Yale Forklift ERC 35-55 HG (С839) Service Manual – PDF DOWNLOAD
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Yale Forklift ERC 35-55 HG (С839) Service Manual – PDF DOWNLOAD
Language : English
Pages :862
Downloadable : Yes
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TABLE OF CONTENTS:
Yale Forklift ERC 35-55 HG (С839) Service Manual – PDF DOWNLOAD
toc 1
AC Motor Controllers/Display Panel 1
Safety Precautions Maintenance and Repair 2
Description 5
General 5
AC Motors 5
Motor Controllers 5
Master Controller 5
Dash Display 5
Controller Area Network Bus (CANbus) 5
Master Controller Checks and Adjustments 6
Function Settings 7
General 7
Function Numbers 7
Function Descriptions 10
General 10
Function Number 1 BATTERY VOLTAGE 10
Function Number 2 EXTENDED SHIFT 10
Function Number 3 ACCELERATION 1 10
Function Number 4 ACCELERATION 2 10
Function Number 5 TOP SPEED LIMIT 10
Function Number 6 REGEN BRAKING 10
Function Number 7 AUTO DECELERATION 11
Function Number 8 BDI ADJUSTMENT 11
Function Number 9 LIFT INTERRUPT 11
Function Number 10 POWER STEERING TIME DELAY 11
Function Number 11 SERVICE REMINDER 11
Function Number 12 CUSTOM 11
Function Number 13 PUMP SPEED 1 11
Function Number 14 PUMP SPEED 2 12
Function Number 15 PUMP SPEED 3 12
Function Number 16 PUMP ACCELERATION 12
Troubleshooting 12
General 12
Controller Status Light Emitting Diodes (LEDs) 13
Master Controller 13
AC Motor Controllers 13
Status Codes 19
AC Motor Controllers Status Code Charts 21
Troubleshooting When Dash and/or Lift Truck is not Operational 42
Typical Symptoms 42
Truck Runs but Dash Display is not Operational, or Only Displays 42
Truck Does Not Run and Dash is Not Operational or Only Displays 43
Hydraulics Operate Normally, Traction Does Not Operate Correctly 44
Traction Operates Normally, Hydraulics do Not Operate Correctly, 44
AC Transistor Motor Controller Replacement 44
General 44
General Maintenance Instructions 50
Special Precautions 50
Fuses 51
Fan Test 51
Contactors 51
Repair 51
Thermal Sensors 55
Motor Controller, Replace 55
Display Panel 56
General 56
Premium Display Panel 56
Standard Display Panel 56
Display Functions and Features 57
Key-On Initialization 57
Standard Display 58
Premium Display 58
Lift Truck Inspection Function 59
Access to Service Functions 59
Service Functions 59
Service Functions 60
Performance Modes 62
Battery Discharge Indicator (BDI) 62
Hourmeter 63
Dash Display Service Menu Navigation 69
General 69
Moving Through Menu Selections 69
Editing and Adding Information 69
tables 1
Table 1 Factory Parameters for ERP20-30ALF (ERP040-060DH) (D216 7
Table 2 Factory Setting for ERC020-032AGF (ERC40-65GH) (A908) 8
Table 3 Factory Setting for ERC/P16-20AAF (ERC030-040AH) (B814/ 8
Table 4 Factory Parameters for ERC35-55HG (ERC70-120HH) (B839/C 9
Table 5 List of Status Codes 19
Table 6 42-Pin Connections/Descriptions for Master Controller 52
Table 7 Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo 54
Table 8 Pin Connections/Descriptions for 36/48 and 72v/80v (Gen 54
toc 73
AC Motor Repair 73
Safety Precautions Maintenance and Repair 74
General 77
AC Motor Repair 77
Disassemble 77
Assemble 81
Troubleshooting 83
toc 87
Brake System 87
Safety Precautions Maintenance and Repair 88
General 91
Description and Operation 91
Brake Booster and Master Cylinder 91
Master Cylinder 91
Service Brake Assembly 91
Parking Brake 95
Seat Brake 96
Brake Shoe Assemblies Repair 97
Remove and Disassemble 97
Clean and Inspect 97
Assemble and Install 99
Master Cylinder Repair103
Master Cylinder For Lift Truck Models GC/GLC70-120LG/MG (B818) a103
Remove103
Disassemble103
Assemble104
Install104
Master Cylinder For Lift Truck Models ERC70-120HD, ERC70-120HG (105
Remove and Disassemble105
Clean and Inspect106
Assemble and Install106
Brake Booster Repair106
Remove106
Disassemble106
Clean and Inspect107
Assemble108
Install108
Brake System Air Removal108
Brake Pedal Adjustment108
Brake Pedal GP/GLP/GDP70-120LG/MG (B813) With Manual Transmissio108
Brake Shoes Adjustment110
Parking Brake Adjustment110
Parking Brake Adjustment, Lift Truck Models GC/GLC70-120LG/MG (B110
Parking Brake Lever and Switch Adjustment ERC70-120HD and ERC70-111
Seat Brake Assembly112
Remove112
Clean and Inspect112
Install112
Adjustments114
Solenoid Adjustment114
Traction cutoff Switch Adjustment114
Cable Adjustment114
Brake Booster Relief Valve Check117
Troubleshooting117
toc123
Capacities and Specifications123
Safety Precautions Maintenance and Repair124
Lift Truck Lifting Capacity127
Counterweight Weights127
Tire Sizes127
Capacities128
Hydraulic System128
Steering System129
Specifications129
Turning Radius129
Mast Speeds130
Maximum Carriage and Tilt Creep Rates131
Battery Specifications131
Traction Motor Speed132
Battery Current at Hoist Relief132
Torque Specifications132
Brake System132
Differential133
Drive Axle133
Frame133
Mast133
Main Control Valve133
Steering System133
Tilt Cylinders134
Hydraulic System134
Electrical System134
tables123
Table 1 Manual Control Valve128
Table 2 E-Hydraulic Control Valve128
toc137
Cylinder Repair137
Safety Precautions Maintenance and Repair138
General141
Description141
Safety Procedures When Working Near Mast142
Tilt Cylinder Repair144
Remove144
Disassemble145
Inspect145
Clean145
Assemble148
Install149
Tilt Cylinders, Adjust150
Tilt Cylinder Leak Check152
Torque Specifications153
Piston Rod Nut153
Gland153
Tilt Cylinder Mounting Capscrew153
Tilt Cylinder Rod End Nut153
Lift Cylinder Repair154
Main Lift Cylinders154
Remove154
Disassemble155
Clean156
Inspect156
Assemble156
Install156
System Air Bleed Procedures157
Two-Stage FFL Left Side Main Lift Cylinder158
Disassemble158
Clean160
Inspect160
Assemble160
Install160
Free-Lift Cylinder161
Remove161
Disassemble164
Clean164
Inspect165
Assemble165
Install166
Torque Specifications166
Lift Cylinders Leak Check167
tables137
Table 1 Movement Rates (Maximum) for Tilt Cylinders152
toc171
Diagrams171
Safety Precautions Maintenance and Repair172
toc211
Drive Axle, Speed Reducer, and Differential211
Safety Precautions Maintenance and Repair212
General215
Description215
Drive Axle, Speed Reducer, and Differential Repair216
Remove216
General216
Traction Motor, Speed Reducer, and Differential217
