Yale Forklift J877 (GDP130EF, GDP140EF, GDP160EF) Service Manual PDF

Yale Forklift J877 (GDP130EF, GDP140EF, GDP160EF) Service Manual – PDF DOWNLOAD

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Yale Forklift J877 (GDP130EF, GDP140EF, GDP160EF) Service Manual – PDF DOWNLOAD

Language : English
Pages : 1086
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift J877 (GDP130EF GDP140EF GDP160EF) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
550224598 0100YRM2279 (07 2020) US EN 23
Series Code / Model Designation Reference Table 29
General 29
Precautions 29
Section 1 – Cab Repair 30
Operator’s Cab Assembly 30
Tilting the Cab 30
Raising 30
Lowering 31
Remove 32
Install 34
Cab Tilt System 35
Hand Tilt Pump 35
Remove 35
Install 36
Electric Tilt Pump 37
Remove 37
Install 38
Cab Tilt Cylinder 38
Remove 38
Install 39
Latch 40
Remove 40
Install 41
Cab Windows 41
Window Replacement 41
Front Window 41
Remove 41
Install 41
Rear Window 42
Remove 42
Install 42
Top Window 42
Remove 42
Install 42
Door Window 43
Remove 43
Install 43
Sliding Window and Sliding Tracks 43
Remove 43
Install 44
Weather Strip Replacement 44
Window Stopper Replacement 44
Sliding Window Frame 44
Remove 44
Install 44
Window Wipers 45
Window Wiper Assembly Replacement 45
Remove 45
Install 45
Front Window Wiper Motor Assembly 45
Remove 45
Install 46
Rear Window Wiper Motor Assembly 46
Remove 46
Install 46
Top Window Wiper Motor Assembly 47
Remove 47
Install 47
Window Washer System 47
Window Washer Reservoir and Pumps 47
Remove 47
Install 48
Window Washer Hoses 48
Remove 48
Install 49
Window Washer Spray Nozzles 49
Front Window 49
Remove 49
Install 49
Rear Window 49
Remove 49
Install 49
Top Window 50
Remove 50
Install 50
Cab Door Assembly 50
Cab Door 50
Remove 50
Install 51
Door Hinge 51
Remove/Install 51
Door Latch 52
Remove 52
Install 52
Door Handle 52
Remove 52
Install 53
Door Release 53
Remove 53
Install 54
Door Push Button 54
Remove 54
Install 54
Steering Wheel and Steering Column Assembly 54
Steering Wheel and Horn 54
Remove 54
Install 56
Steering Column Assembly 56
Remove 56
Install 57
Shift Lever 57
Remove 57
Install 57
Gear Selection Lever 58
Remove 58
Install 58
Turn Signal Lever 58
Remove 58
Install 58
Pedals 58
Brake and Inching Pedal 58
Remove 58
Install 59
Accelerator Pedal and Sensor 59
Remove 59
Install 59
Adjust Sensor 60
Power Assist Armrest 60
Remove 60
Install 61
Armrest Components 62
Electrical Mini-Levers 62
Remove 62
Install 62
Armrest Switch Groups 63
Remove 63
Install 63
Ignition Key Switch and Start/Stop Button Switch 64
Remove 64
Install 64
Joystick 65
Remove 65
Install 65
USB Power Socket 66
Remove 66
Install 66
12V Power Socket 66
Remove 66
Install 67
Display Replacement 67
Seat Assembly 68
Remove 68
Install 68
Initialize New Seat 69
Cab Interior 69
Floor Mat 69
Remove 69
Install 70
Radio Console 70
Remove 70
Install 70
Air Duct Replacement 71
Remove 71
Install 71
Accessories 72
Mirror Replacement 72
Sunshade Replacement 72
Top 72
Rear 72
Map Light Replacement 72
Interior Fan Replacement 72
Training Seat 73
Field Installation 73
Remove 73
Checks and Adjustments 73
Label Check and Replacement 73
Cab Tilt System Oil Level Check 73
Door Striker Pin Adjustment 74
Section 2 – Cab Heater and Air Conditioner Repair 75
Heater Assembly 75
Access 75
Remove 76
Install 77
Heater Parts 78
Heater Core 78
Remove 78
Install 79
Water Valve 80
Remove 80
Install 80
Heater/Air Conditioning Assembly 81
Remove 81
Install 82
Filtration 82
Fresh Air Filter 82
Remove 82
Install 83
Air Conditioning Technical Detail 84
Maintenance, Service and Repairs 84
Safety Precautions 84
General Statements for Maintenance and Repairs 85
Residual Pressure 85
Refrigeration Circuit 85
