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Clark GEX20-30 (RATED CAPACITY : 2000~3000kg). SERVICE MANUAL (2006) - page 1

Group SA, Safe Maintenance

Chaining the Upright in Raised Position

Raising Rear of Truck

This procedure is used to safely provide clearance for

The truck may be raised at the rear by jacking and block-

access from the front of truck to components on or near

ing under the center of the frame member at either the

the drive axle.

front or rear steer axle mounting, or under the center sec-

tion of the steer axle.

1. Park truck safely.

Refer to truck data plate for truck weights.

2. Put blocks at front of and rear of drive wheels.

3. Raise upright carriage.

!

WARNING

4. Chain the center inner rail tie bar to the top outer rail

An incorrectly installed counterweight can

tie bar as shown.

move or fall unexpectedly. NEVER LIFT OR

BLOCK A TRUCK USING THE COUN-

TERWEIGHT. Failure to follow procedures

outlined in this manual can result in injury or

death.

1. Park truck safely.

2. Put blocks at front and rear of drive wheels.

!

CAUTION

If possible, remove the battery from truck to

reduce weight for added safety and ease of

jacking.

Triple Stage Uprights: Chain the center intermediate rail

3. Put a floor jack under the steer axle mounting frame

tie bar and the lower inner rail tie bar to the top outer rail

member, centered between the two wheels.

tie bar.

!

WARNING

Never lift the truck by the counterweight.

5. Reverse the procedure to remove the chains.

! WARNING

If there is insufficient clearance under frame for your

jack, the truck may first be driven onto shims, such as

Keep hands, tools, etc. out of upright.

25x150x300 mm(1 x 6 x 12 in.) pieces of board, to

increase the truck frame underclearnce.

SM 765, Nov ’06

Lifting, Jacking, and Blocking • SA-2-3

Group SA, Safe Maintenance

4.

Raise the truck only as high as necessary to perform

Raising Entire Truck

the maintenance work.

Refer to truck data plate for truck weights.

5.

Put blocks at both sides of the truck, fully under the

frame main side structure. Put the blocks in front of

1.

Park truck safely. Lower upright fully.

but close to the counterweight and steer wheels for

2.

If necessary, drive truck onto boards to increase

best truck stability.

underclearance.

!

WARNING

SIDE-TO-SIDE TIPOVER. When jacking

side of truck, be sure upright is lowered fully.

Do not raise one side of the truck more than

about 50 mm (2 in.) higher than the other, to

avoid tipping truck over laterally.

END-TO-END TIPOVER. If the upright and

drive axle are removed while the truck is

blocked up, the truck will tip backward due

to the heavy counterweight. Upright and

counterweight must both be removed before

Put an equal number of blocks under each side of the

attempting to raise the truck for drive axle

truck to provide a level working position.

removal. The back of the truck must be sup-

6.

Lower the truck onto the blocks and remove the jack.

ported by blocking under the steer axle to

prevent movement.

! CAUTION

If the counterweight is removed while the

truck is up on blocks, the weight of the

Before performing any maintenance work,

upright and drive axle will cause the truck to

check the truck for stable condition on the

fall forward.

blocking by determining that it will not rock

on blocks.

3.

Put the jack under side frame, near the center of the

truck.

7.

When maintenance work is completed, lower the rear

IMPORTANT

of truck to the floor by reversing the above procedure

and lowering each side of the truck 50 mm (2 in.) at a

Be sure to put the jack squarely and fully

time:

under the main side structure of the frame.

• Put jack under frame and raise truck.

4.

Carefully raise the truck one side at a time, only as

• Carefully remove blocks and lower truck.

high as necessary to do the maintenance work, and

• Remove jack and blocks from drive wheels.

not more than 150 mm (6 in.) total.

SA-2-4 • Lifting, Jacking, and Blocking

SM 765, Nov '06

Group SA, Safe Maintenance

5. Put blocks under the side frame, at each side of the

Shipping Tie-Down Instructions

jack. Spread the blocks close to the steer and drive

wheels for maximum stability.

1. Front of Truck

a. With Upright and Carriage Installed

6. If using one jack, lower the truck onto the blocks and

• Lower the carriage fully.

move the jack to the opposite side. Repeat the lifting

procedure.

• Put a tie-down (e.g., chain) between the car-

riage fork bars.

7. Put the same size blocks under each side of the truck

so it will be leveled.

! CAUTION

b. Without Upright and Carriage Installed

Before performing any maintenance work,

• Put a chain across the truck floor plate. Protect

check the truck for stable condition on the

truck from chain damage by using covered

blocking.

chain or protective material under the chain at

contact points.

8. When maintenance work is completed, lower the

2. Rear of Truck

entire truck to the floor by reversing this procedure.

• Attach the tie-down to the toe-pin in bottom of

Lower the truck one side at a time, while carefully

counterweight.

removing the blocks. Be sure no tools or equipment

are under the truck or wheels.

NOTE

Depending on jack height, shims under the

tires may be needed for clearance to allow

removal of jack.

SM 765, Nov ’06

Lifting, Jacking, and Blocking • SA-2-5

Group SA, Safe Maintenance

If your truck is disabled but can be moved freely on its

4. Check that the counterweight bolts on both trucks are

own wheels without further damage, use the following

in place and properly torqued to 340-380 Nom (250-

procedures to tow the truck safely to a repair area.

280 ft-lb). These bolts are made of special, high-ten-

sile steel and are not commercially available. When

necessary, replace these bolt only with genuine Clark

! WARNING

replacement parts.

For your safety and the care of your truck,

5. Use an approved, solid metal tow bar with towing couplers

use the proper equipment and carefully fol-

that connect to the towing pins in the counterweights of

low these recommendations for safe towing.

each truck.

Do not tow a lift truck if there is a problem

NOTE

with the brakes or tires, or if the steering

DOT-approved towing equipment is available from

cannot be operated.

your Clark dealer.

Do not tow up or down ramps or steep

6. Release the parking brake on the towed vehicle.

inclines.

Place directional control lever in NEUTRAL.

7. Tow the disabled truck backward. An operator must

Do not tow the disabled truck if traction or

be on the disabled truck.

weather conditions are poor.

!

CAUTION

1. Apply the parking brake or block the drive wheels on

the disabled truck while working around it.

The power steering will not operate on the

disabled truck when the power steering

2. When possible, raise the forks on the disabled truck

motor is not running. The steering hand-

300 mm (12 in) from the floor or ground. Secure the

wheel will be difficult to turn.

carriage on the upright with a chain.

3. Use a truck for towing that is of equal or larger

8. Tow the truck slowly. Careful towing is necessary to

capacity than the disabled truck. Carry a partial load

prevent injury to personnel or damage to the disabled

on the towing truck for improved traction

truck. The truck should be towed at a speed of less

than 8 kph (5 mph, or a moderate walking speed)

with a driver in place and steering the disabled truck.

SA-3-2 • Towing

SM 765, Nov '06

Group PS, Periodic Service

GEX Service Chart/Lubrication Points

SM 765, Nov ’06

Maintenance Schedule • PS-1-3

Group PS, Periodic Service

Recommended Periodic Service Schedule

This chart lists maintenance tasks that should be done periodically, the suggested time intervals, and the service manual

Group in which the task is covered. Refer to Operator’s Manual for Daily Checks.

