Yale Forklift ERC20-30AGF Service Manual – PDF DOWNLOAD

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Yale Forklift ERC20-30AGF Service Manual – PDF DOWNLOAD

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Yale Forklift ERC20-30AGF Service Manual – PDF DOWNLOAD

Language : English
Pages : 118
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift ERC20-30AGF Service Manual – PDF DOWNLOAD

BRAKE SYSTEM 1
toc 1
Brake System 1
Safety Precautions Maintenance and Repair 2
General 5
Description and Operation 5
Service Brakes 5
Master Cylinder 6
Parking Brake 7
Service Brakes Repair 7
Remove and Disassemble 7
Clean 11
Inspect 11
Assemble and Install 11
Adjust 14
Parking Brake Repair 16
Remove and Disassemble 16
Assemble and Install 16
Adjust 17
Master Cylinder Repair 21
Remove 21
Disassemble 22
Clean and Inspect 24
Assemble 24
Install 27
Seat Brake Assembly 27
Seat Brake, Adjust – Lift Truck Models ERC20-30AGF (ERC040-065RF 27
Brake Switch, Adjust – Lift Truck Models ERC20-30AGF (ERC040-065 27
Electric Seat Brake, Adjust for Lift Truck Model ERC20-32AGF (ER 28
Electric Seat Brake Adjustment With Handle For Lift truck Models 30
Remove 30
Clean 30
Inspect 30
Install 32
Adjustments 32
Solenoid Adjustment 32
Traction cutoff Switch Adjustment 32
Cable Adjustment 34
Service Brakes Adjustment 36
Brake Pedal Adjustment 36
Master Cylinder Adjustment 36
Brake System Air Removal 36
Parking Brake Not Applied Switch Test 37
Torque Specifications 37
Troubleshooting 37
CAPACITIES AND SPECIFICATIONS 43
toc 43
Capacities and Specifications 43
Safety Precautions Maintenance and Repair 44
Counterweights 47
Hydraulic System 47
Wheels and Tires 48
Battery Specifications 49
ERC20-30ALF 49
ERC20-30AGF (ERC040-065RG/ZG, RF/ZF) 50
Capacities 51
Movement Rates (Maximum) for Tilt Cylinders 51
Mast Speeds 52
ERC20-30ALF Mast Speeds (72 or 80 Volt) Europe 52
ERC20-30ALF Mast Speeds (72 or 80 Volt) Europe 57
ERC040-065RG/ZG (36 or 48 Volt) Americas 60
ERC040-065RG/ZG Mast Speeds (36 or 48 Volt) Americas 64
ERC20-30AGF Mast Speeds (72 or 80 Volt) Europe 67
Torque Specifications 75
Frame 75
Drive Axle, Speed Reducer, and Differential ERC20-30ALF 75
Drive Axle, Speed Reducer, and Differential ERC20-30AGF (ERC040R 76
Steering Axle ERC20-30ALF 76
Steering Axle ERC20-30AGF (ERC040-065RG/ZG, RF/ZF) 76
Masts 76
Seat Brake 77
Adhesives and Sealants 77
DC MOTOR MAINTENANCE 81
toc 81
DC Motor Maintenance 81
Safety Precautions Maintenance and Repair 82
General 85
Brush and Commutator Inspection 85
Hydraulic Pump Motor and Traction Motor 85
Steering Pump Motor 88
Normal Commutator Surface 88
Commutator Problems 89
Brush Replacement 92
Stoning the Commutator 94
Motors Repair 96
Disassemble 96
Traction Motor and Hydraulic Pump Motor 96
Steering Pump Motor 98
Assemble 100
Traction Motor and Hydraulic Pump Motor 100
Steering Pump Motor 101
Brush Alignment, Traction and Hydraulic Motors 103
Tests for Damaged Field and Armature 103
Test for an Open Circuit in One Armature Winding 103
Test for Short Circuit in One Armature Winding 104
Test for Short Circuit to Armature Shaft 104
Test for Open Circuit in Field Coil 104
Test for Short Circuit in Field Coil 105
Test for Short Circuit Between Field and Motor Case 105
Brush Holder Test 105
Troubleshooting 105
tables 81
Table 1 Normal Commutator Surfaces 87
Table 2 Commutator Problems 89
Table 3 Brush Wear Replacement Guide 92
DIAGRAMS (SEM) 111
toc 111
Electrical Diagrams 111
Safety Precautions Maintenance and Repair 112
DIAGRAMS 175
toc 175
Electrical Diagrams 175
Safety Precautions Maintenance and Repair 176
DISPLAY PANEL FOR SEM CONTROLS (DOS VERSION) 245
toc 245
SEM Display Panel 245
Safety Precautions Maintenance and Repair 246
General 249
SEM Display Panel Features 249
Common Features Descriptions 249
LED Symbol Indicators 249
LCD Screen 249
Battery Discharge Indicator (BDI) 249
Service Reminder 250
Status Codes 250
Hourmeter 250
Premium Display Panel Additional Features 251
Additional Features Descriptions (Available With Premium Display 251
LCD Screen 251
Operator Passwords 252
Daily Check List and Service Items 252
Performance Modes 252
Status Code Lists 252
BDI, Adjust 252
SEM Display Panel Indicators 253
All Indicator Symbols 253
Hourmeter Indicator Symbol 253
Wrench Indicator Symbol 253
Battery Indicator Symbol 253
Battery State-of-Charge (BDI) 253
Brake Fluid Low Symbol 253
Parking Brake Symbol 253
Fasten Seat Belt Symbol 253
LCD Screen (Standard Display Panel) 253
Premium Display Panel Additional Components 254