Cooling Water Circuit 85
Maintenance Intervals 85
Repairs 86
Checklist 86
550224599 0700YRM2280 (02 2020) US EN 89
Series Code / Model Designation Reference Table 93
General 93
Cooling System 94
Cooling Core Assembly 94
Remove 95
Disassemble 98
Assemble 99
Install 99
Cooling System Components 102
Cooling Fan 102
Remove 102
Install 102
Checks and Adjustments 103
Cooling System Checks 103
Basic Checks 103
Coolant Quality Checks 104
Coolant Flow Checks 105
Thermostat 105
Water Pump 105
Cooling Core Efficiency 105
Cooling Core Flow Restrictions 106
Engine Leak Tests 106
External Leak Test 106
Check for Coolant Leak Into The Engine Oil Sump 107
Combustion Leak Test 107
Engine Cooling System Maintenance 108
Draining the Engine Cooling System 108
Filling the Engine Cooling System 108
Flushing the Engine Cooling System 109
Cleaning the Engine Cooling System 109
550224600 0900YRM2281 (03 2020) US EN 111
Series Code / Model Designation Reference Table 119
General 119
Precautions 119
Special Tools 120
Section 1 – Drive Shaft Repair 121
Drive Shaft Assembly 121
Remove 121
Disassemble 123
Clean and Inspect 124
Assemble 124
Install 124
Section 2 – Engine and Transmission Repair 125
Engine and Transmission Assembly 125
Remove 125
Precautions 125
Remove Air Conditioning Compressor 125
Drain the Engine Cooling System 126
Drain Hydraulic Oil 127
Drain Transmission Oil 127
Disconnect Drive Shaft, Fan Clutch, Tubes, Pipes, Cables, Wires and Lines 127
Remove Engine and Transmission 132
Install 135
Install Engine and Transmission 135
Install Air Conditioning Compressor 136
Connect Drive Shaft, Fan, Tubes, Pipes, Cables, Wires and Lines 136
Refill the Systems 136
Starting the Engine 137
Engine Repair 138
Transmission Assembly 139
Remove 139
Install 141
Transmission Components 144
Disassemble 144
Transmission Case, Disassemble 144
Oil Pump, Disassemble 151
Clutch K3, Third Speed, Disassemble 153
Clutch K2, Second Speed, Disassemble 159
Clutch KR, Reverse, Disassemble 166
Clutch KV, Forward, Disassemble 173
Input Shaft, Disassemble 180
Clutch K1, First Speed, Disassemble 181
Clean and Inspect 187
Housings 187
Oil Seals and Gaskets 188
Bearings 188
Gears and Shafts 188
Assemble 189
Clutch K1, First Speed, Assemble 189
Input Shaft, Assemble 197
Clutch KV, Forward, Assemble 198
Clutch KR, Reverse, Assemble 207
Clutch K2, Second Speed, Assemble 216
Clutch K3, Third Speed, Assemble 225
Oil Pump, Assemble 233
Transmission Case, Assemble 235
Transmission Oil Filter Assembly 244
Clean 246
Inspect 246
Transmission Control Valve 247
Clean 252
Inspect 252
Transmission Test and Calibration 259
Precautions 259
Transmission Oil Sampling 259
Preparation 259
Sampling Procedure 259
Stall Test 259
Stall Test Procedure 259
Inch Pedal Calibration 260
Brake and Inch Pedal Adjustment 260
Inch Sensor Adjustment 261
Inch Pedal Calibration 261
Preparation 261
Calibration Procedure 262
Clutch Calibration 262
Control Valve Pressure Checks 262
Speed and Temperature Sensor Checks 265
Electrical Specifications 265
Section 3 – Engine Intake and Exhaust Repair 267
Air Filter Assembly 267
Remove 267
Install 267
Exhaust System (Tier 3/Stage IIIA) 269
Remove 269
Install 270
Exhaust System (Tier 4F/Stage IV) 270
Exhaust Pipes High Mount 270
Remove 270
Install 270
Exhaust Pipes and Diffuser Low Mount 271
Remove 271
Install 271
Engine After Treatment (EAS) System (Tier4F\Stage IV) 272
Engine After Treatment System Assembly 273
Preparation 273
Remove 273
Install 274
Engine After Treatment (EAS) System Components 275
Exhaust Seal Rings 275
Selective Catalytic Reducer (SCR) 276
Remove 276
Install 276
Decomposition Reactor Tube (DRT) 276
Remove 276
Install 277
Diesel Oxidation Catalyst (DOC) 277
