Yale Forklift E877 (GDP300EC, GDP330EC, GDP360EC) Service Manual PDF

Yale Forklift E877 (GDP300EC, GDP330EC, GDP360EC) Service Manual – PDF DOWNLOAD

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Yale Forklift E877 (GDP300EC, GDP330EC, GDP360EC) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1540
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift E877 (GDP300EC, GDP330EC, GDP360EC) Service Manual – PDF DOWNLOAD

524150779 1400YRM0046 (08 2012) US EN 1
toc 1
Differential 1
Safety Precautions Maintenance and Repair 2
General 5
Description 5
Differential Repair 5
Remove 5
Differential Carrier From Axle Housing, Remove 5
Differential and Ring Gear From Differential Carrier, Remove 9
Drive Pinion and Pinion Carrier From Differential Carrier, Remov 11
Disassemble 12
Differential and Ring Gear Assembly, Disassemble 12
Drive Pinion and Pinion Carrier, Disassemble 13
Clean and Inspect 16
Assemble 17
Pinion, Bearings, and Pinion Carrier, Assemble 17
Pinion Bearings, Adjust Preload 17
Press Method 17
Yoke or Flange Method 18
Triple-Lip Seal, Install 19
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion) 20
Differential and Ring Gear, Assemble 22
Differential Gears Rotating Torque, Check 24
Differential and Ring Gear Assembly, Install 25
Differential Bearings, Preload Adjust 26
Ring Gear, Runout Check 27
Ring Gear Backlash, Adjust 28
Gear Set, Tooth Contact Pattern Check 30
Thrust Screw, Install and Adjust 33
Install 33
Differential Assembly Into Axle Housing, Install 33
Specifications 34
Troubleshooting 38
tables 1
Table 1 Ring Gear Backlash Adjustment Specifications 29
Table 2 Ring and Pinion Tooth Contact Adjustment 30
Table 3 General Specifications 34
Table 4 Rivet Installation Pressure 34
Table 5 Pinion Adjustment 34
Table 6 Pinion Preload Pressure 35
Table 7 Torque Specifications 36
Table 8 Torque Specifications for Metric Hardware 37
Table 9 Torque Specifications for Metric (Fine) Hardware 37
524150780 1400YRM0944 (08 2012) US EN 41
toc 41
Planetary Drive Axle 41
Safety Precautions Maintenance and Repair 42
General 45
Description 45
Operation 47
Identification 47
Removal 48
Disassembly 48
Planetary Spider and Gearing Assembly GDP80-120DB (GP170-280DB) 49
Planetary Spider and Gearing Assembly GDP130-160EB (GP300-360EB) 50
Wheel End 52
Spindle and Piston Housing 53
Cleaning 54
Clean Ground or Polished Parts 54
Clean Parts With Rough Finish 54
Clean Axle Assemblies 54
Drying Cleaned Parts 54
Corrosion Prevention 54
Parts Inspection 55
Tapered Roller Bearings 55
Bevel Pinion and Ring Gear Sets 56
Main Differential Assembly 56
Axle Shafts 56
Yoke 56
Brakes 56
Repair or Replace Parts 56
Repair Welding 57
Apply Silicone Gasket Material 57
Assembly 57
Spindle and Piston Housing to Axle Housing 57
Wet Disc Brakes 58
Adjust Wheel Bearing Preload 59
Planetary Spider and Gearing Assembly GDP80-120DB (GP170-280DB) 60
Planetary Spider and Gearing Assembly GDP130-160EB (GP300-360EB) 60
Planetary Spider Assembly 61
Installation 62
Fill Wet Disc Brakes With Hydraulic Fluid 62
Torque Specifications 63
Lubrication Specification 64
524150781 1400YRM0945 (08 2011) US EN 67
toc 67
Planetary Drive Axle 67
Safety Precautions Maintenance and Repair 68
General 71
Description 71
Operation 73
Identification 73
Removal 74
Disassembly 75
Brake Drum 75
Planetary Spider and Gearing Assembly GDP/GLP80-120DB (GDP/GLP17 76
Dry Brakes 76
Planetary Spider and Gearing Assembly GDP/GLP130-160EB (GDP/GLP3 78
Spindle and Brake Spider 80
Cleaning 80
Ground or Polished Parts 80
Parts With Rough Finish 81
Axle Assemblies 81
Drying Cleaned Parts 81
Corrosion Prevention 81
Parts Inspection 81
Tapered Roller Bearings 81
Bevel Pinion and Ring Gear Sets 82
Main Differential Assembly 83
Axle Shafts 83
Yoke 83
Brakes 83
Repair or Replace Parts 83
Repair Welding 83
Apply Silicone Gasket Material 83
Assembly 84
Spindle, Brake Spider, and Brake 84
Wheel End 85
Adjust Wheel Bearing Preload 85
Planetary Spider and Gearing Assembly GDP/GLP80-120DB (GDP/GLP17 86
Planetary Spider and Gearing Assembly GDP/GLP130-160EB (GDP/GLP3 87
Planetary Spider Assembly 87
Installation 88
Torque Specifications 89
Lubrication Specification 90
524150797 8000YRM0231 (02 2023) US EN 93
General 99
Threaded Fasteners 99
Nomenclature, Threads 99
Strength Identification 100
Cotter (Split) Pins 101
Fastener Torque Tables 106
Conversion Table 108
524150797 8000YRM0231 (03 2020) US EN 115
General 119
Threaded Fasteners 119
Nomenclature, Threads 119
Strength Identification 120
Cotter (Split) Pins 121
Fastener Torque Tables 126
Conversion Table 128
524211827 0600YRM1101 (11 2018) US EN 135
Series Code / Model Designation Reference Table 139
General 139
Fault Codes 140
Normal Mode 140
Fault Log Mode 141
Access 141
Exit 141
Clear 141
Electronic Throttle Calibration 141
Electronic Throttle Calibration Procedure 142
Stationary Regeneration Procedure 142
524300813 0700YRM1350 (05 2012) US EN 171
toc 171
Cooling System 171
Safety Precautions Maintenance and Repair 172
General 175
Cooling System Description 175
Cooling Cores 175
Fan and Shroud 176
Engine Cooling System 176
Water Pump 177
Thermostat 177
Expansion Tank And Radiator Cap 178
Cab Heater 178
Coolant 178
Charge Air Cooling System 180
Transmission Oil Cooling System 180
Hydraulic Oil Cooling System 180
Hydraulic Oil Cooling, D876/D877 Trucks 181
Hydraulic Oil Cooling, E876/E877 Trucks 181
Brake Cooling 182
Oil Filtration and Oil Cooling 182
Hydraulic Control System 182
Service and Repair 183
Cooling System Checks 183
Basic Checks 183
Coolant Quality Checks 183
Coolant Flow Checks 184
Thermostat 184
Water Pump 185
Cooling Core Efficiency 185
Cooling Core Flow Restrictions 185
Engine Leak Tests 186
External Leak Test 186
Check for Coolant Leak Into The Engine Oil Sump 187
Combustion Leak Test 187
Engine Cooling System Maintenance 188
Draining the Engine Cooling System 188
Filling the Engine Cooling System 189
Flushing the Engine Cooling System 189
Cleaning the Engine Cooling System 190
Remove and Replace Procedures 190
Drive Belt 190
Remove 190
Install 190
Belt Tensioner 190
Inspect 190
Remove 190
Install 191
Water Pump 191
Inspect 191
Remove 191
Install 191
Thermostat 192
Remove 192
Inspect 192
Install 192
Cooling Core Assembly 192
Removal 192
Cooling Cores 195
Disassembly 195
Assembly 195
Install 195
tables 171
Table 1 Limiting Values 179
Table 2 Thermostat Operating Temperatures 184
Table 3 Temperature Differences Between Core Entry and Core Exi 185
524302733 1300YRM1356 (01 2016) US EN 201
Series Code / Model Designation Reference Table 205
General 205
Transmission Repair 205
Remove 205
Disassemble 209
Reverse and Second-Speed Clutch 239
Clean and Inspect 255
Housings 255
Oil Seals and Gaskets 256
Bearings 256
Gears and Shafts 256
Assemble 256
Reverse and Second-Speed Clutch 266
Install 307
Control Valve Removal and Installation 310
Remove 310
Install 310
