Yale Forklift A7S6 (GP080UX, GP090UX, GP100UX) Service Manual PDF

Yale Forklift A7S6 (GP080UX, GP090UX, GP100UX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A7S6 (GP080UX, GP090UX, GP100UX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 620
Downloadable : Yes
File Type : PDF

PART NO. 550253238

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A7S6 (GP080UX, GP090UX, GP100UX) Service Manual – PDF DOWNLOAD

550253238 8000YRM2398 (07 2023) US EN 1
Forklift Truck Main Parts 9
Description of Forklift Truck Main Parts 9
Forklift Main Technical Parameters 10
Main Technical Parameters 10
Power System 26
Engine System 26
Engine Overview 26
Inspection 36
Operate Mitsubishi Engine 36
Precautions before the Operation 36
Engine Adjustment 37
Engine Fault Codes 38
Fuel System 47
Fuel Tank 47
Fuel Level Sensor 50
Maintenance of Fuel System 50
Fuel Filter For Gas-Fueled Truck 50
Fuel Filter For Diesel-Fueled Truck 50
Fuel-Water Separator (Sediment Bowl) 51
Clean Fuel Tank 51
Maintenance of the Air Filter 51
Hydraulic Transmission Case and Torque Converter 52
Overview 54
Torque Converter 54
Hydraulic Clutch Unit 55
Control Valve 55
Transmission Case 56
Transmission Pump 56
Transmission Hydraulic Schematic 56
Speed Differential 59
Towing of Forklift Truck to be Repaired 60
Oil Inlet/Outlet Connection Location 60
Precautions in case of forklift failure 61
Trouble Shooting 61
Oil Port 64
Drive Axle 66
4-5T 66
5-7T 67
Steering System 74
Steering Axle 78
Brake System 82
Overview 83
Brake Master Cylinder 83
Wheel Brake 84
Automatic Clearance Regulator 85
Manual Brake 85
Adjustment of Brake Pedal 86
Maintenance 86
Disassemble, Wheel Brake 86
Inspect 88
Assemble, Wheel Brake 88
Test Automatic Clearance Regulator 90
Troubleshoot Wheel Brake 92
Hydraulic System 93
Main Pump 95
Multi-way Valve 95
Operation of Spool Valve 95
Primary Relief Valve 96
Steering relief valve 96
Action of Inclined Auto-lock Valve 97
Control Levers of Multi-way Control Valve 98
Hydraulic Oil Tank 98
Hydraulic System Main Oil Circuit 98
Lift Cylinder 102
Shut-off Valve 103
Speed Limit Valve 104
Tilting Cylinder 105
Main Oil Pump 105
Disassemble, Main Oil Pump 105
Assemble, Oil Pump 110
Test 110
Oil Filling Instructions 111
General Inspection Requirements 111
Inspection 111
Fill Level Requirements 111
Troubleshoot Hydraulic System 112
Lifting System 113
Inside and Outside Masts 114
Bracket 114
Safety Procedures When Working Near Mast 115
Adjustment for Lifting System 117
Lifting Cylinder 117
Carriage 117
Installation of Roller 118
Electrical System 120
Overview 120
Truck Operations 120
Start and Stop 120
Driving Operations 121
Combination Switch 121
Horn Button 121
Reverse Light and Signal 121
Light Controls 121
Steering Signal 121
Brake Signal 122
Dash Display 122
Introduction to PDM 127
Battery 127
Truck Safety System (OPS/Park Brake Alarm System) 128
Overview 128
Truck Will Not Start 129
Lift, Lowering and Tilt Functions are not Working 129
Forward and Back Functions are not Working 130
USB 130
Electrical Schematics 130
Troubleshoot with Electrical System 141
Diesel Particulate Filter (DPF) Regeneration Control (Only for the Trucks Equipped with Kubota V3800 Engine) 142
DPF Status 142