Remove 277
Install 277
DEF System 278
DEF System Assembly 278
DEF System Components 278
DEF Tank 278
Remove 278
Install 279
DEF Tank Fill Cap 280
DEF Tank Unit 280
Remove 280
Install 280
DEF Tank Suction Filter 280
Replace 280
DEF Pump Assembly 281
Remove 281
Install 282
DEF Pump Filter 282
Replace 282
DEF Dosing Valve 283
Remove 283
Install 283
DEF System Checks and Adjustments 284
DEF Dosing Valve 284
DEF Pump 284
Fuel Tank 284
Remove 284
Clean and Repair 286
Install 286
Section 4 – Drive Axle Repair 287
Drive Axle Assembly 287
Remove 287
Install 289
Drive Axle Components 290
Planetary Gear Assembly 290
Preparations 291
Repairing and Replacing Parts 296
Welding 296
Clean 296
Ground or Polished Parts 296
Parts With Rough Finishes 297
Axle Assemblies 297
Drying Cleaned Parts 297
Preventing Corrosion 297
Inspect 297
Service Brake Assembly 302
Remove Service Brake 304
Clean 308
Ground and Polished Parts 309
Parts With Rough Finish 309
Wet Disc Brake and Axle Assembly 309
Inspect 309
Face Seals 309
Disc 310
Wear Limits 310
Replace Parts 311
Differential Assembly 317
Preparations 319
Remove 319
Differential Carrier From Axle Housing 319
Main Differential and Ring Gear Assembly From Differential Carrier 320
Drive Pinion and Pinion Carrier From Differential Carrier 322
Disassemble 324
Main Differential and Ring Gear Assembly 324
Drive Pinion, Bearings, and Pinion Carrier 326
Clean and Inspect 328
Assemble 328
Drive Pinion, Bearings, and Pinion Carrier 328
Pinion Bearings Preload Adjustment 330
Press Method 330
Flange Method 331
Triple-Lip Oil Seal 332
Pinion Carrier Shim Set Thickness Adjustment (Depth of Pinion) 334
Main Differential and Ring Gear Assembly 336
Differential Gears Rotating Torque 338
Install 339
Differential and Ring Gear Assembly 339
Differential Bearings Preload Adjustment 340
Method 1 340
Method 2 342
Ring Gear Runout Check 342
Ring Gear Backlash Adjustment 343
Tooth Contact Pattern Check 344
Thrust Screw Installation and Adjustment 347
Differential Carrier Into Axle Housing 347
Parking Brake 348
Preparations 349
Parking Brake Caliper 350
Remove 350
Disassemble 350
Clean and Inspect 350
Assemble 351
Install 351
Parking Brake Caliper Pads 352
Remove 352
Install 352
Drive Axle Checks and Adjustments 352
Oil Drain and Refill Procedures 352
Differential 352
Drain 352
(Re)Fill 353
Hub Assembly 353
Drain 353
(Re)Fill 353
Service Brake 354
Drain 354
(Re)Fill and De-aerate 354
Wheel Bearing Preload 354
Adjust 354
Parking Brake Adjustments 354
Parking Brake Bleed 354
Parking Brake Emergency Release 355
Park Brake Selector Valve Check 355
Park Brake Selector Valve Coil Check 355
Accumulator Pre-Charge Check 356
Parking Brake Pads Adjustment 356
Condition Check, Shuttle Valve L in the Main Control Valve 357
Condition Check, Shuttle Valve N in the Main Control Valve 357
Condition Check, Priority Valve on the Main Control Valve 358
Pressure Check, Port MLS1 358
Drive Axle Torque Specifications 359
Section 5 – Steering Axle Repair 361
Steering Axle Assembly 361
Remove 361
Install 362
Steering Axle Components 363
Tie Rod 363
Remove 363
Clean and Inspect 363
Install 363
Steering Cylinder 364
Remove 364
Clean and Inspect 366
Assemble and Install 366
Hubs 366
Remove and Disassemble 366
Clean and Inspect 367
Assemble and Install 367
Spindle 367
Remove 367
Clean 368
Assemble and Install 368
Steering Axle Checks and Adjustments 368
Maximum Steering Angle Adjustment 368
Torque Specifications 369
Steering Axle 369
Wheel Nuts 369
Steering Cylinder 369
550224601 1900YRM2282 (05 2023) US EN 371
Series Code / Model Designation Reference Table 381
General 381
Precautions 381
Section 1 – Hydraulic System Repair 382
Main Control Valve 382
Remove 382