Every

Every

Every

Every

450- 500 Hours

900- 1000 Hours

2000 Hours

TASKS

1st 50 Hours

50-250 Hours

(or 3 months)

(or 6 months)

(or 1 year)

Group PS - Periodic Maintenance

Perform Planned Maintenance

inspections, lubrications, and adjust-

ments

Group 12 - Battery

Battery electrolyte level - check/add

Battery load voltage test

Battery terminals/cables - clean/

tighten

Group 13 Wiring and Instruments

Hourmeter - check

Lamp check - at start-up

Wiring harness - inspect

Instruments/accessories

Group 16 - Electric Motors

Drive motor - check/air clean

Lift pump motor - check/air clean

Group 17 -Contactors

Contactor tips - check/air clean

Group 19 - Motor Controls

Display - check display for error

codes

Controller - air clean

Controller connectors - check

and lubricate

Group 20 - Drive Axle

Air vent - inspect, clean or replace

Axle mounting bolts - inspect/tighten

.Pressure checks

Fluid change - drain/fill

Fluid filter - replace

Fluid level/condition - check/sample

Group 22 - Wheels And Tires

Wheel mounting bolts - tighten

Tire pressure/condition - check

Group 23 - Brakes

Operation - check

Service brake - check wear

Brake lines - check

Parking brake - check/adjust

PS-1-4 • Maintenance Schedule

SM 765, Nov ’06

Group PS, Periodic Service

TASKS

Every

Every

Every

1st 50

Every

450- 500 Hours

900- 1000 Hours

2000 Hours

Hours

50-250 Hours

(or 3 months)

(or 6 months)

(or 1 year)

Group 25/26 - Steer Axle and Lines

Operation - check

Power steering relief pressure - check

Steer axle mounting - inspect

Steer wheel and trunnion bearings -

check

Steer wheel and trunnion bearings -

lubricate/adjust

Steering cylinder seals - check leakage

Steering linkage - lubricate

Group 29/30 - Hydraulic Lift System

Hydraulic fluid level/condition -

check/sample

Hydraulic fluid change - drain/fill

Hydraulic filler screen - clean

Hydraulic fluid filter - replace

Hydraulic tank breather - clean/replace

Control valve linkage - check/clean

Hydraulic system relief pressure - test/

adjust

Group 32 - Tllt Cylinders

Tilt cylinder adjustment - check/adjust

Tilt cylinder drift - test

Tilt cylinder mounting - check/tighten

Tilt cylinder rod ends - check/tighten/

lubricate

Tilt cylinder rod/seals - check for leaks

Group 34 - Upright, Lift Cylinders, Carriage, Forks

Operation - check

Carriage and lift chain - lubricate

Carriage chain condition - inspect/

adjust

Forks, latches, stop pin - inspect/check

wear

Lift chain condition - inspect/adjust

Load backrest

Upright cylinder/mounting - inspect/

tighten

Upright lift cylinder downdrift - test

Upright rollers - check

Upright trunnion bolts - tighten

SM 765, Nov ’06

Maintenance Schedule • PS-1-5

Group PS, Periodic Service

Use PM Report Form

A planned maintenance program of regular, routine

inspections and lubrication is important for long life and

troublefree operation of your lift truck. Make and keep

records of your inspections. Use these records to help

establish the correct PM intervals for your application and

to indicate maintenance required to prevent major prob-

lems from occurring during operation.

As an aid in performing and documenting your PM

inspections, Clark has prepared an Electric Truck Planned

Maintenance Report form. Copies of this form may be

obtained from your authorized Clark dealer. We recom-

mend that you use this form as a checklist, to make a

record of your inspection and truck condition.

Be sure all capacity, safety, and warning plates or decals

are attached and legible.

The periodic maintenance procedures outlined in this

manual are intended to be used with the PM report form.

They are arranged in groupings of maintenance work that

!

CAUTION

are done in a logical and efficient sequence.

Do not operate a lift truck with damaged or

missing decals and nameplates. Replace them

A check mark or entry is made on the PM Report Form

immediately. They contain important infor-

when the PM is performed. Please note the special coding

mation.

system for indicating the importance of needed repairs

and/or adjustments.

Inspect the truck for signs of external leakage of transmis-

When you have finished the PM inspections, be sure to

sion fluid, etc. Check for hydraulic leaks and loose fit-

give a copy of the report to the designated authority or the

tings. DO NOT use bare hands to check. Hydraulic Fluid

person responsible for lift truck maintenance.

may be hot or under pressure.

Do not make repairs or adjustments unless authorized to

do so.

!

DANGER

HYDRAULIC FLUID PRESSURE: Do not

For safety:

use your hands to check for hydraulic leak-

• Remove all jewelry (watch, rings, bracelets, etc.)

age. Fluid under pressure can penetrate your

before working on the truck.

skin and cause serious injury.

• Disconnect battery from truck receptacle before

working on electrical components.

• Wear safety glasses. Wear a safety (hard) hat in

industrial plants and in special work areas where

protection is necessary or required.

How to Perform the PM Periodic

Inspections and Maintenance

Be sure that the driver’s overhead guard, load backrest

extension, finger guards, and any other safety devices are

Visual Inspection

in place, undamaged, and attached securely.

Perform a visual inspection of the lift truck and its compo-

nents. Walk around the truck and take note of any obvious

!

WARNING

damage and maintenance problems. Check for loose fas-

For trucks equipped with spark-enclosed

teners and fittings.

(EE) construction, or with polyurethane

PS-2-2 • Planned Maintenance

SM 765, Nov ’06

Group PS, Periodic Service

tires, check the ground strap or chain for

!

DANGER

wear and secure attachment.

Uprights can drop suddenly if not properly

Check all of the critical components that handle or carry

blocked. Look at the upright, but keep hands,

the load.

tools, etc. out.

IMPORTANT

Uprights and lift chains require special atten-

tion and maintenance to maintain them in

safe operating condition. Refer to Lift Chain

Check the overhead guard for damage. Be sure that it is

Maintenance in Group 34 for additional

properly positioned and all mounting fasteners are in

information.

place and tight.

Check the upright assembly. Inspect the upright rails, car-

! CAUTION

riage rollers, lift chains, lift and tilt cylinders. Look for

obvious wear and damaged or missing parts. Check for

If load backrest has been removed, a bolt and

any loose parts or fittings. Check for leaks, damaged or

washer must be in place on each end of the

loose rollers, and rail wear (metal flaking). Carefully

top fork bar to act as a fork stop.

check the lift chains for wear, rust and corrosion, cracked

or broken links, stretching, etc. Check that the lift and car-

Check the load backrest for damage. Inspect the welds on

riage chains are correctly adjusted to have equal tension.

the carriage and load backrest for cracks. Be sure that the

Check that the lift chain anchor fasteners and locking

mounting fasteners are all in place and tight.

means are in place and tight.

Be sure all safety guards and chain retainers are in place

and not damaged. Inspect the carriage stops and cylinder

retainer bolts. Check all welded connections.

Inspect all lift line hydraulic connections for leaks. Check

the lift cylinder rods for wear nicks, grooves, and

scratches. Check the cylinder seals for leaks. Refer to

Group 34 for details on uprights.

SM 765, Nov ’06

Planned Maintenance • PS-2-3

Group PS, Periodic Service

Forks

Inspect the load forks for cracks, breaks, bending and

wear. The fork top surfaces should be level and even with

each other. The height difference between both fork tips

should be no more than 6 mm (0.25 in.)

Inspect the fork latches. Be sure they are not damaged or

broken, operate freely and lock correctly. Check the fork

stop pins (or bolt and washer) for secure condition.

Wheels and Tires

NOTE

Your Clark dealer has special tools for mea-

suring fork wear.