Motor, Speed Reducer, and Differential, Remove217
Disassemble220
Speed Reducer220
Differential221
Clean222
Inspect222
Assemble222
Speed Reducer222
Input Gear, Install222
New Pinion, Install222
Differential225
Drive Axle Housing228
Remove228
Clean229
Inspect229
Assemble229
Troubleshooting232
tables211
Table 1 Pinion Assembly Shims Adjustment224
Table 2 Ring and Pinion Tooth Contact Adjustment226
toc235
Electrical System (Trucks With AC Controllers)235
Safety Precautions Maintenance and Repair236
General239
Description240
Features of the Display Panels240
Other Control Components241
Display Panel and Key Switch Replacement242
Display Panel, Replace242
Key Switch, Replace244
Controller Replacement244
Traction and Pump Motor Controller Replacement244
Master Controller, Replace250
Master Controller, Remove ERP20-30ALF (ERP040-060DH) (D216), ERP250
Master Controller, Install ERP20-30ALF (ERP040-060DH) (D216), ER250
Master Controller, Remove ERC/P16-20AAF (ERC030-040AH) (B814/C81252
Master Controller, Install ERC/P16-20AAF (ERC030-040AH) (B814/C8252
Master Controller, Remove ERC35-55HG (ERC070-120HH) (B839/C839)254
Master Controller, Install ERC35-55HG (ERC070-120HH) (B839/C839)254
Control Components Replacement255
General255
Start Switch, Replace255
Brake Light Switch, Replace256
Seat Switch, Replace256
Parking Brake Switch, Replace257
Foot Directional Control Pedal Direction Switches, Replace259
Steering Column Direction Control Switches, Replace262
Remove262
Install262
Brake Fluid Switch, Replace264
Brush Wear and Over Temperature Sensors (DC Pump Motor Only)264
Rocker Switches for Lights, Replace264
Accelerator Position Sensor, Replace265
On-Demand Steering Sensor, Replace266
Lights, Converter, Relay, and Reverse Alarm266
Brake, Tail, and Reverse Light Assembly, Replace267
Incandescent Assembly267
LED Assembly – Remove269
LED Assembly – Install269
Strobe Light Assembly, Replace272
Wire Harness Repair273
Del-City Crimp-Solder-Shrink Splice273
Front, Rear Driving Light or Spot Light Assemblies, Replace274
Converter, Replace274
Remove, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216), ERP274
Install, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216), ER276
Remove, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) and 276
Install, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) and276
Remove, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839)278
Install, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839)278
Reverse Relay, Replace279
Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908), ERC/P16-20A279
Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839)279
Backup Alarm, Replace281
Horn and Horn Button, Replace281
Horn Replacement for Lift Trucks ERP20-30ALF (ERP040-060DH) (D21281
Horn Replacement for Lift Trucks ERC35-55HG (ERC70-120HH) (B839/283
Horn Switch and Cover, Replace284
Hydraulic Pump Switches285
Fan Power Supply, Replace285
Remove, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839)285
Install, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839)285
Remove, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216) and 286
Install, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216) and287
Remove, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908)287
Install, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908)287
Control and Power Fuse Check288
Fuse Locations288
Brake Light Switch Adjustment294
Seat Switch Check295
Seat Brake Adjustment295
Parking Brake Switch Adjustment296
Direction Switches Check296
Foot Directional Control Pedal296
Steering Column297
Foot Directional Control Pedal or Accelerator Pedal Adjustment297
Accelerator Position Sensor Adjustment and Start Switch Adjustme298
Acceleration Position Sensor, Adjust298
Start Switch, Adjust300
tables235
Table 1 Wire Splice Size273
toc303
Frame303
Safety Precautions Maintenance and Repair304
General307
Description307
Overhead Guard Replacement309
Remove309
Install310
Battery and Operator Restraint, Hood and Seat Brake Repair311
Battery Restraint and Hood Repair311
Operator Restraint System and Seat Assembly314
Automatic Locking Retractor (ALR)314
Emergency Locking Retractor (ELR)314
Seat Brake Repair315
Counterweight Replacement315
Remove315
Install316
Traction Motor Repair316
Remove316
Install317
Hydraulic Tank Repair318
Inspect318
Small Leaks, Repair318
Large Leaks, Repair318
Clean318
Steam Method319
Chemical Solution Method319
Additional Preparations For Repair319
Safety Label Replacement320
Battery Specifications322
tables303
Table 1 Torque Values310
Table 2 Weight of Counterweights315
Table 3 Battery Specifications*322
toc325
Hydraulic System325
Safety Precautions Maintenance and Repair326
General329
Description329
Hydraulic System329
Operation337
Hydraulic System337
Hydraulic Gear Pump343
Steering Pump343
Hydraulic Tank Repair351
Tank, Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P1351
Tank, Remove [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) 353
Tank, Remove [ERP20-32ALF (ERP040-065DH) (E216)]354
Hydraulic Tank [ERC35-55HG (ERC70-120HH) (B839/C839)]354
Inspect355
Small Leaks, Repair356
Large Leaks, Repair356
Clean356
Steam Method356
Chemical Solution Method357
Additional Methods for Tank Repair357
Tank, Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P357
Tank, Install [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH)358
Tank, Install [ERP20-32ALF (ERP040-065DH) (E216)]358
Filter Replacement359
All Lift Trucks Except [ERC35-55HG (ERC70-120HH) (B839/C839); ER359
Remove359
Install360
Lift Truck Models [ERC35-55HG (ERC70-120HH) (B839/C839)]360
Remove360
Install360
Lift truck Models [ERC20-32AGF (ERC040-065GH) (A908) and ERC/P16361
Remove361
Install361
Lift Truck Models [ERP20-32ALF (ERP040-065DH) (E216)]363
Remove363
Install363
Hydraulic Pump Repair366
Hydraulic Pump, Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A81366
Hydraulic Pump, Disassemble ERC/P16-20AAF (ERC030-040AF, AG/BG) 366
Inspect368
Clean368
Pump Seal Replace and Pump Assemble368
Assemble Pump on Motor368
Hydraulic Pump and Motor, Install [ERC/P16-20AAF (ERC030-040AF, 370
Hydraulic Pump, Remove [ERP20-30ALF (B216); ERP20-30ALF (ERP040-371
Hydraulic Pump, Disassemble [ERC35-55HG (ERC70-120HH) (B839/C839372