Alpha Numerical Screen 254
STAR Push Button 254
Push Buttons ##1 Through ##5 254
Computer Adjustments 254
Computer System 254
Connect PC to SEM Display Panel 255
ITW Switches Software Program (for SEM Display Panel) 255
Description 255
Where to Get Help 256
Hardware and Software Requirements 256
How to Start ITW Switches Program 256
Menus 257
Create a Setup File 262
SEM Display Panel Replacement 279
General 279
Remove and Replace 279
tables 245
Table 1 Adapter Pins (DB25F to DB9) 254
DISPLAY PANEL FOR SEM CONTROLS (WINDOWS VERSION) 285
toc 285
Display Panel for SEM Controls 285
Safety Precautions Maintenance and Repair 286
General 289
SEM Display Panel Features 289
Descriptions of Common Features 289
LED Symbol Indicators 289
LCD Screen 289
Battery Discharge Indicator (BDI) 290
Service Reminder 290
Status Codes 290
Hourmeter 290
Additional Features of Premium Display Panel 290
Descriptions of Additional Features (Available With Premium Disp 290
LCD Screen 290
Operator Passwords 291
Daily Check List and Service Items 291
Performance Modes 291
Status Code Lists 291
Adjustment of BDI 291
SEM Display Panel Indicators 292
All Indicator Symbols 292
Hourmeter Indicator Symbol 292
Wrench Indicator Symbol 292
Battery Indicator Symbol 292
Battery State-of-Charge (BDI) 292
Brake Fluid Too Low Symbol 293
Parking Brake Symbol 293
Fasten Seat Belt Symbol 293
LCD Screen (Standard Display Panel) 294
Additional Components of Premium Display Panel 294
Alphanumeric Screen 294
STAR Push Button 294
Push Buttons 1 Through 5 294
Adjustments With a Computer 294
Computer System 294
Connect PC to SEM Display Panel 295
ITW Switches Windows Software Program (for SEM Display Panel) 296
Description 296
Getting Help 296
Hardware and Software Requirements 296
Install 296
How to Start ITW Switches Program 296
Menus 300
Sample Sessions 309
Replacement 331
SEM Display Panel 331
Remove and Replace 331
tables 285
Table 1 Adapter Pins (DB25F to DB9) 295
DRIVE AXLE, SPEED REDUCER, AND DIFFERENTIAL 337
toc 337
Drive Axle, Speed Reducer, and Differential 337
Safety Precautions Maintenance and Repair 338
General 341
Description 341
Drive Axle, Speed Reducer, and Differential Repair 343
Drive Axle, Remove 343
Drive Axle, Disassemble 344
Speed Reducer and Differential, Disassemble 344
Clean 346
Inspect 346
Assemble 347
Speed Reducer and Differential, Assemble 347
Input Gear Assembly, Install 347
New Pinion Assembly, Install 348
Drive Axle, Assemble 354
Drive Axle Assembly, Install 354
Torque Specifications 355
Troubleshooting 356
tables 337
Table 1 Adjustment of Shims for Pinion Assembly 348
Table 2 Ring and Pinion Tooth Contact Adjustment 352
ELECTRICAL SYSTEM 359
toc 359
Electrical System 359
Safety Precautions Maintenance and Repair 360
General 365
Description 366
ZX Series Display Panels 366
Optional Basic Display Panel 366
Features of the Optional Basic Display Panel 366
Description of Features on the Optional Basic Display Panel 366
Standard Display Panel 367
Features of the Standard Display Panel 367
Description of Features on the Standard Display Panel 367
Premium Display Panel 368
Features on the Premium Display Panel 368
Description of Features on the Premium Display Panel 369
Curtis 1215 Display Panel 371
Description and Features 371
Operation 371
SEM Display Panels – Features 372
Descriptions of Common Features 373
LED Symbol Indicators – SEM 373
LCD Screen 373
Battery Discharge Indicator (BDI) 373
Service Reminder 374
Status Codes 374
Hourmeter 374
Additional Features of Premium Display Panel 375
Descriptions of Additional Features 375
LCD Screen 375
Operator Passwords 375
Daily Checklist and Service Items 375
Performance Modes 375
Status Code Lists 376
Adjustment of BDI 376
SEM Display Panel Indicators 376
All Indicator Symbols 376
Hourmeter Indicator Symbol 376
Wrench Symbol 376
Battery Symbol 376
Battery Discharge Indicator (BDI) 376
Brake Fluid Too Low Symbol 376
Parking Brake Symbol 376
Fasten Seat Belt Symbol 377
LCD Screen (Standard Display Panel) 377
Additional Components of Premium Display Panel 377
Alpha Numerical Screen 377
STAR Push Button 377
Push Buttons ##1 Through ##5 – SEM 377
Other Control Components 377
Display Panel Components – ZX, and Curtis Replacement 378
ZX Panel Replacement 378
Curtis 1215 Display Panel Replacement 383
Remove 383
Install 383
SEM Display Panel Replacement 384
Motor Controller (SR or SP) Replacement 384
Remove 384
Install 384
Control Components Replacement 386
Start Switch, Replace 386
Brake Light Switch, Replace 387
Seat Switch, Replace 387