Control Valve Components 311
Control Valve Disassemble and Assemble 311
Remove 311
Control Valve Cover 311
Control Valve Components 312
Install 312
Control Valve Components 312
Control Valve Cover 312
Transmission Frame Bracket 313
Torque Specifications 313
Torque Specifications for Lubricated or Plated Screw Threads 313
Troubleshooting 315
524304019 1300YRM1358 (01 2016) US EN 319
Series Code / Model Designation Reference Table 325
General 326
Description 326
General 326
Operation 329
Hydraulic Operation 329
1st/3rd Selector Valve 332
Cooling and Lubrication 334
Control System 335
General 336
APC200 Controller 336
Self Test 336
Protection Modes 336
Limp Home Mode 336
Shut Down Mode 336
Transmission Exceed Codes 337
Fault Codes 337
Description 337
Fault Log Mode 337
Access 337
Exit 338
Clear 338
Fault Rectification 338
Hydraulic Control Valve 340
Hydraulic Control Valve Repair 342
Solenoid Replacement 342
Pressure Check 342
Pressure Specifications 343
Pressure, Speed, and Temperature Sensors 343
Pressure Switch 348
Test 348
Speed Sensor 349
Test 349
Temperature Sensors 350
Test 350
Transmission Test and Calibration 351
Precautions 351
Stall Test 351
Description 351
Stall Test Procedure 351
Clutch Calibration 352
Description 352
Procedure 353
Inching Calibration 353
Description 353
Brake and Inching Pedal Adjustment 354
Inching Sensor Adjustment 354
Inching Sensor Calibration 355
Electrical Specifications 355
APC200 Display information 355
General 356
General Information Group 356
Fault Codes 357
Indication of Protection Modes 357
Test Function Group 358
Digital Input Test 360
Analog Input Test 361
Speed Sensor Test 362
Output Test 363
Voltage Test 364
Calibration Group 366
Calibration Mode 366
Clutch Filling Calibration 366
Heat Up Mode 367
Inching Sensor Calibration 367
Inching Pedal Sensor Adjustment 367
Inching Sensor Calibration 367
TE-Userlink 368
Description 368
Connection 368
368
Diagrams, Schematics, or Arrangements 368
550022606 1300YRM1435 (01 2016) US EN 405
Series Code / Model Designation Reference Table 409
General 409
Transmission Exceed Codes 409
Clutch Calibration Condition Messages 409
Fault Codes During Clutch Calibration 409
APC200 Fault Codes 410
Limp Home Mode 410
Shut Down Mode 410
Pressure Feedback Sensor 410
APC200 Fault Codes 411
Transmission Exceed Codes 411
Clutch Calibration Condition Messages 415
Fault Codes During Clutch Calibration 415
APC200 Fault Codes 418
550033398 0100YRM1459 (12 2018) US EN 445
Series Code / Model Designation Reference Table 449
Description and Operation 449
Heater System 449
General 449
Air Conditioning 450
General 450
Dryer 451
Compressor Lubrication 452
Control Systems, Sensors, and Switches 452
Climate Control 453
Description 453
Service Menu 453
Set Up 454
View 1 and View 2 454
Error List 455
Statistics 455
Exit 455
Temperature Sensors 455
Troubleshooting 455
Water Valve 456
Troubleshooting 456
Remove and Replace 458
Standard Heater Assembly 459
Access 459
Remove 459
Install 460
Standard Heater Parts 461
Heater Core 461
Remove 461
Install 462
Blower 462
Remove 462
Install 463
Water Valve 464
Remove 464
Install 464
Push/Pull Cable 465
Water Valve Cable 465
Remove 465
Install 465
Heater/Air Conditioner Assembly 466
Remove 466
Install 467
Heater/Air Conditioner Parts 467
Vent Door 467
Remove 467
Install 468
Heater Core 468
Remove 468
Install 469
Evaporator Core 470
Remove 470
Install 471
Blower 472
Remove 472
Install 472
Thermostat 473
Remove 473
Install 474
Water Valve 474
Remove 474
Install 475
Air Conditioning Technical Detail 476
550033400 0100YRM1390 (12 2018) US EN 479
Series Code / Model Designation Reference Table 487
General 487
Description of Operation 489
Cab Structure 489
Cab Tilt System 489
Cab Tip-Up System 491
Tilting the Cab 492
Raising 492
Lowering 493
Remove and Install 494
Cab Door Assembly 494
Cab Door 494
Remove 494
Install 494
Door Hinge 495
Remove 495
Install 495
Door Latch 496
Remove 496
Install 496
Door Handle 496
Remove 496
Install 496
Door Release 497
Remove 497
Install 497
Door Push Button 497
Remove 497
Install 498
Cab Tilt System 498
Electric Tilt Pump 498
Remove 498
Install 498
Hand Tilt Pump 498
Remove 498
Install 499
Cab Tilt Cylinder 500
Remove 500
Disassemble 500
Clean 502
Inspect 502
Assemble 502
Install 503
Latch 503
Remove 503
Install 504
Brake and Inching Pedal 505
Remove 505
Install 505
Accelerator Pedal and Sensor 506
Remove 506
Install 506
Adjust Sensor 506
Seat Assembly 506
Seat 506
Remove 506
Install 507
Seat Cushion 507
Remove 507
Install 508
Back Cushion 508
Remove 508
Install 508
Seat Suspension Replacement 508
Boot Replacement 508
Power Assist Armrest 532
Release Cable 532
Remove 532
Install 532
Gas Spring 532
Remove 532
Install 533
Joystick 533
Remove 533
Install 533
Electrical Levers 533
Remove 533
Install 534
Armrest Rocker Switches 534
Remove 534
Install 534
Armrest Top Cover 534
Remove 534
Install 534
Instrument Panel 535
Key Switch 535
Remove 535
Install 535
12V Power Socket 535
Remove 535
Install 535
Electric-Operated Heat Control and Air Recirculation Control (Airco Only) 536
Remove 536
Install 536
Cable-Operated Heater Control (Heater Only) 537
Remove 537
Install 537
Air Conditioning Switch Replacement 537
Instrument Panel Rocker Switches Replacement 537
Parking Brake Switch 538
Remove 538
Install 538
Indicator Display Replacement 538
Instrument Panel Top Console 538
Remove 538
Install 539
Steering Wheel and Column Assembly 539
Steering Wheel and Horn 539
Remove 539
Install 541
Steering Column Assembly 541
Remove 541
Install 542
Adjustment Handle 542
Remove 542
Install 542
Main Warning Lights 543
Remove 543
Install 543
Shift Lever 543
Remove 543
Install 543
Turn Signal Lever 543
Remove 543
Install 543
Window Wipers 544
Window Wiper Assembly Replacement 544
Remove 544
Install 544
Window Wiper Motor Replacement 544
Front Window Wiper Motor 544
Install 544
Rear Window Wiper Motor Assembly 545
Remove 545
Install 545
Top Window Wiper Motor Assembly 545
Remove 545
Install 545
Window Washer System 546
Window Washer Reservoir and Pumps 546
Remove 546
Install 546
Window Washer Hoses 547
Hoses for Top and Rear Window 547
Install 548
Window Washer Spray Nozzles 548
Front Window 548
Remove 548
Install 548
Rear Window 549
Remove 549
Install 549
Top Window 549
Remove 549
Install 549
Window Replacement 549
Front Window 551
Remove 551
Install 551
Rear Window 551
Remove 551
Install 551
Top Window 552
Remove 552
Install 552
Door, Upper/Lower Window 553
Remove 553
Install 553
Sliding Window and Sliding Tracks 553
Remove 553
Install 555
Weather Strip Replacement 555
Window Stopper Replacement 555
Window Seal Replacement 556
Sliding Window Frame 556
Remove 556
Install 556
Floor Mat 556
Front Floor Mat 556
Remove 556
Install 557
Rear Floor Mat 557
Remove 557
Install 558
Radio Console 558
Remove 558
Install 558
Air Duct Replacement 559
Remove Front 559
