-127
Pulse Monitor Trip (РМТ)
(Тraction Circuit Only) 3-128
SRO Circuit (Traction Circuit Only) 3-129
Control Card Adjustments (Traction Circuit) 3-129
Accelerator Control 3-132
SCR Control, Dual Hydraulic Pump Motors 3-132
VOLTAGE ADJUSTMENTS, SCR CONTROL
FOR HYDRAULIC PUMP 3-133
CONTACTORS 3-133
CIRCUIT PROTECTION 3-134
Traction Circuit Fuse 3-134
Current Limit 3-134
Thermal Protection 3-134
Suppressors 3-134
SEQUENCE OF OPERATION 3-134
CONTROL CARD, CHECKS AND
ADJUSTMENTS 3-135
Status Codes 3-135
ТаЫе 16 STATUS CODES LIST 3-136
INSTRUMENT PANEL DISPLAY 3-136
Motor Temperature lndicators 3-141
Brush Wear lndicators 3-141
ТаЫе 17 Terminal And Plug Wire Connections
For Control Card L’f, SCR Control Of
Traction Circuit, Contactor Control Of
Hydraulic Pump, Standard or GE Panel Display,
Without Regenerative Braking, Without Brush
Wear or Motor Temperature lndicators 3-143
ТаЫе 18 Terminal And Plug Wire Connections
For Control Card ZH, SCR Control Of Traction
Circuit, Contactor Control Of Hydraulic Pump,
Performance Panel Display, With Regenerative
Braking, With Brush Wear And Motor
Temperature lndicators 3-144
ТаЫе 19 Terminal And Plug Wire Connections
For Control Card ZH, SCR Control Of Traction
Circuit, SCR Control Of Hydraulic Pump,
Performance Panel Display, With Regenerative
Braking, With Brush Wear And
Motor Temperature lndicators 3-145
ТаЫе 20 Terminal And Plug Wire Connections
For Controller With SCR Control Of Traction
Circuit And SCR Control Of The Hydraulic
Pump Motor- Control Card – Туре ZP 3-146
CONTROL CARD CONNECTIONS 3-147
REGISTER PARAMETERS 3-147
General 3-147
Function Numbers 3-147
CONTROL CARD, CHECKS AND
ADJUSTMENTS 3-147
HAND SET 3-148
How То Check And Adjust The Registers 3-148
How То Scroll Through The Fault Codes And
Clear Them 3-149
Checks And Adjustments Оп
The Work Bench 3-149
When The Hand Set 1s Connected То
А Control Card lnstalled ln А Lift Truck 3-149
COMPUTER SYSTEM 3-151
When А РС 1s Connected То
А Control Card 3-152
Help 3-161
Yale lndustria/ Тrucks
Communications Program (MODEM) 3-162
Monitor Program 3-163
GE SENTRY SOFТWARE) 3-165
Getting Started 3-165
ТаЫе 21 СаЫе Connections – Modem То
Controller 3-165
lnstallation of the
GE SENTRY SOFТWARE 3-166
Configuration of the
GE SENTRY SOFТWARE 3-166
Where То Get Help 3-166
Hardware and Software Requirements 3-166
How То Start The GE SENTRY Program 3-167
How То Reset The MIN and МАХ Display 3-168
HowTo ExitThe GE SENTRY Program 3-168
FUNCTION NUMBER DESCRIPTIONS 3-168
TRACTION CONTROL CARDS
(LABEL LEТТERS – ZH AND ZV) 3-168
PUMP CONTROL CARD (LABEL
LЕТТЕR ZP) 3-174
REGISTER PARAMETERS 3-177
REGISTER MAPS 3-177
ТаЫе 22 REGISTER МАР FOR CONTROL
CARDS ZH AND L’f (ТRACTION) 3-178
ТаЫе 23 REGISTER МАР FOR CONTROL
CARD ZP (HYDRAULIC PUMP) 3-181
ТаЫе 24 EV-100ZX Parameters –
13 lnch 36 to 48V Motor(Traction Card
Туре ZH With Regenerative Braking and