External Seat Switch, Adjust 388
Switch for Optional Seat Brake, Replace 389
Parking Brake Switch, Replace 389
Direction Switches Foot Directional Control Replace 390
Direction Control Switches (Steering Column), Replace 391
Direction Control Switches, ERC070-120HG (Steering Column), Repl 392
Brake Fluid Switch, Replace 392
Brush Wear and Overtemperature Sensors 392
Rocker Switches for Lights 393
Accelerator Position Sensor, Replace 393
On-Demand Steering Components 395
Lights, Converter, Relay, and Reverse Alarm 397
Incandescent Brake, Tail, and Reverse Light Assembly, Replace 397
LED Brake, Tail, and Reverse Light Assembly, Replace 399
Remove 399
Install 399
Flashing Light Assembly, Replace 399
Front, Rear Driving Light, or Spot Light Assemblies, Replace 401
Operator Compartment Light Assembly, Replace 401
Converter, Replace 402
Relay, Replace 402
Reverse Alarm, Replace 402
Horn and Horn Button 402
Horn Switch and Cover 403
Hydraulic Pump Switches 403
Control and Power Fuses Check 404
ZX Motor Controllers 404
SEM Motor Controllers 404
SEM Controller Field Diagnostic Procedure 409
Armature FET Test 409
Field FET Test 409
Brush Wear and Overtemperature Sensors Check – ZX Motor Controll 413
Thermal Sensors – SEM Motor Controllers Check 414
Start Switch Adjustment 415
Accelerator Potentiometer and Start Switch, ERC070-120HG Lift Tr 416
ERC070-120HG 416
Direction Switches Foot Directional Control Pedal 417
Brake Light Switch Adjustment 418
Seat Switch Check 419
Optional Seat Brake Switch Adjustment 419
Parking Brake Switch Adjustment 420
Direction Switches Check 420
Foot Directional Control Pedal 420
Steering Column 421
Hydraulic Pump Switch Adjustment 421
Foot Directional Control or Accelerator Pedal Adjustment 421
Accelerator Position Sensor Adjustment 422
ERC 20-30 AGF (E108) _ SM List 427
yaleaxcessonline com 427
Yale Axcess Online 427
EV-100ZX SCR MOTOR CONTROLLER PARAMETER TABLES 429
toc 429
EV-100ZX™ SCR Motor Controller 429
Safety Precautions Maintenance and Repair 430
Register Parameters 433
General 433
Function Numbers 433
Control Card Checks and Adjustments 434
Register Parameter Tables 434
tables 429
Table 1 EV-100ZX Parameters – ERC040-065RF/ZF, and ERP20-30ALF 435
Table 2 EV-100ZX Parameters – ERC040-065RF/ZF (36 to 48V) (Trac 439
Table 3 EV-100ZX Parameters – ERC20-30AGF, and ERP20-30ALF (72 443
Table 4 EV-100ZX Parameters – ERC20-30AGF (72 to 80V) (Traction 447
Table 5 EV-100ZX Parameters – ERC20-30AGF (72 to 80V) (Low Ener 451
Table 6 EV-100ZX Parameters – ERC70-120HD, ERC040-065RF/ZF, and 455
Table 7 EV-100ZX Parameters – ERC35-55HG, ERC20-30AGF, and ERP2 459
FOUR STAGE MAST 465
toc 465
Four-Stage Mast 465
Safety Precautions Maintenance and Repair 466
General 469
Description 469
Carriages 469
Mast Mounts 470
Mast 470
Description 470
Operation 471
Forks Repair 474
Remove 474
Install 474
Safety Procedures When Working Near Mast 476
Carriage Repair 478
Remove 478
Standard Carriage 478
Sideshift Carriage 479
Repairs 480
Install 480
Standard Carriage 480
Sideshift Carriage 480
Mast Repair 481
Remove 481
Disassemble 481
Clean and Inspect 482
Assemble 483
Install 485
Lift Cylinders Repair 488
Remove 488
Main Lift Cylinders 488
Free-Lift Cylinders 488
Disassemble 488
Assemble 490
Install 492
Main Lift Cylinder 492
Free-Lift Cylinder 493
Header Hose Arrangements 494
Header Hoses, Install 494
Lift and Tilt System Leaks Check 501
Lift Cylinders Leaks Check 501
Tilt Cylinders Leaks Check 501
Tilt Cylinders Adjustment 502
Lift Chain Adjustments 503
Mast Adjustments 504
Carriage Adjustments 506
Troubleshooting 507
tables 465
Table 1 Standard Four-Stage Hose Dimensions 500
Table 2 Hook type Carriage Chain Adjustment 503
Table 3 Pin-Type Carriage Chain Adjustment 504
FRAME 511
toc 511
Frame 511
Safety Precautions Maintenance and Repair 512
General 515
Description 515
Main Frame 515
Other Frame Weldments 517
Overhead Guard 517
Overhead Guard Replacement 519
Remove 519
Install 519
Battery and Operator Restraint System, Hood and Seat Brake, and 526
Battery Restraint System 526
Hood 527
Hood With E-Hydraulics 528
Seat Brake 529
Operator Restraint System and Seat Assembly 529
Automatic Locking Retractor (ALR) 529
Emergency Locking Retractor (ELR) 530
Counterweight Replacement 531
Remove 531
Install 532
Traction Motor Replacement 533
Remove 533
Install 535
Hydraulic Tank Repair 536
Inspect 536
Clean 537
Steam Method 537
Chemical Solution 537
Additional Preparations for Repair 538
Small Leaks, Repair 538
Large Leaks, Repair 538