Clean 385
Inspect 385
Assemble 385
Install 385
Priority Valve (A) 388
Remove 388
Clean 388
Inspect 389
Component Functionality Test 389
Install 389
Check Valve (K) 389
Remove 389
Clean 389
Inspect 389
Component Functionality Test 389
Install 389
Check Valve (I) 389
Remove 389
Clean 389
Inspect 390
Component Functionality Test 390
Install 390
Check Valve (Q) 390
Remove 390
Clean 390
Inspect 390
Component Functionality Test 390
Install 390
Screen Cartridge (O) 390
Disassemble 390
Component Functionality Test 390
Assemble 390
Shuttle Valves (L) and (M) 391
Remove 391
Clean 391
Inspect 391
Component Functionality Test 391
Install 391
Logic Valve (N) 391
Remove 392
Clean 392
Inspect 392
Component Functionality Test 392
Install 392
Full Flow Relief Valve (C) (Relief Spool) 392
Remove 392
Clean 392
Inspect 392
Assemble 392
Install 393
Pilot Supply Valve (F) 393
Remove 393
Clean 393
Inspect 393
Assemble 393
Component Functionality Test 393
Install 393
Load Sense (LS) Relief Valve (H) and Full Flow Relief Valve (G) 393
Remove 393
Clean 393
Inspect 393
Component Functionality Test 393
Install 394
Load Sense Relief Valve (H) Adjustment 394
Full Flow Relief Valve (G) Adjustment 394
Load Sense Selector Valve (D) 394
Remove 394
Clean 394
Inspect 394
Assemble 394
Install 395
Lift Pressure Selector Valve (B) 395
Remove 395
Clean 395
Inspect 395
Assemble 395
Install 395
Variable Displacement Pump (Primary and Secondary) 396
Remove 396
Clean 398
Inspect 398
Install 398
Electrical Actuation Module 400
Remove 400
Clean 400
Inspect 400
Assemble 400
Install 400
Emergency Lowering Valve (Left Slice Only) 402
Remove 402
Clean 402
Inspect 402
Install 402
Load Sense and Pressure Controller Valve on Pump 402
Remove 402
Clean 403
Inspect 403
Assemble 403
Install 403
Carriage Valve 403
Remove 404
Clean and Inspect 404
Assemble 404
Install 404
Manual End Cap 404
Remove 406
Clean 406
Inspect 406
Assemble 406
Install 406
Tilt Lock Valve 406
Remove 406
Clean 408
Inspect 408
Assemble 408
Install 408
Lowering Control Valve 408
Remove 408
Clean 409
Inspect 409
Install 409
Hydraulic Tank 410
Remove 410
Inspect 412
Clean 412
Steam Cleaning Method 413
Chemical Solution Cleaning Method 413
Repair 413
Small Leaks 413
Large Leaks 414
Inspection after Repair 414
Install 414
Hydraulic Checks and Adjustments 416
Adjustment of Pressure Controller on Pump 416
Adjustment of Load Sense Controller on the Secondary Variable Pump 417
Adjustment of Load Sense Controller on the Primary Variable Pump 418
Hydraulic System Torque Specifications 419
Section 2 – Steering System Hydraulics Repair 420
Steering Control Unit 420
Remove 420
Install 421
Steering Cylinder 421
Remove 421
Clean and Inspect 424
Assemble and Install 424
Steering System Torque Specifications 425
Steering Control Unit 425
Steering Cylinder 425
Section 3 – Brake System Hydraulics Repair 426
Brake Treadle Valve 426
Remove 426
Install 426
Accumulator 427
Remove 427
Disassemble 428
Clean 430
Inspect 430
Repair 430
Assemble 430
Install 431
Pre-Charge Filling 431
Parking Brake 432
Parking Brake Caliper 432
Remove 432
Disassemble 433
Clean and Inspect 433
Assemble 434
Install 434
Parking Brake Caliper Pads 435
Remove 435
Install 435
Parking Brake Bleed 435
Parking Brake Emergency Release 436
Brake Flow Distribution Manifold 436
Remove 436
Disassemble 438
Clean and Inspect 438
Assemble 438
Install 438
Brake Control Manifold 439
Remove 439
Install 440
Orifices (F) and (G) 440
Disassemble 440
Assemble 440
Orifice (H) 440
Disassemble 440
Assemble 441
Unloading Valve (B) 441
Disassemble 441
Assemble 441
Screen 441
Disassemble 441
Assemble 441
Check Valve (E) 441
Disassemble 441
Assemble 441
Pressure Reducer Valve (C) 442
Disassemble 442