Field Weakening) 3-185
ТаЫе 25 EV-100ZX Parameters –
11 6 lnch 36 to 48V Motor(Тraction Card
Туре ZH With Regenerative Braking and
Field Weakening) 3-188
ТаЫе 26 EV-100ZX Parameters – 36 to
48 volts (Hydraulic Pump Card Туре ZP) 3-191
TROUBLESHOOTING 3-193
Status Codes 3-194
REPAIRS 3-228
FUSES 3-229
СНЕСК AN SCR 3-229
ТаЫе 27 Fuses 3-229
The SCR 1 AssemЫy 3-231
Thermal Protector 3-231
Replace The SCR 1 AssemЫy 3-231
ТНЕ “OFF” CIRCUIT FOR SCR 1 3-232
Check The Reactor AssemЫy 3-232
Check Suppressors For SCR 2 And
SCR 5 3-232
Vale lndustrial Trucks
Check SCR 2 And SCR 5 3-233
Replace The SCR 2 And SCR 5 3-233
Check Capacitor С1 3-233
DIODES D3 AND D4 3-233
Check The Diodes D3 And D4 3-233
Replacement, Diodes D3 and D4 3-233
MOTOR CURRENT SENSOR 3-234
CONTACTORS 3-234
Contactor Repair 3-235
CONTROL CARD 3-236
CONTROL CARD PLUGS 3-236
CONTROL SWITCHES 3-236
Seat Switch 3-237
Кеу Switch 3-237
Direction Control Switch
(Steering Column) (Earlier) 3-237
Direction Control Switch
(Steering Column) (Later) 3-237
Parking Brake Switch And Buzzer Alarm 3-238
Start Switch 3-238
Brush Wear lndicators 3-238
Over Temperature lndicators 3-239
Direction Switches Of
Direction Control Pedal 3-239
Accelerator Or Direction Control Circuit 3-240
Figure 3-138 Hydraulic Schematic 3-242
Figure 3-139 Schematic Diagram, EV-100ZX or
EV-200ZX SCR Motor Controllers,
36-48 Volts 3-244
Figure 3-140 Wiring Diagram, EV-100ZX or
EV-200ZX SCR Motor Controllers,
36-48 Volts (1 of 6) 3-252
Figure 3-141 СаЫе Diagram, EV-100ZX or
EV-200ZX SCR Motor Controllers,
36-48 Volts 3-262
Figure 3-142 Detail Diagram, EV-100ZX or
EV-200ZX SCR Motor Controllers,
36-48 Volts 3-263
Figure 3-143 Control Panels, EV-100ZX or
EV-200ZX SCR Motor Controllers,
36-48 Volts 3-264
Figure 3-144 Schematic And
Wiring Diagram – 12V Lights 3-266
Section 4
DRIVE AXLE ASSEMBLY 4-1
DESCRIPTION 4-1
DRIVE AXLE, REMOVAL 4-2
Traction Motor, Speed Reducer, and
Differential 4-2
DISASSEMBLY 4-5
Speed Reducer 4-5
Differential 4-5
CLEANING 4-5
INSPECTION 4-5
ASSEMBLY 4-6
Speed Reducer 4-6
TABLE 1 ADJUSTMENT OF SHIMS FOR
ТНЕ PINION ASSEMBLY 4-7
Differential 4-8
DRIVE AXLE HOUSING 4-11
Removal 4-11
Cleaning 4-11
lnspection 4-11
AssemЫy 4-11
TROUBLESHOOTING 4-14
Section 5
ТНЕ BRAKE SVSTEM 5-1
MASTER CYLINDER 5-1
SERVICE BRAKE ASSEMBLY 5-1
PARKING BRAKE 5-1
Brake Shoes, Removal and DisassemЫy 5-2
Cleaning and lnspection 5-3
AssemЫy and lnstallation 5-5
MASTER CYLINDER 5-7
Cleaning and lnspection 5-8
AssemЫy and lnstallation 5-8
CHECKS AND ADJUSTMENTS 5-8
Remove The Air From The Brake System 5-8
Adjust The Brake Pedal 5-8
Adjust The Brake Shoes 5-9
TROUBLESHOOTING 5-10
Section 6
STEERING AXLE ASSEMBLY 6-1
DESCRIPTION 6-1
STEERING AXLE ASSEMBLY 6-1
Removal 6-1
lnstallation 6-1
WHEELS AND HUBS
Removal and DisassemЫy
Cleaning
AssemЫy And lnstallation
SPINDLES, BEARINGS AND TIE RODS
6-2
6-2
6-2
6-2
6-3
