Yale Forklift ERC070-120HG [A839] Service Maintenance Manual 524166847 – PDF DOWNLOAD

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Yale Forklift ERC070-120HG [A839] Service Maintenance Manual 524166847 – PDF DOWNLOAD

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Yale Forklift ERC070-120HG [A839] Service Maintenance Manual 524166847 – PDF DOWNLOAD

Language : English
Pages : 774
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift ERC070-120HG [A839] Service Maintenance Manual 524166847 – PDF DOWNLOAD

toc 1
Capacities and Specifications 1
Safety Precautions Maintenance and Repair 2
Lift Truck Weights 5
Tire Sizes 5
Capacities 5
Hydraulic System 5
Mast Speeds 6
Mast Creep Speeds 7
Battery Specifications 7
Traction Speed and Traction Motor Current 8
Hoist Motor Current 9
Torque Specifications 9
Brake System 9
Differential 9
Drive Axle 9
Frame 9
Mast 9
Main Control Valve 9
Steering System 10
Tilt Cylinders 10
toc 13
DC Motor Maintenance 13
Safety Precautions Maintenance and Repair 14
General 17
Brush and Commutator Inspection 17
Hydraulic Pump Motor and Traction Motor 17
Steering Pump Motor 20
Normal Commutator Surface 20
Commutator Problems 20
Brush Replacement 24
Stoning the Commutator 26
Motors Repair 28
Disassemble 28
Traction Motor and Hydraulic Pump Motor 28
Steering Pump Motor 32
Assemble 32
Traction Motor and Hydraulic Pump Motor 32
Steering Pump Motor 33
Brush Alignment, Traction and Hydraulic Motors 36
Tests for Damaged Field and Armature 36
Test for an Open Circuit in Armature 36
Test for Short Circuit in One Armature Winding 37
Test for Short Circuit to Armature Shaft 37
Test for Open Circuit in Field Coil 37
Test for Short Circuit in Field Coil 37
Test for Short Circuit between Field and Motor Case 38
Brush Holder Test 38
Troubleshooting 38
tables 13
Table 1 Normal Commutator Surfaces 19
Table 2 Commutator Problems 20
Table 3 Brush Wear Replacement Guide 24
toc 43
Diagrams 43
Safety Precautions Maintenance and Repair 44
toc 63
Display Panel for SEM Controls 63
Safety Precautions Maintenance and Repair 64
General 67
SEM Display Panel Features 67
Descriptions of Common Features 67
LED Symbol Indicators 67
LCD Screen 67
Battery Discharge Indicator (BDI) 67
Service Reminder 68
Status Codes 68
Hourmeter 68
Additional Features of Premium Display Panel 68
Descriptions of Additional Features (Available With Premium Disp 68
LCD Screen 68
Operator Passwords 68
Daily Check List and Service Items 69
Performance Modes 69
Status Code Lists 69
Adjustment of BDI 69
SEM Display Panel Indicators 69
All Indicator Symbols 69
Hourmeter Indicator Symbol 70
Wrench Indicator Symbol 70
Battery Indicator Symbol 70
Battery State-of-Charge (BDI) 70
Brake Fluid Too Low Symbol 70
Parking Brake Symbol 70
Fasten Seat Belt Symbol 71
LCD Screen (Standard Display Panel) 71
Additional Components of Premium Display Panel 72
Alphanumeric Screen 72
STAR Push Button 72
Push Buttons 1 Through 5 72
Adjustments With a Computer 72
Computer System 72
Connect PC to SEM Display Panel 73
ITW Switches Windows Software Program (for SEM Display Panel) 73
Description 73
Getting Help 74
Hardware and Software Requirements 74
Install 74
How to Start ITW SWITCHES Program 74
Menus 78
Sample Sessions 85
Replacement 108
SEM Display Panel 108
Remove and Replace 108
tables 63
Table 1 Adapter Pins (DB25F to DB9) 72
toc 113
Drive Axle, Speed Reducer, and Differential 113
Safety Precautions Maintenance and Repair 114
General 117
Description 117
Drive Axle, Speed Reducer, and Differential Repair 118
Remove 118
General 118
Traction Motor, Speed Reducer, and Differential 119