Assemble 442
Park Brake Selector Valve (A) 442
Disassemble 442
Assemble 442
Brake System Checks and Adjustments 443
Hydraulic Pressure Checks Preparation 443
Park Brake Selector Valve Check 443
Park Brake Selector Valve Coil Check 443
Accumulator Pre-Charge Check 444
Parking Brake Adjustment 444
Condition Check, Shuttle Valve (L) in the Main Control Valve 445
Condition Check, Shuttle Valve (N) in the Main Control Valve 445
Condition Check, Priority Valve on the Main Control Valve 445
Pressure Check, Port MLS1 446
Hydraulic Brake Torque Specifications 446
Hydraulic Hose Torque Procedure 447
Section 4 – Cylinder Repair 448
Front End Cylinders 448
Side Shift Cylinder 448
Disassemble 448
Clean and Inspect 449
Assemble 449
Fork Positioner Cylinder 449
Disassemble 449
Clean and Inspect 450
Assemble 451
Tilt Cylinders 451
Disassemble 451
Clean and Inspect 451
Assemble 451
De-Aeration of the Tilt Cylinders before Start-up 452
Lift Cylinders 453
Disassemble 453
Clean and Inspect 454
Assemble 454
550224602 2200YRM2283 (02 2023) US EN 457
Series Code / Model Designation Reference Table 463
General 463
Section 1 – Electrical 463
General Fault Finding 463
Preparation 463
Define the Problem Area 463
Identify Possible Causes of Malfunction 463
Determine the Most Probable Cause 463
Fuse Check 463
Wiring Check 464
Component Check 464
Repair and Test 464
Harnesses and Connectors 464
Harnesses Overview 464
Harness Connectors and Terminals 466
Frame Harness Connectors 466
Cab Rear Wall Harness Connectors 470
Mast Harness Connectors 473
Mast Work Lights and Lights Extension Harness Connectors 473
Closed Cab Harness Connectors 475
Steering Column Harness Connectors 479
Cab Tilt Harness Connectors 480
Cab Lights Harness Connectors (LH harness shown) 482
ECM Harness Connectors (Tier 3/Stage IIIA Engine) 484
EAS/ECM Harness Connectors (Tier 4F/Stage IV Engine) 485
DEF Tank Harness Connectors (Only Tier 4F/Stage IV Engine) 487
Powertrain Harness Connectors 488
Hoodspine Harness Tier 3/Stage IIIA Connectors 490
Hoodspine Harness Tier 4F/Stage IV Connectors 490
Carriage Harness Connectors 491
Rear Harness Connectors 492
Wire Harness Identification and Connector Location 495
Fuses and Relays 495
Fuse Relay Board 500
CANbus Circuit 502
Greasing System Electrical 504
Section 2 – Controls 507
Information Display 507
General 507
Information Display Overview 508
Information Display Diagram and Connectors 509
Fault Codes 511
Transmission Calibration 511
Section 3 – User Interface Display 512
Navigation Key 512
Startup Sequence 513
Home Screen 514
Screen Brightness Menu 515
HVAC Controls Menu 516
Logging in 517
Log In/Out 517
View the fault log 518
Fault Log 518
View the hardware and software versions 519
Calibrations 520
Calibrate the clutch pack 520
Calibrate the brake pedal 521
Calibrate the accelerator pedal 521
Calibrate the load weight sensor 521
Diagnostics Menu 522
Hydraulics 522
H1d 1st Hyd Function 523
H2d 2nd Hyd Function 523
Aux Hyd Functions 523
Drive 523
D1 Engine 524
D9 Transmission 524
Controllers 524
C1d VSM 524
C10d Hydraulic Controller 1 524
C11d Armrest Module 524
C12d High Current Module 525
C99d Light module 525
Overview 525
Settings 525
Hydraulics 525
Operators 526
Truck Setup 526
T1 Display 527
T2 Lights 527
T5 Switches 527
Display Flow Chart 527
550224603 2400YRM2284 (03 2020) US EN 537
Series Code / Model Designation Reference Table 541
General 541
Greasing System 542
Grease Pump Assembly 542
Remove 543
Install 543
Greasing System Components 544
Grease Line Identification 544
Grease Reservoir 547
Disassemble 547
Assemble 548
Refilling the Grease Reservoir 548
Test Cycles Using the Button on the Pump 549
Bleeding the Pump 549
Bleeding the System 549