! WARNING

If the fork blade at the heel is worn down by

more than l0%, the load capacity is reduced

and the fork must be replaced. DO NOT

attempt to fill with weld. See Group 34 for

inspection procedure.

Check the amount of wear at the heel of the fork.

! CAUTION

If the forks are obviously bent or damaged,

have them inspected by a trained mainte-

Check the condition of the drive and steer wheels and

nance person before operating the truck.

tires. Remove objects embedded in the tread. Inspect the

Inspect the forks for twists and bends. To check, put a 2 x

tires for excessive wear, break, “chunking out,” and bond

4 x 24 in. long block on the blade of the fork with the 4 in.

failure between the tire and rim.

surface against the blade. Put a 24 in. carpenter’s square

on the top of the block and against the shank. Check the

fork 18 in. above the blade to be sure it is not bent more

than 14.5 mm (0.6 in.) at Y.

PS-2-4 • Planned Maintenance

SM 765, Nov ’06

Group PS, Periodic Service

2. Using the Display

Seat Belt: At start up this symbol displays

along with an audio alarm for 4 seconds. This

display reminds you to fasten your seat belt.

Parking Brake: The symbol is displayed and "-

255" status code appears on the numeric dis-

play when parking brake is applied. Release

parking brake to operate truck.

Service Status: The following 5 codes are usu-

ally operator fault codes, and can be corrected

by as explained in "Section 5, Operating Proce-

dures." If you see any other codes displayed,

the truck needs to be serviced.

Check all wheel mounting bolts to be sure none are loose

•

-01 Seat Switch Open

or missing.

•

-061, -065 ,-140, -203, -207 Overheat of motor

and controller (Restart after cooling

! CAUTION

down)

Personnel working on wheels and tires must

•

-66 Low Battery (truck will go into lift lockout

be trained and qualified to do wheel and tire

when the dash display shows less than

maintenance.

15%)

•

-77 Maintenance Hours (preset hour meter reading

Replace missing bolts and tighten loose bolts to the cor-

indicating that it is time to have the

rect torque before operating the truck.

truck serviced. Truck will reduce the top

speed if desired)

Operational Checks

•

-79 Incorrect Start Up Sequence (SRO)

•

-217, -245 Wrong set battery

1.

Check horn to be sure it operates.

•

-255 Parking Brake Switch Open

Battery discharge indicator

It displays the battery discharge

condition of forklift truck.

The one bar indicates

10%

Blue color

charging condition.

If the battery is charged more

Red color

than 20% (8 bars or more), blue

LED is displayed, but it is less

than 20% (2 bars or less), red

IMPORTANT

LED is displayed. If it is less than 10% (1 bar), it will

Because the battery is such an important

flicker and buzzer sound.

part of electric truck operation, it requires its

own specialized maintenance program,

which should include full-scale cleaning and

inspection. Refer to Group 13 for specific

instructions.

SM 765, Nov ’06

Planned Maintenance • PS-2-5

Group PS, Periodic Service

Slow-speed indicator (Turtle shaped)

• Release the control lever. It should return to neutral

without binding. The pump motor should turn off.

The traveling speed of truck is limited to

The control lever should not bind when moving it

set speed.

to any position.

The upper mark is slow speed operating

• Repeat procedures with tilt control lever. Forks

icon, and the figure shows the limited

should tilt evenly and smoothly.

max. speed. (In upper example, the lim-

ited max. speed is 2km/h)

• If lift truck is equipped with an attachment, test the

auxiliary control lever for a correct function.

Hourmeter & Speed

• Briefly operate the attachment.

• It displays the accumulated oper-

ating hour and traveling speed of

truck.

• When the traveling speed is less

than 0.5km/h, it displays the accu-

Lift lever

mulated operating hour.

• When the traveling speed is more

than 0.5km/h, it displays the traveling speed.

Tilt lever

Option lever

Message display

The model name, POWER

Normal

selection, travel direction, warn-

4.

Check Drive Motor (Brake) Cut-Off Switch

Error

ing and error message are dis-

• Move the truck forward slowly. Slowly depress

Warning

played.

BATTERY LOW

brake pedal. Drive motor should cut off before the

• In normal operating condition:

brakes apply.

Model name/POWER/Travel direction

• If operation is not satisfactory, DO NOT operate

•

When several messages are simultaneously dis-

the truck. Take truck out of service and report con-

played, it will be displayed in the order of Error,

dition to designated authority.

Warning and Normal condition.

• If many error conditions are

5.

Check Upright

23 : FUSE ERROR

simultaneously

occurred,

the

• Note any excessive “slop” or “noise” in the

56 : FET SHORT

priority 2 Errors will be displayed.

upright. It may indicate roller damage, or that

(The priority means Error number)

roller shimming, repair or adjustment may be

required.

Travel direction icon

6.

Check Tilt Cylinder (Refer to Group 32 to do the

• It displays the traveling direction or angle of

following)

steering wheel..

• Perform drift test.

• The direction icon rotates in 10 degrees.

• Perform check and adjustment procedure.

(Total 36 icon)

• Check rod seal condition.

Error icon

• Check mounting. Tighten as needed.

• Check rod end. Tighten as needed.

• When error occurs this icon is displayed to distin-

guish the condition easily. When the error message

7.

Check Truck Performance

is displayed, this icon is simultaneously displayed.

3. Check Function Control Levers

!

WARNING

• Gently pull back on the lift control lever. The pump

Check all around to be sure that your

motor should turn on and the carriage should begin

intended path of travel is clear of obstruc-

to elevate.

tions and pedestrians.

PS-2-6 • Planned Maintenance

SM 765, Nov ’06

Group PS, Periodic Service

• Drive the truck forward in a straight line at a high

2. Operaten the truck at a slow speed in a forward direc-

rate of speed. Listen for unusual drive train noise.

tion of travel. Reverse direction of travel. The truck

Stop truck.

should slow down to a smooth controlled stop, and

accelerate normally in the opposite direction.

• Check acceleration from a stop to top travel speed.

Acceleration should be smooth without hesitation.

If plugging is as specified, then repeat the procedure

Stop the truck. Repeat procedure in reverse.

at high speed. The truck should come to a smooth

controlled stop in approximately 20 feet (6.10 mm)

• Report condition on PM report form.

with accelerator in maximum travel position.

3. Repeat the procedure at high speed with the direction

lever moved in reverse direction.

If plugging (braking) is not as specified, refer to the

adjustment instructions in Group 19 of this manual.

Report condition to designated authority.

Check Accelerator

1. After checking to see that you have a clear path

ahead, drive the truck in a straight line at a high rate

of speed in a forward direction of travel. Listen for

unusual drive train noise. Stop truck

Test Drive Truck with Load

2. Check acceleration from a stand still condition to top

travel speed. Acceleration should be smooth without

NOTE

hesitation.

Conduct these tests with a rated capacity

3. After checking to see that you have a clear path

load, if possible.

behind, drive the truck in reverse. Check acceleration

from stand still condition through top travel speed.

Test the truck for proper operation and drive train function

Acceleration should be smooth.

by driving the truck in both the forward and reverse direc-

tions. Drive first in a straight line and slowly through a

Check the accelerator pedal while conducting the speed

series of full right and left turns. Then repeat, driving in

range tests. It must move easily and smoothly throughout

the acceleration stroke and return without binding. There

opposite direction.

should be no restriction to movement on either accelera-

tion or deceleration.

Carry Load Low & Tilt Back

Test for correct function of the transistor control.

!