Motor, Speed Reducer, and Differential, Remove 119
Disassemble 122
Speed Reducer 122
Differential 123
Clean 123
Inspect 123
Assemble 123
Speed Reducer 123
Input Gear, Install 123
New Pinion, Install 123
Differential 126
Drive Axle Housing 129
Remove 129
Clean 129
Inspect 130
Assemble 130
Troubleshooting 132
tables 113
Table 1 Pinion Assembly Shims Adjustment 124
toc 135
Electrical System 135
Safety Precautions Maintenance and Repair 136
General 141
Description 142
ZX Series Display Panels 142
Optional Basic Display Panel 142
Features of the Optional Basic Display Panel 142
Description of Features on the Optional Basic Display Panel 142
Standard Display Panel 143
Features of the Standard Display Panel 143
Description of Features on the Standard Display Panel 143
Premium Display Panel 144
Features on the Premium Display Panel 144
Description of Features on the Premium Display Panel 145
Curtis 1215 Display Panel 147
Description and Features 147
Operation 148
SEM Display Panels – Features 149
Descriptions of Common Features 149
LED Symbol Indicators – SEM 149
LCD Screen 149
Battery Discharge Indicator (BDI) 150
Service Reminder 150
Status Codes 150
Hourmeter 151
Additional Features of Premium Display Panel 151
Descriptions of Additional Features 151
LCD Screen 151
Operator Passwords 151
Daily Checklist and Service Items 151
Performance Modes 152
Status Code Lists 152
Adjustment of BDI 152
SEM Display Panel Indicators 152
All Indicator Symbols 152
Hourmeter Indicator Symbol 152
Wrench Symbol 152
Battery Symbol 152
Battery Discharge Indicator (BDI) 152
Brake Fluid Too Low Symbol 152
Parking Brake Symbol 153
Fasten Seat Belt Symbol 153
LCD Screen (Standard Display Panel) 153
Additional Components of Premium Display Panel 153
Alpha Numerical Screen 153
STAR Push Button 153
Push Buttons ##1 Through ##5 – SEM 153
Other Control Components 153
Display Panel Components – ZX, and Curtis Replacement 154
ZX Panel Replacement 154
Curtis 1215 Display Panel Replacement 159
Remove 159
Install 159
SEM Display Panel Replacement 160
Motor Controller (SR or SP) Replacement 162
Control Components Replacement 163
Start Switch, Replace 163
Brake Light Switch, Replace 163
Seat Switch, Replace 164
External Seat Switch, Adjust 165
Switch for Optional Seat Brake, Replace 165
Parking Brake Switch, Replace 166
Direction Switches (Foot Directional Control Pedal), Replace 167
Direction Control Switches (Steering Column), Replace 168
Direction Control Switches, ERC070-120HG (Steering Column), Repl 169
Brake Fluid Switch, Replace 169
Brush Wear and Overtemperature Sensors 169
Rocker Switches for Lights 170
Accelerator Position Sensor, Replace 170
On-Demand Steering Components 172
Lights, Converter, Relay, and Reverse Alarm 174
Brake, Tail, and Reverse Light Assembly, Replace 174
Flashing Light Assembly, Replace 176
Front, Rear Driving Light, or Spot Light Assemblies, Replace 176
Operator Compartment Light Assembly, Replace 177
Converter, Replace 177
Relay, Replace 177
Reverse Alarm, Replace 177
Horn and Horn Button 178
Horn Switch and Cover 178
Hydraulic Pump Switches 179
Control and Power Fuses Check 179
ZX Motor Controllers 179
SEM Motor Controllers 182
Brush Wear and Overtemperature Sensors Check – ZX Motor Controll 187
Thermal Sensors – SEM Motor Controllers Check 188
Start Switch Adjustment 189
Accelerator Potentiometer and Start Switch, ERC070-120HG Lift Tr 189
ERC070-120HG 190
Direction Switches Foot Directional Control Pedal 191
Brake Light Switch Adjustment 192
Seat Switch Check 193
Optional Seat Brake Switch Adjustment 193
Parking Brake Switch Adjustment 194
Direction Switches Check 195