Preparations for Usage After Repair 538
Painting Instructions 538
Safety Label Replacement 540
Battery Specifications 542
tables 511
Table 1 Counterweights 531
Table 2 Lift Truck Models ERC20-30AGF (ERC40-065RF/ZF, ERC40-06 542
Table 3 Lift Truck Models ERC20-30AGF (ERC040-065GH) (A908) 543
HYDRAULIC SYSTEM 547
toc 547
Hydraulic System 547
Safety Precautions Maintenance and Repair 548
General 551
Description 551
Hydraulic System 551
Operation 559
Hydraulic System 559
Hydraulic Gear Pump 565
Steering Pump 565
Hydraulic Tank Repair 573
Tank, Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P1 573
Tank, Remove [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) 575
Tank, Remove [ERP20-32ALF (ERP040-065DH) (E216)] 576
Hydraulic Tank [ERC35-55HG (ERC70-120HH) (B839/C839)] 576
Inspect 577
Small Leaks, Repair 578
Large Leaks, Repair 578
Clean 578
Steam Method 578
Chemical Solution Method 579
Additional Methods for Tank Repair 579
Tank, Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P 579
Tank, Install [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) 580
Tank, Install [ERP20-32ALF (ERP040-065DH) (E216)] 580
Filter Replacement 581
All Lift Trucks Except [ERC35-55HG (ERC70-120HH) (B839/C839); ER 581
Remove 581
Install 582
Lift Truck Models [ERC35-55HG (ERC70-120HH) (B839/C839)] 582
Remove 582
Install 582
Lift truck Models [ERC20-32AGF (ERC040-065GH) (A908) and ERC/P16 583
Remove 583
Install 583
Lift Truck Models [ERP20-32ALF (ERP040-065DH) (E216)] 585
Remove 585
Install 585
Hydraulic Pump Repair 588
Hydraulic Pump, Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A81 588
Hydraulic Pump, Disassemble ERC/P16-20AAF (ERC030-040AF, AG/BG) 588
Inspect 590
Clean 590
Pump Seal Replace and Pump Assemble 590
Assemble Pump on Motor 590
Hydraulic Pump and Motor, Install [ERC/P16-20AAF (ERC030-040AF, 592
Hydraulic Pump, Remove [ERP20-30ALF (B216); ERP20-30ALF (ERP040- 593
Hydraulic Pump, Disassemble [ERC35-55HG (ERC70-120HH) (B839/C839 594
Hydraulic Pump, Inspect [ERC35-55HG (ERC70-120HH) (B839/C839) an 596
Hydraulic Pump, Clean [ERC35-55HG (ERC70-120HH) (B839/C839) and 596
Hydraulic Pump, Assemble [ERC35-55HG (ERC70-120HH) (B839/C839) a 596
Hydraulic Pump and Motor, Install [ERP20-30ALF (B216); ERP20-30A 596
Main Control Valve Repair 598
Steering Pump Repair 598
Pump, Remove and Disassemble [ERC/P16-20AAF (ERC030-040AF, ERC03 598
Pump, Remove and Disassemble [ERP20-30ALF (B216); ERP20-30ALF (E 600
Pump, Assemble and Install 602
Steering Control Unit Replacement 603
Remove 603
Install 603
Steering Cylinder Repair 609
Main Control Valve Check and Adjust 609
Steering Relief Valve Check and Adjust 610
Specifications 610
Relief Valve Pressures* 610
Hydraulic Tank Capacity (dipstick full mark) 611
Hydraulic Pump Capacities – All Models Except ERC35-55HG (ERC70- 611
Hydraulic Pump Capacities – Models ERC35-55HG (ERC70-120HH) (B83 611
Troubleshooting 611
Steering 611
Steering Housing and Steering Control Unit 612
Hydraulic System 613
INDUSTRIAL BATTERY 619
toc 619
Industrial Battery 619
Safety Precautions Maintenance and Repair 620
General 623
Lead-Acid Batteries 623
Specific Gravity 624
Chemical Reaction in a Cell 624
Electrical Terms 625
Battery Selection 626
Battery Voltage 627
Battery as a Counterweight 627
Battery Ratings 628
Kilowatt-Hours 628
Battery Maintenance 628
Safety Procedures 628
Maintenance Records 629
New Battery 629
Cleaning Battery 629
Adding Water to Battery 631
Hydrometer 632
Battery Temperature 632
Charging Battery 633
Types of Battery Charges 634
Methods of Charging 635
Troubleshooting Charger 636
Knowing When Battery Is Fully Charged 636
Where to Charge Batteries 636
Equipment Needed 636
Battery Connectors 637
Battery Care 637
tables 619
Table 1 Battery Capacity Terms 628
INSTRUMENT CLUSTER 641
toc 641
Instrument Cluster 641
Safety Precautions Maintenance and Repair 642
General 645
Description 645
Instrument Cluster Display Panel, Internal Combustion Lift Truck 645
Instrument Cluster Display Panel, Electric Lift Truck Models 652
Optional Basic Display Panel 652
Features of the Optional Basic Display Panel 652
Description of Features on the Optional Basic Display Panel 652
Standard Display Panel 653
Features of the Standard Display Panel 653
Description of Features on the Standard Display Panel 653
Premium Display Panel 654
Features on the Premium Display Panel 654
Description of Features on the Premium Display Panel 655
Curtis 1215 Display Panel 657
Description and Features 657
Operation 658
Cluster-Type Display Panel (Internal Combustion) Replacement 659