DPF Operation Instructions 143
DPF System Status Transiton 143
DPF Indicator Status 145
Drive, Operation, and Routine Maintenance of Forklift Truck 147
Transporting the Forklift Truck 147
Towing 147
Long-Term Storage of Forklift Truck 147
Procedures Prior to Operation 148
Precautions for Use 148
Cooling System 149
Oils Used for Forklift Truck 149
Hydraulic Oil Gauge Clarification and Oil Filling Instruction 152
General inspection requirements 152
Inspection method 152
Technical Requirements for filling Hydraulic Oil reservoir 152
Periodical Maintenance 153
550277201 0100YRM5001 (09 2023) US EN 181
General 187
Description 188
Hood, Seat, Floor Plate and Covers Replacement 190
Disassemble (4-5T Trucks) 190
Re-assemble 196
Steering Column 197
Description 197
Steering Column Repair 197
Disassemble 197
Disassemble Steering Hoses 199
Clean 200
Inspect 200
Re-assemble 200
Counterweight Replacement 201
Remove (4-5T Trucks) 201
Remove (5-7T Trucks) 203
Install (4-5T Trucks) 205
Install (5-7T Trucks) 205
Overhead Guard Replacement 206
Remove and Install 206
Operator Restraint System Replacement 209
Description 209
Emergency Locking Retractor (ELR) 209
Engine and Transmission Replacement 210
Remove 210
Disassemble (4-5T Trucks) 210
Disassemble (5-7T Trucks) 211
Re-assemble (4-5T Trucks) 213
Re-assemble (5-7T Trucks) 213
Exhaust System Repair 214
Remove and Disassemble Exhaust System 214
Inspect 214
Re-assemble Exhaust System 214
Cooling System 215
Description 215
Hydraulic Filter Assembly Repair 216
Disassemble 216
Clean and Inspect 217
Re-assemble 218
Fuel and Hydraulic Tanks Repair 219
Inspect 219
Clean 219
Steam Method of Cleaning 219
Chemical Solution Method of Cleaning 220
Additional Preparations for Repair 221
Small Leaks, Repair 221
Large Leaks, Repair 221
Preparations for Use After Repair 221
Safety Labels 222
550277203 0700YRM5003 (08 2023) US EN 227
General 233
Cooling System Checks 233
Water Flow Restrictions in Radiator 233
Radiator Hoses 233
Water Pump 233
Flushing the Cooling System 234
Cooling System, Clean 234
Radiator Replacement (4-5T Trucks) 236
Remove Radiator 236
Install Radiator 240
Radiator Replacement (5-7T Trucks) 241
Remove Radiator 241
Install Radiator 245
Fan Assembly Replacement 246
Fan Removal 246
Inspect 247
Fan Installation 247
550277204 0900YRM5004 (07 2023) US EN 249
Air-Intake and Exhaust System 255
Air-Intake and Exhaust System (Mitsubishi S6S and Mitsubishi S6S-T Engine) 255
Remove 255
Inspect 255
Install 255
Air-intake System (Kubota Engine) 257
Remove 257
Install 257
LPG Tank and Bracket Replacement with Swing-Out Bracket (Kubota WG3800 Engine) 258
Remove LPG Tank 258
Install LPG Tank 259
Remove LPG Bracket 259
Install LPG Bracket 260
Fuel Filter and Fuel Level Sensor Repair 261
FUEL FILTER ELEMENT (4-5T Trucks) 261
Remove 261
Install (4-5T Trucks) 262
Fuel Level Sensor (4-5T Trucks) 262
Remove (4-5T Trucks) 262
Install (4-5T Trucks) 262
FUEL FILTER ELEMENT (5-7T Trucks) 262
Remove 262
Install (5-7T Trucks) 263
Fuel Level Sensor (5-7T Trucks) 263
Remove (5-7T Trucks) 263
Install (5-7T Trucks) 263
LPG Converter (Kubota WG3800 Dual Fuel Engine) 264
Remove 264
Exhaust System 267
Remove (4-5T Trucks) 267
Install (4-5T Trucks) 269