Remove Rear 559
Install 560
Accessories 560
Mirror Replacement 560
Sunshade Replacement 560
Top 560
Rear 561
Map Light Replacement 561
Interior Fan Replacement 561
Training Seat 561
Field Installation 561
Remove 561
Label Replacement 562
Checks and Adjustments 562
Check Oil Level for Cab Tilt System 562
Door Striker Pin Adjustment 563
Brake Pedal Adjustment 563
Dry Brake 563
Wet Brake 564
Inching Pedal Adjustment 564
Inching Pedal Sensor Adjustment 564
Sensor Adjustment Using Dana Dashboard Software 564
Sensor Adjustment using the APC200 Display 565
Sensor Adjustment for Trucks with ZF Transmission 566
Inching Pedal Sensor Calibration 566
Sensor Calibration using Dana Dashboard Software 566
Sensor Calibration using APC200 Display 566
Sensor Calibration for Trucks with ZF Transmission 567
550035498 2200YRM1481 (08 2012) US EN 571
toc 571
Hydraulic Control System 571
Safety Precautions Maintenance and Repair 572
General 575
Description 575
Control Valve 575
Analog Inputs 576
Levers and Joysticks 576
Sensors 577
Temperature Sensor 577
Pressure Sensor 577
Digital Inputs 577
Switches 577
Interrupts 577
CAN Bus Communication 578
Output Signals 578
Analog Outputs 578
Digital Outputs 578
Programmed Features 578
Anti-Stall (Standard) 578
Temperature Protection (Standard) 578
Low Temperature Protection (Standard) 579
High Temperature Protection (Optional) 579
Dynamic Control (Optional) 579
Loaded Speed Reduction (Optional) 579
Settings 579
Adjustable Parameters 579
Truck Configuration Screen 579
Mode Definition Responsiveness (Smooth, Medium, and Rapid) 579
Set Default Flow Settings Screen 579
Features Screen 579
Loaded Speed Reduction Screen 579
Flow Settings Screen 580
General Functions of the Interface 580
Main Functional Requirements 580
What is Needed for the Hydraulic User Interface Program 580
Installation of the Program 580
Start Screen 583
Reminder Screen 584
Basic Screen Layout of the Hydraulic User Interface Program 585
Truck Configuration Screen 586
Mode Definition Screen 588
Default Flow Settings Screen 589
Load Moment Interrupt Screen 590
Features Screen 591
Dynamic Control Screen 592
Loaded Speed Reduction Screen 593
Temperature Protection Screen 594
Anti-Stall Screen 595
Calibration Screen 596
Calibrating the Connected Levers/Joystick Without the Interface 596
Calibrating the Connected Levers/Joystick With the Interface Sof 596
Profile Configuration Screen 597
Flow Settings Screen 598
Valve Settings Screen 599
Diagnostic Screen 600
Active Errors Screen 601
Error History Screen 602
All Parameters Screen 603
Installing the Hydraulic Controller Software and Read-Only Param 604
Calibration 607
Calibrating the Lever With the Hydraulic User Interface Program 607
Calibrating the Joystick With the Hydraulic User Interface Progr 607
Calibrating the Lever Without the Hydraulic User Interface Progr 607
Calibrating the Joystick Without the Hydraulic User Interface Pr 607
Fault Codes 608
Controller Pinning 618
tables 571
Table 1 Temperature and Maximum Engine Speed 579
Table 2 Hydraulic User Interface Program Overview 581
Table 3 Parameters 588
Table 4 Temperature/Rpm Table 594
Table 5 Fault Codes 608
Table 6 Fixed PT 618
Table 7 Alternating PT 620
Table 8 Empty Container Handler (ECH) 622
Table 9 XML Parameter File Content 623
550035500 0100YRM1496 (11 2015) US EN 629
General 633
Description 633
Air Cleaner 633
Remove 634
Install 634
Exhaust System 634
Remove 635
Install 635
Hood Assembly 635
Remove 636
Install 637
Hydraulic Tank 637
Remove 637
Inspect 640
Clean 640
Additional Preparations for Repair 640
Repair 641
Small Leaks 641
Large Leaks 641
Preparations for use After Repair 641
Install 641
Fuel Tank 643
Remove 643
Repair 647
Install 647
Cab 647
Raising and Lowering Cab 648
Raise Cab 648
Lower Cab 649
Cab Repair 649
Remove 649
Install 650
Oil Filling for Cab Tilt System 652
Engine 652
Remove 653
Install 660
Counterweight 661
General 662
Remove 662
Install 663
Label Replacement 663
550035502 1300YRM1455 (11 2018) US EN 667
Series Code / Model Designation Reference Table 671
General 671
Description 671
General 671
Clutch 676
Operation 676
Hydraulic Operation 676
Clutch Valve 677
Cooling and Lubrication 678
Control System 679
Transmission Control Unit (TCU) 680
Operating Modes 680
Normal Mode 680
Substitute Clutch Control 680
Limp-Home Mode 680
Transmission Shut Down Mode 680
TCU Shut Down Mode 680
Transmission Exceed Codes 680
Self-Test 681
Fault Codes 681
Description 681
Fault Log Mode 681
Access 681
Exit 682
Clear 682
Fault Log Memory 682
Fault Rectification 682
Hydraulic Control Valve 683
Hydraulic Control Valve Repair 684
Solenoid Replacement 684
Pressure Check 684
Pressure Specifications 685
Speed and Temperature Sensors 685
Speed Sensors 686
Test 687
Temperature Sensors 687
Shift Lever 687
PedalFoot Directional Control 687
ZF Transmission Test and Calibration 688
Transmission Test and Calibration 688
Precautions 688
Stall Test 688
Description 688
Stall Test Procedure 688
Inch Pedal Calibration 689
Description 689
Calibration 689
Brake and Inch Pedal Adjustment 689
Inch Sensor Adjustment 689
Inch Pedal Calibration 690
Preparation 690
Calibration Procedure Using the Calibration Switch 690
Calibration Procedure Using the Testman software 690
Inch Pedal Calibration Fault Codes 690
Clutch Calibration 691
Description 691
Clutch Calibration Procedure 692
Manual Clutch Calibration Procedure 692
Testman Clutch Calibration Procedure 693
Testman 693
Description 693
Connection 694
Truck Configuration 694
Configuration 694
Limitations 694
Capacities and Specifications 695
Electrical Specifications 695
Transmission Control Unit Diagram 695
ZF Transmission Fault Codes 697
Transmission Exceed Codes 697
Testman Fault Codes 698
550035503 1300YRM1456 (12 2015) US EN 709
Series Code / Model Designation Reference Table 713
Special Tools List 714
Transmission Repair 715
Remove 715
Disassemble 719
Clean and Inspect 758
Housings 759
Oil Seals and Gaskets 759
Bearings 759
Gears and Shafts 759
Assemble 760
Transmission Oil Filter Assembly Replacement 807
Clean 808
Inspect 808
Install 809
Control Valve Replacement 814
Remove 814
Install 815
Control Valve Repair 816
Disassemble 816
Clean 820
Inspect 820
Assemble 821
550035504 1600YRM1479 (01 2022) US EN 829
General 835
Basic Principles of Flow Control Systems 835
Basic Principles of Flow Control Systems 835
Orifice (Fixed/Variable) 835
Basic Principle 835
Pressure Compensated Flow Control Valve 836
Basic Principle 836
Pressure Compensated Flow Control Valve Functional Description 836
Priority Valve 837
Basic Principle 837
Priority Valve Functional Description 837
Load Sense (LS) 838
Basic Principle 839
Load Sense Functional Description 839
Example 1 839
Example 2 839
Basic Principles of Pressure Control Systems 840
Basic Principles of Pressure Control Systems 840
Direct Acting Relief Valves 840
Basic Principle 840