Hydraulic Pump, Inspect [ERC35-55HG (ERC70-120HH) (B839/C839) an374
Hydraulic Pump, Clean [ERC35-55HG (ERC70-120HH) (B839/C839) and 374
Hydraulic Pump, Assemble [ERC35-55HG (ERC70-120HH) (B839/C839) a374
Hydraulic Pump and Motor, Install [ERP20-30ALF (B216); ERP20-30A374
Main Control Valve Repair376
Steering Pump Repair376
Pump, Remove and Disassemble [ERC/P16-20AAF (ERC030-040AF, ERC03376
Pump, Remove and Disassemble [ERP20-30ALF (B216); ERP20-30ALF (E378
Pump, Assemble and Install380
Steering Control Unit Replacement381
Remove381
Install381
Steering Cylinder Repair387
Main Control Valve Check and Adjust387
Steering Relief Valve Check and Adjust388
Specifications388
Relief Valve Pressures*388
Hydraulic Tank Capacity (dipstick full mark)389
Hydraulic Pump Capacities – All Models Except ERC35-55HG (ERC70-389
Hydraulic Pump Capacities – Models ERC35-55HG (ERC70-120HH) (B83389
Troubleshooting389
Steering389
Steering Housing and Steering Control Unit390
Hydraulic System391
toc397
Industrial Battery397
Safety Precautions Maintenance and Repair398
General401
Lead-Acid Batteries401
Specific Gravity402
Chemical Reaction in a Cell402
Electrical Terms403
Battery Selection404
Battery Voltage405
Battery as a Counterweight405
Battery Ratings406
Kilowatt-Hours406
Battery Maintenance406
Safety Procedures406
Maintenance Records407
New Battery407
Cleaning Battery407
Adding Water to Battery409
Hydrometer410
Battery Temperature410
Charging Battery411
Types of Battery Charges412
Methods of Charging413
Troubleshooting Charger414
Knowing When Battery Is Fully Charged414
Where to Charge Batteries414
Equipment Needed414
Battery Connectors415
Battery Care415
tables397
Table 1 Battery Capacity Terms406
toc419
Electro-hydraulic Control Valve419
Safety Precautions Maintenance and Repair420
General423
Description423
Electro-Hydraulic Control System423
Electro-Hydraulic Control Valve426
Electro-Hydraulic Valve Driver Module442
Mini-Lever Module (MLM)442
Joystick443
Electro-Hydraulic Control Valve Repair444
Remove444
Disassemble453
Solenoid Coil Replacement455
Cartridge Replacement457
Electro-Hydraulic Pressure Reducing Valve (EHPR) Replacement458
Lift Circuit Check Valve Replacement459
Compensator Cartridge Replacement459
Primary and Secondary Relief Valves Replacement459
Tilt Counterbalance Valve Replacement460
Flow Regulator Valve Replacement460
Assemble460
Install460
E-Hydraulics Calibration469
Mini-Lever Module471
Mini-Lever Module (MLM)471
Remove471
Install471
Mini-Lever Replacement471
Remove471
Clean and Inspect472
Install472
Push Button Switch Replacement473
Remove473
Install474
Test475
Mini-levers475
Full Stroke Test475
Function Returns to Neutral Test475
Push Button Switch476
Joystick476
Remove and Disassemble476
Inspect476
Assemble and Install476
Troubleshooting477
tables419
Table 1 Primary and Secondary Relief Valve Values429
Table 2 Solenoid Resistance Values455
Table 3 Cartridge and Solenoid Coil Nut Torque for Lift truck M458
Table 4 Cartridge and Solenoid Coil Nut Torque for Lift truck M458
toc489
Manual hydraulic Control Valve489
Safety Precautions Maintenance and Repair490
General493
Description493
Operation495
Lift Section497
Tilt Section498
Tilt Backward498
Tilt Forward498
Relief Valve500
Solenoid Valve for Auxiliary Function501
Main Control Valve Repair502
Remove and Disassemble – Control Valve Without OPS Solenoid502
Remove and Disassemble – Control Valve With OPS Solenoid502
Clean and Inspect504
Assemble – Control Valve Without OPS504
Assemble – Control Valve With OPS504
Install505
Solenoid Valve for Auxiliary Function Repair505
Remove and Disassemble505
Assemble and Install507
Troubleshooting507
Pressure Relief Valve Check and Adjustment508
Primary Relief Valve508
Secondary Relief Valve508
Control Lever Arrangement and Adjustment509
Specifications511
Troubleshooting511
toc517
Mast Repairs517
Safety Precautions Maintenance and Repair518
Safety Procedures When Working Near Mast521
Fork Replacement523
Remove523
Install524
Checks524
Carriage Replacement525
Remove525
Install531
Disconnecting Attachment Hydraulic Quick Disconnect Hoses532
Connecting Attachment Hydraulic Quick Disconnect Hoses533
Integral Sideshift Carriage Repair533
Remove, for lift truck models ERC35-55HG (ERC70-120HH) (C839), G533
Disassemble534
Assemble536
Install, for lift truck models ERC35-55HG (ERC70-120HH) (C839), 536
Hang On Sideshift Carriage Repair536
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP13536
Disassemble542
Clean and Inspect544
Assemble544
Install545
Two-Stage Mast With Limited Free-Lift Repair546
Remove546
Disassemble548
Clean and Inspect550
Assemble559
Install, GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP5560
Install, GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/G561
Header Hose Alignment571
Two-Stage Mast With Full Free-Lift Repair582
Remove582
Disassemble583
Clean and Inspect589
Assemble590
Install, GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP5592
Install, GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/G594
Header Hose Installation and Adjustment597
Installation597
Adjustment597
Three-Stage Mast With Full Free-Lift Repair598
Remove598
Disassemble599
Clean and Inspect611
Assemble612
Install, GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP5614
Install, GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/G618
Header Hose Alignment for GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,623
Header Hose Alignment for GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP13629
Mast Operation Check633
Tilt Cylinder Adjustment633
Lift Chains Adjustment634
Mast Adjustments635
Load Roller Adjustment635
Mast Side Kicking Adjustment637
Carriage Adjustments638
tables517
Table 1 Fork Tip Alignment524
Table 2 Standard Mast Height; Header Hose Tension Mark Location579
Table 3 Standard Mast Height; Header Hose Tension Mark Location579
Table 4 Standard Mast Height; Header Hose Tension Mark Location580
Table 5 Standard Mast Height; Header Hose Tension Mark Location580
Table 6 Standard Mast Height; Header Hose Tension Mark Location581
Table 7 Standard Mast Height; Header Hose Tension Mark Location626
Table 8 Standard Mast Height; Header Hose Tension Mark Location628