Remove (5-7T Trucks) 273
Install (5-7T Trucks) 278
550286759 1300YRM5005 (07 2023) US EN 281
General 287
Serial Number 288
Transmission 289
Remove and Install 289
Remove 289
Remove Transmission 289
Remove Torque Converter 291
Remove Speed Differential 291
Remove Speed Reducer 292
Disassemble Output Shaft 292
Remove Control Valve and Solenoid Valve 298
Remove Transmission Box 298
Remove Clutch I 298
Remove Clutch II 300
Remove Torque Converter Housing 302
Remove Torque Converter 302
Installation 302
Install Torque Converter 302
Install Clutch I 302
Install Clutch II 303
Install Torque Converter Housing 303
Install Transmission Box 303
Install Speed Differential 303
Re-assemble Output Shaft 303
Install Speed Reducer 303
Install Control Valve and Solenoid Valve 303
Install Torque Converter 304
Clean and Inspect 304
Pedal 305
Remove and Install 305
Remove Pedal 305
Install Pedal 306
Clean and Inspect 306
550286760 1400YRM5006 (07 2023) US EN 309
General 315
Drive Axle Repair 315
Remove and Disassemble 315
Clean and Inspect 320
Re-assemble and Install 320
550286761 1600YRM5007 (09 2023) US EN 323
General 329
Steering Axle Assembly Repair 331
Remove 331
Disassemble (4-5T Trucks) 332
Disassemble (5-7T Trucks) 334
Clean 336
Inspect 336
Re-assemble (4-5T Trucks) 336
Re-assemble (5-7T Trucks) 337
Reinstall 338
Steering Cylinder Repair 339
Remove and Disassemble (4-5T Trucks) 339
Remove and Disassemble (5-7T Trucks) 340
Clean and Inspect 341
Assemble and Install (4-5T Trucks) 341
Assemble and Install (5-7T Trucks) 342
550286762 1800YRM5008 (07 2023) US EN 345
GENERAL 351
SERVICE BRAKE REPAIR 352
REMOVE AND DISASSEMBLE 352
CLEAN 354
INSPECT 354
ASSEMBLE AND INSTALL 355
ADJUST 355
PARKING BRAKE REPAIR 356
REMOVE AND DISASSEMBLE 356
ASSEMBLE AND INSTALL 357
ADJUST 357
MASTER CYLINDER REPAIR 358
REMOVE 358
INSTALL 359
BRAKE SYSTEM TROUBLESHOOTING 360
SERVICE BRAKE ADJUSTMENT 361
SERVICE BRAKE AIR REMOVAL 361
550286763 1900YRM5009 (07 2023) US EN 363
Cylinder 369
General 369
Safety Procedures When Working Near Mast 369
Integral Sideshift Cylinder Repair 369
Remove 369
Disassemble 371
Clean 371
Inspect 372
Re-assemble 372
Install 372
Check Integral Sideshift Cylinder Guide Sleeve Leak 372
Free-Lift Cylinder 373
Remove 373
Disassemble and Re-assemble 375
Clean 375
Inspect 376
Install 378
Main Lift Cylinder Repair 378
Remove 378
Disassemble and Re-assemble 380
Clean 380
Inspect 380
Install 381
MAIN LIFT CYLINDER LEAK CHECK 381
Tilt Cylinder Repair 381
Remove 381
Disassemble and Re-assemble 384
Clean 384
Inspect 384
Install 384
Hydraulic Gear Pump 385
General 385
Hydraulic Gear Pump Repair 386
Remove 386
Disassemble 388
Re-assemble 389
Examination and Repair 390
Pump Body 390
Bearing 391
Gear 392
Oil Seal 392
Main Control Valve 393
General 393
Main Control Valve 393
Description 393
Remove 395
Clean and Inspect 399
Install 399
550286764 2200YRM5010 (09 2023) US EN 401
General 407
Combination Switch 407
Remove and Install 407
Display and Rocker Switch 409
Remove and Install 409
Battery and Power Distribution Module 411
Remove and Install (4-5T Trucks) 411
Remove and Install (5-7T Trucks) 412
Auxiliary Relay and Fuse Box 413
Remove and Install 413
Sensors and Switches 414