CAUTION

Check Controlled Plugging (Braking)

DO NOT operate lift truck if the brakes are

1. Operate the truck with parking brake set. It should

not operating properly. Use only brake fluid,

not move. Release parking brake.

SAE J1703 DOT 3, for ECX / EPX brakes.

SM 765, Nov ’06

Planned Maintenance • PS-2-7

Group PS, Periodic Service

Test the service brake (drive motor cut-off) switch. Drive

shifting from NEUTRAL to REVERSE, then back to

the truck FORWARD (or in REVERSE) at creep speed.

NEUTRAL. Check for positive control action when

While holding the accelerator pedal steady in creep speed

changing directions.

position, depress brake pedal. The braking action should

Listen for clunking, squealing, grinding, scraping, or other

interrupt power to the drive motor and stop the truck.

unusual noises. Check for vibration. Listen for wheel

Release the brake pedal. The drive motor should again

bearing or other specific running noise.

start moving the truck.

Lift Mechanism and Controls

NOTE

Conduct these tests with a rated capacity load.

Test the operation of the hydraulic system and upright.

Brake Pedal

Accelerator Pedal

Test brake operation by depressing and releasing the brake

pedal several times while driving the truck. The brakes

should bring the truck to a smooth stop without pulling,

squealing, or shuddering. Have the brakes adjusted or

repaired as necessary. Drive motor should cut off before

brakes apply.

To check brake holding capability and adjustment, park

the truck on a grade and depress brake pedal. The brake

should hold a lift truck with rated load on a 15% grade.

!

CAUTION

Check Steering

Be sure there is adequate overhead clearance

before raising the upright.

! CAUTION

Cycle (raise to full height and then lower) the upright at

DO NOT operate lift truck if steering system

both slow and fast speed, with the upright tilted slightly

is not operating properly.

backward. Watch the upright assembly as it rises. All

movements of the upright, fork carriage, and lift chains

Check steering control operation. First, drive the truck in a

must be even and smooth, without binding or jerking

straight line. The truck must drive in a straight line with-

motions. Watch for chain wobble or looseness. The chains

out drifting toward either side. Then drive slowly (creep

should have equal tension and move smoothly, without

speed) through a series of full right and left turns. Check

noticeable wobble.

steering response and smoothness of operation. Turning

effort must be the same in either direction. You will hear

Check function of the control lever and main hydraulic

the hydraulic pump operate over relief when in a full turn.

valve. Listen for abnormal noises in the hydraulic valve,

If there is a steering problem, have it repaired.

main hydraulic pump, and system components.

NOTE

If the maximum fork height is not reached, either the fluid

Conduct the following test with a rated

level in the hydraulic sump tank is low, or there is severe

capacity load.

binding within the upright.

Test for general drive train operation. Drive the truck at

various speeds and operating conditions, in both FOR-

WARD and REVERSE directions. Test shifting from

NEUTRAL to FORWARD, then back to NEUTRAL. Test

PS-2-8 • Planned Maintenance

SM 765, Nov ’06

Group PS, Periodic Service

Test for correct tilt cylinder rod adjustment. Raise the car-

! WARNING

riage to an intermediate position. Tilt the upright fully for-

FALLING FORKS. Do not walk or stand

ward without a load on the forks. Check for upright

under raised forks. The forks can fall and

racking (twisting) as the tilt cylinders reach the end of

their stroke. Tilt the upright fully back. The upright should

cause injury or death.

not rack (twist) when the tilt cylinders reach the end of

their travel. If forward upright racking is found, adjust-

ment of the tilt cylinder rod ends (yokes or spacers) is

required. If backward racking is found, adding or remov-

ing shims is required. Refer to Group 32.

!

CAUTION

When you have completed the operational

tests, park and leave truck according to stan-

dard shutdown procedures.

Never Walk Under Raised Forks!

Check the upright rails, rollers, carriage, lift chains, and

cylinders as they move. Watch for binding or excessive

freeplay (looseness) between the carriage and the upright

rails and rollers. Listen for abnormal noises. If there is

excessive clearance between the rails and channels, the

upright roller needs adjustment. If the rails or carriage

bind or hesitate when lowering, the rollers are either dam-

aged or roller adjustment is incorrect.

Check the upright for excessive downdrift. Stop the fork

carriage in an intermediate position. Check that it holds its

position without moving down. If you observe downward

movement (drift) or have a report of a drift problem, the

lift cylinder seals may be worn. With forks elevated, turn

Standard Shutdown Procedures:

key switch off. Pull back on the lift lever. The forks should

• Come to a complete stop.

not lower This tests the check valve.

• Park only in authorized locations.

Test the tilt function. Check for excessive tilt cylinder

• Lower the forks fully, tilt upright forward until fork

drift. Stop the upright at a position near vertical. Check

tips touch floor.

that the upright holds its position without moving forward.

• Allow travel control to return to neutral.

If you observe forward movement (drift) or have a report

of a tilt drift problem, the tilt cylinder seals may be worn.

• Turn the key switch OFF.

• Apply the parking brake.

Check fork height adjustment and carriage chain adjust-

ment. Tilt the upright to the vertical position and fully

• Disconnect Battery

lower the carriage. The forks should stop and be held

approximately 13 mm (0.50 in.) above the floor. If the

Make a record of all maintenance and operating problems

forks hit the floor, the carriage lift chains should be

you find.

adjusted. Also check the rail chains.

If truck is equipped with an attachment, briefly operate

the attachment to check the controls for correct function.

SM 765, Nov ’06

Planned Maintenance • PS-2-9

Group PS, Periodic Service

Battery Compartment Inspection

Turn key switch OFF. Disconnect battery from truck

receptacle. Remove the control compartment cover from

Turn key switch OFF. Disconnect battery from truck

the counterweight.

receptacle.

Discharge the capacitor using a 10W~100W resistance

connected from the +Batt(pos.) to the -Batt(neg.).

Inspect the transistor controls for clean condition. Check

for oily dirt buildup on contactors, Inspect all control wir-

ing terminals for any obvious damage. Look for cracks or

worn areas in the wiring insulation. Check for loose con-

nections at the control terminals. Air-clean as necessary.

Treat the control panel plugs with Clark 1801145”Lectric-

Like” Spray or Clark 1803827-brush on cleaner.

Inspect condition of the battery connector and truck bat-

Hydraulic Compartment Inspection

tery receptacle. Check the spring-loaded terminals, con-

Remove the floorplate.

nectors, and retaining tabs. Look for poor connections due

to burning, bad crimps, or broken or loose retainers.

Check the condition of all hydraulic system components,

Check the molded body for damage from overheating,

hoses, piping, and connections. Check for wear, leakage,

burning, and chips or cracks. Replace receptacle terminals

and damage.

if pitted or corroded.

Remove the battery.

Inspect condition of the battery and cables. Check the bat-

Inspect the drive motor, hydraulic pump motor power

tery cables for wear or other damage. Check for signs of

cables. Check drive motor mounting fasteners. Check

interference or rubbing with other components. Be sure

hydraulic pump motor. Check pump motor mountings.

that the cable terminals are tight and clean. Clean off any

deposits of corrosion found on the battery.

!

DANGER

Never wash the battery when it is in the truck.

HYDRAULIC FLUID PRESSURE: Do not

Check battery post terminals for corrosion and damage.

use your hands to check for hydraulic leak-

Clean all corrosion from cable end and battery post.

age. Fluid under pressure can penetrate your

Check tighmess of cable and post terminals.

skin and cause serious injury.

If necessary, check the state-of-charge condition of the

battery. Take a specific gravity test of the electrolyte with

a hydrometer. Be sure to check a minimum of six battery

cells.