Removal And DisassemЬ/y 6-3
Cleaning 6-4
AssemЬ/y And lnstallation 6-4
STEERING CYLINDER 6-5
Removal And DisassemЬ/y 6-5
Cleaning and lnspection 6-5
AssemЬ/y and lnstallation 6-5
TORQUE SPECIFICATIONS 6-6
TROUBLESHOOTING 6-6
Section 7
POWER STEERING SYSTEM 7-1
GENERAL 7-1
STEERING WHEEL AND
COLUMN ASSEMBLY 7-2
Removal Of The AssemЬ/y Components 7-2
lnstallation Of The AssemЬ/y Components 7-3
POWER STEERING MOTOR AND PUMP 7-5
Removal And DisassemЫy 7-5
AssemЬ/y And lnstallation 7-6
Repairs, Power Steering Pump 7-7
Seal Replacement 7-8
TROUBLESHOOTING, STEERING MOTOR AND
PUMP 7-9
STEERING CONTROL UNIT (ROSS HGF)
Control Valve Section
Metering Section
DisassemЬ/y And lnspection
AssemЬ/y
lnstallation
TROUBLESHOOTING (ROSS HGF)
STEERING CONTROL UNIT (DANFOSS)
Description
Removal
DisassemЬ/y
Cleaning
AssemЬ/y
lnstallation
TROUBLESHOOTING (DANFOSS)
CHECKS AND ADJUSTMENTS
Remove Air From The System
Steering Relief Valve
Check Optical Encoder And Activator
Circuits For “ON-DEMAND” Steering
7-11
7-11
7-11
7-13
7-20
7-27
7-28
7-28
7-28
7-29
7-29
7-32
7-32
7-32
7-36
7-37
7-37
7-37
7-37
Yale lndustria/ Тrucks
Section 8
HYDRAULIC SYSTEM 8-1
DESCRIPTION, HYDRAULIC SYSTEM 8-1
OPERATION, HYDRAULIC SYSTEM 8-2
Hydraulic Pump 8-3
Steering Pump 8-3
HYDRAULIC PUMP, REPAIRS 8-4
Removal 8-4
Seal Replacement 8-5
lnstallation 8-5
CHECKS AND ADJUSTMENTS 8-5
Main Control Valve 8-5
Linkage and Switches 8-7
Relief Valve 8-7
Steering Relief Valve 8-7
SPECIFICATIONS, HYDRAULIC SYSTEM 8-8
TABLE 1 TROUBLESHOOТING,
HYDRAULIC SYSTEM 8-9
LIFT CYLINDERS 8-10
Lowering Control Valve 8-11
Lift Cylinders, Removal 8-11
Standard and Full Free-Lift Masts with the
Lift Cylinder Fastened to а Crosshead 8-11
Lift Cylinders, DisassemЬ/y 8-12
Main Lift Cylinders, AssemЫy 8-14
Main Lift Cylinders, lnstallation
Free-Lift Cylinder, lnstallation
CHECKS AND ADJUSTMENTS
Check For Leaks ln The Lift System
TABLE 3 TROUBLESHOOTING, LIFT
CYLINDERS
TILT CYLINDERS
Description
Tilt Cylinders, Removal
Tilt Cylinders, DisassemЬ/y
Cleaning
Tilt Cylinders, AssemЬ/y
Tilt Cylinders With O-Ring or
Single Lip Seals
Tilt Cylinders, lnstallation
Check The Tilt Cylinders For Leaks
TABLE 4 TORQUE SPECIFICATIONS FOR
ТНЕ TILT CYLINDERS
TABLE 5 INTERNAL LEAK RATES
(MAXIMUM) FOR TILT CYLINDERS
TABLE 6 TROUBLESHOOTING,
TILT CYLINDERS
8-15
8-15
8-15
8-15
8-16
8-17
8-17
8-17
8-17
8-17
8-17
8-17
8-17
8-18
8-19
8-19
8-19
Yale lndustrial Trucks
MAIN CONTROL VALVE
Description
Operation
Lift Section
Tilt Section
Relief Valve
SOLENOID VALVE FOR
AUXILIARY FUNCTION
REPAIRS
Main Control Valve, Removal and
DisassemЫy
Cleaning and lnspection
Main Control Valve, AssemЫy
lnstallation
Solenoid Valve For Auxiliary Function,
Removal and DisassemЫy
Solenoid Valve For Auxiliary Function,
AssemЫy and lnstallation
CHECKS AND ADJUSTMENTS
Relief Valves
Primary Relief Valve
Secondary Relief Valve
CONTROL LEVER ARRANGEMENT