Checks and Adjustments 564
Test Procedures 564
Check pressure switch (valve) and cable 564
Check pump and 5/2-way valve 564
Check for Internal System Leaks 565
Technical Data 566
Pump Unit 566
Grease Recommendations 566
Electrical 567
Torque Specifications 568
550224604 4000YRM2285 (03 2020) US EN 571
Series Code / Model Designation Reference Table 577
General 577
Safety Procedures 577
When Working Near The Mast Always 577
When Working on the Hydraulic System 577
Section 1 – Forks and Carriage Repair 578
Forks 578
Pin-Type Forks 579
Remove 579
Install 580
Hook-Type Forks 581
Remove 581
Install 581
Fork Guide And Fork Pin 581
Remove 581
Install 582
Fork Hanger 582
Remove 582
Install 582
Carriage Assembly 584
Carriage Types 584
Remove 586
Install 587
Carriage Components 590
Carriage Bearing Blocks 590
Remove 590
Install 590
Carriage Load Rollers 591
Replace 591
Side Shift Cylinder 592
Remove 592
Install 593
Fork Positioner Cylinder 593
Remove 593
Install 594
Carriage Valve 594
Remove 595
Install 595
Section 2- Mast Repair 597
Mast Assembly 597
Two-Stage Mast 597
Remove 597
Disassemble 600
Assemble 602
Install 603
Three-Stage Mast 604
Remove 604
Disassemble 605
Assemble 609
Install 609
Mast Components 610
Two-Stage Mast 610
Lift Chains and Top Chain Anchor 610
Remove 610
Install 610
Chain Anchor On Carriage 611
Remove 611
Install 611
Chain Sheave 612
Remove 612
Install 612
Header Hoses and Mast Hoses 613
Remove 613
Install 614
Electric Mast Cable 614
Remove 614
Install 615
Hose Sheave 615
Remove and Disassemble 615
Assemble and Install 615
Inner and Outer Mast Load Rollers 615
Replace 615
Mast Bearing Blocks 616
Remove 616
Install 616
Lift Cylinders 617
Remove 617
Install 618
Tilt Cylinders 619
Remove 619
Install 620
Three-Stage Mast 620
Mast Lift Chains and Chain Anchors 620
Remove 620
Install 621
Carriage Lift Chains and Chain Anchors 622
Remove 622
Install 623
Chain Anchor On Carriage 623
Remove 623
Install 624
Intermediate Mast Chain Sheave 624
Remove 624
Install 625
Inner Mast Chain Sheave 625
Remove 625
Install 626
Mast Hoses 626
Remove 626
Install 627
Electric Mast Cable 627
Remove 627
Install 627
Hose Sheave 627
Remove and Disassemble 627
Assemble and Install 627
Inner, Intermediate, and Outer Mast Load Rollers 628
Replace 628
Intermediate Lift Cylinders 628
Remove 628
Install 629
Inner Lift Cylinders 630
Remove 630
Install 631
Tilt Cylinders 631
Remove 631
Install 632
Mast Checks and Adjustments 632
General Checks 632
Mast Condition Check 632
Mast Operation Check 633
Tilt Lock Valve Check 633
Fork Inspection and Adjustment 633
Lift Chain Inspection 634
Lift Chain Lubricant Requirements 635
Lift Chain Lubrication Procedure 635
Leak Checks 635
Mast Vertical Creep 635
Mast Tilt Drift 636
Adjustments 636
Lift Cylinder Shimming 636
Lift Chain and Fork Height Adjustment 637
Lift Chain Adjustment Procedure 638
Header Hose Tension Adjustment 638
Electric Mast Cable Tension Adjustment 639
Tilt Lock Valve Adjustment 639
Tilt Cylinder Backward Tilt Angle Adjustment 640
Mast Support Pad Adjustment 640
Torque Specifications 641
Torque Values for Mast and Carriage 641
Tightening Torques 642
550224605 8000YRM2286 (03 2020) US EN 647
Series Code / Model Designation Reference Table 651
Counterweight Weights 651
Lift Truck Weights 651
Capacities 652
Electrical System 652
Engine Specifications 653
Mast Speeds 653
Tire Sizes 654
Hydraulic System 654
Torque Specifications, General 655
Transmission ZF 655
Driveline and Axle 655
Counterweight 655
Differential 655
Brakes 655
Steering 655
Wheel Nuts 655
Hydraulic System 655
Mast 656
Carriage 656
Tilt Cylinders 656
Torque Specifications, Cummins Diesel 656
Lubrication System 656
550224606 8000YRM2287 (03 2020) US EN 659