Table 9 Standard Mast Height; Header Hose Tension Mark Location628
Table 10 Hook-Type Carriage Chain Adjustment634
toc641
Metric and Inch (SAE) Fasteners641
Safety Precautions Maintenance and Repair642
General645
Threaded Fasteners645
Nomenclature, Threads645
Strength Identification646
Cotter (Split) Pins646
Fastener Torque Tables651
Conversion Table653
tables641
Table 1 Bolts and Screws647
Table 2 Studs and Nuts648
Table 3 Torque Nuts649
Table 4 Torque Nuts with Nylon Insert650
Table 5 Torque Values for Metric Fasteners*651
Table 6 Torque Values for Inch Fasteners*652
Table 7 Conversion Table for Metric and English Units653
Table 8 Cotter Pin Dimensional Data654
Table 9 Cotter Pin Dimensional Data655
Table 10 Cotter Pin Dimensional Data656
Table 11 Cotter Pin Dimensional Data658
toc661
Periodic Maintenance661
Safety Precautions Maintenance and Repair662
General667
How to Move Disabled Lift Truck667
How to Tow Lift Truck667
How to Put Lift Trucks on Blocks668
How to Raise Drive Tires668
How to Raise Steering Tires668
How to Clean a Lift Truck669
Maintenance Schedule670
Maintenance Procedures Every 8 Hours or Daily674
General674
How to Make Checks With Key Switch OFF675
Tires and Wheels675
Forks675
Remove675
Inspect675
Install676
Adjust676
Inspection of Mast, Mast Pivots, Header Hoses and Lift Chains677
Safety Labels677
Steering Column Latch677
Operator Restraint System678
Automatic Locking Retractor (ALR)678
Emergency Locking Retractor (ELR)678
Battery Restraint System679
Battery680
Hydraulic System681
How to Make Checks With Key Switch ON682
Horn, Lights, and Alarm682
Steering System683
Service Brakes683
Parking Brake683
Seat Brake683
Control Levers and Pedals683
Direction and Speed Control Pedals683
Lift System Operation683
Oil Leaks684
First Service After First 100 Hours of Operation684
Change Hydraulic Oil and Filter684
Lift Truck Models ERC35-55HG (ERC70-120HH) (C839)684
Remove684
Install686
Lift Truck Models ERC35-55HG (ERC70-120HH) (B839)687
Remove687
Install688
Maintenance Procedures Every 500 Hours or 3 Months689
Wheel Nuts689
Header Hose Checks689
Mast Lubrication689
Integral Sideshift Carriage692
Brake Fluid693
Other Lubrication693
Maintenance Procedures Every 1000 Hours or 6 Months693
Differential and Speed Reducer693
Lift Chains693
Wear Check693
Lubrication694
Forks694
Parking Brake694
Brake Linkage Shafts695
Steering Spindles and Tie Rod Ends695
Seat Rails695
Seat Plate Hinges695
Electrical Inspection696
Contactors696
Maintenance Procedures Every 2000 Hours or Yearly698
Brake Fluid698
Hydraulic System699
Hydraulic Tank Breather, Lift Truck Models ERC35-55HG (ERC70-120699
Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models699
Remove699
Install700
Hydraulic Tank Breather, Lift Truck Models ERC35-55HG (ERC70-120701
Remove701
Install701
Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models701
Remove701
Install703
Differential and Speed Reducer703
Service Brakes704
Wheel Bearings704
Steer Wheels, Lubrication704
Drive Wheels, Lubrication704
Lift Chains704
Battery Maintenance705
How to Charge Battery705
How to Change Battery706
Safety Procedures When Working Near Mast709
Lift and Tilt System Leak Check712
Check Lift Cylinders for Leaks712
Check Tilt Cylinders for Leaks712
Lift Chain Adjustments713
Welding Repairs714
Overhead Guard Changes715
Wheels and Tires715
General715
Remove Wheels From Lift Truck715
Remove Tire From Wheel and Install Tire on Wheel715
Remove715
Install715
Install Wheels716
tables661
Table 1 Maintenance Schedule671
Table 2 Battery Specifications*709
Table 3 Hook-Type Carriage Chain Adjustment714
toc719
Steering Axle719
Safety Precautions Maintenance and Repair720
General723
Description723
Steering Axle Assembly Repair728
Steering Axle GP/GLP/GDP070-110LG/MG (B813), GC/GLC070-120LG/MG 728
Remove728
Install728
Steering Axle GDP60-70CA (GP/GLP/GDP135-155CA) (A878, B878), GLP729
Remove729
Install729
Wheels and Hubs Repair (All Units)730
Remove and Disassemble730
Clean730
Inspect730
Assemble and Install730
Spindles and Bearings Repair (All Units)732
Remove732
Clean732
Assemble and Install733
Tie Rods Repair (All Units)734
Remove734
Clean734
Install734
Steering Cylinder Repair737
Remove and Disassemble737
Clean and Inspect737
Assemble and Install737
Troubleshooting738
toc743
Steering Housing and Control Unit743
Safety Precautions Maintenance and Repair744
General747
Description747
Operation748
Steering Wheel and Column Assembly Repair749
Assembly Components, Remove749
Steering Control Unit, Disassemble754
Steering Control Unit, Clean754
Steering Control Unit, Assemble754
Assembly Components, Install756
System Air Removal758
Troubleshooting758
toc763
Steering System for AC Electric Lift Trucks763
Safety Precautions Maintenance and Repair764
General767
Description768
Steering Wheel and Column Assembly Repair769
General769
Assembly Components, Remove771
Assembly Components, Install772
Power Steering Motor and Pump773
Description773
Remove773
Disassemble776
Install776
Power Steering Pump, Repair776
Seal, Replace777
Steering System Air Removal778
Steering Pressure Check778
Steering Motor Circuits Check779
Troubleshooting780
toc785
Troubleshooting and Adjustments Using the AC Controls Program (E785
Safety Precautions Maintenance and Repair786
General789
Computer Requirements789
Software, Install789
Language Selection789
Demo Mode790
Connect PC to Lift Truck794
Starting AC Controls Program796
Lift Truck Control Setup801
Change Lift Truck Serial Number or Hourmeter801
Setting Factory Default Values or Changing Lift Truck Parameters802
Create New Custom Lift Truck Configuration808
Lift Truck Configuration Properties811
Import New Lift Truck Configuration From Disk814
Delete Custom Lift Truck Configuration or Password File816
Dash Display819
Custom Display Languages819
Download Display Language821
Clear Operator Log821
Password Functions824
Enable/Disable Password and Lift Truck Inspection Functions824
Truck Inspection Checklist824
Password824
Password Properties824
Create New Password File829
Download Passwords830
Upload Passwords832
Reports Menu834
Devices Report834
Custom Report834
Password Report834
Operator Report841
Current Settings Report844
Status Code Report848