Check the electrolyte level of the battery. Add distilled

water, as required, to fill each cell to the correct level.

Check to be sure the vent hole in each battery cell cap is

open. If cap vents are plugged with corrosion, remove the

Brake Shoe and Drum Inspection

caps and wash in a solution of baking soda and water.

The brake linings, drum and adjustment setting can be

Refer to Group 12, Battery, for additional information.

inspected without removing the drum or hub. Refer to

Group 23, Section 6 for inspection procedure.

Motor Transistor Controls Inspection

IMPORTANT

Do not clean electrical components with

steam. Only approved solvents should be

used to clean controls.

PS-2-10 • Planned Maintenance

SM 765, Nov ’06

Group PS, Periodic Service

ponents which directly support, handle or control the load,

Air-Cleaning

or protect the operator.

Always maintain a lift truck in a clean condition. Do not

Check torque of critical items, including: overhead guard,

allow dirt, dust, lint, or other contaminants to accumulate

drive axle mounting, drive and steering wheel mounting,

on the truck. Keep the truck free from leaking oil and

counterweight mounting, load backrest extension, tilt cyl-

grease. Wipe up all oil spills. Keep the controls and floor-

inder mounting and yokes, upright mounting and compo-

board clean and dry. A clean truck makes it easier to see

leaks and loose, missing or damaged parts, and will help

nents. Refer to Group 40 for torque specifications.

prevent fires. A clean truck will run cooler.

The environment in which a lift truck operates will deter-

Lubrication, Fluids, and Filters

mine how often and to what extent cleaning is necessary.

For example, trucks operating in manufacturing plants

Hydraulic Sump

which have a high level of dirt or lint (e.g., cotton fibers,

Check the hydraulic sump tank fluid level. Correct fluid

paper dust, etc.) in the air or on the floor, will require

level is important for proper hydraulic system operation.

more frequent cleaning. If air pressure does not remove

heavy deposits of grease, oil, etc., it may be necessary to

Low fluid level can cause pump damage. Overfilling can

use steam or liquid spray cleaner. DO NOT clean electri-

cause loss of fluid or lift system malfunction.

cal components with steam.

Hydraulic fluid expands as its temperature rises. Check

NOTE

the fluid level at operating temperature, after approxi-

mately 30 minutes of truck operation. To check the fluid

See special provision for blowing dust from

level, park the truck on a level surface. Put the upright in a

pump and drive motors on page 14 of this

vertical position and lower the fork carriage fully down.

section.

Remove the floorplate and observe the fluid level marking

on the sump tank. Refer to Group 29, Section 1 for more

! CAUTION

information on the sump tank. DO NOT overfill.

Battery must be disconnected and capacitors

Check the condition of the hydraulic fluid for color, clar-

discharged before inserting air wand through

ity, and contamination. Change (replace) the hydraulic

access holes.

fluid as necessary.

! CAUTION

Wear suitable eye protection and protective

clothing.

Lift trucks should be air-cleaned at every PM interval, and

as often as required.

Air-cleaning should be done using an air hose with special

adapter or extension having a control valve and nozzle to

direct the air properly. Use clean, dry, low-pressure com-

pressed air. Restrict air pressure to 207 kPa (30 psi).

Air-clean the following: upright assembly; drive axle; bat-

tery, cables, switches and wiring harness; transistor con-

trols and wiring; drive and hydraulic pump motors;

steering axle and steering cylinder.

Critical Fastener Torque Checks

Fasteners in highly loaded (critical) components can

Hydraulic Fluid and Filter Change

quickly fail if they loosen. Loose fasteners can cause dam-

age or component failure. For safety, it is important that

Drain and replace the hydraulic sump fluid every 2000

the correct torque be maintained on all fasteners of com-

operating hours, or sooner, as required. Replace the

PS-2-12 • Planned Maintenance

SM 765, Nov ’06

Group PS, Periodic Service

Air Cleaning of Motors

tors by using a

10W~100W resistance

connected from the +Batt(pos.) to the

-

Batt(neg.).

! WARNING

Before inserting metal air cleaning wand, dis-

connect the battery and discharge the capaci-

PS-2-14 • Planned Maintenance

SM 765, Nov ’06

Group PS, Periodic Service

PS-3-2 • The PM Inspection Form

SM 765, Oct ’06

Group 12, Battery

Battery Handling

!

DANGER

Explosive gas is always present around bat-

! CAUTION

teries, especially when they are being

Remove all jewelry (watch, rings, bracelets,

charged.

etc.) before working on electrical systems.

Severe burns can result from contact with

• No smoking allowed in the charging area.

electrical circuits.

• Battery electrolyte must never be checked with

an open flame.

! WARNING

• Open flame, sparks, or electric arcs must never

be allowed in the battery charging area.

Battery service must be done by trained per-

sonnel. Battery acid can cause severe burns

• The battery contains corrosive sulfuric acid

and injury. Do not smoke or have open

which can cause injury. If acid contacts your

flames around batteries.

eyes or skin, flush immediately with water and

get medical assistance.

! WARNING

Electric truck batteries are heavy and awk-

ward to handle. On charge, they give off

hydrogen and oxygen which, in certain con-

centrations, are explosive. Electric truck bat-

teries are also costly, so before you remove,

service, or install a truck battery, consult

BATTERY MANUFACTURER for more rec-

ommendations and instructions on handling

and charging batteries. Carefully read and

follow recommendations and instructions.

Persons maintaining batteries must wear protective cloth-

ing such as:

Change or service batteries only in an area designated for

this purpose. Refer to page 4 for additional information.

• Face and head shields

• Be sure this area has provisions to flush and neu-

• Long shirt sleeves

tralize acid spillage.

• Gauntlet gloves

• Be certain the area has proper ventilation to venti-

• Rubber apron

late fumes from charging batteries.

• Check to see that there is fire protection. Fire extin-

guishers should be properly maintained and

located in designated areas.

12-1-2 • Battery Service

SM 765, Nov ’06

Group 12, Battery

Be sure the battery service area is equipped with material

!

DANGER

handling equipment designed for the purpose of removing

and replacing batteries, such as a conveyer or overhead

Never lay tools or other metal objects on a

hoist equipped with safety hooks.

battery. Metal objects contacting battery ter-

minals will cause short circuits. The shorted

IMPORTANT

circuits could ignite battery fumes and cause

To prevent side forces from damaging the

the battery to explode.

battery, the distance between the lifting

hooks (of the spreader bar) must be adjusted

to the same dimension as measured between

the battery lifting eyes. Make sure the lifting

hooks are the correct size to fit the lifting eyes

of the battery.

• When using an overhead hoist, be sure to use an

insulated spreader bar or similar lifting device.

• Be sure the hoist is equipped with a chain container

to accumulate excess lifting chain. When this is not

possible, be sure the battery is covered with a non-

conductive material, such as plywood, as shown

below.

Battery Removal

• If the battery does not have a cover of its own,

cover it with a non-conductive material such as

1.

Move truck to the designated battery service area.

plywood.

! CAUTION

SAFE PARKING. Before working on truck:

• Park truck on a hard, level and solid surface, such

as a concrete floor with no gaps or breaks.

• Put upright in vertical position and fully lower the

forks or attachment.

• Put all controls in neutral. Turn key switch OFF

and remove key.

• Apply the park brake and block the wheels.

2.

Turn key switch OFF and disconnect battery.

SM 765, Nov ’06

Battery Service • 12-1-3

Group 12, Battery

3. Lift and latch seat deck to access battery.

age andcould ignite battery fumes, causing the bat-

tery to explode.