Direct Acting Relief Valve Functional Description 840
Two-Stage Relief Valve (Pilot Operated Relief Valve) 841
Basic Principle 841
Two-Stage Relief Valve (Pilot Operated Relief Valve) Functional Description 841
Unloading Valve (Accumulator Charging Valve) 842
Basic Principle 842
Unloading Valve (Accumulator Charging Valve) Functional Description 842
Counterbalance Valve 844
Basic Principle 844
Counterbalance Valve Functional Description 844
Pressure Reducer Valve 844
Basic Principle 844
Pressure Reducer Valve Functional Description 845
Steering System Main Component Identification 846
Description and Operation 850
Steering System 850
Introduction 850
Description 850
Hydraulic Oil Flow Path 850
Priority Valve 850
Fundamentals 850
Description 850
Operation 850
Component Validation for Correct Operation 851
Steering Control Unit 851
Description 851
Steering Control Valve 851
Fundamentals 851
Operation 851
Component Validation for Correct Operation 851
Hand Pump 851
Fundamentals 851
Operation 852
Component Validation for Correct Operation 852
LS Relief Valve 852
Fundamental 852
Operation 852
Component Validation for Correct Operation 852
Shock Valve 852
Fundamental 852
Operation 852
Component Validation for Correct Operation 852
Steering Axle 852
Remove and Replace 854
Steering Control Unit 854
Remove 854
Install 855
Steer Axle (E876/E877) (F876 F877) 855
Remove 855
Install 856
Tie Rod (E876/E877) (F876 F877) 858
Remove 858
Clean and Inspect 858
Install 858
Steering Cylinder (E876/E877) (F876 F877) 858
Remove 858
Clean and Inspect 860
Assemble and Install 861
Hubs (E876/E877) (F876 F877) 861
Remove and Disassemble 861
Clean and Inspect 861
Assemble and Install 862
Spindle (E876/E877) (F876 F877) 862
Remove 862
Clean 863
Assemble and Install 863
Hydraulic Troubleshooting Flowcharts 864
Hydraulic Pressure Checks Preparation 864
Steering Relief Pressure Check 864
Pressure Check, Port MLS1 and MLS2 on the Main Control Valve 865
Steering Wheel Lock to Lock Check 865
Flowchart 866
Hydraulic Pressure Checks for Troubleshooting Flowcharts 867
Hydraulic Pressure Checks Preparation 867
Condition Check, Shuttle Valve L and M in the Main Control Valve 867
Condition Check, Logic Element N in the Main Control Valve 868
Condition Check, Priority Valve on the Main Control Valve 868
Steering Cylinder 869
Remove and Disassemble 869
Clean and Inspect 870
Assemble and Install 870
Steering Axle Assembly 873
Steer Axle 873
Remove 873
Install 873
Wheels and Hubs 875
Remove and Disassemble 875
Clean 876
Inspect 876
Assemble and Install 876
Spindles and Bearings 876
Remove 876
Clean 877
Assemble and Install 877
Tie Rods 877
Remove 877
Clean 878
Install 878
Torque Specifications 880
550035504 1600YRM1479 (08 2012) US EN 883
toc 883
Steering System 883
Safety Precautions Maintenance and Repair 884
General 889
Basic Principles of Flow Control Systems 889
Basic Principles of Flow Control Systems 889
Orifice (Fixed/Variable) 889
Basic Principle 889
Pressure Compensated Flow Control Valve 890
Basic Principle 890
Pressure Compensated Flow Control Valve Functional Description 890
Priority Valve 890
Basic Principle 890
Priority Valve Functional Description 891
Load Sense (LS) 892
Basic Principle 892
Load Sense Functional Description 892
Example 1 893
Example 2 893
Basic Principles of Pressure Control Systems 893
Basic Principles of Pressure Control Systems 893
Direct Acting Relief Valves 894
Basic Principle 894
Direct Acting Relief Valve Functional Description 894
Two-Stage Relief Valve (Pilot Operated Relief Valve) 894
Basic Principle 894
Two-Stage Relief Valve (Pilot Operated Relief Valve) Functional 894
Unloading Valve (Accumulator Charging Valve) 895
Basic Principle 895
Unloading Valve (Accumulator Charging Valve) Functional Descript 895
Counterbalance Valve 896
Basic Principle 896
Counterbalance Valve Functional Description 897
Pressure Reducer Valve 897
Basic Principle 897
Pressure Reducer Valve Functional Description 897
Steering System Main Component Identification 898
Description and Operation 901
Steering System 901
Introduction 901
Description 901
Hydraulic Oil Flow Path 901
Priority Valve 901
Fundamentals 901
Description 901
Operation 901
Component Validation for Correct Operation 902
Steering Control Unit 902
Description 902
Steering Control Valve 902
Fundamentals 902
Operation 902
Component Validation for Correct Operation 902
Hand Pump 903
Fundamentals 903
Operation 903
Component Validation for Correct Operation 903
LS Relief Valve 903
Fundamental 903
Operation 903
Component Validation for Correct Operation 903
Shock Valve 903
Fundamental 903
Operation 903
Component Validation for Correct Operation 903
Steering Axle 903
Steering Control Unit 904
Remove 904
Install 905
Hydraulic Troubleshooting Flowcharts 906
Hydraulic Pressure Checks Preparation 906
Steering Relief Pressure Check 906
Pressure Check, Port MLS1 and MLS2 on the Main Control Valve 907
Steering Wheel Lock to Lock Check 907
Flowchart 908
Hydraulic Pressure Checks for Troubleshooting Flowcharts 909
Hydraulic Pressure Checks Preparation 909
Condition Check, Shuttle Valve L and M in the Main Control Valve 909
Condition Check, Logic Element N in the Main Control Valve 910
Condition Check, Priority Valve on the Main Control Valve 910
Steering Cylinder 910
Remove and Disassemble 910
Clean and Inspect 912
Assemble and Install 912
Steering Axle Assembly 914
Steer Axle 914
Remove 914
Install 914
Wheels and Hubs 916
Remove and Disassemble 916
Clean 916
Inspect 916
Assemble and Install 916
Spindles and Bearings 917
Remove 917
Clean 918
Assemble and Install 918
Tie Rods 918
Remove 918
Clean 918
Install 918
Torque Specifications 920
Steering Control Unit 920
Steering Axle 920
Wheel Nuts 920
Steering Cylinder 920
tables 883
Table 1 Definition of Terms 889
Table 2 Definition of Terms 893
Table 3 Internal Components of the Steering Control Unit 902
Table 4 Flowchart 908
550035505 1800YRM1498 (03 2013) US EN 923
toc 923
Brake and Hydraulic Cooling System 923
Safety Precautions Maintenance and Repair 924
General 931
Basic Principles of Flow Control Systems 931
Basic Principles of Flow Control Systems 931
Orifice (Fixed/Variable) 932
Basic Principle 932
Pressure Compensated Flow Control Valve 932
Basic Principle 932
Pressure Compensated Flow Control Valve Functional Description 932
Priority Valve 933
Basic Principle 933
Priority Valve Functional Description 933
Load Sense (LS) 934
Basic Principle 934
Load Sense Functional Description 934
Example 1 935
Example 2 935
Basic Principles of Pressure Control Systems 935
Basic Principles of Pressure Control Systems 935
Direct Acting Relief Valves 936
Basic Principle 936
Direct Acting Relief Valve Functional Description 936
Two-Stage Relief Valve (Pilot-Operated Relief Valve) 937
Basic Principle 937
Two-Stage Relief Valve (Pilot Operated Relief Valve) Functional 937