Remove 659
Install 659
Cluster Display Panel (Electric Lift Truck) Replacement 662
Curtis 1215 Display Panel Replacement 667
Remove 667
Install 667
tables 641
Table 1 Instrument Cluster, Internal Combustion 646
MAIN CONTROL VALVE 671
toc 671
Manual hydraulic Control Valve 671
Safety Precautions Maintenance and Repair 672
General 675
Description 675
Operation 678
ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P16-20AAF (ERC03 678
ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D216) and ERP20- 678
Lift Section 680
Tilt Section 680
Tilt Backward 680
Tilt Forward 680
Relief Valve 682
Main Control Valve Repair 683
Main Control Valve Without OPS Solenoid 683
Remove 683
Disassemble 683
Clean and Inspect 687
Assemble 687
Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P16-20A 688
Install [ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D216) a 688
Main Control Valve With OPS Solenoid 689
Remove 689
Disassemble 689
Clean and Inspect 691
Relief Valve Repair 693
Assemble 694
Install 695
Control Lever Linkage Repair 695
Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814),ERC/P16-20AAF 695
Disassemble [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814),ERC/P16- 695
Assemble and Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) 697
Control Valve Linkage Repair 697
Remove and Disassemble [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A81 697
Assemble and Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814) 698
Control Lever Linkage Repair 698
Remove [ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D216) an 698
Disassemble [ERP20-30ALF (B216), ERP20-30ALF (ERP040-060DH) (D21 700
Assemble and Install [ERP20-30ALF (B216), ERP20-30ALF (ERP040-06 700
Pressure Relief Valve Check and Adjustment 701
Primary Relief Valve 701
Secondary Relief Valve 702
Troubleshooting 703
MAST DESCRIPTION 707
toc 707
Mast 707
Safety Precautions Maintenance and Repair 708
General 711
Description and Operation 711
Carriages 711
Mast Mounts 713
Two-Stage Mast, Limited Free-Lift (LFL) 714
Description and Operation 714
Two-Stage Mast, Full Free-Lift (FFL) 716
Description and Operation 716
Three-Stage Mast, Full Free-Lift (FFL) 718
Description and Operation 718
Four-Stage Mast 720
Description and Operation 720
Cylinder Cushion During Lifting Sequence 724
Cylinder Cushion During Lowering Sequence 725
METRIC AND INCH (SAE) FASTENERS 729
toc 729
Metric and Inch (SAE) Fasteners 729
Safety Precautions Maintenance and Repair 730
General 733
Threaded Fasteners 733
Nomenclature, Threads 733
Strength Identification 734
Cotter (Split) Pins 734
Fastener Torque Tables 739
Conversion Table 741
tables 729
Table 1 Bolts and Screws 735
Table 2 Studs and Nuts 736
Table 3 Torque Nuts 737
Table 4 Torque Nuts with Nylon Insert 738
Table 5 Torque Values for Metric Fasteners* 739
Table 6 Torque Values for Inch Fasteners* 740
Table 7 Conversion Table for Metric and English Units 741
Table 8 Cotter Pin Dimensional Data 742
Table 9 Cotter Pin Dimensional Data 743
Table 10 Cotter Pin Dimensional Data 744
Table 11 Cotter Pin Dimensional Data 746
PERIODIC MAINTENANCE 749
toc 749
Periodic Maintenance 749
Safety Precautions Maintenance and Repair 751
General 757
Serial Number Data 757
How to Move Disabled Lift Truck 757
How to Tow Lift Truck 757
How to Put Lift Truck on Blocks 758
How to Raise Drive Tires 758
How to Raise Steering Tires 758
Maintenance Schedule 759
Maintenance Procedures Every 8 Hours or Daily 766
How to Make Checks With Key OFF 766
Tires and Wheels 766
Forks 767
Adjust 767
Remove 768
Install 768
Forks, Mast, and Lift Chains, Inspect 768
Safety Labels 769
Steering Column Latch 769
Operator Restraint System 769
Battery Restraint System ERC/P16-20AAF (ERC030-040AF – AG/BG), E 770
Battery Restraint System ERP20-30ALF 771
Battery 772
Hydraulic System 773
How to Make Checks With Key ON 773
Gauges, Horn, and Fuses 773
Steering System 774
Service Brakes 774
Parking Brake 774
Control Levers and Pedals 774
Direction and Speed Control Pedals 774
Lift System Operation 775
Maintenance Procedures Every 250 Hours or 6 Weeks 775
Steering Tie Rods 775
Maintenance Procedures Every 500 Hours or 3 Months 776
Hydraulic Tank Breather 776
Differential and Speed Reducer 776
Wheel Nut Torques 777
Steering Axle Spindles 777
Steering Tie Rods 777
Mast 777
Lift Chains 778
Wear Check 778
Forks 779
Brake Fluid 779
Other Lubrication 779
Seat Brake, ERC/P16-20AAF (ERC030-040AF – AG/BG), ERC20-30AGF (E 780
Electrical Inspection 780
Contactors 780
Motor Brushes 785