4. If the battery to be handled is uncovered, cover bat-

• Maintain good battery cable connections.

tery with a non-conductive material (plywood, heavy

cardboard, etc.) prior to removal from truck.

• Check power cables and wiring for damage that

can cause premature drainage of the battery.

IMPORTANT

• Do not overcharge a battery.

Do not wash battery in truck.

• Do not undercharge a battery.

• Follow the instructions provided by the supplier(s)

! CAUTION

of the battery and battery charging equipment.

An overhead hoist of sufficient lifting capac-

• Maintain accurate battery records. If battery trou-

ity (refer to “Weights” in Group 40) should

bles occur, these records will help you and your

be used to lift battery. The safety hooks of the

battery representative determine the nature of the

insulated spreader bar should be attached to

problem.

the lifting eyes provided in the battery casing.

Battery Vents

5. Be sure battery is covered. Attach lifting device. Lift

and remove battery.

•

When Charging Batteries: The vent caps must be

kept in place to avoid electrolyte spray. Care must

Battery Maintenance

be taken to assure that vent caps are functioning.

The vents must be open to allow the battery to

NOTE

breathe. The battery cover must be removed/

To obtain maximum performance and bat-

opened to dissipate heat and explosive gas.

tery life, follow the instructions supplied by

•

When Cleaning Batteries: The vent caps must be

your battery vendor.

tightly in place.

Industrial batteries are used to supply the electrical power

to operate an electric industrial truck. Their voltage

depends on the number of individual cells they contain.

There are approximately two volts for each cell in the

commonly used lead-acid type battery. Batteries normally

range from 6 volts to 72 volts. Their capacity varies

depending on the application. Only use batteries that com-

ply with factory specifications as to size and capacity.

Maximum Battery Life

• Do not add acid to a battery. Only qualified battery

representatives should determine if this is neces-

sary.

• When lifting a battery, use a lifting device designed

for this purpose.

• Check the electrolyte level after placing a battery

on charge. The electrolyte level in a battery should

be slightly below the lower lip of the filling hole

vent. Do not overfill. Overfilling causes loss of

electrolyte.

• Keep the battery clean, dry and in good condition.

• Keep metal objects and tools away from the top of

the battery. Short circuits will cause battery dam-

12-1-4 • Battery Service

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

Standard Truck

13-1-2 • Schematic Electric Circuit Diagrams

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

ELH Options Truck

SM 765, Nov ’06

Schematic Electric Circuit Diagrams • 13-1-3

Group 13, Wiring, Switches, and Instruments

Section 2

General Electrical Service Tips

• Make sure battery is disconnected.

General Electrical Service Tips

3. Discharging Controller Capacitors

CAUTION

It is necessary to discharge the capacitors before you work

Always wear safety glasses.

on the controller.

NOTE

Make sure that the battery has first been dis-

connected at the battery receptacle.

Remove all jewelry before

working on truck.

1. Move truck to service area:

. Park truck on a flat level surface.

. Fully lower upright.

. Tilt forks forward until fork tips touch the floor.

SERVICE AREA

To discharge the capacitors connect a 200 ohm 10

watt resistor between the positive and negative

input post of the controller for 10 seconds.

2. Disable the truck:

• Turn the key switch to OFF.

• Remove key.

SM 765, Nov ’06

General Electrical Service Tips • 13-2-1

Group 13, Wiring, Switches, and Instruments

Checking Power Cables

Torquing Fasteners

Every cable and wiring harness on this truck is manufac-

Improperly torqued fasteners can cause damage

tured to an exact specification. A shorter cable or harness

Use an appropriate wrench and tighten all fasteners to the

will not fit. If either a harness or cable is routed improp-

torque specified in the following inspection procedures.

erly, it will not fit. Subsequently, electrical shorts and

damaged components may result if the replacement part is

the wrong one, or if it is routed incorrectly.

Pivoted

Scale

Handle

Socket

Head

Force or Pull

Pointer

Cuts

Typical Torque Wrench

Connecting and Mounting Compo-

Power cables having small cuts

nents

may be repaired with electrical

tape.

Tape markers are used to correctly position each

wire harness and electrical cable on the truck. When

correctly installed, the tape marker will be hidden by

Repairable Damage

the mounting clamp (guide). Be sure to follow the

instructions, where noted in this manual, when

installing a wire harness or electrical cables. If you

Cables having damage as shown in illustration below

do not, possible shorts and equipment damage may

should be removed immediately and replaced with

result.

new. Be certain the replacement cable is the exact

same length, size and has the proper connector. Make

absolutely certain the cable end is properly crimped

and its connection properly torqued upon installation

Tape Marker

Damaged Casing

Clamp

(and/or Guide)

Break

Markers on Wire Harnesses and Power Cables

Broken Wires

Cable Unfit for Further Service

13-2-2 • General Electrical Service Tips

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

Multiple cable and wire connections must be con-

There is a moisture-resistant seal at each wireend of

nected as illustrated or electrical shorts and control

the connector and between the plug and socket.

damage may result.

Check seals for damage that would make them unfit

for furtherservice (cuts, etc.). Make certain the end

Terminal Barrels

seals are seated flush with the end of the connector

Must Face Opposite

housing. Make certain the plug and socket

Each Other

latchtightly to each other.

Firmly push plug into socket until

Assemble

latch "clicks" locking the two components

together.

Back to Front

Buss Bar

Barrel

Latch

Barrel

End seals

must be firmly

seated within

Seal(s)

the assembly

Multiple Connections

housing.

Seals and Latch

Connector Plugs and Receptacles are permanently

labeled with the proper PL (Plug) and SO (Socket/

Receptacle) number for easy identification. Match the

plug number with the appropriate receptacle number

Retainer plates snap into place to secure the pins and

before making a connection. If you do not, electrical

their sockets.

shorts and possible damage to the equipment may result.

Check the plates and seal for damage and secure

i.e., Plug #PL-6 plugs into pin socket #SO-6, etc.

mounting.

Pin Lock (Arrows must point in direction shown.)

Retainer Plates

Rubber Seal

SO-6 Socket

Retainer Plates

Pin

Retainer Plates

Pin(s)

PL-6 Plug

Example of Pin Lock Plug and Socket

SM 765, Nov ’06

General Electrical Service Tips • 13-2-3

Group 13, Wiring, Switches, and Instruments

Electrical Components

13-3-2 • Wiring and Cables

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

SM 765, Nov ’06

Wiring and Cables • 13-3-3

Group 13, Wiring, Switches, and Instruments

13-3-4 • Wiring and Cables

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

SM 765, Nov ’06

Wiring and Cables • 13-3-5

Group 13, Wiring, Switches, and Instruments

13-3-6 • Wiring and Cables

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

SM 765, Nov ’06

Wiring and Cables • 13-3-7

Group 13, Wiring, Switches, and Instruments

13-3-8 • Wiring and Cables

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

Main Harness

SM 765, Nov ’06

Wiring and Cables • 13-3-9

Group 13, Wiring, Switches, and Instruments

13-3-10 • Wiring and Cables

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

SM 765, Nov ’06

Wiring and Cables • 13-3-11

Group 13, Wiring, Switches, and Instruments

13-3-12 • Wiring and Cables

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

SM 765, Nov ’06

Wiring and Cables • 13-3-13

Group 13, Wiring, Switches, and Instruments

Cables

13-3-14 • Wiring and Cables

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

SM 765, Nov ’06

Wiring and Cables • 13-3-15

Group 13, Wiring, Switches, and Instruments

13-3-16 • Wiring and Cables

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

SM 765, Nov ’06

Wiring and Cables • 13-3-17

Group 13, Wiring, Switches, and Instruments

Accessory Harness and Components

13-3-18 • Wiring and Cables

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

SM 765, Nov ’06

Wiring and Cables • 13-3-19

Group 13, Wiring, Switches, and Instruments

13-3-20 • Wiring and Cables

SM 765, Nov ’06

Group 13, Wiring, Switches, and Instruments

Accelerator Control Switch

Description

trical pulses to the motor, which in turn will supply more

power to the drive train.