Series Code / Model Designation Reference Table 663
Electrical Schematic T3/T4 Final 664
Hydraulic Schematic 692
550224607 8000YRM2288 (03 2020) US EN 701
Series Code / Model Designation Reference Table 705
General 705
Precautions 705
Main Components 705
Hood Assembly 705
Remove 705
Install 707
Running Boards, Steps and Mud Flaps 707
Counterweight 708
Remove 708
Install 709
Label Replacement 710
550224609 8000YRM2290 (07 2020) US EN 713
Series Code / Model Designation Reference Table 719
General 719
Serial Number Data 719
Truck Handling Procedures 720
Moving and Towing a Lift Truck 720
Precautions 720
Towing the Truck 721
Putting a Lift Truck on Blocks 721
Raising the Drive Tires 721
Raising the Steering Tires 722
Cleaning a Lift Truck 723
Safety Procedures Before Starting Maintenance 724
Making Checks From the Driver Seat with Engine Running 724
Fire Hazard 724
Wait 100 Seconds Before Disconnecting Battery 724
Periodic Maintenance Schedule 725
Daily Inspection 726
Daily Condition Checks 726
Daily Fluid Level Checks 726
Daily Checks from the Driver Seat with Engine Running 727
Initial Inspection 728
First Inspection after First 100 Hours of Operation 728
First Inspection after First 250 Hours of Operation 729
Periodic Maintenance 729
Inspect and Adjust 729
Annual Inspection 731
Lubricate 733
Change 734
Periodic Maintenance Procedures 736
Air Conditioning System 736
Attachment 736
Automatic Greasing System (Optional) 736
Greasing System 736
Greasing System Filter 737
Brake Cooling Filter 737
Brake System Accumulator 737
Cab Air Filter 738
Control Levers, Switches, and Pedals 738
Cooling System 738
Coolant Hoses 738
Coolant Level 739
Coolant Quality 739
Cooling Fan 739
Crankcase Breather Element (Tier 4F/Stage IV Only) 740
Diesel Exhaust Fluid (DEF) System 740
DEF Pump Filter 740
DEF Tank Fill Cap 741
DEF Tank Suction Filter 741
Drive Axle, Differential and Axle Hub Assembly 742
Check Oil level 742
Change Oil 742
Drive Wheel Hub Bearing Preload 742
Drive Shaft 742
End Beam Slider Pads 742
Engine Air Filter 743
Engine Air Intake Piping and Charge Air Piping 744
Engine and Transmission Mounts 744
Engine Compartment 744
Engine Drive Belt 745
Engine Drive Belt Tensioner and Pulleys 745
Bearing Condition 745
Pulley Alignment 745
Tensioner Condition 745
Engine Oil 747
Engine Oil Level 747
Engine Oil and Engine Oil Filter 747
Engine Valve Adjustment 748
Extension Beam Wear Pads 750
Fault Codes 751
Forks 751
Fork Guide Bearing Blocks 752
Fork Guide Wear Pads 753
Fork Pins, Carriage Pins, and Carriage Sliding Surfaces 753
Frame, Mast, Carriage and Attachment 753
Fuel, Oil, DEF, or Coolant Leaks 754
Fuel/Water Separator and Final Fuel Filter 754
Fuel Tank Breather 755
Header Hose Assembly 755
Horn, Gauges, Lights, Alarms and Control System 755
Hydraulic System Oil 755
Hydraulic Oil Testing Procedures 756
Hydraulic Oil Replacement 756
Hydraulic Tank Breather 758
Hydraulic Tank Return Filter 758
Inching Pedal Sensor Calibration 758
Lift Chains 758
Check and Lubricate Lift Chains 758
Adjust Lift Chains 759
Inspect Lift Chains 760
Chain Elongation 760
Lift Chain Wear and Damage 760
Lift System Accumulator (Optional) 761
Load Rollers 761
Carriage Load Rollers 761
(Inner) Mast Load Rollers 761
Mast, Carriage, and Attachment 762
Mast Pivot Pins 762
Operator Presence System 762
Operator Restraint System 763
Seat Belt and Seat Rails 763
Steering Column Latch 763
Parking and Service Brakes 763
Radiator Assembly 763
Side Shift Bearing Pads (ECH) 764
Steering Axle Grease Fittings 764
King Pins 764
Tie Rod Pins 764
Steering System 764
Steering Wheel Hub Bearings 764
Remove and Disassemble 764
Clean and Inspect 766
Assemble and Install 766