Motor Brushes, General 785
Maintenance Procedures Every 1000 Hours or 6 Months 793
Lift Chains 793
Forks 793
Check Upper and Lower Bearings, Integral Sideshift Carriage 793
Maintenance Procedures Every 2000 Hours or Yearly 794
Hydraulic System 794
Change Filter for Hydraulic Oil 794
Change Hydraulic Oil 795
Differential and Speed Reducer 795
Service Brakes 795
Contactors 796
Wheel Bearings 796
Steer Wheels, Lubrication 796
Drive Wheels, Lubrication 796
Lift Chains 796
Replace Upper and Lower Bearings, Integral Sideshift Carriage 796
Steering Axle 797
King Pins and Rod Ends (Steering Cylinders) 797
Other Lubrication 797
Battery Maintenance 797
How to Charge Battery 797
How to Change Battery 798
General 798
Change Battery, ERC/P16-20AAF (ERC030-040AF – AG/BG) and ERC20-3 799
Change ERP20-30ALF Battery 802
Lift and Tilt System Leak Check 804
Lift Cylinders Leak Check 804
Tilt Cylinders Leak Check 804
Safety Procedures When Working Near Mast 805
Lift Chain Adjustments 807
PMT Circuit Check 809
Welding Repairs 810
Overhead Guard Changes 810
Wheels and Tire Maintenance 810
Tires and Wheels, ERC/P16-20AAF (ERC030-040AF – AG/BG), ERC20-30 810
Remove Wheels From Lift Truck 811
Remove and Install Tire on Wheel 811
Pneumatic Tires and Wheels ERP20-30ALF 811
Remove Wheels From Lift Truck 811
Remove Wheel From Pneumatic Tire 812
Install Wheel in Pneumatic Tire 813
Install Three- or Four-Piece Wheel in Pneumatic Tire 814
Add Air to Tires 815
Wheels, Install 816
Solid Rubber Tires on Pneumatic Wheels 816
Remove Wheels From Lift Truck 816
Remove Solid Rubber Tire From Pneumatic Wheel 816
Install Solid Rubber Tire on Pneumatic Wheel 818
Wheels, Install 819
SIT Tire, Change 819
Remove SIT Solid Tire From Wheel 820
Install SIT Solid Tire on Wheel 821
Adhesives and Sealants 822
tables 749
Table 1 Maintenance Schedule 761
Table 2 Hook-Type Carriage Chain Adjustment 808
Table 3 Pin-Type Carriage Chain Adjustment 808
SR_SP TRANSISTOR MOTOR CONTROLLER PARAMETER TABLES 825
toc 825
Transistor Motor Controllers 825
Safety Precautions Maintenance and Repair 826
General 829
Function Numbers 829
Motor Controller Checks and Adjustments 830
Parameter Tables 830
tables 825
Table 1 SR (SEM) Register Parameters for Traction Motor Control 830
Table 2 SR (SEM) Register Parameters for Traction Motor Control 834
Table 3 SP Register Parameters for Pump Motor Controller – ERC/ 837
Table 4 SR (SEM) Register Parameters for Traction Motor Control 840
Table 5 SR (SEM) Register Parameters for Traction Motor Control 844
Table 6 SR (SEM) Register Parameters for Traction Motor Control 847
Table 7 SR (SEM) Register Parameters for Traction Motor Control 851
Table 8 SP Register Parameters for Pump Motor Controller – ERC0 854
Table 9 SP Register Parameters for Pump Motor Controller – ERC2 857
Table 10 SR (SEM) Register Parameters for Traction Motor Contro 861
Table 11 SR (SEM) Register Parameters for Traction Motor Contro 864
Table 12 SR (SEM) Register Parameters for Traction Motor Contro 867
Table 13 SP Register Parameters for Pump Motor Controller – ERP 870
Table 14 SP Register Parameters for Pump Motor Controller – ERP 873
SR_SP TRANSISTOR MOTOR CONTROLLERS 879
toc 879
SR/SP Transistor Motor Controllers 879
Safety Precautions Maintenance and Repair 880
Description 885
General 885
Model Number Data for SR/SP Transistor Motor Controllers 886
Motor Controller Checks and Adjustments 889
Checks and Adjustments Using Handset 889
General 889
Connect Handset 890
Start Sequence 890
Check or Delete Stored Status Codes 891
Returning Lift Truck to Normal Operation 893
Workbench Checks and Adjustments 893
How to Check and Adjust Registers 895
Function Parameters Adjustments 895
General 895
Function Numbers 896
When Handset is Connected to Motor Controller in Lift Truck 896
Function Numbers 1 through 15 896
Function Numbers 16 through 30 896
Function Numbers 48 through 63 897
Function Number Descriptions 898
Traction Motor Controller (Label Letter – SR) 898
Function Number 01 AUTO REGEN ENABLE SPEED 898
Function Number 02 CREEP SPEED 898
Function Number 03 CONTROLLED ACCELERATION 898
Function Number 04 ARMATURE CURRENT LIMIT 898
Function Number 05 REGEN RAMP RATE 899
Function Number 06 FIELD WEAKENING (FW) RATIO 899
Function Number 07 MINIMUM FIELD CURRENT 899
Function Number 08 MAXIMUM FIELD CURRENT 899
Function Number 09 REGENERATIVE BRAKING CURRENT LIMIT (C/L) 899
Function Number 10 FIELD CURRENT FOR REGENERATIVE BRAKING 899
Function Number 12 MAXIMUM ARMATURE % ON TIME (Travel Speed Limi 899