Status Codes Log851
Troubleshooting853
Diagnostics853
Help Menu856
General856
Contents856
Technical Support856
About Electric Truck AC Controls Program856toc 1
AC Motor Controllers/Display Panel 1
Safety Precautions Maintenance and Repair 2
Description 5
General 5
AC Motors 5
Motor Controllers 5
Master Controller 5
Dash Display 5
Controller Area Network Bus (CANbus) 5
Master Controller Checks and Adjustments 6
Function Settings 7
General 7
Function Numbers 7
Function Descriptions 10
General 10
Function Number 1 BATTERY VOLTAGE 10
Function Number 2 EXTENDED SHIFT 10
Function Number 3 ACCELERATION 1 10
Function Number 4 ACCELERATION 2 10
Function Number 5 TOP SPEED LIMIT 10
Function Number 6 REGEN BRAKING 10
Function Number 7 AUTO DECELERATION 11
Function Number 8 BDI ADJUSTMENT 11
Function Number 9 LIFT INTERRUPT 11
Function Number 10 POWER STEERING TIME DELAY 11
Function Number 11 SERVICE REMINDER 11
Function Number 12 CUSTOM 11
Function Number 13 PUMP SPEED 1 11
Function Number 14 PUMP SPEED 2 12
Function Number 15 PUMP SPEED 3 12
Function Number 16 PUMP ACCELERATION 12
Troubleshooting 12
General 12
Controller Status Light Emitting Diodes (LEDs) 13
Master Controller 13
AC Motor Controllers 13
Status Codes 19
AC Motor Controllers Status Code Charts 21
Troubleshooting When Dash and/or Lift Truck is not Operational 42
Typical Symptoms 42
Truck Runs but Dash Display is not Operational, or Only Displays 42
Truck Does Not Run and Dash is Not Operational or Only Displays 43
Hydraulics Operate Normally, Traction Does Not Operate Correctly 44
Traction Operates Normally, Hydraulics do Not Operate Correctly, 44
AC Transistor Motor Controller Replacement 44
General 44
General Maintenance Instructions 50
Special Precautions 50
Fuses 51
Fan Test 51
Contactors 51
Repair 51
Thermal Sensors 55
Motor Controller, Replace 55
Display Panel 56
General 56
Premium Display Panel 56
Standard Display Panel 56
Display Functions and Features 57
Key-On Initialization 57
Standard Display 58
Premium Display 58
Lift Truck Inspection Function 59
Access to Service Functions 59
Service Functions 59
Service Functions 60
Performance Modes 62
Battery Discharge Indicator (BDI) 62
Hourmeter 63
Dash Display Service Menu Navigation 69
General 69
Moving Through Menu Selections 69
Editing and Adding Information 69
tables 1
Table 1 Factory Parameters for ERP20-30ALF (ERP040-060DH) (D216 7
Table 2 Factory Setting for ERC020-032AGF (ERC40-65GH) (A908) 8
Table 3 Factory Setting for ERC/P16-20AAF (ERC030-040AH) (B814/ 8
Table 4 Factory Parameters for ERC35-55HG (ERC70-120HH) (B839/C 9
Table 5 List of Status Codes 19
Table 6 42-Pin Connections/Descriptions for Master Controller 52
Table 7 Pin Connections/Descriptions for 72/80 (Gen IV) Volt Mo 54
Table 8 Pin Connections/Descriptions for 36/48 and 72v/80v (Gen 54
toc 73
AC Motor Repair 73
Safety Precautions Maintenance and Repair 74
General 77
AC Motor Repair 77
Disassemble 77
Assemble 81
Troubleshooting 83
toc 87
Brake System 87
Safety Precautions Maintenance and Repair 88
General 91
Description and Operation 91
Brake Booster and Master Cylinder 91
Master Cylinder 91
Service Brake Assembly 91
Parking Brake 95
Seat Brake 96
Brake Shoe Assemblies Repair 97
Remove and Disassemble 97
Clean and Inspect 97
Assemble and Install 99
Master Cylinder Repair103
Master Cylinder For Lift Truck Models GC/GLC70-120LG/MG (B818) a103
Remove103
Disassemble103
Assemble104
Install104
Master Cylinder For Lift Truck Models ERC70-120HD, ERC70-120HG (105
Remove and Disassemble105
Clean and Inspect106
Assemble and Install106
Brake Booster Repair106
Remove106
Disassemble106
Clean and Inspect107
Assemble108
Install108
Brake System Air Removal108
Brake Pedal Adjustment108
Brake Pedal GP/GLP/GDP70-120LG/MG (B813) With Manual Transmissio108
Brake Shoes Adjustment110
Parking Brake Adjustment110
Parking Brake Adjustment, Lift Truck Models GC/GLC70-120LG/MG (B110
Parking Brake Lever and Switch Adjustment ERC70-120HD and ERC70-111
Seat Brake Assembly112
Remove112
Clean and Inspect112
Install112
Adjustments114
Solenoid Adjustment114
Traction cutoff Switch Adjustment114
Cable Adjustment114
Brake Booster Relief Valve Check117
Troubleshooting117
toc123
Capacities and Specifications123
Safety Precautions Maintenance and Repair124
Lift Truck Lifting Capacity127
Counterweight Weights127
Tire Sizes127
Capacities128
Hydraulic System128
Steering System129
Specifications129
Turning Radius129
Mast Speeds130
Maximum Carriage and Tilt Creep Rates131
Battery Specifications131
Traction Motor Speed132
Battery Current at Hoist Relief132
Torque Specifications132
Brake System132
Differential133
Drive Axle133
Frame133
Mast133
Main Control Valve133
Steering System133
Tilt Cylinders134
Hydraulic System134
Electrical System134
tables123
Table 1 Manual Control Valve128
Table 2 E-Hydraulic Control Valve128
toc137
Cylinder Repair137
Safety Precautions Maintenance and Repair138
General141
Description141
Safety Procedures When Working Near Mast142
Tilt Cylinder Repair144
Remove144
Disassemble145
Inspect145
Clean145
Assemble148
Install149
Tilt Cylinders, Adjust150
Tilt Cylinder Leak Check152
Torque Specifications153
Piston Rod Nut153
Gland153
Tilt Cylinder Mounting Capscrew153
Tilt Cylinder Rod End Nut153
Lift Cylinder Repair154
Main Lift Cylinders154
Remove154
Disassemble155
Clean156
Inspect156
Assemble156
Install156
System Air Bleed Procedures157
Two-Stage FFL Left Side Main Lift Cylinder158
Disassemble158
Clean160
Inspect160
Assemble160
Install160
Free-Lift Cylinder161
Remove161
Disassemble164
Clean164
Inspect165
Assemble165
Install166
Torque Specifications166
Lift Cylinders Leak Check167
tables137
Table 1 Movement Rates (Maximum) for Tilt Cylinders152
toc171
Diagrams171
Safety Precautions Maintenance and Repair172
toc211
Drive Axle, Speed Reducer, and Differential211
Safety Precautions Maintenance and Repair212
General215
Description215
Drive Axle, Speed Reducer, and Differential Repair216
Remove216
General216
Traction Motor, Speed Reducer, and Differential217
Motor, Speed Reducer, and Differential, Remove217
Disassemble220
Speed Reducer220
Differential221
Clean222
Inspect222
Assemble222
Speed Reducer222
Input Gear, Install222
New Pinion, Install222
Differential225