Foot Directional Control Pedal 195
Steering Column 195
Hydraulic Pump Switch Adjustment 195
Foot Directional Control or Accelerator Pedal Adjustment 196
Accelerator Position Sensor Adjustment 197
toc 201
Frame 201
Safety Precautions Maintenance and Repair 202
General 205
Description 205
Overhead Guard Repair 208
Remove 208
Install 208
Battery Restraint and Seat Assembly Repair 209
Seat Brake Assembly, Adjust 210
Counterweight Repair 212
Remove 212
Install 212
Traction Motor Repair 213
Remove 213
Install 214
Hydraulic Tank Repair 214
Inspect 214
Small Leaks, Repair 214
Large Leaks, Repair 215
Clean 215
Steam Method 215
Chemical Solution Method 216
Additional Preparations For Repair 216
Painting Instructions 216
Safety Label Replacement 217
tables 201
Table 1 Battery Specifications 206
Table 2 Seat Brake Adjustment 211
Table 3 Counterweights 212
toc 223
Hydraulic System 223
Safety Precautions Maintenance and Repair 224
General 227
Description 227
Hydraulic System 227
Operation 228
Hydraulic System 228
Hydraulic Pump 229
Steering Pump 230
Hydraulic Pump Repair 230
Remove 230
Seal, Replace 231
Install 232
Main Control Valve Check and Adjust 232
Linkage and Switches 233
Relief Valve 233
Steering Relief Valve Check and Adjust 235
Specifications 235
Relief Valve Pressures 235
Capacities 235
Hydraulic Pump Capacities 235
Troubleshooting 236
toc 241
Industrial Battery 241
Safety Precautions Maintenance and Repair 242
General 245
Lead-Acid Batteries 245
Specific Gravity 246
Chemical Reaction in a Cell 246
Electrical Terms 247
Battery Selection 248
Battery Voltage 249
Battery as a Counterweight 249
Battery Ratings 249
Kilowatt-Hours 249
Battery Maintenance 250
Safety Procedures 250
Maintenance Records 250
New Battery 250
Cleaning Battery 251
Adding Water to Battery 252
Hydrometer 252
Battery Temperature 253
Charging Battery 254
Types of Battery Charges 255
Methods of Charging 256
Troubleshooting Charger 256
Knowing When Battery Is Fully Charged 257
Where to Charge Batteries 257
Equipment Needed 257
Battery Connectors 257
Battery Care 258
tables 241
Table 1 Battery Capacity Terms 249
toc 263
Lift Cylinders 263
Safety Precautions Maintenance and Repair 264
Safety Procedures When Working Near Mast 267
General 269
Description 269
Lowering Control Valve (Velocity Fuse) 269
Lift Cylinder Repair 272
Remove 272
Disassemble 273
Assemble 273
Install 273
Lift System Leak Check 274
Troubleshooting 275
toc 279
Lift Cylinders 279
Safety Precautions Maintenance and Repair 280
Safety Procedures When Working Near Mast 283
General 287
Description 287
Lowering Control Valve 287
Cylinders (General) 290
Lift Cylinder Repair 290
Lift Cylinder Removal Without Removing Mast 290
Standard Masts With Main Lift Cylinder Fastened to Crossmember o 290
Standard and Full Free-Lift Masts with Lift Cylinder Fastened to 291
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift 292
Disassemble 292
Assemble 292
Lift Cylinder Installation in Mast 294
Standard Masts With Main Lift Cylinder Fastened to Crossmember o 294
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to 294
Chevron-Style Packing 294
Chevron-Style Packing Installation on Piston 295
Chevron-Style Packing Installation in Packing Gland 297
Lift Cylinders for HI VIS® Masts 298
Description 298
Lowering Control Valve 298
Remove 300
Disassemble 301
Assemble 302
Install 303
Main Lift Cylinders 303
Free-Lift Cylinder 303
Lift System Leak Check 303
Specifications 304
Troubleshooting 305
tables 279
Table 1 Cylinder Retainer Torque Specifications and Weight Guid 304
toc 309
Main Control Valve 309
Safety Precautions Maintenance and Repair 310
General 313
Description 313