Function Number 13 SPEED LIMIT 3 900
Function Number 14 INTERNAL RESISTANCE COMPENSATION 900
Function Number 15 BATTERY VOLTAGE SELECTION 900
Function Number 16 STALL TRIP POINT % ON TIME 901
Function Number 17 CONTROL TYPE SELECTION 901
Function Number 18 STEERING PUMP TIME DELAY 901
Function Number 19 MAINTENANCE CODE TENS AND UNITS 902
Function Number 20 MAINTENANCE CODE THOUSANDS AND HUNDREDS 902
Function Number 21 AUTO REGEN BRAKING CURRENT LIMIT 902
Function Number 23 FOR SPECIAL FUNCTIONS 902
Function Number 24 FIELD WEAKENING START 902
Function Number 25 MONITOR 902
Function Number 26 BASE RATIO 902
Function Number 28 STORED STATUS CODE COUNT POINTER 902
Functions with Premium Display Panel Only 903
Function Number 48 MODE 1 – CONTROLLED ACCELERATION 903
Function Number 49 MODE 1 FIELD WEAKENING (FW) START 903
Function Number 50 MODE 1 – FIELD WEAKENING (FW) RATIO 903
Function 51 MODE 1 – MAXIMUM ARMATURE % ON TIME (MODE 1 – TRAVEL 904
Function 52 MODE 2 – CONTROLLED ACCELERATION 904
Function Number 53 MODE 2 – FIELD WEAKENING (FW) START 904
Function Number 54 MODE 2 – FIELD WEAKENING (FW) RATIO 904
Function Number 55 MODE 2 – MAXIMUM ARMATURE % ON TIME (MODE 2 – 904
Function Number 56 MODE 3 – CONTROLLED ACCELERATION 904
Function Number 57 MODE 3 – FIELD WEAKENING (FW) START 904
Function Number 58 MODE 3 – FIELD WEAKENING (FW) RATIO 904
Function Number 59 MODE 3 – MAXIMUM ARMATURE % ON TIME (MODE 3 – 905
Function Number 60 MODE 4 – CONTROLLED ACCELERATION 905
Function Number 61 MODE 4 – FIELD WEAKENING (FW) START 905
Function Number 62 MODE 4 – FIELD WEAKENING (FW) RATIO 905
Function Number 63 MODE 4 – MAXIMUM ARMATURE % ON TIME (MODE 4 – 905
Pump Motor Controller (Label Letter – SP) 905
Function Number 01 STORED STATUS CODE 905
Function Number 02 INTERNAL RESISTANCE COMPENSATION START 906
Function Number 03 CONTROLLED ACCELERATION 906
Function Number 04 CURRENT LIMIT 906
Function Number 07 INTERNAL RESISTANCE COMPENSATION RATE 906
Function Number 11 SPEED LIMIT 1 (SL1) (Slow Speed) – Tilt and S 906
Function Number 12 SPEED LIMIT 2 (SL2) (Medium Speed) – Slow Lif 906
Function Number 13 SPEED LIMIT 3 (SL3) Fast Lift 906
Function Number 16 SPEED/TORQUE COMPENSATION 907
Function Number 17 CONTROL TYPE SELECTION 907
Function Numbers 18 through 27 TEMPORARY DATA REGISTERS 907
Function Number 28 STORED STATUS CODE COUNT POINTER 907
Functions with Premium Display Panel Only 907
Function Number 48 MODE 1 – CONTROLLED ACCELERATION 908
Function Number 49 MODE 1 – SPEED LIMIT 2 908
Function Number 50 MODE 1 – SPEED LIMIT 3 908
Function Number 52 MODE 2 – CONTROLLED ACCELERATION 908
Function Number 53 MODE 2 – SPEED LIMIT 2 908
Function Number 54 MODE 2 – SPEED LIMIT 3 908
Function Number 56 MODE 3 – CONTROLLED ACCELERATION 908
Function Number 57 MODE 3 – SPEED LIMIT 2 908
Function Number 58 MODE 3 – SPEED LIMIT 3 909
Function Number 60 MODE 4 – CONTROLLED ACCELERATION 909
Function Number 61 MODE 4 – SPEED LIMIT 2 909
Function Number 62 MODE 4 – SPEED LIMIT 3 909
Troubleshooting 913
General 913
Status Codes 914
SR (SEM) and SP Status Code Charts 916
SR/SP Transistor Motor Controller Repair 950
General 950
General Maintenance Instructions 950
Special Precautions 953
Fuses 953
Contactors 954
Repair 954
Contactor Driver Module 956
Contactor Driver, Replace 956
Motor Controller Plug 956
Brush Wear Indicators 961
Thermal Sensors 961
Motor Controller, Replace 961
Theory of Operation 962
General 962
SEM System Description 962
SEM System Operation (SR Motor Controller) 962
Reverse Circuit 962
Performance and Efficiency 964
Field Weakening 964
Regenerative Braking 964
SEM System Operation (SP Motor Controller) 965
Creep Speed 965
Controlled Acceleration 965
Current Limit (CL) 965
Braking 965
Regenerative Braking to Zero Speed 965
Pedal Position Braking 966
Auto Braking 966
Auxiliary Speed Control 966
Field Weakening 966
Speed Limits 966
Ramp Operation 966
Ramp Start 966
Anti-rollback 966
Steer Pump Contactor Time Delay 966
Coil Drivers and Internal Coil Suppression 966
System Protective Override 966
Static Return to Off (SRO) 966
Accelerator Volts Hold Off 967
Pulse Monitor Trip (PMT) 967
Thermal Protector (TP) 967
Low Voltage 967
SP Pump Motor Controllers 967
Contactor Driver Module 968
Diagnostics 968
Systems Diagnostics 968
Standard Status Codes 968
Stored Status Codes 968
Hourmeter Readings 968
Maintenance Management Capability 968
tables 879
Table 1 List of Status Codes 892
Table 2 Speed/Torque Compensation 906
Table 3 Function Map for Motor Controllers SR (Traction) 909