Drive Axle Housing228
Remove228
Clean229
Inspect229
Assemble229
Troubleshooting232
tables211
Table 1 Pinion Assembly Shims Adjustment224
Table 2 Ring and Pinion Tooth Contact Adjustment226
toc235
Electrical System (Trucks With AC Controllers)235
Safety Precautions Maintenance and Repair236
General239
Description240
Features of the Display Panels240
Other Control Components241
Display Panel and Key Switch Replacement242
Display Panel, Replace242
Key Switch, Replace244
Controller Replacement244
Traction and Pump Motor Controller Replacement244
Master Controller, Replace250
Master Controller, Remove ERP20-30ALF (ERP040-060DH) (D216), ERP250
Master Controller, Install ERP20-30ALF (ERP040-060DH) (D216), ER250
Master Controller, Remove ERC/P16-20AAF (ERC030-040AH) (B814/C81252
Master Controller, Install ERC/P16-20AAF (ERC030-040AH) (B814/C8252
Master Controller, Remove ERC35-55HG (ERC070-120HH) (B839/C839)254
Master Controller, Install ERC35-55HG (ERC070-120HH) (B839/C839)254
Control Components Replacement255
General255
Start Switch, Replace255
Brake Light Switch, Replace256
Seat Switch, Replace256
Parking Brake Switch, Replace257
Foot Directional Control Pedal Direction Switches, Replace259
Steering Column Direction Control Switches, Replace262
Remove262
Install262
Brake Fluid Switch, Replace264
Brush Wear and Over Temperature Sensors (DC Pump Motor Only)264
Rocker Switches for Lights, Replace264
Accelerator Position Sensor, Replace265
On-Demand Steering Sensor, Replace266
Lights, Converter, Relay, and Reverse Alarm266
Brake, Tail, and Reverse Light Assembly, Replace267
Incandescent Assembly267
LED Assembly – Remove269
LED Assembly – Install269
Strobe Light Assembly, Replace272
Wire Harness Repair273
Del-City Crimp-Solder-Shrink Splice273
Front, Rear Driving Light or Spot Light Assemblies, Replace274
Converter, Replace274
Remove, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216), ERP274
Install, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216), ER276
Remove, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) and 276
Install, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908) and276
Remove, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839)278
Install, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839)278
Reverse Relay, Replace279
Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908), ERC/P16-20A279
Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839)279
Backup Alarm, Replace281
Horn and Horn Button, Replace281
Horn Replacement for Lift Trucks ERP20-30ALF (ERP040-060DH) (D21281
Horn Replacement for Lift Trucks ERC35-55HG (ERC70-120HH) (B839/283
Horn Switch and Cover, Replace284
Hydraulic Pump Switches285
Fan Power Supply, Replace285
Remove, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839)285
Install, Lift Truck Models ERC35-55HG (ERC70-120HH) (B839/C839)285
Remove, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216) and 286
Install, Lift Truck Models ERP20-30ALF (ERP040-060DH) (D216) and287
Remove, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908)287
Install, Lift Truck Models ERC20-32AGF (ERC040-065GH) (A908)287
Control and Power Fuse Check288
Fuse Locations288
Brake Light Switch Adjustment294
Seat Switch Check295
Seat Brake Adjustment295
Parking Brake Switch Adjustment296
Direction Switches Check296
Foot Directional Control Pedal296
Steering Column297
Foot Directional Control Pedal or Accelerator Pedal Adjustment297
Accelerator Position Sensor Adjustment and Start Switch Adjustme298
Acceleration Position Sensor, Adjust298
Start Switch, Adjust300
tables235
Table 1 Wire Splice Size273
toc303
Frame303
Safety Precautions Maintenance and Repair304
General307
Description307
Overhead Guard Replacement309
Remove309
Install310
Battery and Operator Restraint, Hood and Seat Brake Repair311
Battery Restraint and Hood Repair311
Operator Restraint System and Seat Assembly314
Automatic Locking Retractor (ALR)314
Emergency Locking Retractor (ELR)314
Seat Brake Repair315
Counterweight Replacement315
Remove315
Install316
Traction Motor Repair316
Remove316
Install317
Hydraulic Tank Repair318
Inspect318
Small Leaks, Repair318
Large Leaks, Repair318
Clean318
Steam Method319
Chemical Solution Method319
Additional Preparations For Repair319
Safety Label Replacement320
Battery Specifications322
tables303
Table 1 Torque Values310
Table 2 Weight of Counterweights315
Table 3 Battery Specifications*322
toc325
Hydraulic System325
Safety Precautions Maintenance and Repair326
General329
Description329
Hydraulic System329
Operation337
Hydraulic System337
Hydraulic Gear Pump343
Steering Pump343
Hydraulic Tank Repair351
Tank, Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P1351
Tank, Remove [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH) 353
Tank, Remove [ERP20-32ALF (ERP040-065DH) (E216)]354
Hydraulic Tank [ERC35-55HG (ERC70-120HH) (B839/C839)]354
Inspect355
Small Leaks, Repair356
Large Leaks, Repair356
Clean356
Steam Method356
Chemical Solution Method357
Additional Methods for Tank Repair357
Tank, Install [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814); ERC/P357
Tank, Install [ERP20-30ALF (B216) and ERP20-30ALF (ERP040-060DH)358
Tank, Install [ERP20-32ALF (ERP040-065DH) (E216)]358
Filter Replacement359
All Lift Trucks Except [ERC35-55HG (ERC70-120HH) (B839/C839); ER359
Remove359
Install360
Lift Truck Models [ERC35-55HG (ERC70-120HH) (B839/C839)]360
Remove360
Install360
Lift truck Models [ERC20-32AGF (ERC040-065GH) (A908) and ERC/P16361
Remove361
Install361
Lift Truck Models [ERP20-32ALF (ERP040-065DH) (E216)]363
Remove363
Install363
Hydraulic Pump Repair366
Hydraulic Pump, Remove [ERC/P16-20AAF (ERC030-040AF, AG/BG) (A81366
Hydraulic Pump, Disassemble ERC/P16-20AAF (ERC030-040AF, AG/BG) 366
Inspect368
Clean368
Pump Seal Replace and Pump Assemble368
Assemble Pump on Motor368
Hydraulic Pump and Motor, Install [ERC/P16-20AAF (ERC030-040AF, 370
Hydraulic Pump, Remove [ERP20-30ALF (B216); ERP20-30ALF (ERP040-371
Hydraulic Pump, Disassemble [ERC35-55HG (ERC70-120HH) (B839/C839372
Hydraulic Pump, Inspect [ERC35-55HG (ERC70-120HH) (B839/C839) an374
Hydraulic Pump, Clean [ERC35-55HG (ERC70-120HH) (B839/C839) and 374
Hydraulic Pump, Assemble [ERC35-55HG (ERC70-120HH) (B839/C839) a374