Operation 314
Lift Section 314
Tilt Section 314
Tilt Backward 314
Tilt Forward 314
Relief Valve 318
Solenoid Valve for Auxiliary Function 319
Main Control Valve Repair 320
Remove and Disassemble 320
Clean and Inspect 320
Assemble 320
Install 320
Solenoid Valve for Auxiliary Function Repair 321
Remove and Disassemble 321
Assemble and Install 321
Troubleshooting 321
Pressure Relief Valve Check and Adjustment 323
Primary Relief Valve 323
Secondary Relief Valve 324
Control Lever Arrangement and Adjustment 324
Specifications 326
Troubleshooting 326
toc 331
Masts 331
Safety Precautions Maintenance and Repair 332
General 335
Description and Operation 335
Carriages 335
Two-Stage Mast With Limited Free-Lift 335
Two-Stage Mast With Full Free-Lift 336
Three-Stage Mast With Full Free-Lift 337
Safety Procedures When Working Near Mast 339
Fork Replacement 341
Remove 342
Install 342
Carriage Repair 343
Remove 343
Sideshift Carriage Repair 344
Remove 344
Disassemble 344
Assemble 344
Install 344
Two-Stage Mast with Limited Free-Lift Repair 345
Remove – GP/GLP/GDP070-120LJ/MJ Model Lift Trucks 345
Remove – GC070-120LJ/MJ and ERC070-120HG Model Lift Trucks 347
Disassemble 347
Clean and Inspect 350
Assemble 350
Install – GP/GLP/GDP070-120LJ/MJ Lift Truck Models 352
Install – GC070-120LJ/MJ and ERC070-120HG Lift Truck Models 352
Two-Stage Mast with Full Free-Lift Repair 355
Remove 355
Disassemble 355
Clean and Inspect 355
Assemble 355
Install 357
Three-Stage Mast with Full Free-Lift Repair 359
Remove 359
Disassemble 359
Clean and Inspect 362
Assemble 362
Install 364
Mast Operation Check 368
Lift and Tilt System Leak Check 368
Lift System 368
Tilt System 369
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 370
Lift Chain Adjustments 371
Mast Adjustments 374
Carriage Adjustment 376
Troubleshooting 376
tables 331
Table 1 Tilt Cylinder Leak Check Specifications, GC070-120LJ/MJ 370
Table 2 Hook type Carriage Chain Adjustment 372
Table 3 Pin-Type Carriage Chain Adjustment 372
toc 381
Masts 381
Safety Precautions Maintenance and Repair 382
General 385
Description and Operation 385
Carriages 385
Two-Stage Mast With Limited Free-Lift 385
Two-Stage Mast With Full Free-Lift Mast 386
Three-Stage Mast With Full Free-Lift 387
Safety Procedures When Working Near Mast 389
Forks Replacement 391
Remove and Install 391
Hook Fork 391
Remove 391
Install 391
Pin Fork 392
Remove 392
Install 392
Carriage Repair 392
Remove 392
Sideshift Carriage Repair 394
Sideshift Carriage (Earlier Designs) 394
Disassemble 394
Assemble 395
Install 398
Sideshift Carriage (1993 and Later Design) 398
Remove 398
Repairs 398
Install 398
Weight of Mast Parts 401
Two-Stage Mast With Limited Free-Lift Repair 401
Remove 401
Disassemble 403
Clean and Inspect 403
Assemble 403
Install 405
Two-Stage Mast With Full Free-Lift Repair 405
Remove 405
Disassemble 405
Clean and Inspect 407
Assemble 407
Install 407
Three-Stage Mast With Full Free-Lift 408
Remove 408
Disassemble 408
Clean and Inspect 408
Assemble 408
Install 410
Mast Operation Check 412
Lift and Tilt System Leak Check 413
Lift System 413
Tilt System 413
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment 414
Lift Chain Adjustments 414
Mast Adjustments 415
Carriage Adjustment 417
Troubleshooting 418
toc 423
Periodic Maintenance 423
Safety Precautions Maintenance and Repair 424
General 427
Serial Number Data 427
How to Move Disabled Lift Truck 427
How to Tow Lift Truck 427
How to Put Lift Truck on Blocks 428
How to Raise Drive Tires 428
How to Raise Steering Tires 429
Maintenance Schedule 429
Maintenance Procedures Every 8 Hours or Daily 432