Unloading Valve (Accumulator Charging Valve) 938
Basic Principle 938
Unloading Valve (Accumulator Charging Valve) Functional Descript 938
Counterbalance Valve 939
Basic Principle 939
Counterbalance Valve Functional Description 939
Pressure Reducer Valve 940
Basic Principle 940
Pressure Reducer Valve Functional Description 940
Brake System Main Component Identification 940
Description 946
Brake Pressure System 946
Main System 946
Introduction 946
Service Brakes 946
Park Brake 946
Description 946
Hydraulic Oil Flow Path 946
Brake Accumulator Charging System 946
Service Brake System 947
Park Brake System 947
Priority Valve 947
Fundamentals 947
Description 947
Operation 947
Component Validation for Correct Operation 947
Brake Control Manifold 947
Description 947
Orifice (F) 948
Fundamentals 948
Description 948
Operation 948
Component Validation for Correct Operation 949
Unloading Valve 949
Fundamentals 949
Operation 949
Component Validation for Correct Operation 949
Screen 949
Description 949
Component Validation for Correct Operation 949
Check Valve 949
Description 949
Component Validation for Correct Operation 949
Pressure Reducer Valve 949
Fundamentals 949
Operation 949
Component Validation for Correct Operation 949
Park Brake Selector Valve 949
Fundamentals 949
Operation 949
Component Validation for Correct Operation 949
Brake Accumulator 950
Fundamentals 950
Operation 950
Component Validation for Correct Operation 950
Brake Treadle Valve 950
Fundamentals 950
Description 950
Operation 950
Wet Disc Brake Cooling System 950
Main System 950
Introduction 950
Description 950
Hydraulic Oil Flow Path 950
Gear Pump 951
Fundamentals 951
Operation 951
Brake Cooling Valve 951
Description 951
Operation 951
Thermostatic Bypass Valve 951
Fundamental 951
Operation 951
Component Validation for Correct Operation 951
Brake Flow Distribution Manifold 951
Fundamentals 951
Operation 951
Component Validation for Correct Operation 952
Hydraulic Oil Cooler Core 952
Fundamentals 952
Operation 952
Brake Return Line Filter ( E876 & E877 Only) 953
Operation 953
Cooling System Air Brakes 953
Main System 953
Description 953
Hydraulic Oil Flow Path 953
Component Explanation 953
Brake Treadle Valve Repair 954
Remove 954
Install 954
Accumulator 955
Remove 955
Disassemble 956
Clean 957
Inspect 957
Repair 958
Assemble 958
Install 958
Pre-Charge Filling 959
Parking Brake 960
Parking Brake Caliper 960
Remove 960
Disassemble 961
Clean and Inspect 961
Assemble 963
Install 963
Parking Brake Caliper Pads 963
Remove 963
Install 964
Parking Brake Bleed 964
Parking Brake Emergency Release 965
Brake Flow Distribution Manifold 965
Remove 965
Pressure Relief Valve 967
Disassemble 967
Clean and Inspect 967
Assemble 967
Install 967
Brake Control Manifold 968
Remove 968
Orifices F and G 969
Disassemble 969
Assemble 969
Orifice H 969
Disassemble 969
Assemble 969
Unloading Valve (B) 969
Disassemble 969
Assemble 969
Screen 969
Disassemble 969
Assemble 969
Check Valve (E) 970
Disassemble 970
Assemble 970
Pressure Reducer Valve (C) 970
Disassemble 970
Assemble 970
Park Brake Selector Valve (A) 971
Disassemble 971
Assemble 971
Install 971
Brake Cooling Valve 972
Remove 972
Install 972
Filter Restriction Indicator (Optional) 973
Remove 973
Install 973
Filter 974
Remove 974
Install 974
Brake Return Line Filter ( E876 & E877 Only) 975
Brake Return Line Filter Assembly 975
Remove 975
Install 976
Filter 976
Remove 976
Install 976
Gear Pump 976
Remove 976
Disassemble 976
Clean 978
Inspect 978
Assemble 979
Install 979
Hydraulic Troubleshooting Flowcharts 980
Mechanical Troubleshooting 984
Checks and Adjustments 986
Hydraulic Pressure Checks Preparation 986
Park Brake Selector Valve Check 986
Park Brake Selector Valve Coil Check 986
Accumulator Pre-Charge Check 986
Parking Brake Adjustment 987
Condition Check, Shuttle Valve L in the Main Control Valve 988
Condition Check, Shuttle Valve N in the Main Control Valve 988
Condition Check, Priority Valve on the Main Control Valve 988
Pressure Check, Port MLS1 989
Torque Specifications 989
Hydraulic Hose Torque Specifications 989
tables 923
Table 1 Definition of Terms 931
Table 2 Definition of Terms 935
Table 3 Internal Components of the Brake Control Manifold 948
Table 4 Internal Components of the Brake Cooling Valve 952
Table 5 Low Brake Pressure Warning Is Intermittent or Constantl 981
Table 6 Service Brake Is Soft or Spongy 982
Table 7 Hydraulic Oil is Overheating 983
Table 8 Parking Brake Will Not Disengage With the Parking Brake 983
Table 9 Lining-to-Disc Clearance 988
550035506 1900YRM1478 (11 2018) US EN 993
Series Code / Model Designation Reference Table 1001
Fundamentals 1001
Basic Principles of Flow Control Systems 1001
Orifice (Fixed/Variable) 1001
Basic Principle 1001
Pressure Compensated Flow Control Valve 1002
Basic Principle 1002
Pressure Compensated Flow Control Valve Functional Description 1003
Priority Valve 1003
Basic Principle 1003
Priority Valve Functional Description 1003
Load Sense (LS) 1004
Basic Principle 1004
Load Sense Functional Description 1005
Example 1 1005
Example 2 1005
Basic Principles of Pressure Control Systems 1005
Direct Acting Relief Valves 1006
Basic Principle 1006
Direct Acting Relief Valve Functional Description 1006
Two-Stage Relief Valve (Pilot-Operated Relief Valve) 1006
Basic Principle 1006
Two-Stage Relief Valve (Pilot-Operated Relief Valve) Functional Description 1007
Pilot-Operated Selector Valves 1007
Fundamentals 1007
Function Description 1008
Pump Pressure Free Flow Side 1008
Function Pressure Blocked Flow Side 1008
Unloading Valve (Accumulator Charging Valve) 1009
Basic Principle 1009
Unloading Valve (Accumulator Charging Valve) Functional Description 1009
Counterbalance Valve 1010
Basic Principle 1010
Counterbalance Valve Functional Description 1010
Pressure Reducer Valve 1011
Basic Principle 1011
Pressure Reducer Valve Functional Description 1011
Description and Operation 1011
Component Location and Identification 1012
Main Control Valve 1018
Introduction 1018
Flow Path 1018
Main Manifold 1018
Introduction 1018
Priority Valve (A) 1018
Fundamentals 1018
Description 1019
Operation 1019
Component Functionality Test 1019
Check Valve (I) 1019
Function Description 1019
Function Operation 1019
Component Functionality Test 1019
Pilot Supply Circuit 1019
Function Description 1019
Pilot Supply Valve (F) 1019
Fundamentals 1019
Function Description 1019
Function Operation 1019
Component Functionality Test 1019
Lift Pressure Selector Valve (B) 1020
Function Description 1020
Function Operation 1020
Component Functionality Test 1020
Check Valve (K) 1020
Function Description 1020
Component Functionality Test 1020
Check Valve (Q) 1020
Function Description 1020
Component Functionality Test 1020
Screen (O) 1020
Function Description 1020
Component Functionality Test 1020
Relief Valve 1020
Function Description 1020