General 414
Accelerator Pedal Position Sensor 414
Remove and Install 414
Parking Brake Sensor 414
Remove and Install 414
Fuel Level Sensor (4-5T Trucks) 415
Remove and Install 415
Fuel Level Sensor (5-7T Trucks) 416
Remove and Install 416
Torque Converter Temperature Sensor 417
Remove and Install 417
Engine Coolant Temperature Sensor 418
Remove and Install 418
Oil Pressure Sensor 420
Remove and Install 420
Lights 423
Lights 423
Remove and Install 423
550286765 4000YRM5011 (09 2023) US EN 425
General 431
Safety Procedures When Working Near Mast 432
Fork Replacement 433
Standard Carriage and Integral Sideshift Carriage 433
Remove 433
Install 434
Checks 434
Carriages Repair, Three-Stage FFL Mast 436
Standard Carriage 436
Remove 436
Clean and Inspect 436
Install 437
Integral Sideshift Carriage 437
Remove 437
Clean and Inspect 441
Assemble 441
Install 441
Three-Stage Mast With Full Free-Lift Repair 442
Remove 442
Disassemble and Re-assemble 443
Clean and Inspect 445
Carriage Adjustments 446
Lift Chains Adjustment 447
Mast Adjustments 448
Load Roller, Adjust 448
Mast Side Kicking, Adjust 449
550286766 8000YRM5012 (07 2023) US EN 451
Electrical Schematics 457
Electrical Schematics 457
Hydraulic Schematics 460
Hydraulic System Main Oil Circuit 460
Power Distribution Module (PDM) Schematics 462
550286767 8000YRM5013 (07 2023) US EN 489
General 495
How to Move a Disabled Truck 495
How to Tow Truck 495
How to Put a Truck on Blocks 496
How to Raise Drive Tires 496
How to Raise Steering Tires 496
HOW TO CLEAN A Truck 497
Maintenance Schedule 499
Periodical Maintenance 499
Oils Used for Truck 520
Maintenance Procedures Every 8 Hours or Daily 521
How to Make Checks With Engine Stopped 521
Tires and Wheels 521
Safety Labels 521
Mast, Carriage, Lift Chains, Header Hoses, and Attachment 521
Emergency Locking Retractor (ELR) 522
Adjust Seat – Standard Full Suspension 522
Hood and Seat Latches 523
Engine Compartment 523
Fuel, Oil, and Coolant Leaks, Check 523
Hydraulic Hoses 524
Coolant Hoses 524
Steering Column 524
Transmission 524
Hydraulic System Oil 524
Engine Oil 524
Check Engine Oil Level 524
Forks 525
Inspect 525
Remove 526
Adjust 526
How to Make Checks With Engine Running 526
Indicator Lights, Horn, Fuses, and Relays 526
Service Brakes 529
Operation, Check 529
Parking Brake 529
Engine Oil Pressure 529
Cooling System 529
Steering System 529
Control Levers and Pedals 529
Lift System, Operate 530
Maintenance Procedures Every 50 Hours or Daily 531
Kubota V3800 Engine 531
Fuel Tank Water Drainage (Mitsubishi Engine S6S) 531
Maintenance Procedures Every 250 Hours or Quarterly 532
Mitsubishi Engine S6S 532
Engine Oil and Oil Filter 532
Drain Engine Oil 532
Refill Engine Oil 532
Change Oil Filter 533
Inspect and Adjust Belt and Tension 534
Inspect Belt 534
Adjust Belt Tension (Alternator Side) 534
Check and Clean Radiator Fins 535
Kubota V3800 Engine and Kubota WG3800 Engine 535
Check Radiator Hose and Clamp Bands 535
Clean Air Cleaner Primay Element 536
Adjust Fan Belt Tension 537
Maintenance Procedures Every 500 Hours or Semi-annually 540
Mitsubishi Engine S6S 540
Replace Fuel Filter 540
Kubota V3800 Engine and Kubota WG3800 540
Change Engine Oil 540
Replace Oil Filter Cartridge 542