Tilt Cylinder Pivot Pins 767
Transmission 767
Transmission Clutch Calibration 767
Transmission Oil Level 767
Transmission Oil and Oil Filter 768
Twist locks 768
Inspect 768
Lubricate 769
Replace 769
Vibration Damper (Viscous) 769
Warning and Safety Labels 770
Windows and Mirrors 770
Windshield Washer Fluid Level 770
Wheels and Tires 771
Wheels, Tires, and Tire Pressure 771
Remove Wheels from Lift Truck 772
Adding Air Pressure to Pneumatic Tires 778
Install Wheels on Lift Truck 783
Capacities and Specifications 784
Approved Fuel and Engine Oils 784
Approved Oils, Fluids, and Grease 784
Engine Oil Viscosity 785
Lift Chain Lubricant Requirements 786
Electrical Components 786
Cab Electric Group 786
Check the Fuses 786
Power Distribution Group 789
550224610 8000YRM2291 (03 2020) US EN 795
Series Code / Model Designation Reference Table 799
General 799
Weight and Dimensions 799
Loading Procedures 807
Loading A Truck on a Transport 807
Preparing Truck for Loading on a Trailer with Mast Installed 807
Install the Tilt Extension Brackets 807
Loading Disassembled Components 808
Unloading Procedures 810
Unloading A Truck From Transport 810
Preparing Truck with Mast Installed for Unloading from a Trailer 810
Remove the Tilt Extension Bracekts 810
Lifting a Truck 810
Driving a Truck Off a Trailer 811
Unloading Disassembled Components 811
Removal of Forks Attached to a Basic Truck 811
Removal of Forks Attached to the Carriage 813
Moving and Towing 814
Moving a Disabled Lift Truck 814
Precautions 814
Towing A Lift Truck 815
Safety Procedures When Working Near The Mast 816
When Working Near The Mast Always 816
Before Starting Repairs To The Hydraulic System Always 816
Truck Assembly 817
Mast Assembly 817
Preparations 817
Installing the Mast 817
Installing the Tilt Cylinders 820
Adjusting the Tilt Cylinders 820
Removing the Carriage Transport Lock 821
Connecting the Lift Cylinders 821
Connecting the Mast Supply Hoses 821
Carriage and Forks 823
Install Carriage 823
Connecting Hoses and Electrical Cable 823
Install Forks 824
Adjust Carriage 825
Install Cab Lights 826
Lubricate 827
General Checks After Assembly 827
Plumbing Check 827
Lubrication Check 827
Fluid Level Check 827
Functionality Check 827
Literature Package Check 827
Cleaning 827
Labels 827
Wheels and Tires 828
Remove Wheels From Lift Truck 828
Remove Pneumatic Tire From Wheel 829
Install Pneumatic Tire on Wheel 830
Adding Air Pressure to Tires 831
Remove Solid Rubber Tire From Wheel 832
Install Solid Rubber Tire on Wheel 833
Install Wheels on Lift Truck 834
Pre-Delivery 835
Perform Pre-Delivery Inspection 835
Delivery 835
Instructions Operating Manual 835
Instructions Daily Maintenance 835
Handing Over Truck 835
550224611 8000YRM2292 (08 2022) US EN 837
Model Designation / Series Code 843
General 843
Section 1 – Troubleshooting 843
Cab Heater and Air Conditioning 843
Preliminary Checks 843
Checking System Air Output 843
Check The Sight Glass for Bubbles 843
Troubleshooting Procedures 844
General System 844
Climate Control Display Diagnostics Menu Errors 846
Mast 847
Section 2 – Error Codes 850
Armrest 850
Cabin Tip 858
Communications 859
Engine (Cummins) 862
Cummins Engine 862
General 862
Fault Code Descriptions 862
Finding Fault Code Information 862
Electronic Throttle Calibration 862
Stationary Regeneration Procedure 863
Engine (Mercedes-Benz) 906
General 906
Finding Fault Code Information 906
ACM Faults 906
CPC4 Faults 928
MCM Faults 956
Greasing (Frame) 996
Greasing (Spreader) 997
Heating Ventilation and Air Conditioning (HVAC) 998
Hydraulic Controller 1000
Hydraulic Controller 1 1000
Hydraulic Controller 2 1001
Spreader 1002
Telemetry 1012
TPMS 1013
Transmission (ZF) 1014
VSM 1055
Other 1084