How to Make Checks with Key Switch OFF 432
Tires and Wheels 432
Forks 432
Adjust 432
Remove 432
Install 434
Inspect Mast, Forks, and Lift Chains 434
Safety Labels 435
Steering Column Latch 435
Operator Restraint System 435
Battery Restraint System 436
Battery 437
Hydraulic System 437
How to Make Checks with Key Switch ON 438
Gauges, Horn, and Fuses 438
Steering System 438
Service Brakes 438
Parking Brake 438
Control Levers and Pedals 438
Lift System Operation 439
Maintenance Procedures Every 500 Hours or 3 Months 439
Differential and Speed Reducer 439
Wheel Nuts 439
Steering Axle Spindles 439
Mast 440
Brake Fluid 440
Other Lubrication 441
Seat Brake 441
Electrical Inspection 441
Contactors 441
Motor Brushes 441
Maintenance Procedures Every 1000 Hours or 6 Months 443
Lift Chains 443
Wear Check 443
Lubrication 443
Forks 443
Maintenance Procedures Every 2000 Hours or Yearly 444
Hydraulic System 444
Hydraulic Tank Breather 444
Change Filter for Hydraulic Oil 444
Change Hydraulic Oil 444
Differential and Speed Reducer 444
Service Brakes 445
Contactors 445
Wheel Bearings 445
Steer Wheels, Lubrication 445
Drive Wheels, Lubrication 445
Lift Chains 445
Battery Maintenance 446
How to Charge Battery 446
How to Change Battery 447
Safety Procedures When Working Near Mast 450
Lift and Tilt System Leaks Check 452
Check Lift Cylinders for Leaks 452
Check Tilt Cylinders for Leaks 452
Lift Chain Adjustments 453
How to Check PMT Circuit 455
Welding Repairs 456
Overhead Guard Changes 456
Tires and Wheels 456
General 456
Remove Wheels from Lift Truck 457
Remove Tire from Wheel and Install Tire on Wheel 457
Install Wheels 457
Battery Specifications 458
tables 423
Table 1 Maintenance Schedule 430
Table 2 Hook-Type Carriage Chain Adjustment 453
Table 3 Pin-Type Carriage Chain Adjustment 454
toc 461
SEM Display Panel 461
Safety Precautions Maintenance and Repair 462
General 465
SEM Display Panel Features 465
Common Features Descriptions 465
LED Symbol Indicators 465
LCD Screen 465
Battery Discharge Indicator (BDI) 465
Service Reminder 466
Status Codes 466
Hourmeter 466
Premium Display Panel Additional Features 467
Additional Features Descriptions (Available With Premium Display 467
LCD Screen 467
Operator Passwords 468
Daily Check List and Service Items 468
Performance Modes 468
Status Code Lists 468
BDI, Adjust 468
SEM Display Panel Indicators 469
All Indicator Symbols 469
Hourmeter Indicator Symbol 469
Wrench Indicator Symbol 469
Battery Indicator Symbol 469
Battery State-of-Charge (BDI) 469
Brake Fluid Low Symbol 469
Parking Brake Symbol 469
Fasten Seat Belt Symbol 469
LCD Screen (Standard Display Panel) 469
Premium Display Panel Additional Components 470
Alpha Numerical Screen 470
STAR Push Button 470
Push Buttons ##1 Through ##5 470
Computer Adjustments 470
Computer System 470
Connect PC to SEM Display Panel 471
ITW Switches Software Program (for SEM Display Panel) 471
Description 471
Where to Get Help 472
Hardware and Software Requirements 472
How to Start ITW Switches Program 472
Menus 473
Create a Setup File 478
SEM Display Panel Replacement 495
General 495
Remove and Replace 495
tables 461
Table 1 Adapter Pins (DB25F to DB9) 470
toc 501
Steering Axle 501
Safety Precautions Maintenance and Repair 502
General 505
Description 505
Steering Axle Assembly Repair 505
Steering Axle GP/GLP/GDP070-110LG/MG, GC/GLC070-120LG/MG, GC070- 505
Remove 505
Install 506
Steering Axle GDP60-70CA (GP/GLP/GDP135-155CA), GLP/GDP165-280DA 507
Remove 507
Install 507
Wheels and Hubs Repair (All Units) 509
Remove and Disassemble 509
Clean 509
Inspect 509
Assemble and Install 509
Spindles and Bearings Repair (All Units) 511