Load Sense Relief Valve (H) 1020
Fundamentals 1020
Functional Operation 1020
Component Functionality Test 1020
Pressure Controller on Pump 1021
Fundamentals 1021
Functional Operation 1021
Component Functionality Test 1021
Full Flow Relief Valve (C) and (G) 1021
Fundamentals 1021
Functional Operation 1021
Component Functionality Test 1021
Shuttle Valve (L) and (M) 1021
Function Description 1021
Component Functionality Test 1021
Logic Valve (N) 1022
Function Description 1022
Function Operation 1022
Load Sense Selector Valve (D) 1022
Function Description 1022
Component Functionality Test 1022
Directional Control Valve Section 1022
Functional Operation (System Level) 1022
Directional Control Valve 1023
Fundamentals 1023
Description 1023
Functional Operation 1023
Electrical Actuation Module (Solenoid End Cap) 1023
Functional Operation 1023
Component Functionality Test 1024
Lift Function 1024
Function Description 1024
Pilot-Operated Check Valve 1024
Fundamentals 1024
Function Description 1025
Function Operation 1025
Emergency Lowering Valve (LH Lift Section ONLY) 1025
Function Description 1025
Lowering Control Valve 1025
Fundamentals 1025
Function Description 1025
Tilt Function 1025
Function Description 1025
Impact Relief Valve 1026
Fundamentals 1026
Function Description 1026
Counterbalance Valve 1026
Fundamentals 1026
Function Description 1026
Auxiliary Function 1026
Function Description 1026
Carriage Valve Bank 1026
Introduction 1026
Functional Operation 1027
Inlet Module 1027
Directional Control Valve Section 1027
Directional Control Valve 1027
Electrical Actuation Module (Solenoid End Cap) 1028
Variable Displacement Pump 1028
Function Description 1028
Basic Functional Operation 1029
Pressure Control Valve 1029
Fundamentals 1029
Operation 1029
Load Sense Pressure Regulator 1029
Fundamentals 1029
Functional Operation 1029
Repair 1030
Main Control Valve 1030
Remove 1030
Clean 1035
Inspect 1035
Assemble 1035
Install 1035
Priority Valve (A) 1038
Remove 1038
Clean 1038
Inspect 1039
Component Functionality Test 1039
Install 1039
Check Valve (K) 1039
Remove 1039
Clean 1039
Inspect 1039
Component Functionality Test 1039
Install 1039
Check Valve (I) 1039
Remove 1039
Clean 1039
Inspect 1040
Component Functionality Test 1040
Install 1040
Check Valve (Q) 1040
Remove 1040
Clean 1040
Inspect 1040
Component Functionality Test 1040
Install 1040
Screen Cartridge (O) 1040
Disassemble 1040
Component Functionality Test 1040
Assemble 1040
Shuttle Valves (L) and (M) 1041
Remove 1041
Clean 1041
Inspect 1041
Component Functionality Test 1041
Install 1041
Logic Valve (N) 1042
Remove 1042
Clean 1042
Inspect 1042
Component Functionality Test 1042
Install 1042
Full Flow Relief Valve ©) (Relief Spool) 1042
Remove 1042
Clean 1042
Inspect 1043
Assemble 1043
Install 1043
Pilot Supply Valve (F) 1043
Remove 1043
Clean 1043
Inspect 1043
Assemble 1043
Component Functionality Test 1043
Install 1043
Load Sense (LS) Relief Valve (H) and Full Flow Relief Valve (G) 1043
Remove 1043
Clean 1043
Inspect 1044
Component Functionality Test 1044
Install 1044
Load Sense Relief Valve (H) Adjustment 1044
Full Flow Relief Valve (G) Adjustment 1044
Load Sense Selector Valve (D) 1044
Remove 1044
Clean 1044
Inspect 1045
Assemble 1045
Install 1045
Lift Pressure Selector Valve (B) 1045
Remove 1045
Clean 1045
Inspect 1046
Assemble 1046
Install 1046
Variable Displacement Pump (Primary and Secondary) 1046
Remove 1046
Clean 1048
Inspect 1048
Assemble 1048
Install 1049
Tilt Cylinder 1050
Remove 1050
Disassemble 1050
Clean 1050
Assemble 1050
Install 1051
Tilt Cylinder Leak Check 1051
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 1052
Counterbalance Valves 1052
Remove 1052
Clean 1053
Inspect 1053
Assemble 1053
Install 1053
Carriage Valve Bank 1053
Remove 1053
Clean 1056
Inspect 1057
Assemble 1057
Install 1057
Electrical Actuation Module 1057
Remove 1057
Clean 1057
Inspect 1057
Assemble 1057
Install 1058
Emergency Lowering Valve (Left Slice Only) 1058
Remove 1058
Clean 1059
Inspect 1059
Install 1059
Load Sense and Pressure Controller Valve on Pump 1059
Remove 1059
Clean 1059
Inspect 1059
Assemble 1060
Install 1060
Adjustment of Pressure Controller on Pump 1060
Adjustment of Load Sense Controller on the Secondary Variable Pump 1061
Adjustment of Load Sense Controller on the Primary Variable Pump 1062
Lowering Control Valve 1063
Remove 1063
Clean 1064
Inspect 1064
Install 1064
Directional Control Valve 1064
Remove 1064
Clean 1064
Inspect 1064
Assemble 1065
Install 1065
Manual End Cap 1065
Remove 1066
Clean 1066
Inspect 1066
Assemble 1066
Install 1066
Troubleshooting 1066
Lift, Tilt, and/or Aux function does not move when applied Steering is operating normal 1066
The truck is not
capable to lift
rated load at expected
max lift
speed 1067
Tilt function
shakes 1067
It is not
possible to
lower the
mast with
ignition key
turned to
ON 1068
Steer and
brake accumulator
charge
function
does not operate 1068
The truck is
hydraulically
loaded
during engine
start
Accumulator
charge
and steering
is possible
during
XMSN calibration 1068
Torque Specifications 1068
Torque Specifications 1068
550035507 2200YRM1499 (04 2011) US EN 1071
toc 1071
Electrical System 1071
Safety Precautions Maintenance and Repair 1072
General 1075
Electrical Schematic and System Description 1075
Electrical Schematic 1075
Schematic Location Number 1077
Electrical Components 1077
Electrical Wires 1077
Wire Identification Number 1077
Electrical Wire Colors 1078
Wire Harnesses 1078
Harness Interconnection 1079
Electrical Connectors 1079
Connector Types 1079
Connector Identification 1079
Connector Pin Numbers 1080
Connector Description 1080
Fuses 1080
Relays 1083
Flyback Diodes 1084
CAN (Controller Area Network) 1084
Diagnostic 1085
Troubleshooting 1085
Instrument Panel 1085
General Fault Finding 1088
Preparation 1088
Define the Problem Area 1088
Identify Possible Causes of Malfunction 1088
Determine the Most Probable Cause 1088
Fuse Check 1088
Wiring Check 1088
Component Check 1088
Repair and Test 1088
Wire Harness Identification and Connector Location 1089
tables 1071
Table 1 Electrical Schematic Index 1075
Table 2 Function ID Numbers 1077
Table 3 Electrical Wire Colors 1078
Table 4 Harnesses by Option 1078
Table 5 Connector Types 1079
Table 6 Flyback Diodes ZF and TE-10 Transmissions 1084
Table 7 Connector Overview 1089
550035508 8000YRM1500 (06 2011) US EN 1119
550035509 8000YRM1475 (07 2019) US EN 1187
General 1193
Serial Number Data 1193
Truck Handling Procedures 1194
Moving and Towing a Lift Truck 1194
Precautions 1194
Moving the Truck 1194
Putting a Lift Truck on Blocks 1195
Raising the Drive Tires 1195
Raising the Steering Tires 1195
Cleaning a Lift Truck 1196
Safety Procedures Before Starting Maintenance 1197
Making Checks From the Driver Seat with Engine Running 1197
Fire Hazard 1197
Hydraulic Service Switch 1198
Transmission Calibration Switch 1198