Hydraulic Pump and Motor, Install [ERP20-30ALF (B216); ERP20-30A374
Main Control Valve Repair376
Steering Pump Repair376
Pump, Remove and Disassemble [ERC/P16-20AAF (ERC030-040AF, ERC03376
Pump, Remove and Disassemble [ERP20-30ALF (B216); ERP20-30ALF (E378
Pump, Assemble and Install380
Steering Control Unit Replacement381
Remove381
Install381
Steering Cylinder Repair387
Main Control Valve Check and Adjust387
Steering Relief Valve Check and Adjust388
Specifications388
Relief Valve Pressures*388
Hydraulic Tank Capacity (dipstick full mark)389
Hydraulic Pump Capacities – All Models Except ERC35-55HG (ERC70-389
Hydraulic Pump Capacities – Models ERC35-55HG (ERC70-120HH) (B83389
Troubleshooting389
Steering389
Steering Housing and Steering Control Unit390
Hydraulic System391
toc397
Industrial Battery397
Safety Precautions Maintenance and Repair398
General401
Lead-Acid Batteries401
Specific Gravity402
Chemical Reaction in a Cell402
Electrical Terms403
Battery Selection404
Battery Voltage405
Battery as a Counterweight405
Battery Ratings406
Kilowatt-Hours406
Battery Maintenance406
Safety Procedures406
Maintenance Records407
New Battery407
Cleaning Battery407
Adding Water to Battery409
Hydrometer410
Battery Temperature410
Charging Battery411
Types of Battery Charges412
Methods of Charging413
Troubleshooting Charger414
Knowing When Battery Is Fully Charged414
Where to Charge Batteries414
Equipment Needed414
Battery Connectors415
Battery Care415
tables397
Table 1 Battery Capacity Terms406
toc419
Electro-hydraulic Control Valve419
Safety Precautions Maintenance and Repair420
General423
Description423
Electro-Hydraulic Control System423
Electro-Hydraulic Control Valve426
Electro-Hydraulic Valve Driver Module442
Mini-Lever Module (MLM)442
Joystick443
Electro-Hydraulic Control Valve Repair444
Remove444
Disassemble453
Solenoid Coil Replacement455
Cartridge Replacement457
Electro-Hydraulic Pressure Reducing Valve (EHPR) Replacement458
Lift Circuit Check Valve Replacement459
Compensator Cartridge Replacement459
Primary and Secondary Relief Valves Replacement459
Tilt Counterbalance Valve Replacement460
Flow Regulator Valve Replacement460
Assemble460
Install460
E-Hydraulics Calibration469
Mini-Lever Module471
Mini-Lever Module (MLM)471
Remove471
Install471
Mini-Lever Replacement471
Remove471
Clean and Inspect472
Install472
Push Button Switch Replacement473
Remove473
Install474
Test475
Mini-levers475
Full Stroke Test475
Function Returns to Neutral Test475
Push Button Switch476
Joystick476
Remove and Disassemble476
Inspect476
Assemble and Install476
Troubleshooting477
tables419
Table 1 Primary and Secondary Relief Valve Values429
Table 2 Solenoid Resistance Values455
Table 3 Cartridge and Solenoid Coil Nut Torque for Lift truck M458
Table 4 Cartridge and Solenoid Coil Nut Torque for Lift truck M458
toc489
Manual hydraulic Control Valve489
Safety Precautions Maintenance and Repair490
General493
Description493
Operation495
Lift Section497
Tilt Section498
Tilt Backward498
Tilt Forward498
Relief Valve500
Solenoid Valve for Auxiliary Function501
Main Control Valve Repair502
Remove and Disassemble – Control Valve Without OPS Solenoid502
Remove and Disassemble – Control Valve With OPS Solenoid502
Clean and Inspect504
Assemble – Control Valve Without OPS504
Assemble – Control Valve With OPS504
Install505
Solenoid Valve for Auxiliary Function Repair505
Remove and Disassemble505
Assemble and Install507
Troubleshooting507
Pressure Relief Valve Check and Adjustment508
Primary Relief Valve508
Secondary Relief Valve508
Control Lever Arrangement and Adjustment509
Specifications511
Troubleshooting511
toc517
Mast Repairs517
Safety Precautions Maintenance and Repair518
Safety Procedures When Working Near Mast521
Fork Replacement523
Remove523
Install524
Checks524
Carriage Replacement525
Remove525
Install531
Disconnecting Attachment Hydraulic Quick Disconnect Hoses532
Connecting Attachment Hydraulic Quick Disconnect Hoses533
Integral Sideshift Carriage Repair533
Remove, for lift truck models ERC35-55HG (ERC70-120HH) (C839), G533
Disassemble534
Assemble536
Install, for lift truck models ERC35-55HG (ERC70-120HH) (C839), 536
Hang On Sideshift Carriage Repair536
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP13536
Disassemble542
Clean and Inspect544
Assemble544
Install545
Two-Stage Mast With Limited Free-Lift Repair546
Remove546
Disassemble548
Clean and Inspect550
Assemble559
Install, GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP5560
Install, GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/G561
Header Hose Alignment571
Two-Stage Mast With Full Free-Lift Repair582
Remove582
Disassemble583
Clean and Inspect589
Assemble590
Install, GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP5592
Install, GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/G594
Header Hose Installation and Adjustment597
Installation597
Adjustment597
Three-Stage Mast With Full Free-Lift Repair598
Remove598
Disassemble599
Clean and Inspect611
Assemble612
Install, GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP5614
Install, GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/G618
Header Hose Alignment for GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,623
Header Hose Alignment for GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP13629
Mast Operation Check633
Tilt Cylinder Adjustment633
Lift Chains Adjustment634
Mast Adjustments635
Load Roller Adjustment635
Mast Side Kicking Adjustment637
Carriage Adjustments638
tables517
Table 1 Fork Tip Alignment524
Table 2 Standard Mast Height; Header Hose Tension Mark Location579
Table 3 Standard Mast Height; Header Hose Tension Mark Location579
Table 4 Standard Mast Height; Header Hose Tension Mark Location580
Table 5 Standard Mast Height; Header Hose Tension Mark Location580
Table 6 Standard Mast Height; Header Hose Tension Mark Location581
Table 7 Standard Mast Height; Header Hose Tension Mark Location626
Table 8 Standard Mast Height; Header Hose Tension Mark Location628
Table 9 Standard Mast Height; Header Hose Tension Mark Location628
Table 10 Hook-Type Carriage Chain Adjustment634
toc641
Metric and Inch (SAE) Fasteners641
Safety Precautions Maintenance and Repair642