Remove 511
Clean 511
Assemble and Install 511
Tie Rods Repair (All Units) 512
Remove 512
Clean 512
Install 512
Steering Cylinder Repair 515
Remove and Disassemble 515
Clean and Inspect 515
Assemble and Install 515
Troubleshooting 516
toc 521
Steering Control Unit 521
Safety Precautions Maintenance and Repair 522
General 525
Description 525
Control Valve Section 525
Metering Section 525
Disassembly and Inspection 526
Disassemble and Inspect 530
Assembly 546
Assemble 546
Troubleshooting 569
toc 573
Steering System for Electric Lift Trucks 573
Safety Precautions Maintenance and Repair 574
General 577
Description 579
Steering Wheel and Column Assembly Repair 580
Assembly Components, Remove 580
Assembly Components, Install 584
Power Steering Motor and Pump 585
Description 585
Remove and Disassemble, Models ERC 20-30AGF (ERC040-065RF/ZF, RG 586
Remove and Disassemble, Models ERC35-55HG (ERC70-120HD, ERC70-12 587
Remove and Disassemble, Models ERP20-30ALF 590
Remove and Disassemble, Models ERC/P16-20AAF (ERC040-065AF, AG/B 590
Assemble and Install, All Models With A Vertical Mount Except ER 591
Assemble and Install, Models ERP20-30ALF 591
Assemble and Install, Models ERC/P16-20AAF (ERC030-040AF, AG/BG) 592
Power Steering Pump, Repair 592
Seal, Replace 593
Hydraulic Steering Motor 594
Steering System Air Removal 594
Steering Pressure Check 594
Optical Encoder and Activator Circuits Check 595
Troubleshooting 597
toc 601
Tilt Cylinders 601
Safety Precautions Maintenance and Repair 602
General 605
Description 605
Tilt Cylinder Repair 605
Remove 605
Disassemble 605
Clean 605
Assemble 606
Tilt Cylinders With O-Ring or Single-Lip Seals 606
Tilt Cylinders 607
Install 608
Tilt Cylinder Leak Check 609
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 610
Torque Specifications 610
Piston Rod Nut 610
Retainer 610
Troubleshooting 611
tables 601
Table 1 Movement Rates (Maximum) for Tilt Cylinders 609
toc 615
Transistor Motor Controllers (SR and SP) 615
Safety Precautions Maintenance and Repair 616
Description 619
Model Number Data for Transistor Motor Controllers (SR and SP) 620
Motor Controller Checks and Adjustments 623
Checks and Adjustments Using a Handset 623
General 623
Connect Handset 624
Start Sequence 624
Check or Delete Stored Status Codes 625
Returning Lift Truck to Normal Operation 626
Checks and Adjustments on Workbench 626
How to Check and Adjust Registers 627
Function Parameters Adjustments 628
General 628
Function Numbers 629
When Handset is Connected to Motor Controller in Lift Truck 629
Function Numbers 1 through 15 629
Function Numbers 16 through 30 629
Function Numbers 48 through 63 630
Function Number Descriptions 630
Traction Motor Controller (Label Letter – SR) 631
Functions with Premium Display Panel Only 635
Pump Motor Controller (Label Letter – SP) 638
Functions With Premium Display Panel Only 640
Troubleshooting 646
General 646
Status Codes 646
Status Code Charts 649
Transistor Motor Controllers Repairs 683
General 683
General Maintenance Instructions 685
Special Precautions 685
Fuses 685
Contactors 686
Repair 686
Contactor Driver Module 688
Contactor Driver, Replace 688
Motor Controller Plug 688
Brush Wear Indicators 690
Thermal Sensors 691
Motor Controller, Replace 691
Parameter Tables 694
General 694
Function Numbers 694
Motor Controller Checks and Adjustments 694
Parameter Tables 694
Theory of Operation 701
General 701
SEM System Description 701
SEM System Operation (SR Motor Controller) 702
Reverse Circuit 702
Performance and Efficiency 703
Field Weakening 703
Regenerative Braking 704
Creep Speed 704
Controlled Acceleration 705