Table 4 Function Map for Motor Controller SP (Lift Pump Motor) 912
Table 5 List of Status Codes 914
Table 6 Large (P) Plug (23-Pin) Connections/Descriptions for Mo 957
Table 7 Small Plug (12-Pin) Connections/Descriptions for Motor 958
STEERING AXLE 971
toc 971
Steering Axle 971
Safety Precautions Maintenance and Repair 972
General 975
Description 975
Steering Axle Assembly Replacement 976
Remove 976
Install 977
Wheels Repair 977
Remove and Disassemble 977
Clean 977
Inspect 978
Assemble and Install 978
Spindles, Bearings, and Tie Rods Repair 980
Remove and Disassemble 980
Assemble and Install 980
Steering Cylinder Repair 981
Remove and Disassemble 981
Clean and Inspect 982
Assemble and Install 982
Torque Specifications 983
Troubleshooting 983
STEERING HOUSING AND CONTROL UNIT (EARLY MODELS) 987
toc 987
Steering Housing and Control Unit 987
Safety Precautions Maintenance and Repair 988
General 991
Description 991
Operation 992
Steering Wheel and Column Assembly Repair 993
Steering Column Assembly, Remove 993
Steering Control Unit 998
Disassemble 998
Clean 1001
Assemble 1002
Install 1009
Steering Column Assembly, Install 1011
System Air Removal 1012
Remove 1012
Troubleshooting 1012
STEERING HOUSING AND CONTROL UNIT (LATER MODELS) 1017
toc 1017
Steering Housing and Control Unit 1017
Safety Precautions Maintenance and Repair 1018
General 1021
Description 1021
Operation 1022
Steering Wheel and Column Assembly Repair 1023
Assembly Components, Remove 1023
Steering Control Unit, Disassemble 1028
Steering Control Unit, Clean 1028
Steering Control Unit, Assemble 1028
Assembly Components, Install 1030
System Air Removal 1032
Troubleshooting 1032
STEERING SYSTEM 1037
toc 1037
Steering System for Electric Lift Trucks 1037
Safety Precautions Maintenance and Repair 1038
General 1041
Description 1043
Steering Wheel and Column Assembly Repair 1044
Assembly Components, Remove 1044
Assembly Components, Install 1048
Power Steering Motor and Pump 1049
Description 1049
Remove and Disassemble, Models ERC 20-30AGF (ERC040-065RF/ZF, RG 1050
Remove and Disassemble, Models ERC35-55HG (ERC70-120HD, ERC70-12 1051
Remove and Disassemble, Models ERP20-30ALF 1054
Remove and Disassemble, Models ERC/P16-20AAF (ERC040-065AF, AG/B 1054
Assemble and Install, All Models With A Vertical Mount Except ER 1055
Assemble and Install, Models ERP20-30ALF 1055
Assemble and Install, Models ERC/P16-20AAF (ERC030-040AF, AG/BG) 1056
Power Steering Pump, Repair 1056
Seal, Replace 1057
Hydraulic Steering Motor 1058
Steering System Air Removal 1058
Steering Pressure Check 1058
Optical Encoder and Activator Circuits Check 1059
Troubleshooting 1061
TILT CYLINDERS 1065
toc 1065
Tilt Cylinders 1065
Safety Precautions Maintenance and Repair 1066
General 1069
Description 1069
Tilt Cylinder Repair 1069
Remove 1069
Disassemble 1069
Clean 1069
Assemble 1070
Tilt Cylinders With O-Ring or Single-Lip Seals 1070
Tilt Cylinders 1071
Install 1072
Tilt Cylinder Leak Check 1074
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 1075
Torque Specifications 1075
Piston Rod Nut 1075
Retainer 1075
Troubleshooting 1076
tables 1065
Table 1 Movement Rates (Maximum) for Tilt Cylinders 1074
TROUBLESHOOTING AND ADJUSTMENTS 1081
toc 1081
Troubleshooting and Adjustments With a Computer 1081
Safety Precautions Maintenance and Repair 1082
Computer System 1085
Connect a PC to a Control Card 1086
Installation 1087
SMARTSET™ Windows Software Program 1087
How to Start the Program 1087
DEMO Mode 1088
Selecting the Communications Port 1090
Verification of Controller and Lift Truck 1091
Select Lift Truck Series 1093
Controller Card Register Parameter List 1094
How to Change a Parameter 1095
How to Save a Changed Parameter File 1096
How to Load a Saved Parameter File 1098
How to Show and Remove Saved Parameter Files 1098
How to Return to Factory Default Settings 1099
How to Save Changes to Control Card 1100
How to View Status Codes 1101
Saving Status Codes 1102
How to Show and Remove Saved Status Code Files 1103
Closing and Clearing Status Code List 1104
How to View Saved Register Data and Saved Status Data 1105
How to Save Register Data and Status Code Data In RTF and TXT 1107
GE Sentry™ Software Program 1108
Installation 1108
Description 1108
How to Start GE SENTRY Program 1108
How to Reset MIN and MAX Display 1113
Graphing Mode 1114
How to Exit GE SENTRY Program 1115
tables 1081
Table 1 Cable Connections – Computer to Control 1085
Table 2 Adapter Pins (DB25F to DB9) 1086
Table 3 Plug-Z Connection 1087

S.V 07/24