Replace Water Separator Filter – Kubota V3800 Engine 542
Cleaning Water Jacket and Radiator Interior – Kubota V3800 Engine 543
Maintenance Procedures Every 1000 Hours or Annually 546
Mitsubishi Engine S6S 546
Inspect Starter 546
Inspect Alternator 546
Kubota V3800 Engine 546
Check Valve Clearance 546
Kubota WG3800 Engine 549
Check Valve Clearance 549
Maintenance Procedures Every 1500 Hours or Annually 550
Kubota V3800 Engine and Kubota WG3800 Engine 550
Replace Air Cleaner Element 550
Kubota WG3800 Engine 550
Clean Water Jacket and Radiator Interior 550
Maintenance Procedures Every 3000 Hours or Two Years 552
Mitsubishi Engine S6S 552
Change Coolant 552
Safety Procedures When Working Near Mast 553
550286768 8000YRM5014 (07 2023) US EN 555
Truck Main Technical Parameters 561
Main Technical Parameters 561
Truck Lifting Capacity 573
Counterweight Weights 573
Tire Sizes 573
Capacities 574
Recommended Lubricants 575
Lubricant Specifications 575
Electrical System 576
Transmission Oil Pressures 577
Hydraulic System Relief Pressures 577
Steering System 578
Mast Speeds 578
Tilt Angles 578
Engine Specifications 579
550286769 8000YRM5015 (07 2023) US EN 583
Operator Station General Description and Principles of Operation 589
General Description and Location 589
Display Switch Cluster 591
Dash Display 591
Manual Control Levers 593
General Description 593
System Components 593
Lift/Lower 593
Tilt 593
Sideshift 593
Sideshift Fork Positioner 593
Accelerator Control 594
Description 594
Remove and Install 594
Combination Switch 594
Sequential Seatbelt Module 596
General Description 596
Seat Switch/Sensor 596
Buckle Switch 596
Sequential Seatbelt Module 596
Lighting 596
Front End, Mast 597
Description 597
Carriages 597
Description 597
Principles of Operation 597
Integral Sideshift Carriage 597
Mast Mounts 598
Description 598
Principles of Operation 598
Two-Stage Limited Free-Lift (LFL) Mast 600
Description 600
Principles of Operation 600
Two-Stage Full Free-lift (FFL) Mast 602
Description 602
Principles of Operation 602
Three-Stage Full Free-Lift (FFL) Mast 603
Description 603
Principles of Operation 603
Lift Cylinders 605
Description 605
Tilt and Sideshift Cylinders 608
Description 608
Tilt Cylinder 608
Sideshift Cylinder 608
Lowering Control Valves 608
Description 608
Chassis 609
Description 609
Examination and Maintenance 610
Leakage of Hydraulic Oil and Transmission Case Oil 610
Tire Air Pressure (Pneumatic Tire) 610
Wheel Hub Nut Torque 610
Overhead Guard 612
Coolant Level (Mitsubishi S6S Engine) 612
Engine Oil Level 612
Fan Belt Tension Level 612
Rear Combination Light 613
Hydraulic Oil Level 613
Pipeline Cylinder 613
Transmission Oil Level 613
Backrest 615
Fork and Fork Positioning Pin 616
Headlights 616
Gear-shift Handle 616
Multi-way Valve Operating Handle 616
Parking Brake Operation 616
Display Panel 616
Fuel Level 616
Lights 616
Turn Signal 617
Horn Pushbutton 617
Idle Stroke of Brake Pedal 617
Mast Operation 617
Lifting Chain Tension 617
Steering Wheel Free Stroke 617
Exhaust Gas 618
Inching Pedal (Hydraulic Transmission lift truck) 618
Brake 618
Steering Wheel 618
Parking Brake 618
Reversing light and Reversing Buzzer 618
Troubleshooting 619