Wait 100 Seconds Before Disconnecting Battery 1198
Periodic Maintenance Schedule 1198
Daily Inspection 1199
Daily Condition Checks 1199
Daily Fluid Level Checks 1200
Daily Checks from the Driver Seat with Engine Running 1201
Initial Inspection 1202
First Inspection after First 100 Hours of Operation 1202
Periodic Maintenance 1202
Inspect and Adjust 1202
Lubricate 1206
Change 1207
Periodic Maintenance Procedures 1208
Air Conditioning System 1208
Attachment 1208
Brake System Accumulator 1208
Cab Air Filter 1209
Cab Door Hinges 1209
Chain Sheave Bearings 1209
Control Levers, Switches, and Pedals 1209
Cooling System 1210
Coolant Hoses 1210
Coolant Level 1210
Coolant Quality 1210
Cooling Fan 1210
Cooling Fan Drive Belts 1211
Cooling Fan Drive Belt Tensioner and Pulleys 1211
Bearing Condition 1211
Pulley Alignment 1211
Tensioner Condition 1211
Drive Axle and Differential 1212
Check Oil level 1212
Change Oil 1213
Drive Shaft 1213
End Beam Slider Pads 1213
Engine Air Filter 1213
Engine Air Intake Piping and Charge Air Piping 1214
Engine and Transmission Mounts 1214
Engine Compartment 1214
Engine Oil 1214
Engine Oil Level 1214
Engine Oil and Engine Oil Filter 1215
Engine Valve Adjustment 1215
Extension Beam Wear Pads 1218
Fault Codes 1219
Forks 1219
Fork Pins, Carriage Pins, and Carriage Sliding Surfaces 1220
Frame, Mast, Carriage and Attachment 1220
Fuel, Oil or Coolant Leaks 1221
Fuel/Water Separator and Final Fuel Filter 1221
Header Hose Assembly 1221
Horn, Gauges, Lights, Alarms and Control System 1222
Hydraulic System Oil 1222
Hydraulic Oil Testing Procedures 1223
Hydraulic Oil Replacement 1223
Hydraulic Tank Breather 1224
Hydraulic Tank Return Filter 1224
Inching Pedal Sensor Calibration 1225
Lift Chains 1225
Check and Lubricate Lift Chains 1225
Adjust Lift Chains 1225
Inspect Lift Chains 1226
Chain Elongation 1226
Lift Chain Wear and Damage 1227
Lift System Accumulator (Optional) 1227
Mast, Carriage, and Attachment 1228
Mast Pivot Pins 1228
Operator Presence System 1228
Operator Restraint System 1228
Seat Belt and Seat Rails 1228
Steering Column Latch 1229
Parking and Service Brakes 1229
Powered Pile Slope Cylinders (Optional) 1230
Radiator Assembly 1230
Side Shift Bearing Pads (ECH) 1230
Signals from the Spreader Control System 1230
Steering Axle Grease Fittings 1230
King Pins 1230
Tie Rod Pins 1230
Steering System 1231
Steering Wheel Hub Bearings 1231
Remove and Disassemble 1231
Clean and Inspect 1231
Assemble and Install 1231
Tilt Cylinder Pivot Pins 1232
Transmission 1232
Transmission Clutch Calibration 1232
Transmission Oil Level 1232
Transmission Oil and Oil Filter For TE-10 Transmissions 1233
Transmission Oil and Oil Filter For ZF Transmissions 1233
Twist locks 1234
Inspect 1234
Lubricate 1235
Replace 1235
Vibration Damper (Rubber) 1235
Warning and Safety Labels 1236
Windows and Mirrors 1236
Windshield Washer Fluid Level 1236
Wheels and Tires 1236
Wheels, Tires, and Tire Pressure 1236
Remove Wheels from Lift Truck 1237
Adding Air Pressure to Pneumatic Tires 1243
Install Wheels on Lift Truck 1247
Capacities and Specifications 1249
Approved Fuel and Engine Oils 1249
Approved Oils, Fluids, and Grease 1249
Engine Oil Viscosity 1250
Lift Chain Lubricant Requirements 1250
Fuses and Relays 1250
Side Console 1251
550035510 8000YRM1501 (07 2013) US EN 1255
toc 1255
Capacities and Specifications 1255
Safety Precautions Maintenance and Repair 1256
Counterweight Weights 1259
Lift Truck Weights 1259
Capacities 1260
Engine Specifications 1260
Hydraulic System 1261
Electrical System 1261
Tire Sizes 1262
Mast Speeds 1262
Torque Specifications, Cummins Diesel 1263
Lubrication System 1263
Torque Specifications, General 1263
Transmission TE-10 1263
Transmission ZF 1264
Driveline and Axle 1264
Counterweight 1264
Differential 1264
Brakes – Wet 1264
Brakes – Dry 1264
Steering 1264
Wheel Nuts 1265
Hydraulic System 1265
Mast 1265
Carriage 1265
Tilt Cylinders 1266
Wiper Arms, Front 1266
tables 1255
Table 1 Counterweight Weights 1259
Table 2 Basic Truck 1259
550036815 1800YRM1477 (05 2012) US EN 1269
toc 1269
Dry Brake System 1269
Safety Precautions Maintenance and Repair 1270
General 1275
Air Brake System Description 1275
Air Compressor 1275
Air Dryer Assembly 1275
Air Pressure Regulation 1275
Discharging the Air Compressor 1275
Filtration of Air Admitted to the System 1276
Reduction of Air Humidity 1276
Silencer 1278
Heater Element 1278
Air Tank 1278
Drum Brakes 1278
Air Chamber 1278
Parking Brake Piston 1278
Service Brake Piston 1279
Manual Brake Release 1280
Parking Brake Valve 1280
Brake Treadle Valve 1280
Quick Release Valve 1281
Double Check Valve 1281
Operational Procedures 1282
Tilting the Operator’s Cab 1282
Manual Brake Release Procedure 1282
Releasing Air Pressure From the Brake System 1282
Checking For Leaks 1282
Air Hose Seal Replacement 1282
Air Pressure Checks 1282
Cleaning 1283
Corrosion Protection 1283
Air Tank Replacement 1284
Removal 1284
Installation 1284
Drain Valve 1285
Air Dryer Assembly 1285
Removal 1285
Installation 1285
Purge Valve Silencer 1285
Removal 1285
Installation 1285
Air Dryer Filter Element 1287
Removal 1287
Installation 1287
Regeneration Valve Assembly 1287
Removal 1287
Installation 1287
Purge Valve 1287
Removal 1287
Installation 1287
Outlet Check Valve Assembly 1287
Removal 1287
Installation 1287
Electrical Heating Element 1287
Removal 1287
Installation 1289
Double Check Valve Assembly 1289
Removal 1289
Installation 1289
Brake Treadle Valve 1290
Remove 1290
Disassembly 1290
Assembly 1291
Install 1291
Air Chambers 1292
Remove 1292
Disassembly 1292
Assembly 1293
Install 1294
Actuator Arm 1294
Removal 1294
Inspection 1294
Installation 1294
Brake Assembly 1295
Brake Drum Remove 1295
Brake Shoes, D876 and E876 Series 1296
Disassemble 1296
Brake Shoes, D877 and E877 Series 1297
Disassemble 1297
Inspection 1299
General 1299
Brake Shoes 1299
Spider Bushings 1299
Brake Drum 1299
Camshaft Bushings 1299
Brake Shoe, Install, D876 and E876 Series 1300
Brake Shoe, Install, D877 and E877 Series 1300
Brake Drum Install 1301
Camshaft 1302
Access 1302
Remove 1302
Cleaning and Inspection 1302
Install 1302
Brake Shoe Adjustment 1304
Piston Rod Travel Measurement 1304
Brake Adjustment 1304
Specifications 1305
Troubleshooting 1306
Service Brakes 1306
Service Brakes, Park Function 1308
550041025 1300YRM1536 (08 2011) US EN 1311
toc 1311
Transmission Repair 1311
Safety Precautions Maintenance and Repair 1312
General 1315
Transmission Repair 1315
Remove 1315
Disassemble 1319
Transmission Case, Disassemble 1320
Torque Converter Housing, Disassemble 1335
Forward Clutch, Disassemble 1340
First-Speed Clutch, Disassemble 1344
Reverse and Second-Speed Clutch 1349
Reverse Clutch, Disassemble 1349
Second-Speed Clutch, Disassemble 1353
Third-Speed Clutch, Disassemble 1356
Third Clutch Shaft, Disassemble 1358
Turbine Shaft, Disassemble 1359