Current Limit 705
Braking 705
Regenerative Braking to Zero Speed 705
Pedal Position Braking 705
Auto Braking 705
Auxiliary Speed Control 705
Field Weakening 705
Speed Limits 706
Ramp Operation 706
Ramp Start 706
Anti-Rollback 706
Steer Pump Contactor Time Delay 706
Coil Drivers and Internal Coil Suppression 706
System Protective Override 706
SRO (Static Return to Off) 706
Accelerator Volts Hold Off 706
Pulse Monitor Trip (PMT) 706
Thermal Protector (TP) 706
Low Voltage 707
SP Pump Motor Controllers 707
Contactor Driver Module 707
Diagnostics 707
Systems Diagnostics 707
Standard Status Codes 708
Stored Status Codes 708
Hourmeter Readings 708
Maintenance Management Capability 708
tables 615
Table 1 Speed/Torque Compensation 639
Table 2 Function Map for Motor Controllers SR (Traction) 642
Table 3 Function Map for Motor Controllers SP (Lift Pump Motor) 644
Table 4 List of Status Codes 647
Table 5 Large (P) Plug (23-Pin) Connections/Descriptions for Mo 689
Table 6 Small Plug (12-Pin) Connections/Descriptions for Motor 690
Table 7 Traction Control – SR Transistor Control Settings, 11-I 695
Table 8 Traction Control – SR Transistor Control Settings, 13-I 696
Table 9 Traction Control – SR Transistor Control Settings, 13-n 698
Table 10 Hydraulic Pump – SR Transistor Control Settings (36/48 700
toc 711
Troubleshooting and Adjustments With a Computer 711
Safety Precautions Maintenance and Repair 712
Computer System 715
Connect a PC to a Control Card 716
Installation 717
SMARTSET™ Windows Software Program 717
How to Start the Program 717
DEMO Mode 718
Selecting the Communications Port 720
Verification of Controller and Lift Truck 721
Select Lift Truck Series 723
Controller Card Register Parameter List 725
How to Change a Parameter 726
How to Save a Changed Parameter File 727
How to Load a Saved Parameter File 728
How to Show and Remove Saved Parameter Files 729
How to Return to Factory Default Settings 730
How to Save Changes to Control Card 731
How to View Status Codes 732
Saving Status Codes 733
How to Show and Remove Saved Status Code Files 734
Closing and Clearing Status Code List 735
How to View Saved Register Data and Saved Status Data 736
How to Save Register Data and Status Code Data In RTF and TXT 738
GE Sentry™ Software Program 739
Installation 739
Description 739
How to Start GE SENTRY Program 739
How to Reset MIN and MAX Display 744
Graphing Mode 745
How to Exit GE SENTRY Program 746
tables 711
Table 1 Cable Connections – Computer to Control 715
Table 2 Adapter Pins (DB25F to DB9) 716
Table 3 Plug-Z Connection 717
toc 749
Brake System 749
Safety Precautions Maintenance and Repair 750
General 753
Description and Operation 753
Brake Booster and Master Cylinder 753
Master Cylinder 753
Service Brake Assembly 753
Parking Brake 756
Brake Shoe Assemblies Repair 757
Remove and Disassemble 757
Clean and Inspect 757
Assemble and Install 759
Master Cylinder Repair 762
Master Cylinder GC/GLC70-120LG/MG and GP/GLP/GDP70-120LG/MG 762
Remove 762
Disassemble 763
Assemble 763
Install 763
Master Cylinder ERC70-120HD and ERC70-120HG 764
Remove and Disassemble 764
Clean and Inspect 766
Assemble and Install 766
Brake Booster Repair 766
Remove 766
Disassemble 766
Clean and Inspect 767
Assemble 767
Install 767
Brake System Air Removal 768
Brake Pedal Adjustment 768
Brake Pedal GP/GLP/GDP70-120LG/MG with Manual Transmission and E 768
Brake Shoes Adjustment 769
Parking Brake Adjustment 770
Parking Brake Adjustment GC/GLC70-120LG/MG and GP/GLP/GDP70-120L 770
Parking Brake Lever and Switch Adjustment ERC70-120HD and ERC70- 770
Brake Booster Relief Valve Check 770
Troubleshooting 771

S.V 07/24