The accelerator control is operated by the accelerator foot

An internal spring returns the control to start position. The

pedal to send a signal for power demand to the control.

accelerator is an integral unit and is not serviceable. Open-

At the start, the accelerator control is stroked (by the

ing of the unit will void the warranty.

action of the accelerator pedal), and in turn sends a signal

to the motor control, requesting it to produce longer elec-

A

Torque:

8-10 N.m

(71-88 in-lb)

Accelerator

Pedal

C

Torque:

5-6 N.m

(44-53 in-lb)

Accelerator

Control Switch

Roller

B

Torque

20-25 N.m

(177-221 in-lb)

13-4-2 • Switches and Sensors

SM 765, Sep ’06

Group 13, Wiring, Switches, and Instruments

Program Adjustment

• Display will show software version

• Turn the key switch Off and remove the tester cord

from the control

! CAUTION

• Plug the dash display harness into the "B" plug of

Before any adjustments are done, safely jack

the control

up the truck, block the drive wheels off the

• Lower truck to the ground and test drive truck

floor and disconnect the battery.

Use the following method to program the accelerator con-

Brake Switches

trol to the contol panel with the handset:

(Detailed handset operation instructions are in Group 19.)

Service Brake Switch Description

•

Disconnect the dash display harness from the con-

The foot brake switch is on the brake link end, under the

trol panel

flow plate. The switch operates when it is released by the

•

Plug handset into plug "B" of the control

brake pedal lever during braking. Depressing or releasing

•

Plug in the battery

the switch operates a set of contacts that alternate from

•

Turn the key switch On

open to closed to activate the Pedal Braking function of

the control. This function uses the motor to help bring the

•

Handset will go through startup and display soft-

truck to a controlled stop.

ware version

•

Press the “ENTER” button

Service Brake Switch Adjustment

•

Display will read "MAIN MENU' "PARAMETER

CHANGE".

Adjust the switch so that it “clicks” just before the end of

•

Press the “ROLL UP” button five times

pedal “freeplay” (the lag between pressing the brake and

operating the master cylinder, covered in Group

23).

•

Display will read "MAIN MENU" “PROGRAM

Adjust switch as follows.

VACC”

•

Press the "ENTER" button

1. Turn key switch OFF.

•

Display will read "VACC SETTINGS"

2. Make sure freeplay is properly adjusted as described

•

Press the "ENTER” button

in Group 23.

•

Display will read "MIN VACC MAX"

3. Loosen brake switch mounting screws.

•

Move the directional lever to Forward position

4. Rotate switch against pedal until switch trips. (A

•

Depress the accelerator pedal to the floor and than

click can be heard.) Tighten mounting screws.

release slowly

5. Check operation of switch by depressing brake pedal.

•

Move the directional lever to the Reverse position

Switch should actuate just before the end of freeplay

•

Depress the accelerator pedal to the floor and than

(at which time you feel resistance in the pedal caused

release slowly

by the master cylinder beginning to operate.)

•

Press the "ENTER" button

•

Press the “OUT” button

•

Display will read "ARE YOU SURE"

"YES=ENTER" "NO=OUT"

•

Press "ENTER" button (this stores the value for

MIN and MAX accelerator voltage)

Capscrew height

•

Display will show new settings

control

•

Press the “OUT” button

•

Display will read "MAIN MENU" “PROGRAM

Brake

VACC”

Switch

•

Press "OUT button

SM 765, Sep ’06

Switches and Sensors • 13-4-3

Group 13, Wiring, Switches, and Instruments

Parking Brake Switch Description

Parking Brake Operation

The parking brake switch is mounted to the hood under of

The operator applies the parking brake by pull up on a

parking brake assembly. The brake handle center pin

parking brake, which is then held by a ratchet. The pull-

depresses the switch when the hand lever is not applied.

ing up the brake lever tensions cables connected to a brake

This depressing of the switch closes the contacts.

shoe at each brake assembly, thereby applying the brakes.

The operator releases the parking brake by push down on

When the parking brake is applied, it releases the switch,

a Parking lever. Return spring returns the lever and

allowing the contacts to return their normally open posi-

cable to the off position. The lever also operates the park-

tion. This open circuit signals the controller to disable the

ing brake interlock switch and the parking brake indicator

drive motors.

light switch.

IMPORTANT

The switch must cut electrical current to the

drive motor before the brakes apply. Other-

wise, excessive lining wear will result and the

drive motor will overheat.

Parking Brake Switch Adjustment

1. Turn key switch OFF.

2. Loosen parking brake switch mounting screws.

3. Adjust position of switch so that there is contact with

the center pin and the switch actuates (clicks) just as

the parking brake lever is fully released.

4. Tighten mounting screws.

5. Check operation of switch before truck is returned to

service.

Parking Brake Switch

13-4-4 • Switches and Sensors

SM 765, Sep ’06

Group 13, Wiring, Switches, and Instruments

Seat Switch

Lift and Tilt Pump Switches

The GEX trucks are equipped with a seat switch that sig-

nals the control to cut the power when the operator

Description

leaves the seat.

The pump control switches are mounted on brackets at the

When the seat switch is open, a -01 fault code will be dis-

valve spools and they are normally open. Movement of th

played on the dash display.

valve spools from the neutral position trips the switches

and closes their contacts. Current flow through the con-

There is a 1.5 second time delay built into the control to

tacts signals the pump controller to operate the pump

allow for momentary opening of the seat switch. If the

motor at the set speed for the selected function.

truck is operated over rough surfaces and the operator is

bounced, causing a momentary opening of the seat switch,

The lift lever activates a lift enable switch and also acti-

the truck will not shut down.

vates a Lift Pot. This potentiometer signals the pump con-

troller to run at an increasing speed proportional to the

rearward movement of the lever.

Azdel Seat pan

Switch Adjustment

1. Turn key switch to the OFF position.

SUSPENSION SEAT

2. Loosen switch mounting screws.

3. Adjust switch to activate after spool moves from neu-

Seat Switch

tral.

Wire harness

4. Tighten mounting screws.

5. Check operation of switch before truck is returned to

Seat Flexolater

service.

STATIC SEAT

SM 765, Sep ’06

Switches and Sensors • 13-4-5

Group 13, Wiring, Switches, and Instruments

Lift Pot Adjustment

•

Display will read "CONFIG MENU' "SET

MODEL"

1. Insure that the flag of the actuator is properly posi-

•

Press "ENTER" button

tioned on the flat of the large nut.

•

Display will read "CONNECTED TO 3"

2. Tighten the lock nut against the bottom of the actua-

•

Press "PARAM SET UP" button two (2) times

tor.

•

Display will read "CONNECTED TO 5"

3. Loosen the capscrews on the switch mounting

•

Press "OUT" button

bracket and adjust the Pot to the point that it just

•

Display will read "ARE YOU SURE"

touches the actuator plate. Insure that the Pot is paral-

"YES=ENTER" "NO=OUT"

lel with the lift linkage.