Output Shaft, Disassemble 1360
Turbine, Disassemble 1361
Clean and Inspect 1363
Housings 1363
Oil Seals and Gaskets 1363
Bearings 1364
Gears and Shafts 1364
Assemble 1364
Turbine, Assemble 1364
Impeller, Assemble 1366
Output Shaft, Assemble 1368
Turbine Shaft, Assemble 1370
Third Clutch Shaft, Assemble 1371
Third-Speed Clutch, Assemble 1372
Reverse and Second-Speed Clutch 1375
Second-Speed Clutch, Assemble 1375
Reverse Clutch, Assemble 1378
First-Speed Clutch, Assemble 1382
Forward Clutch, Assemble 1387
Torque Converter Housing, Assemble 1391
Transmission Case, Assemble 1396
Install 1413
Control Valve Removal and Installation 1415
Remove 1415
Install 1416
Control Valve Components 1416
550041030 1300YRM1537 (03 2012) US EN 1421
toc 1421
Transmission Operation and Diagnostics 1421
Safety Precautions Maintenance and Repair 1422
Description 1425
General 1425
Operation 1427
Hydraulic Operation 1427
Clutch Release 1429
Anti-Drain 1429
Cooling and Lubrication 1430
Control System 1432
General 1432
APC200 Controller 1432
Self Test 1432
Protection Modes 1432
Limp Home Mode 1432
Shut Down Mode 1432
Transmission Exceed Codes 1432
Fault Codes 1432
Description 1432
Fault Log Mode 1433
Access 1433
Exit 1433
Clear 1434
Fault Rectification 1434
Hydraulic Control Valve 1434
Pressure Check 1435
Pressure Specifications 1436
Pressure, Speed, and Temperature Sensors 1436
Pressure Sensors 1439
Test 1439
Speed Sensor 1439
Test 1439
Temperature Sensors 1440
Test 1440
Electrical Specifications 1441
Transmission Test and Calibration 1441
Precautions 1441
Stall Test 1442
Description 1442
Stall Test Procedure 1442
Clutch Calibration 1442
Description 1442
Procedure 1443
Inching Calibration 1443
Description 1443
Brake and Inching Pedal Adjustment 1444
Inching Sensor Adjustment 1444
Inching Sensor Calibration 1445
APC200 Display information 1445
General 1445
General Information Group 1445
Fault Codes 1447
Indication of Protection Modes 1447
Test Function Group 1447
Digital Input Test 1448
Analog Input Test 1449
Speed Sensor Test 1450
Output Test 1451
Voltage Test 1451
Calibration Group 1454
Calibration Mode 1454
Clutch Filling Calibration 1454
Heat Up Mode 1455
Inching Sensor Calibration 1455
Inching Pedal Sensor Adjustment 1455
Inching Sensor Calibration 1456
TE-Userlink 1456
Description 1456
Connection 1456
Diagrams, Schematics, and Arrangements 1457
tables 1421
Table 1 Gear Selection and Activated Valves 1430
Table 2 Control Valve Pressure Check Ports 1436
Table 3 Transmission Housing Check Ports 1438
Table 4 Sensors and Switches 1438
Table 5 Speed Sensor Check Values 1440
Table 6 Temperature Sensor (In Speed Sensor) Resistance Versus 1441
Table 7 General Information Group 1446
Table 8 Digital Input Test 1449
Table 9 Analog Input Test 1450
Table 10 Speed Sensor Test 1450
Table 11 Output Test 1451
Table 12 Voltage Test 1452
Table 13 APC200 Wire Number to Yale Wire Number Conversion 1452
550088524 4000YRM1647 (07 2016) US EN 1461
Series Code / Model Designation Reference Table 1467
General 1467
Description And Operation 1467
Mast System 1467
Tilting 1467
Lifting 1468
Operation 1468
Pilot Operated Check Valves 1469
Gland Lubrication 1470
Emergency Lowering Valve 1470
Operation 1470
Lift Chains 1471
Elongation Through Wear 1471
Speed of Wear 1471
Plate Height Wear 1472
Lubrication 1472
Restoring The Oil Film 1472
Maintenance 1472
Maintaining The Presence of Oil 1473
Corrosion Protection 1473
Requirements for Chain Lubricant 1473
Load Rollers 1474
Bearing Blocks 1474
Carriage 1475
Standard Carriage with Manual Fork Positioning 1475
Standard Carriage with Hydraulic Fork Positioning 1475
Dual Function Side Shift and Fork Positioning (DFSSFP) Carriage 1476
Integral Side Shift 1476
Carriage Valve 1477
Alternating Pressure and Tank (P & T) 1477
Fixed Pressure and Tank (P & T) 1477
Flow Divider for Simultaneous Fork Positioning 1477
Valve for Dual Function with Side Shift and Fork Positioning (DFSSFP) 1479
Fixed Pressure and Tank System (Fixed P & T) 1481
Forks 1483
Safety Procedures When Working Near Mast 1484
Before Starting Repairs to the Hydraulic System, Always: 1485
Remove and Replace 1485
Forks 1485
Remove 1485
Install 1486
Fork Guide And Fork Pin 1487
Remove 1487
Install 1487
Carriage 1488
1488
Remove 1488
Install 1489
Carriage Bearing Blocks 1490
Remove 1490
Install 1491
1491
Carriage Load Rollers 1491
Replace 1491
1493
Side Shift Cylinder 1493
Remove 1493
Disassemble 1493
Clean And Inspect 1494
Assemble 1494
Install 1495
Fork Positioner Cylinder 1495
Remove 1495
Disassemble 1496
Clean and Inspect 1496
Assemble 1497
Install 1497
Carriage Valves 1497
Remove 1497
Install 1498
1498
Valve for Fixed P & T Systems 1498
Remove and Disassemble 1498
Clean and Inspect 1500
Assemble and Install 1500
Flow Divider for Simultaneous Fork Positioning Valve 1501
Restrictor Valve and Relief Valve Replacement 1501
Dual Function Valve for Side Shifting and Fork Positioning 1501
Solenoid Valve Replacement 1501
Relief Valve Replacement 1502
Remove 1502
Install 1502
Mast 1502
Lift Chains and Top Chain Anchor 1502
Remove 1502
Install 1502
Chain Anchor On Carriage 1503
Remove 1503
Install 1503
Chain Sheave 1504
Remove 1504
Install 1504
Header Hoses 1505
Remove 1505
Install 1507
Electric Mast Cable 1507
Remove 1507
Install 1507
Hose Sheave 1508
Remove and Disassemble 1508
Assemble and Install 1508
Mast Assembly 1509
Remove 1509
Disassemble 1511
Assemble 1512
Install 1513
Inner Mast Load Rollers 1515
Replace 1515
Mast Bearing Blocks 1516
Remove 1516
Install 1516
Lift Cylinders 1517
Remove 1517
Disassemble 1520
Clean and Inspect 1520
Assemble 1520
Install 1521
Tilt Cylinders 1522
Remove 1522
Disassemble 1523
Clean and Inspect 1523
Assemble 1523
Install 1524
Checks and Adjustments 1525
General Checks 1525
Mast Condition Check 1525
Mast Operation Check 1526
Counterbalance Valve Check (for E876 and E877 Only) 1526
Fork Inspection and Adjustment 1526
Lift Chain Inspection 1527
Lift Chain Lubricant Requirements 1528
Lift Chain Lubrication Procedure 1528
Leak Checks 1528
Mast Vertical Creep 1528
Mast Tilt Drift 1529
Adjustments 1529
Lift Cylinder Shimming 1529
Lift Chain and Fork Height Adjustment 1531
Header Hose Tension Adjustment 1533
Electric Mast Cable Tension Adjustment 1533
Counterbalance Valve Adjustment 1533
Tilt Cylinder Backward Tilt Angle Adjustment 1534
Mast Support Pad Adjustment 1534
Troubleshooting 1534
Introduction 1535
No Hydraulic Movement With Engine Running 1535
Initial Basic Check 1535
1536
Electrical Supply 1536
Hydraulic Supply 1536
Fault Code 1536
No Lowering Possible with Engine OFF 1537
Incorrect Movement 1537
Irregular (shaking) Movement
or
Slight Carriage Movement When Starting Engine
1537
Unequal Movement of Left And Right Tilt Cylinder 1537
Insufficient Lifting Speed 1537
Insufficient Lifting Capacity 1538
Incorrect Lowering Speed 1538
Lift Cylinder Creep 1538
Tilt Cylinder Creep 1538