General645
Threaded Fasteners645
Nomenclature, Threads645
Strength Identification646
Cotter (Split) Pins646
Fastener Torque Tables651
Conversion Table653
tables641
Table 1 Bolts and Screws647
Table 2 Studs and Nuts648
Table 3 Torque Nuts649
Table 4 Torque Nuts with Nylon Insert650
Table 5 Torque Values for Metric Fasteners*651
Table 6 Torque Values for Inch Fasteners*652
Table 7 Conversion Table for Metric and English Units653
Table 8 Cotter Pin Dimensional Data654
Table 9 Cotter Pin Dimensional Data655
Table 10 Cotter Pin Dimensional Data656
Table 11 Cotter Pin Dimensional Data658
toc661
Periodic Maintenance661
Safety Precautions Maintenance and Repair662
General667
How to Move Disabled Lift Truck667
How to Tow Lift Truck667
How to Put Lift Trucks on Blocks668
How to Raise Drive Tires668
How to Raise Steering Tires668
How to Clean a Lift Truck669
Maintenance Schedule670
Maintenance Procedures Every 8 Hours or Daily674
General674
How to Make Checks With Key Switch OFF675
Tires and Wheels675
Forks675
Remove675
Inspect675
Install676
Adjust676
Inspection of Mast, Mast Pivots, Header Hoses and Lift Chains677
Safety Labels677
Steering Column Latch677
Operator Restraint System678
Automatic Locking Retractor (ALR)678
Emergency Locking Retractor (ELR)678
Battery Restraint System679
Battery680
Hydraulic System681
How to Make Checks With Key Switch ON682
Horn, Lights, and Alarm682
Steering System683
Service Brakes683
Parking Brake683
Seat Brake683
Control Levers and Pedals683
Direction and Speed Control Pedals683
Lift System Operation683
Oil Leaks684
First Service After First 100 Hours of Operation684
Change Hydraulic Oil and Filter684
Lift Truck Models ERC35-55HG (ERC70-120HH) (C839)684
Remove684
Install686
Lift Truck Models ERC35-55HG (ERC70-120HH) (B839)687
Remove687
Install688
Maintenance Procedures Every 500 Hours or 3 Months689
Wheel Nuts689
Header Hose Checks689
Mast Lubrication689
Integral Sideshift Carriage692
Brake Fluid693
Other Lubrication693
Maintenance Procedures Every 1000 Hours or 6 Months693
Differential and Speed Reducer693
Lift Chains693
Wear Check693
Lubrication694
Forks694
Parking Brake694
Brake Linkage Shafts695
Steering Spindles and Tie Rod Ends695
Seat Rails695
Seat Plate Hinges695
Electrical Inspection696
Contactors696
Maintenance Procedures Every 2000 Hours or Yearly698
Brake Fluid698
Hydraulic System699
Hydraulic Tank Breather, Lift Truck Models ERC35-55HG (ERC70-120699
Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models699
Remove699
Install700
Hydraulic Tank Breather, Lift Truck Models ERC35-55HG (ERC70-120701
Remove701
Install701
Change Hydraulic Oil and Hydraulic Oil Filter, Lift Truck Models701
Remove701
Install703
Differential and Speed Reducer703
Service Brakes704
Wheel Bearings704
Steer Wheels, Lubrication704
Drive Wheels, Lubrication704
Lift Chains704
Battery Maintenance705
How to Charge Battery705
How to Change Battery706
Safety Procedures When Working Near Mast709
Lift and Tilt System Leak Check712
Check Lift Cylinders for Leaks712
Check Tilt Cylinders for Leaks712
Lift Chain Adjustments713
Welding Repairs714
Overhead Guard Changes715
Wheels and Tires715
General715
Remove Wheels From Lift Truck715
Remove Tire From Wheel and Install Tire on Wheel715
Remove715
Install715
Install Wheels716
tables661
Table 1 Maintenance Schedule671
Table 2 Battery Specifications*709
Table 3 Hook-Type Carriage Chain Adjustment714
toc719
Steering Axle719
Safety Precautions Maintenance and Repair720
General723
Description723
Steering Axle Assembly Repair728
Steering Axle GP/GLP/GDP070-110LG/MG (B813), GC/GLC070-120LG/MG 728
Remove728
Install728
Steering Axle GDP60-70CA (GP/GLP/GDP135-155CA) (A878, B878), GLP729
Remove729
Install729
Wheels and Hubs Repair (All Units)730
Remove and Disassemble730
Clean730
Inspect730
Assemble and Install730
Spindles and Bearings Repair (All Units)732
Remove732
Clean732
Assemble and Install733
Tie Rods Repair (All Units)734
Remove734
Clean734
Install734
Steering Cylinder Repair737
Remove and Disassemble737
Clean and Inspect737
Assemble and Install737
Troubleshooting738
toc743
Steering Housing and Control Unit743
Safety Precautions Maintenance and Repair744
General747
Description747
Operation748
Steering Wheel and Column Assembly Repair749
Assembly Components, Remove749
Steering Control Unit, Disassemble754
Steering Control Unit, Clean754
Steering Control Unit, Assemble754
Assembly Components, Install756
System Air Removal758
Troubleshooting758
toc763
Steering System for AC Electric Lift Trucks763
Safety Precautions Maintenance and Repair764
General767
Description768
Steering Wheel and Column Assembly Repair769
General769
Assembly Components, Remove771
Assembly Components, Install772
Power Steering Motor and Pump773
Description773
Remove773
Disassemble776
Install776
Power Steering Pump, Repair776
Seal, Replace777
Steering System Air Removal778
Steering Pressure Check778
Steering Motor Circuits Check779
Troubleshooting780
toc785
Troubleshooting and Adjustments Using the AC Controls Program (E785
Safety Precautions Maintenance and Repair786
General789
Computer Requirements789
Software, Install789
Language Selection789
Demo Mode790
Connect PC to Lift Truck794
Starting AC Controls Program796
Lift Truck Control Setup801
Change Lift Truck Serial Number or Hourmeter801
Setting Factory Default Values or Changing Lift Truck Parameters802
Create New Custom Lift Truck Configuration808
Lift Truck Configuration Properties811
Import New Lift Truck Configuration From Disk814
Delete Custom Lift Truck Configuration or Password File816
Dash Display819
Custom Display Languages819
Download Display Language821
Clear Operator Log821
Password Functions824
Enable/Disable Password and Lift Truck Inspection Functions824
Truck Inspection Checklist824
Password824
Password Properties824
Create New Password File829
Download Passwords830
Upload Passwords832
Reports Menu834
Devices Report834
Custom Report834
Password Report834
Operator Report841
Current Settings Report844
Status Code Report848
Status Codes Log851
Troubleshooting853
Diagnostics853
Help Menu856
General856
Contents856
Technical Support856
About Electric Truck AC Controls Program856
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