TABLE 7 RELIEF VALVE SEТТINGS
8-20
8-20
8-21
8-22
8-22
8-25
8-26
8-26
8-26
8-26
8-27
8-27
8-27
8-28
8-29
8-29
8-29
8-29
8-29
8-31
TABLE 8 TROUBLESHOOTING 8-31
TROUBLESHOOTING, SOLENOID VALVE FOR
AUXILIARY FUNCTION 8-32
Section 9
MAST
DESCRIPTION AND OPERATION
Carriages
Simplex Mast With Limited Free-lift
Duplex Mast With Full Free-lift
Triplex Mast With Full Free-lift
TABLE 1 WEIGHT OF MAST PARTS
SAFEТY PROCEDURES WHEN WORKING
NEAR ТНЕ MAST
REPAIRS
Forks
Forks, Removal And lnstallation
Carriage, Removal
Side-shift Carriage, Removal
Side-shift Carriage, Repairs
Side-shift Carriage, lnstallation
Simplex Mast With Limited Free-lift,
Removal
9-1
9-1
9-1
9-1
9-2
9-3
9-5
9-6
9-7
9-7
9-7
9-8
9-8
9-9
9-9
9-10
Simplex Mast With Limited Free-lift,
DisassemЫy
Cleaning and lnspection
Simplex Mast With Limited Free-lift,
AssemЫy
Simplex Mast With Limited Free-lift,
lnstallation
Duplex Mast With Full Free-lift, Removal
DisassemЫy
Cleaning and lnspection
Duplex Mast With Full Free-lift, AssemЫy
Duplex Mast With Full Free-lift, lnstallation
Triplex Mast With Full Free- Lift, Removal
Triplex Mast With Full Free-
Lift, DisassemЫy
Cleaning And lnspection
Triplex Mast With Full Free- Lift, AssemЫy
lnstallation
CHECKS AND ADJUSTMENTS
Check The Operation Of The Mast
Adjust The Tilt Cylinder Stroke And
The Backward Тilt Angle
Lift Chain Adjustments
Mast Adjustments
Carriage Adjustments
TROUBLESHOOTING, MAST
Section 10
9-11
9-12
9-13
9-13
9-14
9-14
9-14
9-14
9-16
9-17
9-17
9-18
9-18
9-19
9-19
9-19
9-19
9-20
9-21
9-22
9-24
ТНЕ INDUSTRIAL ВАПЕRУ 10-1
GENERAL 10-1
LEAD-ACID BATTERIES 10-1
SPECIFIC GRAVIТY 10-1
ТНЕ CHEMICAL REACTION IN А CELL 10-2
ELECTRICAL TERMS 10-3
HOW ТО SELECT ТНЕ ВАТТЕRУ 10-3
VOLTAGE OF А ВАТТЕRУ 10-3
ТНЕ ВАТТЕRУ AS А COUNTERWEIGHT 10-4
ВАТТЕRУ RATINGS 10-4
Kilowatt-Hours 10-4
ВАТТЕRУ MAINTENANCE 10-5
SAFEТY PROCEDURES 10-5
MAINTENANCE RECORDS 10-6
ТНЕ NEW ВАТТЕRУ 10-6
HOW ТО CLEAN ТНЕ ВАТТЕRУ 10-6
HOW ТО ADD WATER 1 О-7
ТНЕ HYDROMETER 10-7
ВАТТЕRУ TEMPERATURE 10-8
CHARGING ТНЕ BATTERY 10-9
Types Of Battery Charges 10-9
Methods Of Charging 10-1 О
TrouЫeshooting The Charger 10-11
How То Know When The Battery 1s
Fully Charged 10-11
WHERE ТО CHARGE ТНЕ BAТТERIES 10-11
Equipment Needed 10-11
ВАТТЕRУ CONNECTOR 10-12
ВАТТЕRУ CARE 10-12
ВАТТЕRУ INDICATORS 10-14
Description, “LX” Series 10-14
Battery lndicators Replacement 10-14
Controller For The Battery lndicator,
Replacement 10-15
ИJ/е lndustrial Trucks
ВАТТЕRУ INDICATORS USED WITH ТНЕ “ZX”
MOTOR CONTROLLER 10-15
Battery lndicator, Standard Display Panel 10-15
Battery lndicator, Diagnostic Display Panel 10-15
Battery lndicator, Performance
Display Panel 10-16
CHECKSANDADJUSTMENTS 10-16
“LX” Battery lndicator Without Lift lnterrupt 10-16
“LX” Battery lndicator With Lift lnterrupt 10-16
Reset Potentiometer 10-16
Discharge Potentiometer 10-17
LED Display With Lift lnterrupt 10-17

S.V 07/24