Pot mounting screw

•

Press "ENTER" button (this stores the connected

to value)

Lift sensor

•

Display will read "CONFIG MENU" “CON-

NECTED TO”

Actuator

•

Press "OUT" button

•

Display will read Software Version for Pump Con-

trol

•

Press the “ENTER” button

•

Display will read "MAIN MENU' "PARAMETER

CHANGE".

•

Press the “ROLL UP” button five times

•

Display will read "MAIN MENU" “PROGRAM

VACC”

•

Press the "ENTER" button

•

Display will read "VACC SETTINGS"

•

Press the "ENTER” button

•

Display will read "MIN VACC MAX"

Program Adjustment

•

Move the lift lever to full raised position

•

Release the lift lever to the neutral position

! CAUTION

•

Press the “OUT” button

Before any adjustments are done, safely jack

•

Display will read "ARE YOU SURE"

up the truck, block the drive wheels off the

"YES=ENTER" "NO=OUT"

floor and disconnect the battery.

•

Press "ENTER" button (this stores the value for

MIN and MAX lift potentiometer voltage)

Use the following method to program the Lift Potentiome-

ter to the control panel with the handset:

•

Display will show new settings

•

Press the “OUT” button

(Detailed handset operation instructions are in Group 19.)

•

Display will read "MAIN MENU" “PROGRAM

• Disconnect the dash display harness from the con-

VACC”

trol panel

•

Press "OUT button

• Plug handset into plug "B" of the control

•

Display will show software version

• Plug in the battery

•

Turn the key switch Off and remove the tester cord

• Turn the key switch On

from the control

• Handset will go through startup and display soft-

•

Plug the dash display harness into the "B" plug of

ware version

the control

• Press both the "ROLL UP" and "PARAM SET UP"

•

Lower truck to the ground and test drive truck

buttons (top outside buttons) simultaneously.

13-4-6 • Switches and Sensors

SM 765, Sep ’06

Group 13, Wiring, Switches, and Instruments

Section 5

Instrument Panel

Dash Display

SM 765, Sep ’06

Instrument Panel • 13-5-1

Group 13, Wiring, Switches, and Instruments

Dash Display

The Dash Display provides the operator with an easily understandable,

visual feedback of the status of the truck and its system components..

1

2

3

4

6

7

8

9

10

05/8/

10 [WED]

11

12

13

14

5

1. Fuel level Indication

8. Error LED

2. Slow-speed icon (Turtle shaped)

9. Down arrow button (Mode button)

3. Date & Time

10. Up arrow button (Enter button)

4. Hourmeter & Speed

11. Left arrow button (Slow speed button)

5. Message display & Travel direction icon

12. Right arrow button (Power button)

6. Parking brake LED

13. Plus button

7. Seat belt LED

14. Minus button

13-5-2 • Instrument Panel

SM 765, Sep ’06

Group 13, Wiring, Switches, and Instruments

Seat Belt: At start up this symbol displays

max. speed. (In upper example, the limited max.

along with an audio alarm for 4 seconds. This

speed is 2km/h)

display reminds you to fasten your seat belt.

Hourmeter & Speed

• It displays the accumulated oper-

ating hour and traveling speed of

Parking Brake: The symbol is displayed and "-

truck.

255" status code appears on the numeric dis-

• When the traveling speed is less

play when parking brake is applied. Release

than 0.5km/h, it displays the accu-

parking brake to operate truck.

mulated operating hour.

• When the traveling speed is more

than 0.5km/h, it displays the traveling speed.

Service Status: The following 5 codes are usu-

ally operator fault codes, and can be corrected

by as explained in "Section 5, Operating Proce-

Message display

dures." If you see any other codes displayed,

The model name, POWER

the truck needs to be serviced.

Normal

selection, travel direction, warn-

Error

• -01 Seat Switch Open

ing and error message are dis-

Warning

played.

•-061, -065 ,-140,

-203, -207 Overheat of

BATTERY LOW

• In normal operating condition:

motor and controller (Restart after

Model name/POWER/Travel direction

cooling down)

•

When several messages are simultaneously dis-

• -66 Low Battery (truck will go into lift lock-

played, it will be displayed in the order of Error,

out when the dash display shows less

Warning and Normal condition.

than 15%)

• If many error conditions

• -77 Maintenance Hours (preset hour meter

23 : FUSE ERROR

are

simultaneously

reading indicating that it is time to have

56 : FET SHORT

occurred, the priority

2

the truck serviced. Truck will reduce the

Errors will be displayed.

top speed if desired)

(The priority means Error number)

• -79 Incorrect Start Up Sequence (SRO)

• -217, -245 Wrong set battery

Travel direction icon

• -255 Parking Brake Switch Open

• It displays the traveling direction or angle of

steering wheel..

Battery discharge indicator

• The direction icon rotates in 10 degrees.

It displays the battery discharge

(Total 36 icon)

condition of forklift truck.

The one bar indicates

10%

Blue color

Error icon

charging condition.

If the battery is charged more

When error occurs this icon is displayed to dis-

Red color

than 20% (8 bars or more), blue

tinguish the condition easily. When the error

LED is displayed, but it is less

message is displayed, this icon is simulta-

than 20% (2 bars or less), red

neously displayed.

LED is displayed. If it is less than 10% (1 bar), it will

flicker and buzzer sound.

Slow-speed indicator (Turtle shaped)

The traveling speed of truck is limited to

set speed.

The upper mark is slow speed operating

icon, and the figure shows the limited

SM 765, Sep ’06

Instrument Panel • 13-5-3

Group 13, Wiring, Switches, and Instruments

MODE SELECTION BUT-

Right arrow button (Power

TON.

selection button)

• 6 mode selection buttons are

1.Pressing this button, it will move to right

located on right side of LCD.

menu.

• Each button has specific function,

2.In normal operating condition, it will select/

and some have multiple functions.

release Power.

-Power mode is composed of 3 steps, and it

can be adjusted by use of "+/-" buttons. After

adjusting the speed, press "Enter" (Up arrow)

button to store it.

-Power mode

In the order of Economy

→ Normal →

Down arrow button (Mode but-

Power; Pressing "+" button to move right, and

ton)

"-" left.

1.Pressing this button in normal operating

•Economy: It is Slow speed mode to save the

condition, it will move to Menu mode.

battery consumption as minimizing the accel-

eration function.

2.Pressing it in Menu mode, it will move to

lower menu.

•Normal: It is normal operating mode, and

smooth acceleration can be done.

3.Pressing it in the lowest mode, there will be

•Power: Powerful acceleration is possible and

no change.

the work ability will be improved.

Up arrow button (Enter button)

Plus(+) button

1.Pressing this button, it will move to upper

Increase the data as set value in the cur-

menu.

rent Menu mode.

2.It will also take role of "Enter" button when

confirming the changed password or main

parameters.

Minus(-) button

Left arrow button (Slow speed

Decrease the data as set value in the cur-

button)

rent Menu mode.

1.Pressing this button, it will move to left

menu.

2.In normal operating condition, it will select/

release Slow speed.

-When pressing, the following figure will be

displayed and Slow speed selected.

-Press once more to release.

-The figure will be disappeared and Slow

speed released.

Chang of slow speed

Use "+/-" buttons to change the set speed

while the Slow speed is selected. After adjust-

ing the speed, press "Enter" (Up arrow) button

to store it.

The speed can be set from 2 km/h to 9km/h

with unit of 1km/h.

13-5-4 • Instrument Panel

SM 765, Sep ’06

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